Graco Husky 15120 Use and care manual

Repair/Parts
Husky™ Husky™
Husky™15120 15120 15120Air-Operated Air-Operated Air-Operated
Diaphragm Diaphragm
DiaphragmPump Pump Pump3A2889D
EN
Polypropylene Polypropylene
Polypropyleneor or orPVDF PVDF PVDFpumps pumps pumpsfor for for󰘱uid 󰘱uid 󰘱uidtransfer transfer transferapplications, applications, applications,including including includinghigh high highviscosity viscosity viscositymaterials. materials. materials.For For For
professional professional
professionaluse use useonly. only. only.
Not Not
Notfor for foruse use usein in inEuropean European Europeanexplosive explosive explosiveatmosphere atmosphere atmospherelocations. locations. locations.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanual.
Save Save
Savethese these theseinstructions. instructions. instructions.
MaximumWorkingPressure:125psi
(0.86MPa,8.6bar)
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
Warnings...........................................................3
OrderingInformation...........................................6
RelatedManuals................................................6
Con󰘰gurationNumberMatrix...............................7
Troubleshooting..................................................8
Repair................................................................10
PressureReliefProcedure............................10
ReplaceCompleteAirValve.........................10
ReplaceSealsorRebuildAirValve...............11
CheckValveRepair.....................................13
DiaphragmandCenterSectionRepair...........14
TorqueInstructions.............................................18
Parts..................................................................19
Accessories........................................................31
TechnicalData...................................................32
GracoStandardHuskyPumpWarranty................34
23A2889D

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.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareantistaticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
•Routeexhaustawayfromallignitionsources.Ifdiaphragmruptures,󰘱uidmaybeexhausted
withair.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
•Donotoperateelectrostaticgunsinequipmentworkarea.
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.
3A2889D3

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.
THERMAL THERMAL
THERMALEXPANSION EXPANSION EXPANSIONHAZARD HAZARD HAZARD
Fluidssubjectedtoheatincon󰘰nedspaces,includinghoses,cancreatearapidriseinpressure
duetothethermalexpansion.Over-pressurizationcanresultinequipmentruptureandserious
injury.
•Openavalvetorelievethe󰘱uidexpansionduringheating.
•Replacehosesproactivelyatregularintervalsbasedonyouroperatingconditions.
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.
43A2889D

Warnings
WARNING WARNING
WARNING
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.
3A2889D5

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.
OR OR
OR
UsetheOnline Online
OnlineHusky Husky HuskySelector Selector SelectorTool Tool ToolontheProcess Process Process
Equipment Equipment
Equipmentpageatwww.graco.com www.graco.com www.graco.com. . .
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󰘰ndpartnumbersfornewpumpsorkits,use
theOnline Online
OnlineHusky Husky HuskySelector Selector SelectorTool Tool Tool.
2.To󰘰ndpartnumbersforreplacementparts:
a.Usethecon󰘰gurationnumberfromtheID
plateonthepump.Ifyouonlyhavethe
Graco6–digitpartnumber,usetheselector
toolto󰘰ndthecorrespondingcon󰘰guration
number.
b.UsetheCon󰘰gurationNumberMatrixonthe
nextpagetounderstandwhichpartsare
describedbyeachdigit.
c.RefertothemainPartsillustrationandtothe
Parts/KitsQuickReference.Followthepage
referencesonthesetwopagesforfurther
orderinginformation,asneeded.
3.PleasecallGracoCustomerServicetoorder.
Related Related
RelatedManuals Manuals Manuals
Manual
Number
Title
3A2888Husky15120Air-OperatedDiaphragm
Pump,Operation
63A2889D

CongurationNumberMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrix
Checktheidenti󰘰cationplate(ID)fortheCon󰘰gurationNumberofyourpump.Usethefollowingmatrixto
de󰘰nethecomponentsofyourpump.
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:15120P 15120P
15120P- - -PP01AP1PPPTFKPT PP01AP1PPPTFKPT PP01AP1PPPTFKPT
15120 15120
15120P P
PP P PP01A P01A
P01AP1 P1 P1PP PP
PPPT PT PTFK FK FKPT PT PT
PumpSizeFluid
Section
Material
Drive
Type
CenterSection
andAirValve
FluidCoversand
Manifolds
SeatsBallsDiaphragmsManifoldandSeat
Seals
Pump Pump
PumpFluid Fluid
FluidSection Section Section
Material Material
Material
Drive Drive
DriveType Type TypeCenter Center
CenterSection Section Sectionand and andAir Air Air
Valve Valve
ValveMaterial Material Material
For For
ForUse Use Use
With With
With
Fluid Fluid
FluidCovers Covers Coversand and andManifolds Manifolds Manifolds
15120 15120
15120P P
PPolypropy-
lene
P P
PPneumaticP01A P01A
P01APolypropyleneStandard
Diaphragms
P1 P1
P1Polypropylene,CenterFlange,
ANSI/DIN
15120 15120
15120F F
FPVDFP01G P01G
P01GPolypropyleneOvermolded
Diaphragms
P2 P2
P2Polypropylene,EndFlange,
ANSI/DIN
F2 F2
F2PVDF,EndFlange,ANSI/DIN
Seat Seat
SeatMaterial Material MaterialBall Ball
BallMaterial Material MaterialDiaphragm Diaphragm DiaphragmMaterial Material MaterialManifold Manifold
Manifoldand and andSeat Seat Seat
Seal Seal
SealMaterial Material Material
PP PP
PPPolypropyleneFK FK FKFKMFK FK FKFKMPT PT PTPTFE
PV PV
PVPVDFPT PT PTPTFEPO PO
POPTFE/EPDMOvermolded
SP SP
SPSantopreneSP SP
SPSantoprenePT PT
PTPTFE/Santoprene2–Piece
SS SS
SSStainless
SteelSP SP
SPSantoprene
3A2889D7

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.
Pumpwillnotcycle,orcyclesonce
andstops.
Dispensingvalveclogged.Relievepressureandclearvalve.
Cloggedsuctionline.Inspect;clear.
Stickyorleakingcheckvalveballs.Cleanorreplace..
Diaphragm(orbackup)ruptured.Replace.
Restrictedexhaust.Removerestriction.
Pilotvalvesdamagedorworn.Replacepilotvalves.
Airvalvedamaged.Replaceairvalve.
Airvalvegasketdamaged.Replaceairvalvegasket.
Airsupplyerratic.Repairairsupply.
Pumpoperateserratically.
Exhaustmuf󰘱ericing.Usedrierairsupply.
83A2889D

Troubleshooting
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Suctionlineisloose.Tighten.
Diaphragm(orbackup)ruptured.Replace.
Loosemanifolds,damagedseatsor
o-rings.
Tightenmanifoldboltsorreplace
seatsoro-rings.
Pumpcavitation.Reducepumpspeedorsuctionlift.
Airbubblesin󰘱uid.
Loosediaphragmshaftbolt.Tighten.
Diaphragm(orbackup)ruptured.Replace. Exhaustaircontains󰘱uidbeing
pumped.Loosediaphragmshaftbolt.Tightenorreplace.
Moistureinexhaustair.Highinletairhumidity.Usedrierairsupply.
Wornairvalvecuporplate.Replacecupandplate.
Damagedairvalvegasket.Replacegasket.
Damagedpilotvalve.Replacepilotvalves.
Pumpexhaustsexcessiveairat
stall.
Wornshaftsealsorbearings.Replaceshaftsealsorbearings.
Airvalveor󰘱uidcoverscrewsloose.Tighten.
Diaphragmdamaged.Replacediaphragm.
Pumpleaksairexternally.
Airvalvegasketdamaged.Replacegasket.
Loosemanifoldscrewsor󰘱uidcover
screws.
Tightenmanifoldscrewsor󰘱uid
coverscrews.
Pumpleaks󰘱uidexternallyfrom
joints.
Manifoldo-ringswornout.Replaceo-rings.
3A2889D9

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.Openthe󰘱uiddrainvalvetorelieve󰘱uid
pressure.Haveacontainerreadytocatchthe
drainage.
Replace Replace
ReplaceComplete Complete CompleteAir Air AirValve Valve Valve
FollowtheseinstructionstoinstallAirValve
ReplacementKit24B773.
1.Stopthepump.Followthe
PressureReliefProcedure,page10.
2.Disconnecttheairlinetothemotor.
3.Removenuts(104).Removetheairvalve(102)
andgasket(105).
4.Alignthenewairvalvegasket(105*)onthe
centerhousing,thenattachthenewairvalve.
FollowtheTorqueInstructions,page18.
5.Reconnecttheairlinetothemotor.
103A2889D

Repair
Replace Replace
ReplaceSeals Seals Sealsor or orRebuild Rebuild RebuildAir Air AirValve Valve Valve
Followtheseinstructionstoservicetheairvalvewith
oneoftheavailablerepairkits.AirValveSealKit
partsaremarkedwitha†.AirValveRepairKitparts
aremarkedwitha♦.AirValveEndCapKitparts
aremarkedwitha‡.
Disassemble Disassemble
Disassemblethe the theAir Air AirValve Valve Valve
1.Performsteps1-3under
ReplaceCompleteAirValve,page10.
2.UseaT10Torxscrewdrivertoremovetwo
screws(209).Removethevalveplate(205),cup
assembly(212-214),spring(211),anddetent
assembly(203).
3.Pullthecup(213)offofthebase(212).Remove
theo-ring(214)fromthecup.
4.Removetheretainingring(210)fromeachend
oftheairvalve.Usethepiston(202)topush
theendcap(207)outofoneend.Removethe
u-cupseal(208)fromthepiston.Pullthepiston
outoftheendandremovetheotheru-cupseal
(208).Removetheotherendcap(207)andthe
endcapo-rings(206).
5.Removethedetentcam(204)fromtheairvalve
housing(201).
Reassemble Reassemble
Reassemblethe the theAir Air AirValve Valve Valve
NOTE: NOTE:
NOTE:Applylithium-basedgreasewheninstructed
togrease.OrderGracoPN111920.
1.Useallpartsintherepairkits.Cleanotherparts
andinspectfordamage.Replaceasneeded.
2.Greasethedetentcam(204♦)andinstallinto
housing(201).
3.Greasetheu-cups(208♦†)andinstallonthe
pistonwithlipsfacingtowardthecenterofthe
piston.
1
Lipsface
down. down.
down.
2
Lipsface
up. up.
up.
4.Greasebothendsofthepiston(202♦)andthe
housingbore.Installthepistoninthehousing
(201),withthe󰘱atsidetowardthecup(213♦).
Becarefulnottotearu-cups(208♦†)when
slidingpistonintohousing.
5.Greasenewo-rings(206♦†‡)andinstallonthe
endcaps(207‡).Installtheendcapsintothe
housing.
6.Installaretainingring(210‡)oneachendtohold
endcapsinplace.
3A2889D11

Repair
7.Greaseandinstallthedetentassembly(203♦)
intothepiston.Installtheo-ring(214♦)onthe
cup(213♦).Applyalight󰘰lmofgreasetothe
outsidesurfaceoftheo-ringandtheinside
matingsurfaceofthebase(212♦).
Orienttheendofthebasethathasamagnet
towardtheendofthecupthathasthelarger
cutout.Engagetheoppositeendoftheparts.
Leavetheendwiththemagnetfree.Tiltthebase
towardthecupandfullyengagetheparts,using
caresothattheo-ringremainsinplace.Install
thespring(211♦)ontotheprotrusiononthecup.
Alignthemagnetinthebasewiththeairinletand
installthecupassembly.
8.Greasethecupsideandinstallthevalveplate
(205♦).Alignthesmallholeintheplatewiththe
airinlet.Tightenthescrews(209♦†)toholditin
place.
1
Applylithium-
basedgrease.
2
U-cuplipsmust
facepiston.
3
Applylithium-
basedgreaseto
contactsurface.
4
Airinlet.
123A2889D

Repair
Check Check
CheckValve Valve ValveRepair Repair Repair
NOTE: NOTE:
NOTE:Kitsareavailablefornewcheckvalveballs
andseatsinarangeofmaterials.Seepage27
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.NOTE: NOTE:
NOTE:Usehandtoolsuntilthread-locking
adhesivepatchreleases.Usea17mm(11/16in)
socketwrenchtoremovethemanifoldfasteners
(5),thenremovethemanifold(3).
4.Removetheo-rings(9),seats(7),andballs(8).
5.Turnthepumpoverandremovetheinlet
manifold(4).
6.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).
Figure1Checkvalveassembly
1
Torqueto190to200in-lb(21to25
N·m).Followtorquesequence.See
TorqueInstructions,page18.
2
Arrow(A)mustpointtowardoutlet
manifold
3
Thechamferedsideoftheseatmustface
theball.
3A2889D13

Repair
Diaphragm Diaphragm
Diaphragmand and andCenter Center CenterSection Section SectionRepair Repair Repair
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.Seepages28–29.ACenter
RebuildKitalsoisavailable.Seepage23.Parts
includedintheCenterRebuildKitaremarkedwithan
*.Forbestresults,useallkitparts.
Disassemble Disassemble
Disassemblethe the theDiaphragm Diaphragm Diaphragmand and andCenter Center Center
Section Section
Section
1.FollowthePressureReliefProcedure,page10.
2.Removethemanifoldsanddisassemble
theballcheckvalvesasexplainedin
CheckValveRepair,page13.
NOTE: NOTE:
NOTE:Youmaywishtoremovetheinner󰘱uid
coverbolts(5)asyouremoveeachmanifold,for
convenience.
3.Overmolded Overmolded
OvermoldedDiaphragms Diaphragms Diaphragms( ( (PO PO POmodels) models) models)
a.Orientthepumpsooneofthe󰘱uidcovers
(2)facesup.Usea17mmsocketwrenchto
removethe󰘱uidcoverbolts(5,6),thenpull
the󰘱uidcoverupoffthepump.
b.Theexposeddiaphragm(12)willscrewoffby
hand.Theshaftwilleitherreleaseandcome
offwiththisdiaphragm,orremainattachedto
theotherdiaphragm.Ifthediaphragmshaft
bolt(14)remainsattachedtotheshaft(108),
removeit.Removetheairsidediaphragm
plate(11)andwasher(17).
c.Turnthepumpoverandremovetheother
󰘱uidcover.Removethediaphragm(andthe
shaft,ifnecessary).
d.Iftheshaftisstillattachedtoeither
diaphragm,graspthediaphragm󰘰rmlyand
useawrenchonthe󰘱atsoftheshaftto
remove.Alsoremovetheairsidediaphragm
plate(11)andwasher(17).Continuewith
Step5.
4.All All
AllOther Other OtherDiaphragms Diaphragms Diaphragms
a.Orientthepumpsooneofthe󰘱uidcovers
facesup.Usea17mmsocketwrenchto
removethe󰘱uidcoverscrews(5,6),thenpull
the󰘱uidcover(2)upoffthepump.Turnthe
pumpoverandremovetheother󰘱uidcover.
b.Holdthehexofone󰘱uidsidediaphragm
plate(15)witha1–1/2socketorboxend
wrench.Useanotherwrench(samesize)
onthehexoftheotherplatetoremove.
Thenremoveallpartsofeachdiaphragm
assembly.
5.Inspectthediaphragmshaft(108)forwearor
scratches.Ifitisdamaged,inspectthebearings
(107)inplace.Iftheyaredamaged,usea
bearingpullertoremovethem.
NOTE: NOTE:
NOTE:Do Do Donot not notremove remove removeundamaged undamaged undamagedbearings. bearings. bearings.
6.Useano-ringpicktoremovetheu-cuppackings
(106)fromthecenterhousing.Bearings(107)
canremaininplace.
7.Ifnecessary,useasocketwrenchtoremovethe
pilotvalves(111).
8.Removethepilotvalvecartridgesonlyif
necessaryduetoaknownorsuspectedproblem.
After After
Afterremoving removing removingpilot pilot pilotvalves, valves, valves,useahextoremove
thecartridges(109),thenremovecartridge
o-rings(110).Ifstripped,usetwoscrewdriversto
screwoutthecartridge.
NOTE: NOTE:
NOTE:Do Do Donot not notremove remove removeundamaged undamaged undamagedpilot pilot pilotvalve valve valve
cartridges. cartridges.
cartridges.
143A2889D

Repair
Reassemble Reassemble
Reassemblethe the theDiaphragm Diaphragm Diaphragmand and andCenter Center CenterSection Section Section
Followallnotesintheillustration.Thesenotes
containimportant important
importantinformation.
NOTE: NOTE:
NOTE:Applylithium-basedgreasewhenever
instructedtogrease.
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
2.Ifremoved,greaseandinstallthenewpilotvalve
cartridges(109),cartridgeo-rings(110),and
retainingrings(113).
NOTE: NOTE:
NOTE:Cartridges(109)
must beinstalledbefore
pilotvalves(111).
3.Greaseandinstallthepilotvalves(111).Torque
to20-25in.-lb(2-3N•m),at110rpm.Donot
over-torque.
4.Greaseandinstallthediaphragmshaftu-cup
packings(106)sothelipsfaceout out
outofthehousing.
5.Ifremoved,insertthenewbearings(107)into
thecenterhousing.Useapressorablockand
rubbermallettopress-󰘰tthebearingsoitis󰘱at
withthesurfaceofthecenterhousing.
6.Overmolded Overmolded
OvermoldedDiaphragms Diaphragms Diaphragms(PO) (PO) (PO)
a.Clamptheshaft󰘱atsinavise.
b.Ifdiaphragmsetscrewcomeslooseoris
replaced,applypermanent(red)thread
lockertodiaphragmsidethreads.Screwinto
diaphragmuntiltight.
c.Assembletheairsideplate(11)andwasher
(17)ontothediaphragm.Theroundedside
oftheplatemustfacethediaphragm.
d.Applyprimerandmedium-strength(blue)
threadlockertothethreadsofthediaphragm
assembly.Screwtheassemblyintotheshaft
astightaspossiblebyhand.
e.Greasetheshaftu-cups(106*)andthe
lengthandendsofthediaphragmshaft
(108*).Slidetheshaftintothehousing.
f.Reattachone󰘱uidcover(3).Arrow(A)
mustpointtowardtheairvalve.See
TorqueInstructions,page18.
g.RepeatStepsb-dfortheotherdiaphragm
assemblyandinstallontheexposedendof
theshaft.
h.Tightenbyhandasmuchaspossible.Go
toStep8.
7.All All
AllOther Other OtherDiaphragms Diaphragms Diaphragms
a.Assemblethediaphragm(12),thebackup
diaphragm(13,ifpresent),theairside
diaphragmplate(11),andthewasher(17)
onthe󰘱uidsideplate(10)exactlyasshown.
b.Applyprimerandmedium-strength(blue)
threadlockertothethreadsofthescrewon
the󰘱uidsideplate.Screwtheassemblyinto
theshafthand-tight.
c.Greasetheshaftu-cups(106*)andthe
lengthandendsofthediaphragmshaft
(108*).Slidetheshaftintothehousing.
d.Repeatfortheotherdiaphragmassembly
andinstallontheexposedendoftheshaft.
e.Holdoneoftheplateswithawrench,
andtorquetheotherplateto65–70ft-lb
(88–95N•m)at100rpmmaximum.Donot
over-torque.
f.Reattachone󰘱uidcover(3).Arrow(A)
mustpointtowardtheairvalve.See
TorqueInstructions,page18.
3A2889D15

Repair
SP SP
SPand and andFK FK FKModels Models ModelsPO PO POModels Models Models
PT PT
PTModels Models Models
1
Roundedsidefacesdiaphragm
2
Applylithiumbasedgrease.
3
Applyprimerandmedium-strength(blue)thread
locker.Torqueto65-70ft-lb(88–95N•m).
4
AIRSIDEmarkingsondiaphragmmustface
centerhousing.
5
Ifscrewcomeslooseorisreplaced,apply
permanent(red)threadlockertodiaphragmside
threads.Applyprimerandmedium-strength(blue)
threadlockertoshaftsidethreads.
6
Lipsmustfaceoutofhousing.
7
Cartridges(109)mustbeinstalledbeforepilot
valves(111).
8
Torqueto20-25in.-lb(2-3N•m).
163A2889D

Repair
8.Toensureproperseatingandextenddiaphragm
life,applyairpressuretothepumppriorto
attachingthesecond󰘱uidcover.
a.Placethesuppliedtool(302)wheretheair
valvegasket(105)normallygoes.Arrows
(A)mustfacetowardthe󰘱uidcoverthatis
alreadyattached.
Figure2Fluidcovertool
b.Reattachtheairvalve.
c.Supplyaminimumof20psi(0.14MPa,1.4
bar)airpressuretotheairvalve.Shopair
maybeused.Thediaphragmwillshiftsothe
second󰘱uidcoverwillseatproperly.Keep
airpressureonuntilthesecond󰘱uidcover
isattached.
d.Attachthesecond󰘱uidcover(3).See
TorqueInstructions,page18.
e.Removetheairvalveandthetool(302),
replacethegasket(105),andreattachtheair
valve.SeeTorqueInstructions,page18.
NOTE: NOTE:
NOTE:Ifyouarereplacingthediaphragms
butnottheairvalve,youmustremovetheair
valveandgasket,putthetoolinplaceofthe
gasket,andputtheairvalvebackontoget
theairpressureneededforproperinstallation
ofthesecond󰘱uidcover.Rememberto
removethetoolandreplacethegasketwhen
󰘰nished.
f.Reassembletheballcheckvalves
andmanifoldsasexplainedin
CheckValveRepair,page13.
3A2889D17

TorqueInstructions
Torque Torque
TorqueInstructions Instructions Instructions
If󰘱uidcoverormanifoldfastenershavebeen
loosened,itisimportanttotorquethemusingthe
followingproceduretoimprovesealing.
NOTE: NOTE:
NOTE:Fluidcoverandmanifoldfastenershavea
thread-lockingadhesivepatchappliedtothethreads.
Ifthispatchisexcessivelyworn,thefastenersmay
loosenduringoperation.Replacescrewswithnew
onesorapplymedium-strength(blue)Loctiteor
equivalenttothethreads.
NOTE: NOTE:
NOTE:Alwayscompletelytorque󰘱uidcoversbefore
torquingmanifolds.
1.Startall󰘱uidcoverscrewsafewturns.Then,turn
downeachscrewjustuntilheadcontactscover.
2.Turneachscrewby1/2turnorlessworkingina
crisscrosspatterntospeci󰘰edtorque.
3.Repeatformanifolds.
Fluid Fluid
Fluidcover cover coverand and andmanifold manifold manifoldfasteners: fasteners: fasteners:190to220
in-lb(21to25Nm)
4.Retorquetheairvalvefastenersinacrisscross
patterntothespeci󰘰edtorque.
Air Air
Airvalve valve valvefasteners: fasteners: fasteners:45to55in-lb(5to6Nm)
5.Retorquethepilotvalvestothespeci󰘰edtorque.
Do Do
Donot not notovertorque. overtorque. overtorque.
Pilot Pilot
Pilotvalves: valves: valves:20to25in-lb(2to3Nm)
Fluid Fluid
FluidCover Cover CoverScrews Screws Screws
Inlet Inlet
Inletand and andOutlet Outlet OutletManifold Manifold ManifoldScrews Screws Screws
Air Air
AirValve Valve ValveScrews Screws Screwsand and andPilot Pilot PilotValves Valves Valves
183A2889D

Parts
Parts Parts
Parts
3A2889D19

Parts
Parts/Kits Parts/Kits
Parts/KitsQuick Quick QuickReference Reference Reference
Usethistableasaquickreferenceforparts/kits.Gotothepagesindicatedinthetableforafulldescriptionof
kitcontents.
Ref. Ref.
Ref.Part/Kit Part/Kit Part/KitDescription Description DescriptionQty. Qty. Qty.
124X348CenterHousingKit;
Polypropylene
1
10224B773AirValve; seepage24 1
FluidCoverKits; seepage
26
24W210Polypropylene
2
24W216PVDF
2
OutletManifoldKits; see
page26
24W232Polypropylene,center
󰘱ange
24W214Polypropylene,end󰘱ange
3
24W265PVDF,end󰘱ange
1
InletManifoldKits; see
page26
24W264Polypropylene,center
󰘱ange
24W215Polypropylene,end󰘱ange
4
24W266PVDF,end󰘱ange
1
524W213ManifoldFastenerKit;
see
page26
2
624W211FluidCoverFastenerKit;
seepage26
2
Seats;4-pack, seepage27
24W225Polypropylene
24W223PVDF
24W226Santoprene
7
24W227StainlessSteel
1
BALLS,valve,check;
4–pack; seepage27
24W230FKM
24W228PTFE
8
24W229Santoprene
1
Ref. Ref.
Ref.Part/Kit Part/Kit Part/KitDescription Description DescriptionQty. Qty. Qty.
924W212O-RING,seat;8–pack,
see
page30
1
FluidSideDiaphragm
Plate;
seepage29
24W221Polypropylene
10
24W222PVDF
2
1124W231AirSideDiaphragmPlate;
includeswasher(Ref.17);
seepage29
2
DiaphragmKits;2–pack,
seepages28to29
24W219FKMFluoroelastomer,
1–piece,bolt-through
24W218Santoprene,1–piece,
bolt-through
24W217PTFE/EPDMOvermolded;
includesscrew(Ref.14)
12
24W220PTFE/Santoprene2-Piece,
bolt-through;includes
backupdiaphragm(Ref.
13)
1
13———DIAPHRAGM,backup,
Santoprene
1
14———SCREW,set;includedwith
POdiaphragms(Ref.12).
15———NUT,includedwithRef.616
16———WASHER,includedwith
Ref.5andRef.6
40
17———WASHER,includedwith
Ref.11
1
18188621sLABEL,warning1
1924P932Muf󰘱er;includeso-ringand
mountinghardware
1
2016X034sTAG,torqueinstructions1
21198382sLABEL,warning,
multilingual
1
sReplacementWarninglabels,signs,tags,and
cardsareavailableatnocost.
203A2889D