Graco Husky 1040 Operation manual

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INSTRUCTI@;N L!ST
ORACO
First choice when
quality cguits.'*
308-479
, Rev. G
\ Supersedes Rev. A
and PCNs B td E
' (includes Rev. F)
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ALUMINUM AND STAINLESS STEEL !
''n,Husky *' 1040 Air-Operated
. :,.t. i J .,; I :. l;r,f :.; ;'
Di,aphrcigm ,Pumps
120 psi (0.84 MPi,'8.4 bar)-:AttaxiiAuq Fluid WorXing Pressure
120 psi (0.84 MPa, 8.4 ba\ Maximum Air lnput Pressure
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*Model No, D73-_ Aluminum Pumps
: *Modet tto. oza-T stainless steel Fr-p=
*NOTE: Referto the Pump'Matrix on page 22 to
determine the Model No. of your pump.
US and Foreign Patents Pending
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GRACO INC.
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P.O. BOX'.I2t41 MINNEAPOLIS, MN 5540-1441
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-:9raco lirc. is registered to l.S. EN ISO 9001
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This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
- INSTRUCNONS
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Table of Contents
Safety Warnings
Symbols
lnstallation,..,
Qperation:....
Maintenance . . .
Troubleshooting
Service,
Pump Matrii.. .
Repair Kit Matrix
Parts .
Dimensional Drawings . :.. :. :.. i. . :.
Technical Data and Performance Chart
Warranty
Graco Phone Number
Warning Symbol
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
'Caution Symbot
This symbolalerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
* 'Ji1'" Symbols
r ' o1' ,ltt
2
2
4
10
11 "
12
14
22
23
24
28
29
32
32
[W
A CEUTION
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to'rupture or malfunction and result in serious injury.
o This equipment is for professional use only.
. Read all instruction manuals, tags, and labels before operating the equipment.
o Use the equipment only for its intended purpose. lf you are not sure, call your Graco distributor:
o Do not alter or modiff this equipment.
. Check equipment daily. Repair or replace worn or damaged parts immediately.
o Do not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 120 psi (0.84 MPa,8.4 bar) maximum working pressure at 120 psi
(0.84 MPa, 8.4 bar) maximum incoming air pressure.
o Use nuiOs and solvents which are compatible with the equipment wetted O"nr. *"r", to the Tech-
nical Data seclion of all equipment manuals. Read the fluid and solvent manufacturer's wam-
i ings. i
o Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion
. Do not use hoses to pull equipment.
o Route hoses away from traffic areas, sharp edges, moMng parts, and hot surfaces. Do not ex-
pose Graco hoses to temperatures above 82'C (180'D or below *40"C (*40"D.
o Do not lift pressurized equipment.
. Comply with all applicable local, state, and national fire, electrical, and safety regulations.
2 308-479

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a
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AN
ii*til*u
#fl\ TOXIC FLUID HAZARD
Hazardous fluid or.toxic fumes can cause serious injury or death if splashed in the eyes or on the 'r
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 nationalguidelines. :
. Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer. .
o Pipe and dispose of the exhaust air safely, away fom people, animals, and food handling areas.
lf the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on
page 8.
ilH:::;il::::]l*ffi:, names orsparks can cause, r,,.",.0o," conoitiqn ano
result in a fire or explosion and serious injury.
o Ground the equipment. Referto Grounding on page 4.
o lf 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 identiff and correct the problem. I
o Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
. Pipe and dispose of the exhaust.air safely, away,fom,all'iourees of ignition. lf the'diaphragm'
fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 8.
o Keep the work area free of debris, including solvent, rags, and gasoline. l'
. Electrically disconnect all equipment in the work area. j 'i
o Extinguish all open flames or pilot lights in the work area. l
o Do not smoke in the work area. : : , " i
o Do not turn on or off any light switch in the work area while operating or if fum'es are present.
o Do not operate a gasoline engine in the work area. ,
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308-479 3

.l
lnstal,lation
General lnformation
. The Typical lnstallations shown in Figs. 24 are
only guides for selecting and installing system
components. Contact your Graco distributor for
assistance in planning a system to suit your needs.
o Always use Genuine Graco Parts and Accessories.
Referto Product Data Sheet 305-588.
o Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 24-25.
o' Aluminum Husky 1040 Pump Model No.239-823,
with straight-thread manifolds, is available and can
be ordered separately.
Grounding
To reduce the risk of static"sparking, ground the pump
and all oth'er equipment used or located in the pumping
area. Check your local electrical code for detailed
grounding instructions for your area and type of
equipment. Ground all of this equipment.
o Pump: Connect a ground wire and clamp as shown
in Fig. 1. Loosen the grounding lug locknut (VV) and
washer (X). lnsert one end of a 12 ga (1.5 mm2)
minimum ground wire (Y) into the slot in the lug (4
and tighten the locknut securely. Connect the clamp
end of the ground wire to a true earth ground.
Order Part No. 222-011 Ground \Mre and Clamp.
Z
x
W
Fig. 102646
o Air and fluid hoses: Use only grounded hoses with
a maximum of 500 ft (150 m) combined hose
length to ensure grounding continuity.
o Air compresson Follow the manufacturer's
recommendations.
o 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 thg local,code
.-1.,,s 1u.li. *1! 4
Y
+
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
Technica! Data section of all equipment manu-
als. Read the fluid and solvent manufacturer's
warnings.
W
nt
Nl/
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before
operating the pump, ground the system
as explained below. Also, read the sec-
tion FIRE AND EXPLOSION HAZARD,
on page 3.
W
4 308-479

!nstallation
Mountings A CEUTION
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. 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.
Air Line
lnstall the air line accessories as shown in Figs.
24 on pages 6 and 7. Mount these accessories
on the wall or on a bracket. Be sure the air line
supplying the accessories is grounded.
a. lnstall 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. '' Lbcate one bleed-type mlster 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. lnstall a grounded, flexible air hose (A) between
the accessories and lhe 112 npt(f) pump air inlet
(N). See Fig.5. Use a minimum 3/8'(9.5 mm) lD
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.
Fluid Suction Line
1. Use grounded fluid hoses. The pump fluid inlet (R)
is 1" npt(f). See Fig. 5. Screw the fluid fitting into
the pump inlet securely.
2. lf the fluid inlet pressure to the pump is more than
25o/o of lhe outletworking pressure, the ballcheck
valves will not close fast enough, resulting in
inefiicient pu mp operation.
3. At inlet fluid pressures greater than 15 psi (0.1
MPa, 1 bar), diaphragm life will be shortened. I
4. See the Technical Data on page 29 for maximum
suction lift (wet and dry)
Fluid Outlet Line
1. Use grounded fluid hoses (L). The pump fluid
outlet (S) is 1l npt(f). See Fig. 5. Screw the fluid
fitting into the pump outlet securely. i
.t''
2. lnstall a fluid drbin valve (J) near the fluid outlet.
See the WARNING above, and Figs. 24 on
pages 6 and 7.
3. lnstalla shutoff valve (K) in the fluid outlet line
A bleed-type master air valve (B) is required in
your system to'relieve airtrapped 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. 3.
WD
7
A fluid drain valve, (J) is required to relieve pres-
sure in the hose if it is plugged. The drain valve l
reduces the risk of serious injury including splash-
ing in the eyes or on the skin, or contamination I
from hazardous fluids when relieving pressure.'ln=
stall the valve close to the pump fluid outlet. See
Fig. 3.
IIIAENINTC
308-479 r 5

'I
lnstallation
KEY FOR FIG.2
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 Fluid Suction Line
H Bung Adapter
J Fluid Drain Valve (required)
K Fluid ShutoffValve
L Fluid Line
Y Ground V1/ire (required; see page 4
. for installation instructions)
TYPICAL BUNG-MOU NT INSTALLATION
E F CB A
L
D
J
Y
H
tJ
z
02648
Fig. 2
E F CB
. TYPICAL FLOOR-MOUNT INSTALLATION
L
KEY FOR FIG.3
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 Fluid Suction Line
J Fluid Drain Valve (required)
K Fluid ShutoffValve
L Fluid Line
Y Ground Wre (required; see page 4
for installation instructions)
A
K
J
Y
Fig.3 .
6 308-479
G
D
02651

I!nstallation
KEY FOR FIG.4
A Air Supply Line
B Bleed-Type Master Air Valve
(required for pump)
C Air Regulator
D Air Line Quick Disconnect
E Master Air \hlve (for accessories)
F Air Line Filter
G Fluid Suction Line
J Fluid Drain \hlve (required)
K Fluid ShutofiValve
L Fluid Line
M \ hll Mounting Bracket
Y Ground \Mre (reguired; see page 4
for installation instructio ns)
EFCB
D
G
TYPICAL WALL.MOU NT INSTALLATION
AK
M
J
Y
02649
Fig.4
Changing the Orientation of the Fluid lnlet
and Outlet Ports
On aluminum pumps, the fluid inlet and outlet
manifolds have threaded ports on both ends. The
pump is shipped with a plug installed in one end of
each manifold, and the opposite end open. See Fig. 5.
To change the orientation of the inlet and/or outlet port,
remove the plug from one end of a manifold and install
it in the opposite end.
On stainless steel pumps, the fluid inlet and outlet
manifolds have threaded ports on one end only. The
pump is shipped with the ports facing the same
direction. To reverse the orientation of the ports:
1. Remove the screws and nuts holding the inlet
and/or outlet manifold to the covers.
2. Reverse the manifold and reattach. lnstallthe
screws and torque to 120-150 in-lb (14-17 N.m).
KEY
N 1/2 npt(f) Air lnlet Port
P Muffler;.Air Exhau$ Port is 3/4 npt(f)
R 1'npt(f) Fluid lnlet Port
S 1'npt(f) Fluid Outlet Port
1 06 Manifold and Cover Screws
3 Air Valve Screws A
A
Apply mediurn-
strength (blue) Loc-
tite@ or equivalent to
the threads, and
torque to 12G-150 r
inJb
(14-17 N.m).
Torque to 38-43 in-lb
(4.4-5.0 N.m).
106 aS
1064
R
s263?
Ag
N
P
.s'c'&f,rr:* Fig.5 308-479 7

FIRE AND EXPLOSION HAZARD
Be sure to read and follow the warnings
and precautions regarding TOXIC
FLUID HAZARD, and FIRE OR EXPLO-
, SION HAZARD on page 3, before op-
erating this pump.
Be sure the system is properly ventilated for your
type of installation. You must vent the exhaust to a
safe place, away fom people, animals, food handl-
ing 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. 6.
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lnstallation
Air Exhaust Ventilation The air exhaust port is 3/4 npt(D. Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
eriatic pump operation.
To provide a remote exhaust:
1. Remove the mufiler (P) from the pump air exhaust
port.
2. lnstall a grounded air exhaust hose ([) and
connect the mufiler (P) to the other end of the
hose. The minimum size for the air exhaust hose
is 3/4 in. (19 mm) lD. lf 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.6.
'VENTING EXHAUSTAIR
E ,F C B \
i
KEY
A Air Supply Line
B Bleed-Type Masler 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
02650
A
T
DU
P
Fig.6
" 8 308-479

Fluid Pressure Relief Kit
KEY
R 1" npt(f) optional Fluid lnlet Port
S 1" npt(f) Optional Fluid Outlet Port
V Pressure Relief Kit
A
A
A
lnstall kit between fluid inlet and outlet manifolds.
Connect fluid inlet line here.
Connect fluid outlet line here.
!nstallation
As
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02653
Fig.7
A CNUTION
Pressure Relief Kit 235-409 (V) is available for Aluminum Pumps, to prevent overpressurization and rupture of
the pump or hose. See Fig. 7. The kit includes instructions.
Thermalexpansion of fluid in the outlet line can cause overpressurization. This can occurwhen 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 in-
take valve of the piston pump does not close, causing fluid to back up in the outlet line.
308-1479 I

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 '
o Check, clean or service any system equipment
o lnstall or clean fluid nozzles
W
Operation
Pressure Relief Procedure
1. Shut off the airto the pump.
2. Open the dispensing valve, if used
3. Open the fluid drain valve to relieve allfluid
pressure, having a container ready to catch the
drainage.
Flush the Pump Before First Use
The pump was tested in water. lf the water could
contaminate the fluid you are pumping, flush the pump
thoroughly with a compatible solvent. Follow the steps
under Starting.and Adjusting the Pump,
Starting and Adjusting the Pump
1. Be sure the pump is properly grounded. Refer to
Grounding on page 4.
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
flttings securely.
3. Place the suction tube (if used).in the fluid to be,
pumped. ;
NOTE: lf the fluid inlet pressure to the pump is more
lhan 25% of the butlet 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).
6. Close the pump air regulator (C). Open all
bleed-type master air valves (B, E).
7. lf the fluid hose has a dispensing device, hold it
' open while continuing with the following step.
8. Slowly open the air regulator (C) untilthe pump
- starts to cycle. Allow the pump to cycle slowly until
all air is pushed out of the lines and the pump is
primed.
lf 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
At the end of the work shift, relieve the pressure
/
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
IIIr/TENINTC
7
TOXIG FLUID HAZARD
To reduce the risk of serious injury,
splashing in the eyes or on the skin, and
toxic fluid spills, never move or lift a
pump under pressure. lf dropped, the fluid section
may rupture. Always follow the Pressure Relief
Procedure Warning above before lifting the pump
tlilillir
fiil ITAENINTC
i 10 308-479

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 oilto the air
inlet. A 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
Flush the pump often enough to prevent the fluid you
are pumping from drying or treezing in the pump and
damaging it. Use a compatible solvent.
Always flush the pump and relieve the pressure before
storing it for any length of time.
Tightening Threaded Connections I
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.
At least every six months, check and retorque all
threaded connections, including manifold and cover
screws, plugs, and air valve screws.
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.
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
W
308-479 : 11

Troubleshooting
o 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 10.
W
PROBLEM GAUSE 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 16
Pump will not cycle, or cycles once
and stops. Air valve is stuck oi dirty. Disassemble and clean air valve. See pages 14-14. 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
16.
l.t
Check valve ball (301) is wedged
into seat (201), due to overpressur-
ization.
I nstall Pressure Relief Valve
(see page 9).
Dispensing valve clogged. Relieve pressure and clear valve.
Pump operates erratically. Clogged suction line lnspect; clear
Sticky or leaking balls (301) Clean or replace. See page 16
Diaphragm ruptured Replace. See pages 17-19
Restricted exhaust. Remove restriction.
Air bubbles in fluid; Suction line is loose Tightenr
Diaphragm ruptured. Replace. See pages 17-19.
Loose inlet manifold (102), dam-
aged seal between manifold and
seat (201), damaged o-rings (202)
Tighten manifold bolts (106) or re-
place seats (201) or o-rings (202).
See page 16.
Loose diaphragm shaft bolt (107) Tighten or replace (pages 17-19)
Damaged o-ring (108) Replace. See pages 17-19
12 308-479

Troubleshooting
PROBLEM CAUSE SOLUTION
Fluid in exhaust air. Diaphragm ruptured. Replace. See pages 17-19
I
Loose diaphragm shafi bolt (107) Tighten or replace (pages 17-19).
Damaged o-ring ('108). Replace. See pages 17-19.
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
't+-14. ri
Worn shaft seals (402) Replace. See pages 17-19
Pump leaks air extemally. Air valve cover (2) or air valve cover
screws (3) are loose. Tighten screws. See page 14
Air valve gasket (4) or air cover
gasket (22) is damaged. lnspect; replace. See pages 14-14,
20-21 i
Air cover screws (25) are loose. Tighten screws. See pages 20-21:
Pump leaks fluid extemally from ball
check valves. Loose manifolds (102, 103), dam-
aged seal between manifold and
seat (201), damaged o-rings (202).
Tighten manifold bolts (106) or re- ,
place seats (201) or o-rings (202).
See page 16.
308-'479 : r 13

Sewice
Repairing the Air Valve
Toots Required
o Torque wrench
o Tox screwdriver or 8 mm (5/16') socket wrench
o Needle-nose pliers -
o O-ring pick
o Lithium base grease
NOTE: Air Valve Repair Krt236-273 is available.
Referto page 23. Parts included in the kit are marked
with a symbol, for example (3f). Use all the parts in
the kit for the best results.
Disassembly
1. ., Relieve the pressure.
2. With a tox screwdriver or 8 mm (5/16") socket
wrench, remove the six screws (3), air valve cover
(2), and gasket (4). See Fig. 8.
3. Move the valve caniage (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, pullthe pilot block (18) straight
up and out of the cavity. See Fig. 9.
4. Pull the two actuator pistons (11) out of the
bearings (12). Remove the u-cup packings (10)
. from the pistons. Pullthe'pilot pins (16) out of the
bearings (15). Remove the o-rings (17) from the
push pins. See Fig. 10.
5. lnspect the valve plate (8) in place. lf damaged,
use a tox screwdriver or 8 mm (5/16") socket
wrench'to remove the three screws (3). Remove
the valve plate (8) and seal (9). See Fig. 11.
6. lnspectthe bearings (12,15) in place. See Fig. 10
The bearings are tapered and, if damaged, must
be removed from the outside. This requires
disassembly of the fluid section. See page 20.
7. Clean all parts and inspect for wear or damage.
Replace as needed. Reassemble as explained on
page 14.
Reassembly
1 . tf you replaced the bearings (12, 15), reinstall as
explained on page 20. Reassemble the fluid
section-
2. lnstallthe valve plate seal (9f) into the groove at
the bottom of the valve cavity. The rounded side of
the seal mustface down into the groove. See
Fig. 11
3. lnstallthe valve plate (8) in the cavity. The plate is
reversible, so either side can face up. lnstallthe
. three screws (3f), using a tox screwdriver or 8
mm (5/16) socket wrench. Tighten until the
screws bottom out on the housing. See Fig. 11.
4. lnstallan o-ring (17t) on each pilot pin (16).
Grease the pins and o'rings. lnsert the pins into
the bearings (15'1, narrow end first. See Fig. 10.
5. lnstalla u-cup packing (10t) on each actuator
piston (11), so the lips of the packings face the
narrowend of the pistons. See Fig. 10.
6. Lubricate the u-cup packings (10t) and actuator
pistons (11). lnsert the actuator pistons in the
bearings (12), wide end first. Leave the nanow
end of the pistons exposed. See Fig. 10.
7 . Grease the lower face of the .pilot block (18f) and
install so its tabs snap into the grooves on the
ends of the pilot pins (16). See Fig. 9.
8. Grease the o-ring (6f) and installit in the valve
block (7t). Push the block onto the valve carriage
(5). Grease the lower face of the valve block. See
Fig.9.
9. lnstallthe valve carriage (5) so its tabs slip into the
grooves on the narrow end of the actuator pistons
(11). See Fig. 9.
10. Align the valve gasket (4t) and cover (2) with the
six holes in the center housing (1). Secure with six
screws (3f), using a tox screwdriver or 8 mm
(5/16') socket wrench. Torque to 38-43 in-lb
(4.3-4.9 N.m). See Fig. 8.
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
W
" 14 308-479

Seruice
A Torqueto 38-43
6 in-lb
(4.3-4.9 N.m).
gra A
Alnsert narrow end' fi rst.
Grease.
OtAA
114
4t l\ lnstallwith lips facing '
-^- narrow end ofpiston (11).
,/a\ lnsert wide end first.
12
J
\A17t 15 16A
02644 m643
Fig.8
Detail
5
Fig. 10
A
A3tA
Rounded side must face down. '
Tighten screws '
untilthey bottom
out on the hous-
A
A
AAto
Atz tng.
Atg
See Detail at right.
Grease.
Grease lower face. N
\.O
-.@ I
1AA
ln o
o
02642 02645
Fig. 9
onFig.11
308-479 r 15

Ball Check Valve Repair
' Tools Required
. Torque wrench
. 10 mm socket wrench
o O-ring pick
Disassembly
NOTE: A Fluid Section Repair Kit is available. Referto
page 23 to orddr the conect kit for your pump. Parts
included in the kit are marked with an asterisk, for
example'(201*). Use allthe parts in the kit forthe best
results. ,
NOTE: To ensure proper seating of the balls (301),
always replace the seats (201) when replacing the
balls. Also, on some models, replace the o-rings (202).
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) and nuts (114, used on sfain/ess sfee/
pumps only) holding the outlet manifold (103) to
the fluid covers (101). See Fig. 12.
4. Remove the o-rings (202, not used on some
models), 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, not used on some
models), 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. 12. Be sure the ball checks and
manifolds are assembled exactly as.shown. The
arrows (A) on the fluid Govers (101) must point
toward the outlet_manifold (103). :
Apply medium-strength (blue) Loctite@ or equivalent to
the threads, and torque to 120-150 in-lb (14-17 N.m).
Arrow (A) must point toward outlet manifold (103).
Beveled seating surface must face the ball (301).
Not used on some models.
Aluminum Model Shown
Service
A
A
A
A
Ar
Al\
103
301"
201-A
202*a
101
301 *
201-l\
202*a
102
Fig.12
7
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
IVtrrTENINTd
i 16 308-479
106l\ 026474

Seruice
Diaphragm Repair
Tools Required
. Torque wrench
o 10 mm socket wrench
o 15 mm socket wrench (aluminum models) or
1' socket wrench (stainless steel models)
o 19 mm socket wrench
o O-ring pick
o Lithium-base grease
Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to
page 23 to order the conect kit for your pump. Parts
included in the kit are marked with an asterisk, for
example (401). Use allthe parts in the kit forthe best
results.
1. Relieve the pressure
2. Remove the manifolds and disassemble the ball
checkvalves ad explained on page 16.
3. Using a 10 mm socket wrench, remove the screws
(106) holding the fluid covers (101) to the air
covers (23). Pullthe fluid Govers (101) off the
pump.See Fig. 13.
AApply medium-strength (blue) Loctite@ or
equivalent to the threads, and torque to
121150 in;lb (14717 N.m).
A Arrow (A) must pointtoward airvalve (B).
B
23
@r*
1o1
A
A
106 A
0263s
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
W
Fig. 13
308-479' ; 17

Service
4. Loosen but do not remove the diaphragm shaft
bolts (107), using a 15 mm socketwrench'(1" on
stainless steel models) on both bolts.
5. Unscrew one bolt from the diaphragm shaft (24)
and remove the o-ring (108), fluid side diaphragm
plate (105), Teflono diaphragm (403, used on
Teflon@ models only), diaphragm (401), and air
, side diaphragm plate (104). See Fig. 14.
6. Pull the other diaphragm assembly and the
diaphragm shafi (24) out of the center housing (1).
Hold the shaft flats with a 19 mm socket wrench,
and rembve the bolt (107) from the shaft.
Disassemble the remaining diaphragm assembly.
7. lnspect the diaphragm shaft (24) for wear or
, scratches. lf it is damaged, inspect the bearings
(19) in place. lf the bearings are damaged, referto
page 20.
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
bearings (19) in place.
9. Clean all parts and inspect for wear or damage.
Replace parts as needed.
Reassembly
1. lnstall the shaft u-cup packings (402*) so the lips
face outof the housing (1). Lubricate the
packings. See Fig. 14.
2. lnstall the diaphragm assembly on one end of the
shaft (24) as follows:
alnstall the o-ring.(108") on the shaft bolt (107).
b. lnstall the fluid side diaphragm plate (105) on
the bolt so the rounded side faces the
diaphragm (401).
NOTE: On sfain/ess steel pumps only,lhe fluid side
diaphragm plate (105) is stainless steel. This plate is
nof stamped with its part number. Be sure to install
this plate on the fluid side of the diaphragm,
c. On Teflono models only installthe Teflono
diaphragm (403-). Make certain the side
marked AIR SIDE faces the center
housing (1).
d. lnstallthe diaphragm (401) on the bolt. Make
certain the side marked AIR SIDE faces the
center housing (1).
e. lnstall the air side diaphragm plate (104) so
the rounded side faces the diaphragm (401).
This plate is used on allmodels, and is '
stamped with its part number.
f. Apply medium-strength (blue) Loctite@ or
equivalent 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 20-25 ft-lb (27-34 N.m) at 100
rpm maximum.
6. Align the fluid covers (101) and the center housing
. (1) so the arows (A).on the covers faie the same
direction as the air valve (B). Apply
medium-strength (blue) Loctite@ or equivalent to
the threads of the screws (106). Secure the
covers with the screws handtight. See Fig. 13.
Using a 10 mm socket wrench, torque the screws
oppositely and evenly to 120-150 in-lb (14-17
N.m).
7. Reassemble the ball check valves and manifolds
as explained on page 16.
18 308-479

Service
ros I
rozlN
403"
/\
19 '+oz{
1'24 104 401*
AAA
Cutaway Vtew, with Diaphragms in Place
1
02638 a2637
24a\
Cutaway View, with Diaph ragms Removed
ro+A +or.A +os-,/N,/4.
ros I
rozA
Lips face out of housing (1 ).
Rounded side faces diaphragm (401).
Air Side must hce center housing (1).
Grease.
Apply medium-strength'(blue) Loctite@ or
equivalent. Torque to2V25 ft-lb (27-3a N-m)
at 100 rpm maximum.
Used on pumps with Teflon@ diaphragms only.
02636
08*
1
I244
A
A
A
A
A'
' Fig. 14
A
'308-479' i 19

Seruice
:oi
Bearing and Air Gasket Removal
Tools Required
o Torque wrench
o 10 mm socket wrench
o Bearing puller
o O-ring pick .
. Press, or block and mallet
Disassembly
NOTE: Do not remove undamaged bearings.
1. . Relieve the pressure.
2. Remove the manifolds and disassemble the ball
checkvalves as explained on page 16.
3. . Remove the fluid covers and diaplragm
assemblies as explained on page 17.
NOTE: lf you are removing only the diaphragm shaft
bearing (19), skip step 4.
4. Disassemble the air valve as explained on page
14
5. Using a 10 mm socket wrench, remove the screws
(25) holding the air covers (23) to the center
housing (1). See Fig. 15.
6. Remove the air cover gaskets (22). Always replace
the gaskets with new ones.
7. Use a bearing pullerto remove the diaphragm
shaft bearings (19), air valve bearings (12) or pilot
pin bearings (15). Do not remove undamaged
bearings.
8. lf you removed the diaphragm shaft bearings (19)
reach into the center housing (1) with an o-ring
pick and hook the u-cup packings (402), then pull
them out ofthe housing. lnspectthe packings. See
Fig. 14.
Reassembly
1. lf removed, installthe shafi u-cup packings (402")
so the lips face out of the housing (1).
2. The bearings (12, 15, and 19) are tapered and can
only be installed one way. lnsert the bearings into
the center hciUsing (1), tapered end first. Using a
press or a block and rubber mallet, press-fit the
beariig so it is flush with the surface of the center
housing.
3. Reassemble the air valve as explained on page
'14.
4. Align the new air cover gasket (22) so the pilot pin
(16) protruding fom the center housing (1) fits
through the proper hole (H) in the gasket.
5. Align the air cover (23) so the pilot pin (16) fits in
the middle hole (M) of the three small holes near
the center of the cover. lnstallthe screws (25),
handtight. Apply medium-strength (blue) Loctite@
or equivalent to the threads of the screws (25).
See Fig. 15. Using a 10 mm socket wrench, torque
the screws oppositely and evenly to 130-150 in-lb
(1s-17 N.m).
6. lnstallthe diaphragm assemblies and fluid covers
as explained on page 17.
7. Reassemble the ball check valves and manifolds
as explained on page 16.
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressur6 Relief Procedure on page 10.
W
20 308-479 't