Graco Husky 307 Operation manual

ACETAL AND POLYPROPYLENE
Husky™307 Air–Operated
Diaphragm Pumps
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 E
*Model No. D32 Polypropylene Pumps, Series E
*Model No. D3A Acetal BSPT Pumps, Series E
*Model No. D3B Polypropylene BSPT Pumps, Series E
* To determine the Model No. for your pump and for additional models, refer to the Pump Matrix
on page 26.
Patent No.
US 5,240,390
US 5,280,808
Instructions–Parts List
308553AF
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
01428B

2 308553
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service
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
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 100 psi (0.7 MPa, 7 bar) maximum working pressure at 100 psi
(0.7 MPa, 7 bar) maximum incoming air pressure.
DUse 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.
DDo not kink or overbend hoses or use hoses to pull equipment.
DRoute 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).
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
WARNING
WARNING
INSTRUCTIONS

308553 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.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
DPipe 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.
DTo 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.
DGround the equipment. Refer to Grounding on page 5.
DNever 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.
DIf 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.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being pumped.
DPipe 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.
DKeep the work area free of debris, including solvent, rags, and gasoline.
DElectrically disconnect all equipment in the work area.
DExtinguish all open flames or pilot lights in the work area.
DDo not smoke in the work area.
DDo not turn on or off any light switch in the work area while operating or if fumes are present.
DDo not operate a gasoline engine in the work area.
DKeep a fire extinguisher in the work area.
WARNING
WARNING

4 308553
Installation
General Information
DThe Typical Installations in Fig. 4 to Fig. 7 are only
guides for selecting and installing system compo-
nents. Contact your Graco distributor for assistance
in planning a system to suit your needs.
DAlways 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.
DUse 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.
DReference numbers and letters in parentheses refer
to the callouts in the Figures and the parts lists on
pages 28 to 29.
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 manu-
als. Read the fluid and solvent manufacturer’s
warnings.
WARNING
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 operat-
ing temperature range. Consult engineering guides
for chemical compatibilities and temperature limits,
or contact your Graco distributor.
CAUTION
Tightening Threaded Fasteners Before
First Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque Se-
quence, 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
DBe sure the mounting can support the weight of the
pump, hoses, and accessories, as well as the
stress caused during operation.
DThe 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).
DFor all other mountings, be sure the pump is ade-
quately secured.
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.

308553 5
Installation
Grounding
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before
operating the pump, ground the system
as explained at right. Also read the sec-
tion 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/me-
ter (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.
WARNING
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 equip-
ment.
Ground all of this equipment:
DPump: 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
of the ground wire to a true earth ground. Order
Part No. 222011 Ground Wire and Clamp.
NOTE: When pumping conductive flammable fluids
with a polypropylene 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
Y
112
27
29
28
01432B
DAir and fluid hoses: Use only electrically conductive
hoses.
DAir compressor: Follow the manufacturer’s recom-
mendations.
DSolvent 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.
DFluid supply container: Follow your local code.

6 308553
Installation
Air Line
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.
WARNING
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.
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 acces-
sories 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
DIf using a conductive (acetal) pump, use conductive
hoses. If using a non-conductive (polypropylene)
pump, ground the fluid system. See Grounding on
page 5.
DThe 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.
DAt inlet fluid pressures greater than 15 psi (0.1
MPa,1 bar), diaphragm life will be shortened.
DSee the Technical Data on pages 33 and 34 for
maximum suction lift and flow rate loss at various
lift distances.
Fluid Outlet Line
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.
DUse 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.
DInstall 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.
DInstall a fluid drain valve (J) near the fluid outlet.
See the WARNING above.

308553 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,
page 32. Do not over-torque.
Fig. 2
1
3
4
21/4 npt(f) air inlet
01459B
Apply thread lube, and torque to 50 to 60 in-lb
(5.6 to 6.8 N-m). See Torque Sequence, page
32. Do not over-torque.
3/8 npt(f) fluid inlet
3/8 npt(f) fluid outlet
53/8 npt(f) air exhaust port 1
2
3
5
4
Acetal Pump Shown
Fluid Pressure Relief Valve
CAUTION
Some systems may require installation of a pres-
sure 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 ambi-
ent 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.
Connect fluid outlet line here.
Fig. 3
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)
1
3
2Connect fluid inlet line here. Use a compat-
ible liquid thread sealant or PTFE tape on
connection to prevent air from getting into
the material line.
Install valve between fluid inlet and outlet ports.
C
A
B1
2
3
01539B
1

8 308553
Installation
Fig. 4
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)
H
J
STAND-MOUNTED AIR SPRAY INSTALLATION
01433B
A
C
D
G
K
L
M
NP
R
S
Y
F BE
Fig. 5
PAIL-MOUNTED HVLP AIR SPRAY INSTALLATION
01434B
H
J
A
C
DG
K
L
M
N
P
R
Y
S
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)
FBE

308553 9
Installation
Fig. 6
BUNG-MOUNT TRANSFER INSTALLATION
01444B
Y
J
C
N
L
FHBE
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)
M
AD
Fig. 7 01457B
WALL-MOUNT TRANSFER INSTALLATION
Y
J
NC
L
FHBE
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)
S
T
D
A

10 308553
Installation
Air Exhaust Ventilation
FIRE AND EXPLOSION HAZARD
Be sure to read FIRE OR 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 appropri-
ate container at the end of the air exhaust line to
catch the fluid. See Fig. 8.
WARNING
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.
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.
WARNING
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.
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.
01445A
Z
X
11

308553 11
Operation
Pressure Relief Procedure
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually relieved to
prevent the system from starting or spraying acci-
dentally. To reduce the risk of an injury from acci-
dental spray from the gun, splashing fluid, or mov-
ing parts, follow the Pressure Relief Procedure
whenever you
DAre instructed to relieve the pressure
DStop spraying
DCheck or service any of the system equipment
DInstall or clean the spray tips
WARNING
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 pres-
sure, having a container ready to catch the drain-
age.
Flush the Pump Before First Use
The pump was tested in water. If 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
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
1. Be sure the pump is properly grounded. Read
FIRE OR 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
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
At the end of the work shift, relieve the pressure.

12 308553
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
1. Relieve the pressure before checking or servicing
the equipment.
2. Check all possible problems and causes before
disassembling the pump.
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.

308553 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 com- patible 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.

14 308553
Maintenance
Lubrication
The air valve is designed to operate unlubricated,
however if lubrication is desired, every 500 hours of
operation (or monthly) remove the hose from the pump
air inlet and add two drops of machine oil to the air
inlet.
CAUTION
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
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
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 lubri-
cant to the bolts and be sure to torque the nuts (113)
to 50 to 60 in-lb (5.6 to 6.8 NSm). See Fig. 9. See
Torque Sequence, page 32.
01446B
Fig. 9
1
111
Apply thread lube and torque nuts to 50 to 60 In-lb
(5.6 to 6.8 NSm). See Torque Sequence, page 32.
1113
Preventive Maintenance Schedule
Establish a preventive maintenance schedule, based
on the pump’s service history. This is especially impor-
tant for prevention of spills or leakage due to dia-
phragm failure.

308553 15
Notes

16 308553
Service
Replacing the Air Valve
Tools Required
DTorque wrench
DPhillips screwdriver
DO-ring pick
NOTE: Air Valve Kit 239952 is available. Parts
included in the kit are marked with a dagger, for exam-
ple (2{). A tube of general purpose grease (26{) is
supplied in the kit. Install the kit as follows.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
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).

308553 17
Service
01436B
Fig. 10
1
3
2
{21
01458
1
VALVE PLATE DETAIL
GREASE APPLICATION
19{
15
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{).
3
112
1
2
4
4
9{
12
13
10
A
{14
21{
{16
03412A
19{
3
3
3
3

18 308553
Service
Repairing the Air Valve
Tools Required
DTorque wrench
DPhillips screwdriver
DO-ring pick
DRubber mallet
Disassembly
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
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, page 19.
Fig. 11
NOTE: ALL PARTS SHOWN ARE INCLUDED
IN AIR VALVE KIT 239952.
01431A
{2
7{
{4
{18
{16
{20
{21
{22
{17
{14
{15
{3
5{
8{
6{
19{

308553 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
1
2
01437
{18
2{
6{
{8
7{
{21
Apply grease (26{).
Press fit with rubber
mallet.
{20
1
1
1
1
2
H
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
{17
{3
1
3
2
{16
2{
4{
8{
5{
{22
Apply grease (26{).
Bumps face up.
Reset shaft square must engage
with square hole.
2
3
1
1
1
2
7505A
1
1
1

20 308553
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.
Fig. 14
1
2
Apply grease (26{).
Torque to 7 to 9 in-lb (0.8 to 1.0 N-m).
{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 hous-
ings, damaging the cover (101).