Graco Husky 1040 Operation manual

Instructions - Parts List
ACETAL, POLYPROPYLENE, AND PVDF
Husky™1040 Air-Operated
Diaphragm Pumps 308443ZAE
EN
1–inch AODD pump for fluid transfer applications. For professional use only.
Not approved to European explosive atmosphere requirements.
See Models on page 2 for a list of pump models and descriptions.
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
Important Safety Instructions
Read all warnings and instructions in the manual.
Save these instructions.

2308443
Table of Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Repairing the Air Valve . . . . . . . . . . . . . . . . 16
Ball Check Valve Repair . . . . . . . . . . . . . . . 18
Diaphragm Repair . . . . . . . . . . . . . . . . . . . 19
Bearing and Air Gasket Removal . . . . . . . . 23
Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Repair Kit Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . 33
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Performance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Technical Data and Performance Chart . . . . . . . . . . 35
Graco Standard Husky Pump Warranty . . . . . . . . . . 36
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Models
*NOTE: Refer to the Pump Matrix on page 26 to determine the Model No. of your pump.
NOTE: Plus Models include stainless steel center sections.
**CERTIFICATION NOTE: Acetal Pump Models D71______ and D81______ are certified:
II 2 GD
Ex h IIC 66°...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 temperature for
your specific pump model.
Model No. Description
**D71______ Acetal Pumps (see certification note below)
**D81______ Acetal Pumps, Remote (see certification note below)
*D72______ Polypropylene Pumps
*D82______ Polypropylene Pumps, Remote
*D75______ PVDF Pumps
*D85______ PVDF Pumps, Remote
*DR2______ Polypropylene Plus Pumps
*DS2______ Polypropylene Plus Pumps, Remote
*DR5______ PVDF Plus Pumps
*DS5______ PVDF Plus Pumps, Remote
24B754 PVDF Plus Pump with overmolded diaphragms
24B755 Polypropylene Plus Pump with overmolded diaphragms
24B756 Polypropylene Pump with overmolded diaphragms
24B757 Polypropylene Pump with overmolded diaphragms and sst seats
24B831 PVDF Pump with overmolded diaphragms

308443 3
Warnings
Symbols
Warning Symbol
WARNING
WARNING
Caution Symbol
This symbol alerts you to the possibility of serious injury
or death if you do not follow the instructions.
CAUTION
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the
instructions.
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 120 psi (0.8 MPa, 8 bar) maximum working pressure at 120 psi (0.8 MPa,
8 bar) maximum incoming air pressure.
•Use 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.
•Do not use hoses to pull equipment.
•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).
•Do not lift pressurized equipment.
•Comply with all applicable local, state, and national fire, electrical, and safety regulations.

WARNING
4308443
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.
•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. See Air Exhaust Ventilation on
page 11.
•To pump acids, always use a PVDF or 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.
•Ground the equipment. Refer to Grounding on page 6.
•Never use a polypropylene or PVDF pump with non-conductive flammable fluids as specified by
your local fire protection code. Refer to Grounding on page 6 for additional information. Consult
your fluid supplier to determine the conductivity or resistivity of your fluid.
•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. See Air Exhaust Ventilation on page 11.
•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.

308443 5
Installation
General Information
•The Typical Installations shown in Figs. 2 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.
•Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 29–31.
WARNING
1. Read TOXIC FLUID HAZARD on page 4.
2. Use 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.
Tightening Screws Before First Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque Sequence,
page 32. 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
Hazardous fluid or toxic fumes can cause
serious injury or death if splashed in the
eyes or on the skin, inhaled, or swallowed.

6308443
Grounding
WARNING
Ground all of this equipment.
•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.
NOTE: When pumping conductive flammable fluids with
a polypropylene or PVDF pump, always ground the
entire fluid system. See the WARNING at left. Fig. 2
shows a recommended method of grounding flammable
fluid containers during filling. This is only a guide;
contact your Graco distributor for assistance in
grounding your system.
Fig. 1
•Air and fluid hoses: Use only grounded hoses with a
maximum of 500 ft (150 m) combined hose length to
ensure grounding continuity.
•Air compressor: Follow the manufacturer’s
recommendations.
•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.
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 4.
The acetal pump contains stainless steel fibers which
make the wetted parts conductive. Attaching the
ground wire to the grounding screw will ground the air
motor and the wetted parts.
The polypropylene and PVDF pumps are not
conductive. Attaching the ground wire to the
grounding screw will ground only the air motor. 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. 2). Never use a polypropylene or PVDF
pump with non-conductive flammable fluids as
specified by your local fire protection code.
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.
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.
Y
W

308443 7
Installation
Air Line
WARNING
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 at left. 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. 2. Use a minimum 3/8” (10 mm) ID air
hose. Screw an air line quick disconnect coupler (D)
onto the end of the air hose (A), and screw the
mating fitting into the pump air inlet snugly. Do not
connect the coupler (D) to the fitting until you are
ready to operate the pump.
Key:
A Air supply hose
B Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
G Fluid suction line
H Fluid supply
J Fluid drain valve (required)
K Fluid shutoff valve
L Fluid line
N 1/2 npt(f) air inlet port
R 1” fluid inlet port
S 1” fluid outlet port
Y Ground wire (required; see page 6 for
installation instructions)
ECBA
N
F
SKL
H
G
J
R
D
Y
FLOOR MOUNT TYPICAL INSTALLATION
Fig. 2 _____________________________________________________________________________________
A bleed-type master air valve (B) is required in your
system to relieve air trapped between this valve and
the pump. Trapped air can cause the pump to cycle
unexpectedly, which could result in serious injury,
including splashing in the eyes or on the skin, injury
from moving parts, or contamination from hazardous
fluids. See Fig. 2.

8308443
Installation
Mountings
CAUTION
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 bolted
directly to the mounting surface.
3. 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.
4. Rubber Foot Mounting Kit 236452 is available to
reduce noise and vibration during operation.
5. Prolonged exposure to UV radiation will degrade
natural polypropylene components of the pumps. To
prevent potential injury or equipment damage, do
not expose pump or the plastic components to direct
sunlight for prolonged periods.
Installation of Remote Pilot Air Lines
1. Refer to Parts Drawings. Connect air line to pump
as in preceding steps.
2. Connect 1/4 in. O.D. tubing to push type connectors
(14) on air motor of pump.
NOTE: by replacing the push type connectors, other
sizes or types of fittings may be used. The new fittings
will require 1/8 in. npt threads.
3. Connect remaining end of tubes to external air
signal, such as Graco’s Cycleflo (P/N 195264) or
Cycleflo II (P/N 195265) controllers.
NOTE: the air pressure at the connectors must be at
least 30% of the air pressure to the motor for the pump
to operate.
Fluid Suction Line
•If using a conductive (Acetal) pump, use conductive
hoses (G). If using a non-conductive (polypropylene
or PVDF) pump, ground the fluid system. See
Grounding on page 6.
•The pump fluid inlet (R) is a 1” raised face flange.
See Flange Connections on page 9.
•If the fluid inlet pressure to the pump is more than
25% of the outlet working pressure, the ball check
valves will not close fast enough, resulting in
inefficient pump operation.
•At inlet fluid pressures greater than 15 psi (104 kPa,
1 bar), diaphragm life will be shortened.
•See the Technical Data on page 34 for maximum
suction lift (wet and dry).
Fluid Outlet Line
WARNING
1. Use grounded fluid hoses (L). The pump fluid out-
let (S) is 1” npt(f). See Fig. 5. Refer to Flange Con-
nections on page 9.
2. Install a fluid drain valve (J) near the fluid outlet. See
the WARNING above.
3. Install a shutoff valve (K) in the fluid outlet line.
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 11.
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.

308443 9
Installation
Flange Connections
The fluid inlet and outlet ports are 1” raised face flanges.
Connect 1” flanged plastic pipe to the pump as follows.
You will need:
•Torque wrench
•Adjustable wrench
•One 4.25” diameter, 1/8” thick PTFE gasket, with
four 0.62 diameter holes and a 1.15” diameter
center
•Four 1/2” x 2.5” bolts
•Four 1/2” spring lockwashers
•Eight 1/2” flat washers
•Four 1/2” nuts.
1. Place a lockwasher and a flat washer on each bolt.
Refer to Fig. 3.
2. Align the holes in the gasket and the pipe flange
with the holes in the pump flange.
3. Lubricate the threads of the four bolts. Install the
bolts through the holes and secure with the washers
and nuts.
4. Hold the nuts with a wrench. Refer to the tightening
sequence in Fig. 3 and torque the bolts to 10 to 15
ft-lb (14 to 20 N-m). Do not Over-torque.
BOLT TIGHTENING SEQUENCE
KEY
A Flanged plastic pipe
B PTFE gasket
C Bolt
D Lockwasher
E Flat washer
F Nut
R 1”fluid inlet flange
S 1” fluid outlet flange
E
FS
B
A
E
D
C
R
31
42
Torque to 10 to 15 ft-lb (14-20 N-m).
Do not over-torque.
1
1
1
Fig. 3

10 308443
Installation
Changing the Orientation of the Fluid Inlet
and Outlet Ports
The pump is shipped with the fluid inlet (R) and outlet
(S) ports facing the same direction. See Fig. 4. To
change the orientation of the inlet and/or outlet port:
1. Remove the screws (106 or 112) holding the inlet
(102) and/or outlet (103) manifold to the covers
(101).
2. Reverse the manifold and reattach. Install the
screws (106 or 112). Torque the manifold screws to
80 to 90 in-lb (9 to 10 N-m). See Fig. 4. See Torque
Sequence, page 32.
KEY
N 1/2 npt(f) air inlet port
P Muffler; air exhaust port
is 3/4 npt(f)
R 1” fluid inlet port
S 1” fluid outlet port
101 Covers
102 Fluid inlet manifold
103 Fluid outlet manifold
106 Manifold screws
112 Manifold screws
Acetal Model Shown
N
P
103
106 S
101
R
112
102
Torque to 80 to 90ft-lb (9 to 10 N-m).
See Torque Sequence, page 32
1
1
1
Fig. 4
Fluid Pressure Relief Valve
CAUTION
KEY
R 1” fluid inlet port
S 1” fluid outlet port
V Pressure relief valve
Part No. 112119 (stainless steel)
Install valve between fluid inlet and outlet ports
1
Connect fluid inlet line here.
2
Connect fluid outlet line here.
3
S
R
V1
2
3
Fig. 5
Some systems may require installation of a pressure
relief valve at the pump outlet to prevent
overpressurization and rupture of the pump or hose.
See Fig. 5.
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.

308443 11
Installation
Air Exhaust Ventilation
WARNING
The air exhaust port is 3/4 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
erratic pump operation.
To provide a remote exhaust:
1. Remove the muffler (P) from the pump air exhaust
port.
2. Install a grounded air exhaust hose (T) and 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.
VENTING EXHAUST AIR
KEY
A Air supply line
B Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
P Muffler
T Grounded air exhaust hose
U Container for remote air exhaust
ECBA
F
U
P
DT
Fig. 6
FIRE AND EXPLOSION HAZARD
Be sure to read FIRE OR EXPLOSION
HAZARD and TOXIC FLUID HAZARD on
page 4, 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 appropriate
container at the end of the air exhaust line to catch
the fluid. See Fig. 6.

12 308443
Operation
WARNING
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, having a container ready to catch the
drainage.
Flush the Pump Before First Use
The pump was tested with water. If water could
contaminate the fluid you are pumping, flush it
thoroughly with a compatible solvent. Follow the steps
under Starting and Adjusting the Pump.
WARNING
Starting and Adjusting the Pump
1. Be sure the pump is properly grounded. Refer to
Grounding on page 6.
2. Check all fittings to be sure they are tight. Be sure to
use a compatible liquid thread sealant on all male
threads. Tighten the fluid inlet and outlet fittings
securely.
3. Place the suction tube (if used) in the fluid to be
pumped.
NOTE: If the fluid inlet pressure to the pump is more
than 25% of the outlet working pressure, the ball check
valves will not close fast enough, resulting in inefficient
pump operation.
4. Place the end of the fluid hose (L) into an
appropriate container.
5. Close the fluid drain valve (J). See Fig. 2.
6. With the pump air regulator (C) closed, 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 open the air regulator (C) until the pump
starts to cycle. Allow the pump to cycle slowly until
all air is pushed out of the lines and the pump is
primed.
If you are flushing, run the pump long enough to
thoroughly clean the pump and hoses. Close the air
regulator. Remove the suction tube from the solvent
and place it in the fluid to be pumped.
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of serious
injury from pressurized fluid, accidental spray from
the gun or splashing fluid, follow this procedure
whenever you
•Are instructed to relieve pressure
•Stop pumping
•Check, clean, or service any system equipment
•Install or clean fluid nozzles
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.

308443 13
Operation
Operation of Remote Piloted Pumps
1. Follow preceding steps 1 through 7 of Starting and
Adjusting the Pump.
2. Open air regulator (C).
WARNING
3. Pump will operate when air pressure is alternately
applied and relieved to push type connectors (14).
NOTE: Leaving air pressure applied to the air motor for
extended periods when the pump is not running may
shorten the diaphragm life. Using a 3-way solenoid
valve to automatically relieve the pressure on the air
motor when the metering cycle is complete prevents this
from occurring.
WARNING
Pump Shutdown
At the end of the work shift, relieve the pressure.
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
Flushing and Storage
Flush the pump often enough to prevent the fluid you
are pumping from drying or freezing in the pump and
damaging it. Always flush the pump and follow the
Pressure Relief Procedure on page 12 before storing it
for any length of time. Use a compatible solvent.
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 32.
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.
The pump may cycle once before the external signal
is applied. Injury is possible. If pump cycles, wait until
end before proceeding. To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
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.

14 308443
Troubleshooting
WARNING
•Relieve the pressure before checking or servicing
the equipment.
•Check all possible problems and causes before
disassembling the pump.
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
PROBLEM CAUSE SOLUTION
Pump cycles at stall or fails to
hold pressure at stall.
Worn check valve balls (301), seats
(201) or o-rings (202).
Replace. See page 18.
Pump will not cycle, or cycles
once and stops.
Air valve is stuck or dirty. Disassemble and clean air valve. See
pages 16 to 17. 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 overpressurization.
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 to 21.
Restricted exhaust. Remove restriction.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace. See pages 19 to 21.
Loose inlet manifold (102), dam- aged
seal between manifold and seat (201),
damaged o-rings (202).
Tighten manifold bolts (106 or 112) or
replace seats (201) or o-rings (202).
See page 18.
Loose fluid side plate (105). Tighten or replace (pages 19 to 21).
Damaged o-ring (108). Replace. See pages 19 to 21.

308443 15
Troubleshooting
PROBLEM CAUSE SOLUTION
Fluid in exhaust air. Diaphragm ruptured. Replace. See pages 19 to 21.
Loose fluid side plate (105). Tighten or replace (pages 19 to 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 pages 16 to 17.
Worn shaft seals (402). Replace. See pages 19 to 21.
Pump leaks air externally. Air valve cover (2) or air valve cover
screws (3) are loose.
Tighten screws. See page 17.
Air valve gasket (4) or air cover gasket
(22) is damaged.
Inspect; replace. See pages 16 to 17 and 23
to 24.
Air cover screws (25) are loose. Tighten screws. See pages 23 to 24.
Pump leaks fluid
externally from ball check
valves.
Loose manifolds (102, 103), damaged
seal between manifold and seat (201),
damaged o-rings (202).
Tighten manifold bolts (106 or 112) or replace
seats (201) or o-rings (202). See page 18.

16 308443
Service
Repairing the Air Valve
Tools Required
•Torque wrench
•Torx (T20) screwdriver or 7 mm (9/32”) socket
wrench
•Needle-nose pliers
•O-ring pick
•Lithium base grease
NOTE: Air Valve Repair Kit 236273 (aluminum center
housing models) and 255061 (sst center housing
models) are available. Refer to page 29. Parts included
in the kit are marked with a symbol, for example (4).
Use all the parts in the kit for the best results.
Disassembly
WARNING
1. Relieve the pressure.
2. With a Torx (T20) screwdriver or 7 mm (9/32”)
socket wrench, remove the six screws (3), air valve
cover (2), and gasket (4). See Fig. 7.
3. Move the valve carriage (5) to the center position
and pull it out of the cavity. Remove the valve block
(7) and o-ring (6) from the carriage. Using a
needle-nose pliers, pull the pilot block (18) straight
up and out of the cavity. See Fig. 8.
4. Pull the two actuator pistons (11) out of the bearings
(12). Remove the u-cup packings (10) from the
pistons. Pull the pilot pins (16) out of the bearings
(15). Remove the o-rings (17) from the push pins.
See Fig. 9.
5. Inspect the valve plate (8) in place. If damaged, use
a Torx (T20) screwdriver or 7 mm (9/32”) socket
wrench to remove the three screws (3). Remove the
valve plate (8) and on aluminum center housing
models only, remove the seal (9). See Fig. 10.
6. Inspect the bearings (12, 15) in place. See Fig. 9.
The bearings are tapered and, if damaged, must be
removed from the outside. This requires
disassembly of the fluid section. See page 23.
7. Clean all parts and inspect for wear or damage.
Replace as needed. Reassemble as explained on
page 17.
Torque to 50–60 in-lb
(5.6–6.8 N-m).
23
2
4
2
See Detail at right.
1
Grease.
2
Grease lower face.
3
18
5
11
1
3
2
5
6
7
3
Fig. 7
Fig. 8
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.

308443 17
Service
Insert narrow end first.
1
Grease.
2
Install with lips facing narrow end of piston (11).
3
Insert wide end first.
4
102 3
11 4
16 1
215
17
12
04159
Rounded side must face down (aluminum
center housing models only).
1
Tighten screws until they
bottom out on the housing.
2
9
8
3
1
2
04160
Fig. 9
Fig. 10
Reassembly
1. If you removed the bearings (12, 15), reinstall as
explained on page 23. Reassemble the fluid
section.
2. On aluminum center housing models, install the
valve plate seal (9) into the groove at the bottom of
the valve cavity. The rounded side of the seal must
face down into the groove. See Fig. 10.
3. Install the valve plate (8) in the cavity. On
aluminum center housing models, the plate is
reversible, so either side can face up. Install the
three screws (3), using a Torx (T20) screwdriver or
7 mm (9/32”) socket wrench. Tighten until the
screws bottom out on the housing. See Fig. 10.
4. Install an o-ring (17) on each pilot pin (16).
Grease the pins and o-rings. Insert the pins into the
bearings (15), narrow end first. See Fig. 9.
5. Install a u-cup packing (10) on each actuator
piston (11), so the lips of the packings face the
narrow end of the pistons. See Fig. 9.
6. Lubricate the u-cup packings (10) and actuator
pistons (11). Insert the actuator pistons in the
bearings (12), wide end first. Leave the narrow end
of the pistons exposed. See Fig. 9.
7. Grease the lower face of the pilot block (18) and
install so its tabs snap into the grooves on the ends
of the pilot pins (16). See Fig. 8.
8. Grease the o-ring (6) and install it in the valve
block (7). Push the block onto the valve carriage
(5). Grease the lower face of the valve block.
See Fig. 8.
9. Install the valve carriage (5) so its tabs slip into the
grooves on the narrow end of the actuator pistons
(11). See Fig. 8.
10. Align the valve gasket (4) and cover (2) with the
six holes in the center housing (1). Secure with six
screws (3), using a Torx (T20) screwdriver or 7 mm
(9/32”) socket wrench. Torque to 28 to 33 in-lb (3.2
to 3.7 N-m). See Fig. 7.

18 308443
Service
Ball Check Valve Repair
Tools Required
•Torque wrench
•10 mm socket wrench
•O-ring pick
Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to
page 27 to order the correct kit for your pump. Parts
included in the kit are marked with an asterisk, for
example (201*). Use all the parts in the kit for the best
results.
NOTE: To ensure proper seating of the balls (301),
always replace the seats (201) when replacing the balls.
WARNING
1. Relieve the pressure. Disconnect all hoses.
2. Remove the pump from its mounting.
3. Using a 10 mm socket wrench, remove the four
bolts (106) holding the outlet manifold (103) to the
fluid covers (101). See Fig. 11.
4. Remove the seats (201), balls (301), and o-rings
(202) from the manifold.
NOTE: Some models use two o-rings (202), some
models use four o-rings (202), and some models do not
use o-rings.
5. Turn the pump over and remove the inlet manifold
(102). Remove the seats (201), balls (301) and
o-rings (202) 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. 11. Be sure the ball checks exactly as
shown. The arrows (A) on the fluid covers (101)
must point toward the outlet manifold (103).
Torque to 80 to 90 in-lb (9–10 N-m). See Torque Sequence,
page 32.
Arrow (A) must point toward outlet manifold (103).
Beveled seating surface must face the ball (301).
Not used on some models.
1
2
3
4
106
103
301*
1
201*
202*
A
301*
201*
202*
101
102
112
4
3
2
4
3
1
Fig. 11
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.

308443 19
Service
Diaphragm Repair
Tools Required
•Torque wrench
•10 mm socket wrench
•19 mm open–end wrench
•Adjustable wrench
•O-ring pick
•Lithium-base grease
Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to
page 27 to order the correct kit for your pump. Parts
included in the kit are marked with an asterisk, for
example (401*). Use all the parts in the kit for the best
results.
WARNING
1. Relieve the pressure. Disconnect all hoses.
2. Remove the manifolds and disassemble the ball
check valves as explained on page 18.
3. Using a 10 mm socket wrench, remove the screws
(106 and 112) holding the fluid covers (101) to the
air covers (23). Pull the fluid covers (101) off the
pump. See Fig. 12.
You must torque the eight long screws (106) first, then
the short screws (112). Torque to 130 to 150 in-lb (14
to 17 N-m). See Torque Sequence, page 32.
Arrow (A) must point toward air valve (B).
B
101
A2
2
1
113
106
112
1
1
23
Fig. 12
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.

20 308443
Service
4. Unscrew one outer plate (105) from the diaphragm
shaft (24). Remove one diaphragm (401), and the
inner plate (104). See Fig. 13.
For overmolded diaphragms: Grip both diaphragms
securely around the outer edge and rotate
counterclockwise. One diaphragm assembly will
come free and the other will remain attached to the
shaft. Remove the freed diaphragm and air side
plate.
NOTE: PTFE models include a PTFE diaphragm (403)
in addition to the backup diaphragm (401).
5. Pull the other diaphragm assembly and the
diaphragm shaft (24) out of the center housing (1).
Hold the shaft flats with a 19 mm open–end wrench,
and remove the outer plate (105) from the shaft.
Disassemble the remaining diaphragm assembly.
For overmolded diaphragms: Pull the other
diaphragm assembly and the diaphragm shaft (24)
out of the center housing (1). Hold the shaft flats
with a 19 mm open–end wrench, and remove the
diaphragm and air side plate from the shaft.
6. 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 23.
7. Reach into the center housing (1) with an o-ring pick
and hook the u-cup packings (402), then pull them
out of the housing. This can be done with the
bearings (19) in place.
8. Clean all parts and inspect for wear or damage.
Replace parts as needed.
Reassembly – Standard Diaphragms
1. Grease the shaft u-cup packings (402*) and install
them so the lips face out of the housing (1). See
Fig. 13.
2. Grease the length and ends of the diaphragm shaft
(24), and slide it through the housing (1).
3. Assemble the inner diaphragm plates (104),
diaphragms (401*), PTFE diaphragms (403*, if
present), and outer diaphragm plates (105) exactly
as shown in Fig. 13. These parts must be
assembled correctly.
4. Apply medium-strength (blue) Loctite®or equivalent
to the threads of the fluid-side plates (105). Hold
one of the outer plates (105) with a wrench, and
torque the other outer plate to 20 to 25 ft-lb (27 to 34
N-m at 100 rpm maximum. Do not over-torque.
5. 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 the covers with
the screws (106 and 112), handtight. Place the bolt
caps (113*) on the longer screws (106), and install
the longer screws in the top and bottom holes of the
covers. See Fig. 12.
6. First, torque the longer screws (106) oppositely and
evenly to 130 to 150 in-lb (14 to 17 N-m), using a 10
mm socket wrench. Then torque the shorter screws
(112). See Torque Sequence, page 32.
7. Reassemble the ball check valves and manifolds as
explained on page 18.