Graco Husky 307 F Series Operation manual

01428B
Instructions - Parts List
ACETAL AND POLYPROPYLENE
Husky307 Air-Operated
Diaphragm Pumps 308553ZAE
EN
For pumping transfer applications. For professional use only.
Only pumps with acetal fluid sections are approved for use in European explosive
atmosphere locations.
100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure
*Model No. D31 ___ Acetal Pumps**, Series F
*Model No. D32 ___ Polypropylene Pumps, Series F
*Model No. D3A ___ Acetal BSPT Pumps**, Series F
*Model No. D3B ___ Polypropylene BSPT Pumps, Series F
* To determine the Model No. for your pump and for additional models, refer to the Pump Matrix on page 26.
** Pumps with Acetal fluid sections are certified:
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
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 beingpumped. 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.
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2 308553ZAE
Table of Contents
Warnings .........................................................2
Installation......................................................4
Operation......................................................11
Troubleshooting ..........................................12
Maintenance.................................................14
Service..........................................................16
Replacing the Air Valve.........................16
Repairing the Air Valve .........................18
Ball Check Valves..................................21
Diaphragm Repair..................................23
Pump Matrix.................................................26
Additional Diaphragm Pumps........................26
Repair Kit Matrix..........................................27
Parts..............................................................28
Torque Sequence ........................................32
Technical Data and Performance Charts ......33
Dimensions ..................................................35
Graco Warranties ..........................................36
Graco Information .......................................36
Symbols
Warning Symbol
Caution Symbol
WARNING
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.
WARNING
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.
•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 100 psi (7 bar) maximum working pressure at 100 psi (0.7 MPa, 7 bar)
maximum incoming air pressure.
•Use fluids and solvents that are compatiblewith the equipment wetted parts. Refer to the Technical
Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
•Do not kink or overbend hoses or 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.
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308553ZAE 3
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
• 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 10.
• To pump acids, always use a polypropylene pump. Take precautions to avoid acid or acid fumes
from contacting the pump housing exterior. Stainless steel parts will be damaged by exposure to
acid spills and fumes. Never use an acetal pump to pump acids.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and result
in a fire or explosion and serious injury.
•Ground all equipment. Refer to Grounding on page 5.
•Never use a polypropylene pump with non-conductive flammable fluids as specified by your local
fire protection code. Refer to Grounding on page 5 for additional information. Consult your fluid
supplier to determine the conductivity or resistivity of your fluid.
•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 10.
•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.
•Keep a fire extinguisher in the work area.
WARNING
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4 308553ZAE
Installation
General Information
The Typical Installations in FIG. 4 to FIG. 7 are only
guides 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,
available from your Graco distributor. Refer to the
Product Data Sheet for the pump, Form No. 305528
(acetal pumps) or 305543 (polypropylene pumps). If
you supply your own accessories, be sure they are
adequately sized and pressure rated for your system.
Use a compatible, liquid thread sealant or PTFE tape
on all male threads. Tighten all connections firmly to
avoid air or fluid leaks. Do not over-tighten plastic
threads.
Reference numbers and letters in parentheses refer to
the callouts in the Figures and the parts lists on pages
28 to 29.
Tightening Threaded Fasteners
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.
Mountings
Be sure the mounting can support the weight of the
pump, hoses, and accessories, as well as the stress
caused during operation.
The Husky 307 Pump can be used in a variety of
installations, some of which are shown in FIG. 4 to FIG.
7. Kits are available to adapt your pump to your
system. Refer to the Product Data Sheet for the
pump, Form No. 305528 (acetal pumps) or 305543
(polypropylene pumps).
For all other mountings, be sure the pump is
adequately secured.
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.
Dual Manifolds
Dual manifold kits are available to enable you to pump two
fluids simultaneously, or to mix two fluids in the pump.
Order Part No. 237211 for acetal pumps and Part No.
237210 for polypropylene pumps.
WARNING
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause
serious injury or death if splashed in the
eyes or on the skin, inhaled, or swallowed.
1. Read TOXIC FLUID HAZARD on page 3.
2. Use fluids and solvents which are compatible
with the equipment wetted parts. Refer to the
Technical Data section of all equipment
manuals. Read the fluid and solvent
manufacturer’s warnings.
CAUTION
Safe Operating Temperature
Minimum: 40 F (4.4 C); Maximum: 150 F (66 C).
Operating outside these temperature limits will
adversely affect the strength of the pump housing.
Certain chemicals may further reduce the operating
temperature range. Consult engineering guides for
chemical compatibilities and temperature limits, or
contact your Graco distributor.
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308553ZAE 5
Installation
Grounding
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.
Ground all of this equipment:
Pump: Attach a ground wire (Y) to the grounding strip
(112) with the screw (28), lockwasher (29) and nut
(27), as shown in FIG. 1. Connect the clamp end ofthe
ground wire to a true earth ground. Order Part No.
222011 Ground Wire and Clamp.
NOTE: When pumping conductive flammable fluids with
a polypropylene pump, always ground the fluid system.
See the WARNING at left. FIG. 4 through FIG. 7 show
recommended methods of grounding flammable fluid
containers during filling.
FIG. 1 ____________________
Air and fluid hoses: Use only electrically conductive
hoses.
Air compressor: Follow the manufacturer’s
recommendations.
Solvent pails used when flushing: Follow your local
code. Use only metal pails, which are conductive. Do
not place the pail on a non-conductive surface, such
as paper or cardboard, which interrupts the grounding
continuity.
Fluid supply container: Follow your local code.
WARNING
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before
operating the pump, ground the system as
explained at right. Also read the section
FIRE AND EXPLOSION HAZARD on
page 3.
The acetal pump contains stainless steel fibers, which
makes the wetted parts conductive. Attaching the
ground wire to the grounding strip grounds the air
motor and the wetted parts.
The polypropylene pump is not conductive.
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. 4 through FIG. 7). Never use a
polypropylene 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.
Y
112
27
29
28
01432B
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6 308553ZAE
Installation
Air Line
1. Install the air line accessories as shown in FIG. 4 to
FIG. 7. Mount these accessories on the wall or on a
bracket. Be sure the air line supplying the
accessories is grounded.
a. The fluid pressure can be controlled in either of
two ways. To control it on the air side, install an
air regulator (H). To control it on the fluid side,
install a fluid regulator (M) near the pump fluid
outlet (see FIG. 5).
b. Locate one bleed-type master air valve (B) close
to the pump and use it to relieve trapped air. See
the WARNING above. Locate the other master
air valve (E) upstream from all air line
accessories and use it to isolate them during
cleaning and repair.
c. The air line filter (F) removes harmful dirt and
moisture from the compressed air supply.
2. Install an electrically conductive, flexible air hose (C)
between the accessories and the 1/4 npt(f) pump air
inlet (see FIG. 2). Use a minimum 1/4” (6.3 mm) ID air
hose. Screw an air line quick disconnect coupler (D)
onto the end of the air hose (C), and screw the
mating fitting into the pump air inlet snugly. Do not
connect the coupler (D) to the fitting yet.
Fluid Suction Line
If using a conductive (acetal) pump, use conductive
hoses. If using a non-conductive (polypropylene)
pump, ground the fluid system. See Grounding on
page 5.
The pump fluid inlet is 3/8 npt(f). See FIG. 2.
Screw the fluid fitting into the pump inlet snugly. Use a
compatible liquid thread sealant or PTFE tape on
connections to prevent air from getting into material
line.
At inlet fluid pressures greater than 15 psi (0.1 MPa,1
bar), diaphragm life will be shortened.
See the Technical Data on pages 33 and 34 for
maximum suction lift and flow rate loss at various lift
distances.
Fluid Outlet Line
Use electrically conductive fluid hoses (N). The pump
fluid outlet is 3/8 npt(f). See FIG. 2. Screw the fluid
fitting into the pump outlet snugly.
Install a fluid regulator (M) at the pump fluid outlet to
control fluid pressure, if desired (see FIG. 5). See Air
Line, step 1a, for another method of controlling
pressure.
Install a fluid drain valve (J) near the fluid outlet. See
the WARNING above.
WARNING
A bleed-type master air valve (B) is required in your
system to relieve air trapped between this valve and
the pump. See FIG. 4 to FIG. 7. 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.
CAUTION
The pump exhaust air may contain contaminants.
Ventilate to a remote area if the contaminants could
affect your fluid supply. See Air Exhaust Ventilation
on page 10.
WARNING
A fluid drain valve (J) is required in your system to
relieve pressure in the hose if it is plugged. See FIG. 4
to FIG. 7. 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.
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308553ZAE 7
Installation
Changing the Orientation of the Fluid Inlet and
Outlet Ports
The pump is shipped with the fluid inlet and outlet ports
facing the same direction. See FIG. 2. If desired, the
direction of one or both ports can be changed. Remove
the manifold(s) from the pump as explained in steps 1, 2,
and 4 on page 21. Reattach with the port facing the
desired direction. See Torque Sequence on page 32. Do
not over-torque.
Acetal Pump Shown
FIG. 2 _____________________
Fluid Pressure Relief Valve
KEY
A 3/8 npt(f) fluid inlet port
B 3/8 npt(f) fluid outlet port
C Pressure relief valve
Part No. 112119 (stainless steel)
FIG. 3_____________________
01459B
1
2
3
5
4
Apply thread lube, and torque to 50 to 60 in-lb
(5.6 to 6.8 N-m). See Torque Sequence on
page 32. Do not over-torque.
1/4 npt(f) air inlet
3/8 npt(f) fluid inlet
3/8 npt(f) fluid outlet
3/8 npt(f) air exhaust port
1
2
3
4
5
CAUTION
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. 3.
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.
Install valve between fluid inlet and outlet ports.
Connect fluid inlet line here. Use a compatible
liquid sealant or PTFE tape on connection to
prevent air from getting into the material line.
Connect fluid inlet line here.
1
2
3
C
A
B1
2
3
01539B
1
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8 308553ZAE
01434B
H
J
A
C
DG
K
L
M
N
P
R
Y
S
F
BE
H
J
01433B
A
C
D
G
K
L
M
NP
R
S
Y
F BE
Installation
STAND-MOUNTED AIR SPRAY INSTALLATION
KEY
A Husky 307 Pump
B Bleed-Type Master Air Valve
(required for pump)
C Air Supply Hose
D Air Line Quick Disconnect
E Master Air Valve (for accessories)
F Air Line Filter
G Gun Air Regulator
H Pump Air Regulator
J Fluid Drain Valve (required)
K Fluid Recirculation Line
L Fluid Suction Line
M Surge Tank and Filter
N Fluid Supply Hose
P Gun Air Supply Hose
R Air Spray Gun
S Floor Stand
Y Ground Wire (required; see page 5 for installation
instructions)
FIG. 4 _______________________________________________
PAIL-MOUNTED HVLP AIR SPRAY INSTALLATION
KEY
A Husky 307 Pump
B Bleed-Type Master Air Valve (required for pump)
C Air Supply Line
D Air Line Quick Disconnect
E Master Air Valve (for accessories)
F Air Line Filter
G Gun Air Regulator
H Pump Air Regulator
J Fluid Drain Valve (required)
K Agitator
L Fluid Suction Line
M Fluid Regulator
N Fluid Supply Hose
P Gun Air Supply Hose
R HVLP Air Spray Gun
S Pail Cover
Y Ground Wire (required; see page 5 for installation
instructions)
FIG. 5 _______________________________________________
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308553ZAE 9
Installation
BUNG-MOUNT TRANSFER INSTALLATION
FIG. 6 _____________________
WALL-MOUNT TRANSFER INSTALLATION
FIG. 7_____________________
01444B
Y
J
C
N
L
FHBE
M
AD
01457B
Y
J
NC
L
FHBE
S
T
D
A
KEY
A Husky 307 Pump
B Bleed-Type Master Air Valve
(required for pump)
C Air Supply Line
D Air Line Quick Disconnect
E Master Air Valve (for accessories)
F Air Line Filter
H Pump Air Regulator
J Fluid Drain Valve (required)
L Fluid Suction Line
M Fluid Inlet Filter
N Fluid Supply Hose
Y Ground Wire (required; see page 5
for installation instructions)
KEY
A Husky 307 Pump
B Bleed-Type Master Air Valve
(required for pump)
C Air Supply Line
D Air Line Quick Disconnect
E Master Air Valve (for accessories)
F Air Line Filter
H Pump Air Regulator
J Fluid Drain Valve (required)
L Fluid Suction Line
N Fluid Supply Hose
S Wall Bracket
T Bung Adapter
Y Ground Wire (required; see page 5
for installation instructions)
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10 308553ZAE
Installation
Air Exhaust Ventilation
The air exhaust port is 3/8 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
erratic pump operation.
To exhaust to a remote location:
1. Remove the muffler (11) from the pump air exhaust
port.
2. Install an electrically conductive air exhaust hose (X)
and connect the muffler to the other end of the hose.
The minimum size for the air exhaust hose is 3/8 in.
(10 mm) ID. If a hose longer than 15 ft (4.57 m) is
required, use a larger diameter hose. Avoid sharp
bends or kinks in the hose.
3. Place a container (Z) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures. If the
fluid is flammable, ground the container. See FIG. 8.
VENTING EXHAUST AIR (Submerged Installation Shown)
See FIG. 4 for accessories
In a submerged installation (as shown), all wetted and non-wetted pump parts
must be compatible with the fluid being pumped.
FIG. 8 _______________________________________________
WARNING
FIRE AND EXPLOSION HAZARD
Be sure to read FIRE AND EXPLOSION
HAZARD and TOXIC FLUID HAZARD on
page 3, before operating this pump.
Be sure the system is properly ventilated
for your type of installation. You must vent
the exhaust to a safe place, away from
people, animals, food handling areas, and
all sources of ignition when pumping
flammable or hazardous fluids.
Diaphragm failure will cause the fluid being pumped to
exhaust with the air. Place an appropriate container at
the end of the air exhaust line to catch the fluid. See
FIG. 8.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of serious eye injury
from ice particles, never operate the
pump with the air exhaust port open. Ice
may form during pump operation, and ice particles
will be ejected from the port along with the exhaust
air. If the muffler (11) is removed, always connect an
air exhaust hose to the exhaust port.
01445A
Z
X
11
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308553ZAE 11
Operation
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 in water. If 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. Read FIRE
AND EXPLOSION HAZARD on page 3.
2. Check all fittings to be sure they are tight. Be sure to
use a compatible liquid thread sealant or PTFE tape
on all male threads. Tighten the fluid inlet and outlet
fittings snugly. Do not overtighten the fittings into the
pump.
3. Place the suction tube (if used) in the fluid to be
pumped.
4. Place the end of the fluid hose (N) into an appropriate
container. Close the fluid drain valve (J).
5. With the pump air regulator (H) closed, open all
bleed-type master air valves (B, E).
6. If the fluid hose has a dispensing device, hold it open
while continuing with the following step. Slowly open
the air regulator (H) until the pump starts to cycle.
Allow the pump to cycle slowly until all air is pushed
out of the lines and the pump is primed.
If you are flushing, run the pump long enough to
thoroughly clean the pump and hoses. Close the air
regulator. Remove the suction tube from the solvent
and place it in the fluid to be pumped.
Pump Shutdown
At the end of the work shift, relieve the pressure.
WARNING
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually relieved to
prevent the system from starting or spraying
accidentally. To reduce the risk of an injury from
accidental spray from the gun, splashing fluid, or
moving parts, follow the Pressure Relief Procedure
whenever you
Are instructed to relieve the pressure
Stop spraying
Check or service any of the system equipment
Install or clean the spray tips
WARNING
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause
serious injury or death if splashed in the
eyes or on the skin, inhaled, or swallowed.
Do not lift a pump under pressure. If dropped, the
fluid section may rupture. Always follow the Pressure
Relief Procedure above before lifting the pump.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
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12 308553ZAE
Troubleshooting
1. Relieve the pressure before checking or servicing
the equipment.
2. Check all possible problems and causes before
disassembling the pump.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
PROBLEM CAUSE SOLUTION
The pump will not cycle, or cycles
once and stops. The air valve is stuck or dirty. Turn the reset shaft (21).
Disassemble and clean the air valve.
See pages 18, 19.
Use filtered air.
The detent link (22) is worn or
broken. Replace the detent link (22) and ball (8). See pages 18, 19.
The springs (3, 6) and/or valve cup
(5) and plate (13) are broken or
damaged.
Replace these parts.
See pages 18, 19.
The pump cycles at stall or fails to
hold pressure at stall. The check valves or o-rings (108) are leaking. Replace these parts. See page 21.
The check balls (301) or seat (201)
are worn. Replace these parts. See page 21.
The check ball (301) is wedged in the
seat (201). Replace the ball. See page 21.
There is excessive air leakage from
the exhaust port. The air valve cup (5) or plate (13) is worn. Replace these parts. See pages 18, 19.
The shaft seals (30‡) are worn. Replace the seals.
See page 23.
The pump operates erratically. The suction line is clogged. Inspect; clear the line.
The check valve balls (301) are
sticking or leaking. Clean or replace the balls. See page 21.
The diaphragm (401) is ruptured. Replace the diaphragm.
See page 23.
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308553ZAE 13
Troubleshooting
PROBLEM CAUSE SOLUTION
There are air bubbles in the fluid. The suction line is loose, or there is a
lack of thread sealant. Tighten the suction line. Use a compatible liquid thread sealant or
PTFE tape on connections.
The diaphragm (401) is ruptured. Replace the diaphragm.
See page 23.
The manifolds (102) are loose or the
o-rings (108) are damaged. Tighten the manifold bolts (104) or nuts (106); replace the o-rings (108).
See page 21.
The outer diaphragm plates (103) are
loose. Tighten the plates. See page 23.
There is fluid in the exhaust air. The diaphragm (401*) is ruptured. Replace the diaphragm.
See page 23.
The outer diaphragm plates (103) are
loose. Tighten the plates. See page 23.
The pump exhausts air at stall. The air valve cup (5) or plate (13) is
worn. Replace these parts. See pages 18, 19.
The shaft seals (30‡) are worn. Replace the seals.
See page 23.
The pump exhausts air from the
clamps. The clamps (111) are loose. Tighten the clamp nuts (113). See page 14.
The pump exhausts air near the air
valve. The air valve screws (15) are loose. Tighten the screws. See page 16.
The air valve o-ring (19) is damaged. Inspect; replace the o-ring.
See pages 18, 19.
The pump leaks fluid from the check
valves. The o-rings (108) are worn or damaged. Inspect; replace the o-rings. See page 21.
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14 308553ZAE
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.
Flushing and Storage
Flush the pump when necessary to prevent the fluid you
are pumping from drying or freezing in the pump and
damaging it. Use a compatible solvent.
Before storing the pump, always flush the pump and
relieve the pressure.
Tightening Threaded Connections
Before each use, check all hoses for wear or damage,
and replace as necessary. Check to be sure all threaded
connections are tight and leak-free.
Check fasteners. Tighten or retorque as necessary.
Although pump use varies, a general guideline is to
retorque fasteners every two months. See Torque
Sequence, page 32.
Tightening the Clamps
When tightening the clamps (111), apply thread lubricant
to the bolts and be sure to torque the nuts (113) to 50 to
60 in-lb (5.6 to 6.8 Nm). See FIG. 9. See Torque
Sequence on page 32.
FIG. 9 ____________________
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.
CAUTION
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.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
01446B
111
1113
Apply thread lube and torque nuts to 50 to 60 In-lb
(5.6 to 6.8 Nm). See Torque Sequence on
page 32.
1
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308553ZAE 15
Notes
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16 308553ZAE
Service
Replacing the Air Valve
Tools Required
Torque wrench
Phillips screwdriver
O-ring pick
NOTE: Air Valve Kit 239952 is available. Parts included
in the kit are marked with a dagger, for example (2†). A
tube of general purpose grease (26†) is supplied in the
kit. Install the kit as follows.
1. Relieve the pressure.
2. Unscrew the six mounting screws (15) and remove
the air valve (A) from the pump. See FIG. 10.
3. Refer to the Valve Plate Detail in FIG. 10. Remove
the two screws (10) holding the valve plate (13) to the
pump. Use an o-ring pick to remove the valve plate,
seal (12), and bearing (9).
4. Apply grease (26†) to the bearing (9†). Install the
bearing and the seal (12) in the pump housing (1).
Install the valve plate (13) and secure with the two
screws (10†), as shown. Torque the screws to 5 to 7
in-lb (0.6 to 0.8 N-m).
5. Make certain the o-ring (19†) is in place on the air
valve cover (2†).
6. Apply grease (26†) where shown in FIG. 10.
7. Align the new air valve assembly so the reset shaft
(21†) is at the top. Install the valve on the pump,
making sure the valve saddle (14†) engages the
recessed area on the diaphragm shaft (23). Install
the six screws (15) and torque oppositely and evenly,
to 8 to 14 in-lb (0.9 to 1.6 N-m).
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
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308553ZAE 17
Service
FIG. 10 _______________________________________________
01436B
21
01458
1
19
15
3
112
1
2
4
4
9
12
13
10
A
14 21
16
03412A
19
3
3
3
3
VALVE PLATE DETAIL
GREASE APPLICATION
Torque oppositely and evenly to 8 to 14 in-lb (0.9 to 1.6 N-m).
Torque to 5 to 7 in-lb (0.6 to 0.8 N-m).
Apply grease (26†).
1
2
3
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18 308553ZAE
Service
Repairing the Air Valve
Tools Required
Torque wrench
Phillips screwdriver
O-ring pick
Rubber mallet
Disassembly
1. Relieve the pressure.
2. Remove the air valve from the pump (see page 16).
3. Remove the screw (15) and shift saddle (14). See
FIG. 11.
4. Disassemble the link assembly, consisting of the
actuator link (16), spacer (17), detent link (22), spring
(3), stop (4), and valve cup (5).
5. Remove the detent ball (8) and spring (6). The detent
collar (7) is a press-fit and should not need removal;
if it does require replacement, you should also
replace the cover (2).
6. Remove the reset shaft (21), o-ring (20) and washer
(18).
7. Clean all parts and inspect for wear or damage.
Replace as needed. See Reassembly on page 19.
FIG. 11 _______________________________________________
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
01431A
2
7
4
18
16
20
21
22
17
14
15
35
8619
NOTE: ALL PARTS SHOWN ARE INCLUDED IN AIR
VALVE KIT 239952.
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308553ZAE 19
Service
Reassembly
1. If the detent collar (7) was removed, carefully install a
new collar in a new cover (2), using a rubber mallet.
See FIG. 12.
2. Grease the spring (6) and place it in the collar (7).
Grease the ball (8) and set it on the spring.
3. Grease the o-ring (20) and install it in the hole (H) in
the cover (2). See FIG. 12. Slide the washer (18) onto
the blunt end of the reset shaft (21). Insert the shaft
through the cover (2) until it seats.
4. Grease the spring (3). Place the link stop (4) inside
the spring.
FIG. 12 ____________________
5. Grease the detent link (22) and link spacer (17).
Assemble the detent link, link spacer, and actuator
link (16) as shown in FIG. 13. The raised bumps on
the links (22 and 16) must face up.
6. Squeeze the spring (3) and install it and the stop (4)
in the link assembly. The spring tension will hold all
these parts together. Grease the valve cup (5) and
install it in the link assembly as shown.
7. Install the link assembly on the cover (2) so the
pointed end of the reset shaft (21) fits through the
holes in the links and the square part of the shaft
engages the square hole. Make certain the bumps on
the detent link (22) engage the ball (8).
FIG. 13 ____________________
01437
18
2
6
8
7
21
20
1
1
11
2
H
Apply grease (26†).
Press fit with rubber
mallet.
1
2
17
3
16
2
48
5
22
2
3
1
1
1
2
7505A
1
1
1
Apply grease (26†).
Bumps face up.
Reset shaft square must engage
with square hole.
1
2
3
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20 308553ZAE
Service
8. Grease the inside surfaces of the shift saddle (14)
and install it as shown in FIG. 14. Hold the link
assembly firmly in place and install the screw (15).
Torque to 7 to 9 in-lb (0.8 to 1.0 N-m). Install the
o-ring (19) on the cover (2).
9. Reinstall the air valve as explained on page 16.
Apply grease (26†).
Torque to 7 to 9 in-lb (0.8 to 1.0 N-m).
FIG. 14 _______________________________________________
1
2
2
22
5
19
14
15
21
1
1
1
1
2
7506A
CAUTION
Do not over-torque the manifold bolts (104). Doing so
may cause the nuts (106) to spin in the housings,
damaging the cover (101).
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