Graco herkules 338 User manual

Instructions–Parts List
309668H
EN
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
herkules 338 Air–Operated
Diaphragm Pump
100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure
Model No. 234192 Acetal Pump, Series B
herkules Equipment Corporation
2760 Ridgeway Court
Walled Lake M 48390
01428B

2 309668
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service
Replacing the Air Valve 13. . . . . . . . . . . . . . . . . . . . . .
Repairing the Air Valve 15. . . . . . . . . . . . . . . . . . . . . .
Ball Check Valves 18. . . . . . . . . . . . . . . . . . . . . . . . . .
Diaphragm Repair 20. . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Sequence 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data and Performance Charts 27. . . . . . . . . .
Dimensions 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
herkules Information 30. . . . . . . . . . . . . . . . . . . . . . . . . . .
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 herkules distributor.
DDo not alter or modify this equipment. Use only genuine herkules 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 100 psi (0.7 MPa, 7 bar) maximum working pressure at 100 psi
(0.7 MPa, 7 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 hoses to pull equipment.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose herkules 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
WARNING
INSTRUCTIONS

309668 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 8.
DTo pump acids, always use a polypropylene pump. 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. Never use an acetal pump to pump acids.
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 5.
DNever use a polypropylene pump with non-conductive flammable fluids as specified by your local
fire protection code. Refer to Grounding on page 5 for additional information. Consult your fluid
supplier to determine the conductivity or resistivity of your fluid.
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 pumped.
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 8.
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
WARNING

4 309668
Installation
General Information
DContact your herkules distributor for assistance in
planning a system to suit your needs.
DAlways use Genuine herkules Parts and Accesso-
ries, available from your herkules distributor. If you
supply your own accessories, be sure they are
adequately sized and pressure rated for your
system.
DUse a compatible, liquid thread sealant or PTFE
tape on all male threads. Tighten all connections
firmly to avoid air or fluid leaks. Do not over-
tighten plastic threads.
DReference numbers and letters in parentheses refer
to the callouts in the Figures and the parts lists on
pages 23 to 24.
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
Safe Operating Temperature
Minimum: 40_F (4.4_C); Maximum: 150_F (66_C).
Operating outside these temperature limits will
adversely affect the strength of the pump housing.
Certain chemicals may further reduce the operat-
ing temperature range. Consult engineering guides
for chemical compatibilities and temperature limits,
or contact your herkules distributor.
CAUTION
Tightening Threaded Fasteners Before
First Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque Se-
quence, page 26. After the first day of operation,
retorque the fasteners. Although pump use varies, a
general guideline is to retorque fasteners every two
months.
Mountings
DBe sure the mounting can support the weight of the
pump, hoses, and accessories, as well as the
stress caused during operation.
DThe herkules 338 Pump can be used in a variety of
installations. Kits are available to adapt your pump
to your system.
DFor all other mountings, be sure the pump is ade-
quately secured.

309668 5
Installation
Grounding
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before
operating the pump, ground the system
as explained at right. Also read the sec-
tion FIRE AND EXPLOSION HAZARD
on page 3.
The acetal pump contains stainless steel fibers,
which makes the wetted parts conductive.
Attaching the ground wire to the grounding strip
grounds the air motor and the wetted parts.
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.
US Code (NFPA 77 Static Electricity) recommends
a conductivity greater than 50 x 10–12 Siemans/me-
ter (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.
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: Attach a ground wire (Y) to the grounding
strip (112) with the screw (28), lockwasher (29) and
nut (27), as shown in Fig. 1. Connect the clamp end
of the ground wire to a true earth ground. Order
Part No. 222011 Ground Wire and Clamp.
Fig. 1
Y
112
27
29
28
01432B
DAir and fluid hoses: Use only electrically conductive
hoses.
DAir compressor: Follow the manufacturer’s recom-
mendations.
DSolvent pails used when flushing: Follow your 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.
DFluid supply container: Follow your local code.

6 309668
Installation
Air Line
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.
WARNING
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 8.
1. Install the air line accessories. Mount these
accessories on the wall or on a bracket. Be sure
the air line supplying the accessories is grounded.
a. The fluid pressure can be controlled in either
of two ways. To control it on the air side, install
an air regulator (H). To control it on the fluid
side, install a fluid regulator (M) near the pump
fluid outlet.
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 an electrically conductive, flexible air hose
(C) between the accessories and the 1/4 npt(f)
pump air inlet. Use a minimum 1/4” (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
DThe pump fluid inlet is 3/8 npt(f). See Fig. 2.
Screw the fluid fitting into the pump inlet snugly.
Use a compatible liquid thread sealant or PTFE
tape on connections to prevent air from getting into
material line.
DAt inlet fluid pressures greater than 15 psi (0.1
MPa,1 bar), diaphragm life will be shortened.
DSee the Technical Data on page 27 for maximum
suction lift and flow rate loss at various lift dis-
tances.
Fluid Outlet Line
WARNING
A fluid drain valve (J) is required in your system 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.
DUse electrically conductive fluid hoses (N). The
pump fluid outlet is 3/8 npt(f). See Fig. 2. Screw the
fluid fitting into the pump outlet snugly.
DInstall a fluid regulator (M) at the pump fluid outlet
to control fluid pressure, if desired. See Air Line,
step 1a, for another method of controlling pressure.
DInstall a fluid drain valve (J) near the fluid outlet.
See the WARNING above.

309668 7
Installation
Fluid Pressure Relief Valve
CAUTION
Some systems may require installation of a pres-
sure relief valve at the pump outlet to prevent
overpressurization and rupture of the pump or
hose. See Fig. 2.
Thermal expansion of fluid in the outlet line can
cause overpressurization. This can occur when
using long fluid lines exposed to sunlight or ambi-
ent heat, or when pumping from a cool to a warm
area (for example, from an underground tank).
Overpressurization can also occur if the herkules
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.
Connect fluid outlet line here.
Fig. 2
KEY
A 3/8 npt(f) fluid inlet port
B 3/8 npt(f) fluid outlet port
C Pressure relief valve
Part No. 112119 (stainless steel)
1
3
2Connect fluid inlet line here. Use a compat-
ible liquid thread sealant or PTFE tape on
connection to prevent air from getting into
the material line.
Install valve between fluid inlet and outlet ports.
C
A
B1
2
3
01539B
1

8 309668
Installation
Air Exhaust Ventilation
FIRE AND EXPLOSION HAZARD
Be sure to read FIRE OR EXPLOSION
HAZARD and TOXIC FLUID HAZARD
on page 3, before operating 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 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 appropri-
ate container at the end of the air exhaust line to
catch the fluid. See Fig. 3.
WARNING
The air exhaust port is 3/8 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
erratic pump operation.
To exhaust to a remote location:
1. Remove the muffler (11) from the pump air
exhaust port.
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of serious eye injury
from ice particles, never operate the
pump with the air exhaust port open. Ice
may form during pump operation, and ice particles
will be ejected from the port along with the exhaust
air. If the muffler (11) is removed, always connect
an air exhaust hose to the exhaust port.
WARNING
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. If
the fluid is flammable, ground the container. See
Fig. 3.
Fig. 3
VENTING EXHAUST AIR (Submerged Installation Shown)
In a submerged installation (as shown), all wetted and non-wetted
pump parts must be compatible with the fluid being pumped.
01445A
Z
X
11

309668 9
Operation
Pressure Relief Procedure
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually relieved to
prevent the system from starting or spraying acci-
dentally. To reduce the risk of an injury from acci-
dental spray from the gun, splashing fluid, or mov-
ing parts, follow the Pressure Relief Procedure
whenever you
DAre instructed to relieve the pressure
DStop spraying
DCheck or service any of the system equipment
DInstall or clean the spray tips
WARNING
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 pres-
sure, having a container ready to catch the drain-
age.
Flush the Pump Before First Use
The pump was tested in water. If water could contami-
nate the fluid you are pumping, flush it thoroughly with
a compatible solvent. Follow the steps under Starting
and Adjusting the Pump.
Starting and Adjusting the Pump
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can
cause serious injury or death if splashed
in the eyes or on the skin, inhaled, or
swallowed. Do not lift a pump under pressure. If
dropped, the fluid section may rupture. Always
follow the Pressure Relief Procedure above
before lifting the pump.
WARNING
1. Be sure the pump is properly grounded. Read
FIRE OR EXPLOSION HAZARD on page 3.
2. Check all fittings to be sure they are tight. Be sure
to use a compatible liquid thread sealant or PTFE
tape on all male threads. Tighten the fluid inlet and
outlet fittings snugly. Do not overtighten the fittings
into the pump.
3. Place the suction tube (if used) in the fluid to be
pumped.
4. Place the end of the fluid hose (N) into an
appropriate container. Close the fluid drain valve
(J).
5. With the pump air regulator (H) closed, open all
bleed-type master air valves (B, E).
6. If the fluid hose has a dispensing device, hold it
open while continuing with the following step.
Slowly open the air regulator (H) until the pump
starts to cycle. Allow the pump to cycle slowly until
all air is pushed out of the lines and the pump is
primed.
If you are flushing, run the pump long enough to
thoroughly clean the pump and hoses. Close the
air regulator. Remove the suction tube from the
solvent and place it in the fluid to be pumped.
Pump Shutdown
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
At the end of the work shift, relieve the pressure.

10 309668
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
1. Relieve the pressure before checking or servicing
the equipment.
2. Check all possible problems and causes before
disassembling the pump.
PROBLEM CAUSE SOLUTION
The pump will not cycle, or cycles
once and stops. The air valve is stuck or dirty. Turn the reset shaft (21).
Disassemble and clean the air
valve. See pages 15, 16.
Use filtered air.
The detent link (22) is worn or
broken. Replace the detent link (22) and ball (8). See pages 15, 16.
The springs (3, 6) and/or valve cup
(5) and plate (13) are broken or
damaged.
Replace these parts.
See pages 15, 16.
The pump cycles at stall or fails to
hold pressure at stall. The check valves or o-rings (108) are leaking. Replace these parts. See page 18.
The check balls (301) or seat (201)
are worn. Replace these parts. See page 18.
The check ball (301) is wedged in
the seat (201). Replace the ball. See page 18.
There is excessive air leakage from
the exhaust port. The air valve cup (5) or plate (13) is worn. Replace these parts. See pages 15, 16.
The shaft seals (30}) are worn. Replace the seals.
See page 20.
The pump operates erratically. The suction line is clogged. Inspect; clear the line.
The check valve balls (301) are
sticking or leaking. Clean or replace the balls. See page 18.
The diaphragm (401) is ruptured. Replace the diaphragm.
See page 20.

309668 11
Troubleshooting
PROBLEM CAUSE SOLUTION
There are air bubbles in the fluid. The suction line is loose, or there is
a lack of thread sealant. Tighten the suction line. Use a compatible liquid thread sealant or
PTFE tape on connections.
The diaphragm (401) is ruptured. Replace the diaphragm.
See page 20.
The manifolds (102) are loose or
the o-rings (108) are damaged. Tighten the manifold bolts (104) or nuts (106); replace the o-rings
(108). See page 18.
The outer diaphragm plates (103)
are loose. Tighten the plates. See page 20.
There is fluid in the exhaust air. The diaphragm (401*) is ruptured. Replace the diaphragm.
See page 20.
The outer diaphragm plates (103)
are loose. Tighten the plates. See page 20.
The pump exhausts air at stall. The air valve cup (5) or plate (13) is
worn. Replace these parts. See pages 15, 16.
The shaft seals (30}) are worn. Replace the seals.
See page 20.
The pump exhausts air from the
clamps. The clamps (111) are loose. Tighten the clamp nuts (113). See page 12.
The pump exhausts air near the air
valve. The air valve screws (15) are loose. Tighten the screws. See page 13.
The air valve o-ring (19) is
damaged. Inspect; replace the o-ring. See pages 15, 16.
The pump leaks fluid from the
check valves. The o-rings (108) are worn or damaged. Inspect; replace the o-rings. See page 18.

12 309668
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 9.
Flush the pump when necessary to prevent the fluid
you are pumping from drying or freezing in the pump
and damaging it. Use a compatible solvent.
Before storing the pump, always flush the pump and
relieve the pressure.
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 26.
Tightening the Clamps
When tightening the clamps (111), apply thread lubri-
cant to the bolts and be sure to torque the nuts (113)
to 50 to 60 in-lb (5.6 to 6.8 NSm). See Fig. 4. See
Torque Sequence, page 26.
01446B
Fig. 4
1
111
Apply thread lube and torque nuts to
50 to 60 In-lb (5.6 to 6.8 NSm). See
Torque Sequence, page 26.
1113
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.

309668 13
Service
Replacing the Air Valve
Tools Required
DTorque wrench
DPhillips screwdriver
DO-ring pick
NOTE: Air Valve Kit 239952 is available. Parts
included in the kit are marked with a dagger, for exam-
ple (2{). A tube of general purpose grease (26{) is
supplied in the kit. Install the kit as follows.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
1. Relieve the pressure.
2. Unscrew the six mounting screws (15) and remove
the air valve (A) from the pump. See Fig. 5.
3. Refer to the Valve Plate Detail in Fig. 5. Remove
the two screws (10) holding the valve plate (13) to
the pump. Use an o-ring pick to remove the valve
plate, seal (12), and bearing (9).
4. Apply grease (26{) to the bearing (9{). Install the
bearing and the seal (12) in the pump housing (1).
Install the valve plate (13) and secure with the two
screws (10{), as shown. Torque the screws to
5 to 7 in-lb (0.6 to 0.8 N-m).
5. Make certain the o-ring (19{) is in place on the air
valve cover (2{).
6. Apply grease (26{) where shown in Fig. 5.
7. Align the new air valve assembly so the reset shaft
(21{) is at the top. Install the valve on the pump,
making sure the valve saddle (14{) engages the
recessed area on the diaphragm shaft (23). Install
the six screws (15) and torque oppositely and
evenly, to 8 to 14 in-lb (0.9 to 1.6 N-m).

14 309668
Service
01436B
Fig. 5
1
3
2
{21
01458
1
VALVE PLATE DETAIL
GREASE APPLICATION
19{
15
Torque oppositely and evenly to 8 to 14 in-lb (0.9 to 1.6 N-m).
Torque to 5 to 7 in-lb (0.6 to 0.8 N-m).
Apply grease (26{).
3
112
1
2
4
4
9{
12
13
10
A
{14
21{
{16
03412A
19{
3
3
3
3

309668 15
Service
Repairing the Air Valve
Tools Required
DTorque wrench
DPhillips screwdriver
DO-ring pick
DRubber mallet
Disassembly
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
1. Relieve the pressure.
2. Remove the air valve from the pump (see page
13).
3. Remove the screw (15) and shift saddle (14). See
Fig. 6.
4. Disassemble the link assembly, consisting of the
actuator link (16), spacer (17), detent link (22),
spring (3), stop (4), and valve cup (5).
5. Remove the detent ball (8) and spring (6). The
detent collar (7) is a press-fit and should not need
removal; if it does require replacement, you should
also replace the cover (2).
6. Remove the reset shaft (21), o-ring (20) and
washer (18).
7. Clean all parts and inspect for wear or damage.
Replace as needed. See Reassembly, page 16.
Fig. 6
NOTE: ALL PARTS SHOWN ARE INCLUDED
IN AIR VALVE KIT 239952.
01431A
{2
7{
{4
{18
{16
{20
{21
{22
{17
{14
{15
{3
5{
8{
6{19{

16 309668
Service
Reassembly
1. If the detent collar (7) was removed, carefully
install a new collar in a new cover (2), using a
rubber mallet. See Fig. 7.
2. Grease the spring (6) and place it in the collar (7).
Grease the ball (8) and set it on the spring.
3. Grease the o-ring (20) and install it in the hole (H)
in the cover (2). See Fig. 7. Slide the washer (18)
onto the blunt end of the reset shaft (21). Insert
the shaft through the cover (2) until it seats.
4. Grease the spring (3). Place the link stop (4) inside
the spring.
Fig. 7
1
2
01437
{18
2{
6{
{8
7{
{21
Apply grease (26{).
Press fit with rubber
mallet.
{20
1
1
1
1
2
H
5. Grease the detent link (22) and link spacer (17).
Assemble the detent link, link spacer, and actuator
link (16) as shown in Fig. 8. The raised bumps on
the links (22 and 16) must face up.
6. Squeeze the spring (3) and install it and the stop
(4) in the link assembly. The spring tension will
hold all these parts together. Grease the valve cup
(5) and install it in the link assembly as shown.
7. Install the link assembly on the cover (2) so the
pointed end of the reset shaft (21) fits through the
holes in the links and the square part of the shaft
engages the square hole. Make certain the bumps
on the detent link (22) engage the ball (8).
Fig. 8
{17
{3
1
3
2
{16
2{
4{8{
5{
{22
Apply grease (26{).
Bumps face up.
Reset shaft square must engage
with square hole.
2
3
1
1
1
2
7505A
1

309668 17
Service
8. Grease the inside surfaces of the shift saddle (14)
and install it as shown in Fig. 9. Hold the link
assembly firmly in place and install the screw (15).
Torque to 7 to 9 in-lb (0.8 to 1.0 N-m). Install the
o-ring (19) on the cover (2).
9. Reinstall the air valve as explained on page 13.
Fig. 9
1
2
Apply grease (26{).
Torque to 7 to 9 in-lb (0.8 to 1.0 N-m).
{2
{22
{5
19{
{14
15{
21{
1
1
1
1
2
7506A

18 309668
Service
CAUTION
Do not over-torque the manifold bolts (104). Doing
so may cause the nuts (106) to spin in the hous-
ings, damaging the cover (101).
Ball Check Valves
Tools Required
DTorque wrench
D1/2” (13 mm) socket wrench
DO-ring pick
NOTE: A Fluid Section Repair Kit is available. Parts
included in the kit are marked with an asterisk, for
example (301*). Use all the parts in the kit for the best
results. Always replace the o-rings (108) with new
ones whenever the old ones are removed.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
1. Relieve the pressure. Disconnect all hoses.
Remove the pump from its mounting.
2. Using a 1/2” socket wrench, remove the nuts (106)
holding the top manifold (102) to the covers (101).
Lift the manifold off the pump. See Fig. 10.
3. Remove the outer o-ring (108), ball guide (202),
ball (301), seat (201), and inner o-ring (108) from
each of the covers.
4. Turn the pump over. Pull the tie rods (104) out of
the pump, leaving the four nuts (106) on the rods.
Remove the feet (107) and lower manifold (102).
5. Remove the outer o-ring (108), seat (201), ball
(301), ball guide (202), and inner o-ring (108) from
each of the covers (101).
6. Clean all parts and inspect for wear or damage.
Replace parts as needed.
7. Reassemble the intake ball checks in the bottom of
the pump, following all notes in Fig. 10. Be sure
the ball checks are assembled exactly as shown.
8. Set the lower manifold (102) and feet (107) in
place on the bottom of the pump.
9. Insert the long threads of each rod (104) through
the feet and lower manifold. Push the rods up
through the covers (101) until the nut (106) on the
end of the rods bottoms on the foot. Make sure the
rods are pushed all the way through. Turn the
pump upright (the rods are a slight interference fit
and will hold the pump parts securely in place).
10. Reassemble the outlet ball checks in the top of the
pump, following all notes in Fig. 10. Be sure the
ball checks are assembled exactly as shown. To
avoid leaks, run your finger over the o-rings (108)
to ensure that they are properly seated.
11. Install the top manifold (102) and four nuts (106).
Torque to 50 to 60 in-lb (5.6 to 6.8 N-m). Do not
over-torque. See Torque Sequence, page 26.

309668 19
Service
02457C
Fig. 10
102
101
102
107
201*
202*
201*
202*
106
106
1
3
4
2
Apply thread lubricant.
Do not over-torque.
Flat side faces ball.
Beveled end up.
Torque to 50 to 60 in-lb (5.6 to
6.8 N-m). See Torque Se-
quence, page 26.
5
301*
108*
108*
301*
108*
108*
1
3
2
4 5
4 5
3
2
104
6Long threads at top.
6

20 309668
Service
Diaphragm Repair
Tools Required
DTorque wrench
DOne 7/16” (11 mm) and two 1/2” (13 mm)
socket wrenches
DPhillips screwdriver
DO-ring pick
D13/32” EZY-OUT bearing extractor
DRubber mallet
DVise with soft jaws
Disassembly
NOTE: A Fluid Section Repair Kit is available. 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 9.
1. Relieve the pressure. Disconnect all hoses.
2. Remove the air valve from the pump (see page
13).
3. Remove the manifolds (102) and disassemble the
ball check valves as explained on page 18. Always
replace the o-rings (108) with new ones.
4. Using a 7/16” socket wrench, remove the clamp
nuts (113) and the grounding strip (112). Loosen
the clamps (111) and slip them over the housing
(1). Pull the covers (101) off the pump, then
remove the clamps from the housing. See the
Detail in Fig. 11.
5. Using a 1/2” socket wrench on both outer dia-
phragm plates (103), unscrew one plate from the
diaphragm shaft (23). Remove one diaphragm
(401), inner diaphragm plate (118), and o-ring
(404). Pull the opposite diaphragm assembly and
the diaphragm shaft out of the pump housing (1).
See Fig. 11. Clamp the shaft in a vise with soft
jaws and unscrew the outer plate (103), then
disassemble the remaining diaphragm assembly.
6. Inspect the diaphragm shaft (23}) for wear or
scratches. If it is damaged, check the bearings
(31}) also. Replace parts as needed. To remove
the bearings, place a 13/32 EZY-OUT in a vise.
Position the pump housing (1) over the EZY-OUT
(see Fig. 11). Turn the housing in the direction
shown by the arrows to remove the bearing.
7. Hook the shaft seals (30}) with an o-ring pick and
pull them out of the housing (1).
8. Clean all parts and inspect for wear or damage.
Replace parts as needed.