Graco Husky 1050HP Use and care manual

Repair/Parts
Husky™ Husky™
Husky™1050HP 1050HP 1050HP2:1 2:1 2:1
Air Air
Air- - -Operated Operated OperatedDiaphragm Diaphragm DiaphragmPump Pump Pump334390E
EN
1 1
1- - -inch inch inchhigh high high- - -pressure pressure pressurepump pump pumpwith with withmodular modular modularair air airvalve valve valvefor for for󰘱uid 󰘱uid 󰘱uidtransfer transfer transferapplications. applications. applications.For For Forprofessional professional professionaluse use use
only. only.
only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandinyour
Operationmanual.Save Save
Savethese these theseinstructions. instructions. instructions.
MaximumFluidWorkingPressure:
250psi(1.72MPa,17.2bar)
MaximumAirInputPressure:125psi
(0.86MPa,8.6bar)
Seepage4forapprovals.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals................................................2
OrderingInformation...........................................3
Con󰘰gurationNumberMatrix...............................4
Warnings...........................................................5
Troubleshooting..................................................8
Repair................................................................10
PressureReliefProcedure............................10
ReplaceCompleteAirValve.........................10
ReplaceSealsorRebuildAirValve...............12
ReplaceCompleteHigh/LowValve...............14
ReplaceSealsorRebuildtheHigh/Low
Valve.............................................15
CheckValveRepair.....................................16
DiaphragmandCenterSectionRepair...........17
TorqueInstructions.............................................24
Notes.................................................................25
Parts..................................................................26
TechnicalData...................................................44
FluidTemperatureRange....................................45
GracoStandardHuskyPumpWarranty................46
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualNo. No. No.Description Description Description
334014Husky1050HP2:1Air-OperatedDiaphragmPump,Operation
2334390E

OrderingInformation
Ordering Ordering
OrderingInformation Information Information
To To
ToFind Find FindYour Your YourNearest Nearest NearestDistributor Distributor Distributor
1.Visitwww.graco.com.
2.ClickonWhere Where
Whereto to toBuy Buy BuyandusetheDistributor Distributor Distributor
Locator. Locator.
Locator.
To To
ToSpecify Specify Specifythe the theCon󰘰guration Con󰘰guration Con󰘰gurationof of ofa a aNew New New
Pump Pump
Pump
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
To To
ToOrder Order OrderReplacement Replacement ReplacementParts Parts Parts
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
Distributor Distributor
DistributorNote Note Note
1.To󰘰ndpartnumbersforreplacementparts:
a.Usethe20–digitnumberfromtheIDplate
onthepump.
b.UsetheCon󰘰gurationNumberMatrixonthe
nextpagetounderstandwhichpartsare
describedbyeachdigit.
c.RefertothemainPartsillustrationandtothe
Parts/KitsQuickReference.Followthepage
referencesonthesetwopagesforfurther
orderinginformation,asneeded.
2.PleasecallGracoCustomerServicetoorder.
334390E3

CongurationNumberMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrix
Checktheidenti󰘰cationplate(ID)forthe20–digit
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:
1050HP 1050HP
1050HPA01A A01A A01AA1 A1 A1SS SS SSSP SP SPSP SP SPPT PT
PT
PumpModelCenterSection
andAirValve
ManifoldsSeatsBallsDiaphragmsManifold
O-Rings
Pump Pump
PumpCenter Center
CenterSection Section Sectionand and andAir Air AirValve Valve Valve
Material Material
Material
Air Air
AirValve Valve ValveManifolds Manifolds
Manifolds
A1 A1
A1Aluminum,standardports,npt
A2 A2
A2Aluminum,standardports,bsp
S1 S1
S1Stainlesssteel,standardports,npt
1050HP 1050HP
1050HP
Aluminum
AluminumA01A A01A
A01AStandard
S2 S2
S2Stainlesssteel,standardports,bsp
Check Check
CheckValve Valve ValveSeats Seats SeatsCheck Check CheckValve Valve ValveBalls Balls BallsDiaphragm Diaphragm
DiaphragmMaterial Material MaterialManifold Manifold
ManifoldO O O- - -Rings Rings Rings
GE GE
GEGeolast®CW CW
CWPolychloroprene
WeightedBN BN
BNBuna-NPT PT PTPTFE
SP SP
SPSantoprene®GE GE
GEGeolastCO CO COPolychloroprene
Overmolded
SS SS
SS316StainlessSteelSP SP
SPSantoprenePT PT
PTPTFE/Santoprene
Two-Piece
SS SS
SS316StainlessSteelSP SP
SPSantoprene
Approvals Approvals
Approvals
Allmodelsarerated:
II 2 GD
Ex h IIC 66ºC...135ºC Gb
Ex h IIIC T135ºC Db
4334390E

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Tohelp
prevent󰘰reandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Useonlygroundedhoses.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
•Routeexhaustawayfromallignitionsources.Ifdiaphragmruptures,󰘱uidmaybeexhausted
withair.
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
334390E5

Warnings
WARNING WARNING
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestMSDSfromdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
PRESSURIZED PRESSURIZED
PRESSURIZEDALUMINUM ALUMINUM ALUMINUMPARTS PARTS PARTSHAZARD HAZARD HAZARD
Useof󰘱uidsthatareincompatiblewithaluminuminpressurizedequipmentcancauseserious
chemicalreactionandequipmentrupture.Failuretofollowthiswarningcanresultindeath,
seriousinjury,orpropertydamage.
•Donotuse1,1,1–trichloroethane,methylenechloride,otherhalogenatedhydrocarbon
solventsor󰘱uidscontainingsuchsolvents.
•Donotusechlorinebleach.
•Manyother󰘱uidsmaycontainchemicalsthatcanreactwithaluminum.Contactyourmaterial
supplierforcompatibility.
THERMAL THERMAL
THERMALEXPANSION EXPANSION EXPANSIONHAZARD HAZARD HAZARD
Fluidssubjectedtoheatincon󰘰nedspaces,includinghoses,cancreatearapidriseinpressure
duetothethermalexpansion.Over-pressurizationcanresultinequipmentruptureandserious
injury.
•Openavalvetorelievethe󰘱uidexpansionduringheating.
•Replacehosesproactivelyatregularintervalsbasedonyouroperatingconditions.
6334390E

Warnings
WARNING WARNING
WARNING
PLASTIC PLASTIC
PLASTICPARTS PARTS PARTSCLEANING CLEANING CLEANINGSOLVENT SOLVENT SOLVENTHAZARD HAZARD HAZARD
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.
•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.
•SeeTechnical Technical
TechnicalData Data Datainthisandallotherequipmentinstructionmanuals.Read󰘱uidand
solventmanufacturer’sMSDSsandrecommendations.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadMSDSstoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Routeexhaustawayfromworkarea.Ifdiaphragmruptures,󰘱uidmaybeexhaustedinto
theair.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
334390E7

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Pumpisrunningtoofast,causing
cavitationbeforeprime.
Reduceairinletpressure.
Checkvalveballseverelywornor
wedgedinseatormanifold.
Replaceballandseat.
Seatseverelyworn.Replaceballandseat.
Outletorinletclogged.Unclog.
Inletoroutletvalveclosed.Open.
Inlet󰘰ttingsormanifoldsloose.Tighten.
Pumpcyclesbutwillnotprime.
Manifoldo-ringsdamaged.Replaceo-rings.
Pumpcyclesatstallorfailstohold
pressureatstall.
Worncheckvalveballs,seats,or
o-rings.
Replace.
Airvalveisstuckordirty.Disassembleandcleanairvalve.
Use󰘰lteredair.
Checkvalveballseverelywornand
wedgedinseatormanifold.
Replaceballandseat.
Pilotvalveworn,damaged,or
plugged.
Replacepilotvalve.
Airvalvegasketdamaged.Replacegasket.
Dispensingvalveclogged.Relievepressureandclearvalve.
Pumpwillnotcycle,orcyclesonce
andstops.
High/Lowvalveshiftleverisnotfully
seatedintotheHighorLowposition.
Shiftleverallthewayintoeither
HighorLowposition.
Cloggedsuctionline.Inspect;clear.
Stickyorleakingcheckvalveballs.Cleanorreplace.
Diaphragmruptured.Replace.
Restrictedexhaust.Removerestriction.
Pilotvalvesdamagedorworn.Replacepilotvalves.
Airvalvedamaged.Replaceairvalve.
Airvalvegasketdamaged.Replaceairvalvegasket.
Airsupplyerratic.Repairairsupply.
Pumpoperateserratically.
Exhaustmuf󰘱ericing.Usedrierairsupply.
8334390E

Troubleshooting
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Suctionlineisloose.Tighten.
Diaphragmruptured.Replace.
Loosemanifolds,damagedseatsor
o-rings.
Tightenmanifoldboltsorreplace
seatsoro-rings.
Pumpcavitation.Reducepumpspeedorsuctionlift.
Airbubblesin󰘱uid.
Loosediaphragmshaftbolt.Tighten.
Diaphragmruptured.Replace.
Exhaustaircontains󰘱uidbeing
pumped.Loosediaphragmshaftbolt.Tightenorreplace.
Moistureinexhaustair.Highinletairhumidity.Usedrierairsupply.
Wornairvalvecuporplate.Replacecupandplate.
Damagedairvalvegasket.Replacegasket.
Damagedpilotvalve.Replacepilotvalves.
Pumpexhaustsexcessiveairat
stall.
Wornshaftsealsorbearings.Replaceshaftsealsorbearings.
Airvalveor󰘱uidcoverscrewsloose.Tighten.
Diaphragmdamaged.Replacediaphragm.
Airvalvegasketdamaged.Replacegasket.
Pumpleaksairexternally.
High/Lowvalveshiftleverisnotfully
seatedintotheHighorLowposition.
Shifttheleverallthewayintoeither
HighorLowposition.
Loosemanifoldscrewsor󰘱uidcover
screws.
Tightenmanifoldscrewsor󰘱uid
coverscrews.
Pumpleaks󰘱uidexternallyfrom
joints.
Manifoldo-ringswornout.Replaceo-rings.
PumpwilloperateintheLow
pressuresetting,butwillnotoperate
intheHighpressuresetting.
ThehosesfortheHigh/Lowvalve
arenotinstalledcorrectly.
Installhosesasshowninthe󰘰gure
onpage10.
334390E9

Repair
Repair Repair
Repair
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressure
isrelievedmanually.Tohelppreventserious
injuryfrompressurized󰘱uid,suchassplashing
intheeyesoronskin,followthePressureRelief
Procedurewhenyoustoppumpingandbeforeyou
clean,check,orservicetheequipment.
1.Shutofftheairsupplytothepump.
2.Openthedispensingvalve,ifused.
3.ShifttheHigh/Lowpressureleverbackandforth
twotimes.Leavetheleverinthe“Low”position
asshowninFig.1.
Figure1High/LowPressureLever
4.Openthe󰘱uiddrainvalve(installedonthe
system)torelieveall󰘱uidpressure.Havea
containerreadytocatchthedrainage.
Replace Replace
ReplaceComplete Complete CompleteAir Air AirValve Valve Valve
FollowtheseinstructionstoinstallAirValve
Replacement24W897.
1.Stopthepump.FollowthePressure Pressure
PressureRelief Relief Relief
Procedure Procedure
Procedureintheprevioussection.
2.Disconnectthemainairline.
3.Removefourscrews(217).Removetheairvalve
(212).Removethesixo-rings(208,209,and
210).
4.Torepairtheairvalve,gotoDisassemble Disassemble
Disassemblethe the the
Air Air
AirValve Valve Valve,step2,inthenextsection.Toinstalla
replacementairvalve,continuewithstep5.
5.Installthenewo-rings(208,209,and210)on
theHigh/Lowmanifold,thenattachtheairvalve.
Applythreadlubricantandtorquescrews(217)
to80in-lb(9N•m).
6.Reconnectthemainairline.
10334390E

Repair
Applythreadlubricanttothreads
beforeassembly.
Torquescrewsto80in-lb(9N•m).
334390E11

Repair
Replace Replace
ReplaceSeals Seals Sealsor or orRebuild Rebuild RebuildAir Air AirValve Valve Valve
Followtheseinstructionstoservicetheairvalvewith
oneoftheavailablerepairkits.AirValveSealKit
partsaremarkedwitha†.AirValveRepairKitparts
aremarkedwitha♦.AirValveEndCapKitparts
aremarkedwitha‡.Kit24W952alsoisavailableto
replacethe6o-ringsbetweentheairvalveandthe
High/Lowmanifold.
Disassemble Disassemble
Disassemblethe the theAir Air AirValve Valve Valve
1.Performsteps1-3under
ReplaceCompleteAirValve,page10.
2.UseaT8Torxscrewdrivertoremovetwo
screws(309).Removethevalveplate(305),cup
assembly(312-314),spring(311),anddetent
assembly(303).
3.Pullthecup(313)offofthebase(312).Remove
theo-ring(314)fromthecup.
4.Removetheretainingring(310)fromeachend
oftheairvalve.Usethepiston(302)topush
theendcap(307)outofoneend.Removethe
u-cupseal(308)fromthepiston.Pullthepiston
outoftheendandremovetheotheru-cupseal
(308).Removetheotherendcap(307)andthe
endcapo-rings(306).
5.Removethedetentcam(304)fromtheairvalve
housing(301).
Reassemble Reassemble
Reassemblethe the theAir Air AirValve Valve Valve
NOTE: NOTE:
NOTE:Applylithium-basedgreasewheninstructed
togrease.OrderGracoPN111920.
1.Useallpartsintherepairkits.Cleanotherparts
andinspectfordamage.Replaceasneeded.
2.Greasethedetentcam(304♦)andinstallinto
housing(301).
3.Greasetheu-cups(308♦†)andinstallonthe
pistonwithlipsfacingtowardthecenterofthe
piston.
Lipsface
down. down.
down.
Lipsface
up. up.
up.
4.Greasebothendsofthepiston(302♦)andthe
housingbore.Installthepistoninthehousing
(301),withthe󰘱atsidetowardthecup(313♦).
Becarefulnottotearu-cups(308♦†)when
slidingpistonintohousing.
5.Greasenewo-rings(306♦†‡)andinstallonthe
endcaps(307‡).Installtheendcapsintothe
housing.
6.Installaretainingring(310‡)oneachendtohold
endcapsinplace.
12334390E

Repair
7.Greaseandinstallthedetentassembly(303♦)
intothepiston.Installtheo-ring(314♦)onthe
cup(313♦).Applyalight󰘰lmofgreasetothe
outsidesurfaceoftheo-ringandtheinside
matingsurfaceofthebase(312♦).
Orienttheendofthebasethathasamagnet
towardtheendofthecupthathasthelarger
cutout.Engagetheoppositeendoftheparts.
Leavetheendwiththemagnetfree.Tiltthebase
towardthecupandfullyengagetheparts,using
caresothattheo-ringremainsinplace.Install
thespring(311♦)ontotheprotrusiononthecup.
Alignthemagnetinthebasewiththeairinletand
installthecupassembly.
8.Greasethecupsideandinstallthevalveplate
(305♦).Alignthesmallholeintheplatewiththe
airinlet.Tightenthescrews(309♦†)toholdit
inplace.
9.Followsteps5–6under
ReplaceCompleteAirValve,page10,toreplace
thesealsandreattachtheairvalve.
Applylithium-
basedgrease.
U-cuplipsmust
facepiston.
Applylithium-
basedgreaseto
contactsurface.
Airinlet.
334390E13

Repair
Replace Replace
ReplaceComplete Complete CompleteHigh/Low High/Low High/LowValve Valve Valve
1.Stopthepump.Followthe
PressureReliefProcedure,page10.
2.Disconnectthemainairline.Releasethequick
disconnect󰘰ttingstoremovetheairmanifold
hoses(108).
3.TorepairtheHigh/Lowvalve,gotoDisassemble Disassemble
Disassemble
the the
theHigh/Low High/Low High/LowValve Valve Valve,step2,inthenextsection.
ToinstallareplacementHigh/Lowvalve,continue
withstep4.
4.Removefourscrews(217).Removetheairvalve
(212).Removethesixo-rings(208,209,and
210).
5.Removefourscrews(217).Removethe
High/Lowvalve(211)andgasket(213).
6.Alignthenewgasket(213)ontheprimarycenter
section,thenattachthenewHigh/Lowvalve
(211).Applythreadlubricantandtorquescrews
(217)to80in-lb(9N•m).
7.Installthenewo-rings(208,209,and210)on
theHigh/Lowmanifold,thenattachtheairvalve.
Applythreadlubricantandtorquescrews(217)
to80in-lb(9N•m).
8.Reconnectthemainairlineandtheairmanifold
hoses(108).
Applythreadlubricanttothreadsbefore
assembly.
Torquescrewsto80in-lb(9N•m).
14334390E

Repair
Replace Replace
ReplaceSeals Seals Sealsor or orRebuild Rebuild Rebuildthe the theHigh/Low High/Low High/LowValve Valve Valve
FollowtheseinstructionstoservicetheHigh/Low
valve.High/LowValveSealKit24W949isavailable
toreplaceo-rings402and405.Kit24W952alsois
availabletoreplacethe6o-ringsbetweentheair
valveandtheHigh/Lowmanifold.Kit24W950is
availabletoreplacethespool(404).
Disassemble Disassemble
Disassemblethe the theHigh/Low High/Low High/LowValve Valve Valve
1.Followsteps1and2under
ReplaceCompleteHigh/LowValve,page14.
2.Usea5/16inAllenwrenchtoremovetwoscrews
(407).
3.RemovetheHigh/Lowvalve(406).Unscrewthe
handle(403)fromthespool(404),thenremove
thespool.Useano-ringpicktoremoveall
o-rings(402and405)fromthespool.
NOTE: NOTE:
NOTE:TheHigh/Lowmanifoldblockdoesnot
havetoberemovedfromtheprimarycenter
section.
Reassemble Reassemble
Reassemblethe the theHigh/Low High/Low High/LowValve Valve Valve
NOTE: NOTE:
NOTE:Applylithium-basedgreasewheninstructed
togrease.
1.Useallpartsinthesealkit.Cleanotherparts
andinspectfordamage.Replaceasneeded.
2.Greasetwoo-rings(402)andinstalltheminthe
manifoldblock(401).
3.Greaseandinstallthreeo-rings(402and405)
onthespool(404).
4.Greasetheoutsideedge,theninstallthespool
(404)intheHigh/Lowvalve(406).Installthe
lever(403).
5.Usetwoscrews(407)toreattachtheHigh/Low
valve.Torqueto340–360in-lb(38–41N•m).
6.Reconnectthemainairlineandtheairmanifold
hoses(108).
Applylithium-basedgrease.
Torqueto340–360in-lb(38–41N•m).
334390E15

Repair
Check Check
CheckValve Valve ValveRepair Repair Repair
NOTE: NOTE:
NOTE:Kitsareavailablefornewcheckvalveballs
andseats.SeeSeatsandCheckBalls
toorderkitsinthematerial(s)desired.O-ringand
fastenerkitsalsoareavailable.
NOTE: NOTE:
NOTE:Toensureproperseatingofthecheckballs,
alwaysreplacetheseatswhenreplacingtheballs.
Also,replacetheo-ringseverytimethemanifoldis
removed.
Disassemble Disassemble
Disassemblethe the theCheck Check CheckValve Valve Valve
1.FollowthePressureReliefProcedure,page10.
Disconnectallhoses.
2.Removethepumpfromitsmounting.
3.Usea10mmsocketwrenchtoremovethe
manifoldfasteners(5),thenremovetheoutlet
manifold(3).
4.Removetheo-rings(9),seats(7),andballs(8).
5.Removethenuts(27).
6.Turnthepumpoverandremovetheinlet
manifold(4).
7.Removetheo-rings(9),seats(7),andballs(8).
Reassemble Reassemble
Reassemblethe the theCheck Check CheckValve Valve Valve
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
2.Reassembleinthereverseorder,followingall
notesintheillustration.Puttheinletmanifoldon
󰘰rst.Besuretheballchecks(7-9)andmanifolds
(3,4)areassembledexactly exactly
exactlyasshown.Theball
mustseatonthechamferedsideoftheseat.
Thearrows(A)onthe󰘱uidcovers(2)must must
mustpoint
towardtheoutletmanifold(3).
Figure2Checkvalveassembly
Torqueto100in-lb(11.3N·m).
Followtorquesequence.See
TorqueInstructions,page24.
Arrow(A)mustpointtowardoutlet
manifold
Thechamferedsideoftheseatmustface
theball.
16334390E

Repair
Diaphragm Diaphragm
Diaphragmand and andCenter Center CenterSection Section SectionRepair Repair Repair
NOTE: NOTE:
NOTE:SeeDiaphragms
forreplacementdiaphragmkits.CenterRebuild
Kit24W946alsoisavailable.Partsincludedinthe
CenterRebuildKitaremarkedwithan*.Forbest
results,useallkitparts.
Disassemble Disassemble
Disassemblethe the theFluid Fluid FluidDiaphragms Diaphragms Diaphragms
1.FollowthePressureReliefProcedure,page10.
2.Removethemanifoldsanddisassemble
theballcheckvalvesasexplainedin
CheckValveRepair,page16.
3.Removethemuf󰘱er(18).
4.Usea10mmsocketwrenchtoremovethe󰘱uid
coverscrews(5),thenremovethe󰘱uidcovers
(2).
5.Bolt-Through Bolt-Through
Bolt-ThroughDiaphragms: Diaphragms: Diaphragms:Usea15mmsocket
wrenchtoremovethediaphragmshaftbolt(14)
ononesideofthepump.Iftheshaft(206)
remainsattachedtothebolt,useawrenchon
the󰘱atsoftheshafttoremoveit.Then,remove
allpartsofthatdiaphragmassembly.
Overmolded Overmolded
OvermoldedDiaphragms: Diaphragms: Diaphragms:Thediaphragm(12)
ononesideofthepumpwillscrewoffbyhand.
Thediaphragmsetscrewshouldremainattached
tothediaphragm.Iftheshaft(206)remains
attachedtothediaphragmsetscrew,usea
wrenchonthe󰘱atsoftheshafttoremoveit.
Removetheairsidediaphragmplate(11).
6.Repeatfortheotherdiaphragm.
Disassemble Disassemble
Disassemblethe the theCenter Center CenterSection Section Section
1.Usea10mmsocketwrenchtoremovethe
screws(5),thenseparatetheprimaryairmodule
(101)fromthesecondaryairmodule(102).
2.Removethediaphragm(109),theairplates(103
and105),andthesetscrew(104).
3.Inspectthediaphragmshafts(206)forwearor
scratches.Ifdamaged,inspectthebearings
(203)inplace.Iftheyaredamaged,usea
bearingpullertoremovethem.
NOTE: NOTE:
NOTE:Do Do Donot not notremove remove removeundamaged undamaged undamagedbearings. bearings. bearings.
4.Useano-ringpicktoremovetheu-cuppackings
(202)fromtheprimaryairmoduleandthe
secondaryairmodule.Bearings(203)can
remaininplace.
5.Ifnecessary,useaboxendwrenchtoremove
thepilotvalves(205,primaryairmodule)or
thesecondarypilotplugs(220,secondaryair
module).
6.Removethepilotvalvecartridgesonlyif
necessaryduetoaknownorsuspectedproblem.
After After
Afterremoving removing removingpilot pilot pilotvalves valves valves(primary (primary (primaryside) side) side)or or or
secondary secondary
secondarypilot pilot pilotplugs plugs plugs(secondary (secondary (secondaryside), side), side),usea
hextoremovethecartridges(204),thenremove
cartridgeo-rings(219).Ifstripped,crosstwo
screwdriversintheshapeofanX.Insertthe
bladesintotheareaaroundthe10mmhex.
Revolvethebladesagainsteachotherwhile
holdingthetipsagainsttheouterareaofthe
recesstounscrewthecartridge.
NOTE: NOTE:
NOTE:Do Do Donot not notremove remove removeundamaged undamaged undamagedpilot pilot pilotvalve valve valve
cartridges. cartridges.
cartridges.
334390E17

Repair
Reassemble Reassemble
Reassemblethe the theCenter Center CenterSection Section Section
Followallnotesintheillustrations.Thesenotes
containimportant important
importantinformation.
NOTE: NOTE:
NOTE:Applylithium-basedgreasewhenever
instructedtogrease.
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
NOTE: NOTE:
NOTE:FollowSteps2–5forboththePrimary Primary PrimaryAir Air Air
Module Module
ModuleandtheSecondary Secondary SecondaryAir Air AirModule Module Module.
2.Ifremoved,greaseandinstallthenewpilotvalve
cartridges(204*)andcartridgeo-rings(219*).
Screwinuntilseated.
NOTE: NOTE:
NOTE:Cartridges(204*)mustbeinstalledbefore
pilotvalves(205*)orsecondarypilotplugs(220*).
3.Greaseandinstallthepilotvalves(205*,primary
side)orsecondarypilotplugs(220*,secondary
side).Torqueto20–25in-lb(2–3N•m)at100
rpmmaximum.Donotovertorque.
4.Greaseandinstallthediaphragmshaftu-cup
packings(202*)sothelipsfaceoutofthe
housing.
5.Ifremoved,insertthenewbearings(203*)into
theprimaryairmoduleand/orthesecondary
airmodule.Useapressorablockandrubber
mallettopress-󰘰tthebearingsoitis󰘱ushwith
thesurfaceofthemodule.
18334390E

Repair
Primary Primary
PrimaryAir Air AirModule Module Module
Secondary Secondary
SecondaryAir Air AirModule Module Module
1
Applylithiumbasedgrease.
2
Lipsmustfaceoutofhousing.
3
Cartridges(204)mustbeinstalledbeforepilotvalves(205)orsecondarypilotplugs(220).
4
Torqueto20-25in.-lb(2-3N•m).
334390E19

Repair
Reassemble Reassemble
Reassemblethe the theFluid Fluid FluidDiaphragms Diaphragms Diaphragms
Followallnotesintheillustrations.Thesenotes
containimportant important
importantinformation.
NOTE: NOTE:
NOTE:Applylithium-basedgreasewhenever
instructedtogrease.
1.Assemblethecenterdiaphragmsection:
a.Assembletheprimarysideairplate(105*),
thecenterdiaphragm(109*),andthe
secondarysideairplate(103*)ontheset
screw(104*).
b.IMPORTANT: IMPORTANT:
IMPORTANT:Themarked“Air”sideofthe
centerdiaphragmmust must
mustfacetheprimaryair
sideplateandtheprimaryairmodule.
c.Installashaft(206*)oneachend.
d.Tightenuntilassemblyisfullyseatedand
partsdonotfreelyrotate.
1
Roundedsidefacesdiaphragm.
2
Applylithiumbasedgrease.
3
AIRSIDEmarkingsoncenterdiaphragm
mustfacetheprimaryairmodule.
4
Torqueto100in-lb(11.3N•m).
20334390E