Graco Husky 3300e Use and care manual

Repair/Parts
Husky™ Husky™
Husky™3300e 3300e 3300e
Electric Electric
Electric- - -Operated Operated OperatedDiaphragm Diaphragm DiaphragmPump Pump Pump3A7037G 3A7037G
3A7037G
EN EN
EN
3 3
3- - -Inch Inch Inchpumps pumps pumpswith with withelectric electric electricdrive drive drivefor for for󰘱uid 󰘱uid 󰘱uidtransfer transfer transferapplications. applications. applications.
Not Not
Notapproved approved approvedfor for foruse use usein in inexplosive explosive explosiveatmospheres atmospheres atmospheresor or orhazardous hazardous hazardouslocations locations locationsunless unless unlessotherwise otherwise otherwisestated. stated. stated.For For For
professional professional
professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
ReadallwarningsandinstructionsinthismanualandinyourHusky
3300eOperationmanual.Save Save
Savethese these theseinstructions. instructions. instructions.
Maximumworkingpressure:80psi
(0.55MPa,5.5bar)
Seepage7forapprovals.
PROVENQUALITY.LEADINGTECHNOLOGY.
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Contents Contents
Contents
Related Related
RelatedManuals Manuals Manuals. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .2 2 2
Warnings Warnings
Warnings. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .3 3 3
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrix. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .6 6 6
Ordering Ordering
OrderingInformation Information Information. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .8 8 8
Troubleshooting Troubleshooting
Troubleshooting. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .9 9 9
Repair Repair
Repair. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .11 11 11
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .11 11 11
Check Check
CheckValve Valve ValveRepair Repair Repair. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .11 11 11
Standard Standard
StandardDiaphragm Diaphragm DiaphragmReplacement Replacement Replacement. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .13 13 13
Center Center
CenterSection Section SectionRepair Repair Repair. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .15 15 15
Leak Leak
LeakSensor Sensor SensorRepair Repair Repair. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .19 19 19
Replace Replace
Replacethe the theCompressor Compressor Compressor. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .20 20 20
Torque Torque
TorqueInstructions Instructions Instructions. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .21 21 21
Torque Torque
Torquesequence sequence sequence. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .21 21 21
Parts Parts
Parts. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .24 24 24
Kits Kits
Kitsand and andAccessories Accessories Accessories. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .34 34 34
Technical Technical
TechnicalData Data Data. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .35 35 35
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
3A7036Husky™3300eElectric-OperatedDiaphragmPump,Operation
23A7037G
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Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
DANGER
SEVERE SEVERE
SEVEREELECTRIC ELECTRIC ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentcanbepoweredbymorethan240V.Contactwiththisvoltagewill
causedeathorseriousinjury.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesand
beforeservicingequipment.
•Thisequipmentmustbegrounded.Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocal
codesandregulations.
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reand
explosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
•Donotoperateelectrostaticgunsinequipmentworkarea.
3A7037G3
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Warnings
WARNING
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.
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,requestSafetyDataSheet(SDS)fromdistributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
PRESSURIZED PRESSURIZED
PRESSURIZEDALUMINUM ALUMINUM ALUMINUMPARTS PARTS PARTSHAZARD HAZARD HAZARD
Useof󰘱uidsthatareincompatiblewithaluminuminpressurizedequipmentcancauseserious
chemicalreactionandequipmentrupture.Failuretofollowthiswarningcanresultindeath,
seriousinjury,orpropertydamage.
•Donotuse1,1,1-trichloroethane,methylenechloride,otherhalogenatedhydrocarbon
solventsor󰘱uidscontainingsuchsolvents.
•Donotusechlorinebleach.
•Manyother󰘱uidsmaycontainchemicalsthatcanreactwithaluminum.Contactyourmaterial
supplierforcompatibility.
43A7037G
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Warnings
WARNING
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’sSafetyDataSheet(SDS)andrecommendations.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•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.
3A7037G5
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CongurationNumberMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrix
Checktheidenti󰘰cationplate(ID)forthe
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:3300A 3300A
3300A- - -EA04AA1TPTPTP EA04AA1TPTPTP EA04AA1TPTPTP- - -- - -
3300 3300
3300A A
AE E EA A A04 04
04A A
AA1 A1
A1TP TP
TPTP TP TPTP TP TP- -
-- - -
Pump
Model
Wetted
Section
Material
DriveCenter
Section
Material
GearBox
andCom-
pressor
MotorFluidCoversand
Manifolds
SeatsBallsDiaphragmsManifold
O-Rings
NOTE: NOTE:
NOTE:Somecombinationsarenotpossible.PleaserefertoOrderingInformation,page8.
Pump Pump
PumpWetted Wetted
WettedSection Section Section
Material Material
Material
Drive Drive
DriveType Type TypeCenter Center
CenterSection Section Section
Material Material
Material
Gearbox Gearbox
Gearboxand and and
Compressor Compressor
Compressor
Motor Motor
Motor
3300 3300
3300A A
AAluminumE E EElectricA A AAluminum94 94
94NoGearboxor
CompressorA A
AStandard
InductionMotor
P P
PPolypropylene04 04
04HighSpeedGear
RatioC C
CATEXInduction
Motor
S S
SStainlessSteel06 06
06HighSpeed
GearRatio/240V
Compressor
D D
DFlameproof
InductionMotor
G G
GNoMotor
63A7037G
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CongurationNumberMatrix
Fluid Fluid
FluidCovers Covers Coversand and and
Manifolds Manifolds
Manifolds
Seat Seat
SeatMaterial Material MaterialBall Ball
BallMaterial Material MaterialDiaphragm Diaphragm DiaphragmMaterial Material MaterialManifold/Seat Manifold/Seat
Manifold/Seat
O O
O- - -Rings Rings Rings
A1 A1
A1Aluminum,
center󰘱ange,
npt
AC AC
ACAcetalAC AC ACAcetalGE GE GEGeolast– –
–– – –Modeldoes
notuse
o-rings*
A2 A2
A2Aluminum,
center󰘱ange,
bspt
AL AL
ALAluminumBN BN BNBuna-NPT PT PTPTFE/EPDM
2–PieceBN BN
BNBuna-N
P1 P1
P1Polypropylene,
center󰘱angeBN BN
BNBuna-N*CR CR
CRPolychloropreneSP SP SPSantopreneFK FK
FKFKMFluoroe-
lastomer
S1 S1
S1Stainlesssteel,
nptFK FK
FKFKMFluoroe-
lastomer*CW CW
CWPolychloroprene
WeightedTP TP
TPTPEPT PT PTPTFE
S2 S2
S2Stainlesssteel,
bsptGE GE
GEGeolastFK FK
FKFKM
Fluoroelastomer
S51 S51
S51Stainlesssteel,
center󰘱angePP PP
PPPolypropy-
leneGE GE
GEGeolast
SP SP
SPSantoprenePT PT
PTPTFE
SS SS
SS316Stainless
SteelSP SP
SPSantoprene
TP TP
TPTPE*TP TP TPTPE
*ModelswithBuna-N,FKM,orTPEseatsdonothavemanifold/seato-rings.
Approvals Approvals
Approvals
✦Aluminumandstainlesssteelpumpswith
motorcodeCarecerti󰘰edto:
II2GExhdIIBT3Gb
✚Aluminumandstainlesssteelpumpswith
motorcodeGarecerti󰘰edto:
II2GExhIIBT3Gb
★MotorscodedDarecerti󰘰edto:
ClassI,Div1,GroupD,T3B
ClassII,Div1,GroupF&G,T3B
AllModels(exceptgearboxandcompressor
code05ormotorcodeD)aremarked:
3A7037G7
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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 DistributorLocator. Locator. Locator.
To To
ToSpecify Specify Specifythe the theCon󰘰guration Con󰘰guration Con󰘰gurationof of ofa a aNew New NewPump Pump Pump
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
OR OR
OR
UsetheOnline Online
OnlineDiaphragm Diaphragm DiaphragmPump Pump PumpSelector Selector SelectorTool Tool Toolat at atwww.graco.com www.graco.com www.graco.com. . .SearchforSelector. Selector. Selector.
To To
ToOrder Order OrderReplacement Replacement ReplacementParts Parts Parts
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
83A7037G
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Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
•FollowthePressureReliefProcedure,page11,
beforecheckingorservicingtheequipment.
•Checkallpossibleproblemsandcausesbefore
disassembly.
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Pumpisrunningtoofast,causing
cavitationbeforeprime.
Slowdownthecontroller(VFD)
Centersectionhasnoairpressure,
orairpressureistoolow.
Applyairpressuretocentersection
peryourapplicationrequirements.
Checkvalveballisseverelywornor
wedgedinseatormanifold.
Replacetheballandseat.
Thepumphasinsuf󰘰cientsuction
pressure.
Increasethesuctionpressure.See
theOperationmanual.
Seatisseverelyworn.Replacetheballandseat.
Outletorinletisrestricted.Removetherestriction.
Inlet󰘰ttingsormanifoldsareloose.Tighten.
Pumpcyclesbutwillnotprime
and/orpump.
Manifoldo-ringsaredamaged.Replaceo-rings.
Thecentersectionisexcessively
hot.
Thedriveshaftisbroken.Replace.
Checkvalveballs,seats,oro-rings
areworn.
Replace.
Manifoldscrewsor󰘱uidcover
screwsareloose.
Tighten.
Pumpfailstohold󰘱uidpressureat
stall.
DiaphragmshaftboltislooseTighten.
Motororcontrolleriswired
improperly.
Wirepermanual. Pumpwillnotcycle.
Theleakdetector(ifinstalled)has
tripped.
Checkdiaphragmforruptureor
incorrectinstallation.Repairor
replace.
Themotorisoperating,butthe
pumpwillnotcycle.
Thejawcouplingbetweenthe
motorandgearboxisnotconnected
properly.
Checktheconnection.
Suctionlineisclogged.Inspect;clear.
Checkballsarestickyorleaking.Cleanorreplace.
Pump󰘱owrateiserratic.
Diaphragm(orbackup)ruptured.Replace.
Pumpmakesunusualnoises.Pumpisoperatingnearoratstall
pressure.
Adjustairpressureorslowthepump
speed.
3A7037G9
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Troubleshooting
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
A󰘰ttingisloose.Tighten.Inspectthreadsealant.
Looseordamagedo-ringsorshaft
seal.
Replace.
Airconsumptionishigherthan
expected.
Diaphragm(orbackup)ruptured.Replace.
Suctionlineisloose.Tighten.
Diaphragm(orbackup)ruptured.Replace.
Loosemanifolds,damagedseatsor
o-rings.
Tightenmanifoldboltsorreplace
seatsoro-rings.
Airbubblesin󰘱uid.
Loosediaphragmshaftbolt.Tighten.
Loosemanifoldscrewsor󰘱uidcover
screws.
Tighten.
Pumpleaks󰘱uidexternallyfrom
joints.
Manifoldo-ringswornout.Replaceo-rings.
AGFCIhastripped.Removethecontrollerfromthe
GFCIcircuit.
Supplypowerispoor.Determineand󰘰xthesourceofthe
powerproblem.
Thecontrollerfaultsorshutsdown.
Operationalparametersare
exceeded.
Seeperformancechart;ensure
pumpisoperatingwithinthe
continuousdutyrange.
Inletcheckclogged/improperly
installed
Removedebris/installproperly
Excessivemotorregenerationfault
fromVFD
BrokendiaphragmboltReplacebolt
NOTE: NOTE:
NOTE:ForproblemswithaVariableFrequencyDevice(VFD),seeyourVFDmanual.
103A7037G
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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.Removepowertothesystem.
2.Openthe󰘱uiddrainvalvetorelieve󰘱uid
pressure.Haveacontainerreadytocatchthe
drainage.
3.Shutoffthemasterairvalve.
4.Turndowncentersectionregulatortozeroto
relieveairpressureincentersection.
Check Check
CheckValve Valve ValveRepair Repair Repair
NOTE: NOTE:
NOTE:Kitsareavailablefornewcheckvalveballs
andseatsinarangeofmaterials.O-ringandfastener
kitsalsoareavailable.
NOTE: NOTE:
NOTE:Toensureproperseatingofthecheckballs,
alwaysreplacetheseatswhenreplacingtheballs.
Also,replacetheo-ringseverytimethemanifoldis
removed.
Disassemble Disassemble
Disassemblethe the theCheck Check CheckValve Valve Valve
1.FollowthePressureReliefProcedure,page11.
Removepowertothemotor.Disconnectall
hoses.
2.NOTE NOTE
NOTEfor for forplastic plastic plasticpumps: pumps: pumps:Usehandtoolsuntil
thread-lockingadhesivepatchreleases.
3.Removethemanifoldfasteners(29)andnuts
(33;usedonlyonstainlesssteelandplastic
models),andwashers(28;usedonlyonstainless
steelandplasticmodels),thenremovetheoutlet
manifold(24).
4.Removetheseats(26),balls(27),ando-rings
(25)ifpresent.
NOTE: NOTE:
NOTE:Somemodelsdonotuseo-rings(25).
5.Repeatfortheinletmanifold(23),o-rings(25)if
present,seats(26),andballs(27).
Tocontinuedisassembly,see
DisassembletheStandardDiaphragms,page13.
Reassemble Reassemble
Reassemblethe the theCheck Check CheckValve Valve Valve
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
2.Reassembleinthereverseorder,followingall
notesintheillustration.Puttheinletmanifoldon
󰘰rst.Besuretheballchecksandmanifoldsare
assembledexactly exactly
exactlyasshown.Thearrows(A)on
the󰘱uidcovers(2)must must
mustpointtowardtheoutlet
manifold(24).
3A7037G11
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Repair
Check Check
Checkvalve valve valveassembly, assembly, assembly,aluminum aluminum aluminummodel model modelshown shown shown
1
Applymedium-strength(blue)threadlocker.Torquetothevaluespeci󰘰edforyourpump.See
TorqueInstructions,page21.
2
Arrow(A)mustpointtowardoutletmanifold
3
Notusedonsomemodels.
4
Plasticandstainlesssteelmodelsincludenuts(33)andwashers(28).
123A7037G
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Repair
Standard Standard
StandardDiaphragm Diaphragm DiaphragmReplacement Replacement Replacement
Disassemble Disassemble
Disassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page11.
Removepowertothemotor.Disconnectall
hoses.
2.Removethemanifoldsanddisassemble
theballcheckvalvesasexplainedin
CheckValveRepair,page11.
3.Removethebolts(29)fromthe󰘱uidcovers,then
pullthe󰘱uidcoversoffofthepump.
4.Toremovethediaphragms,thepistonmust
bemovedfullytooneside.Ifthepumpisnot
attachedtothegearbox,turntheshaftbyhand
tomovethepiston.Ifthepumpisstillattached
tothegearbox,loosenthescrewsandremove
thefancover.Turnthefanbyhandtorotatethe
shafttoshiftthepistontooneside.
5.Holda28mmwrenchonthewrench󰘱atsofthe
exposedpistonshaft.Useanotherwrenchon
theshaftbolt(20)toremoveit.Thenremoveall
partsofthediaphragmassembly.
6.Rotatethedriveshafttomovethepistonfullyto
theotherside.Seeinstructionsinstep4.Repeat
step5.
7.Tocontinuewithdisassembly,see
DisassembletheCenterSection,page15.
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Repair
Reassemble Reassemble
Reassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthe
centersection(driveshaft,piston,etc.),see
CenterSectionRepair,page15,beforeyouputthe
diaphragmsbackon.
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.Besurethecenter
sectioniscleananddry.
2.Thoroughlycleanorreplacethediaphragmbolt
(20).Installtheo-ring(54,metalpumponly)and
washer(21,metalpumponly).
3.Assemblethe󰘱uidsideplate(19),thediaphragm
(16),thebackupdiaphragm(17),andtheair
sidediaphragmplate(15)ontheboltexactlyas
shown.
4.Cleanthefemalethreadsofthepistonshaft
withawirebrushdippedinsolventtoremove
anyresidualthreadlocker.Applythread-locking
primerandallowittodry.
5.Applymedium-strength(blue)threadlockerto
thethreadsofthebolt.
6.Holda28mmwrenchonthewrench󰘱atsofthe
pistonshaft.Screwtheboltontotheshaftand
torqueto150ft-lb(203N•m).
7.Rotatethedriveshafttomovethepistonfully
tooneside.Seeinstructionsinstep4of
DisassembletheStandardDiaphragms,page13.
8.Repeattoinstalltheotherdiaphragmassembly.
9.Attachthe󰘱uidcovers.Thearrowoneach󰘱uid
covermustpointtowardtheoutletmanifold.
Applymedium-strength(blue)threadlockertothe
boltthreads.SeeTorqueInstructions,page21,
totighten.
10.Reassemblethecheckvalvesandmanifolds.
SeeReassembletheCheckValve,page11.
11.Restoremotorcoolingfancoverandpin(131)to
theiroriginallocations.
1
Roundedsidefacesdiaphragm.
2
Applymedium-strength(blue)thread
lockertothethreads.
3
AIRSIDEmarkingsondiaphragmmust
facethecenterhousing.
4
Torqueto150ft-lb(203N•m)at100
rpmmaximum.
5
Applyprimertothefemalethreads.
Allowtodry.
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Repair
Center Center
CenterSection Section SectionRepair Repair Repair
Disassemble Disassemble
Disassemblethe the theCenter Center CenterSection Section Section
SeetheillustrationsinCenterSection,page28.
1.FollowthePressureReliefProcedure,page11.
Removepowertothemotor.Disconnectall
hoses.
2.Removethemanifoldsand
checkvalvepartsasdirectedin
DisassembletheCheckValve,page11.
3.Removethe󰘱uidcoversand
diaphragmsasdirectedin
DisassembletheStandardDiaphragms,page13.
TIP: TIP:
TIP:Clampthegearboxbracket(6or8)tothe
bench.Leavethepumpconnectedtothemotor.
4.Usea10mmhexwrenchtoremove4bolts(3).
Pullthepumpoffthealignmenthousing(110).
TIP: TIP:
TIP:Itmaybenecessarytotapthepumpwitha
rubbermallettodisengagethecoupler.
5.Usea5/16hexwrenchtoremovetheplug(124).
Usea30mmsocketwrenchtoremovethe
bearingbolt(114)andtheo-ring(113)fromthe
top.
6.Turntheshaftsothegrooveontheshaft(B)isat
thetop,inlinewiththealignmentmarkings(C).
7.Usea3/4-16bolttopushoutthedriveshaft
assembly(109).Youcanalsousethebearing
bolt(114),butremovethebearing(112)󰘰rst.Be
surethatthegrooveonthedriveshaftremains
alignedwiththemarkingsinthecentersection.
NOTE: NOTE:
NOTE:Removetheboltafterthedriveshaftis
freed.
NOTICE NOTICE
NOTICE
Properalignmentisessential.Donotapply
morethanabout10ft-lb(14N•m)oftorque.
Excessivetorquecoulddamagethehousing
thread.Ifyouencounterresistance,check
alignmentorcontactyourdistributor.
8.Theshaftcoupler(115)mightcomeoutwith
thedriveshaftassembly.Ifnot,removefrom
gearbox(118).
9.Removethesealcartridge(106),theo-ring(108)
andtheradialseal(107)fromthedriveshaft
assembly.
10.Slidethepistonassembly(105)outofthecenter.
11.Onlyremovethealignmenthousing(110)if
needed.Usea10mmhexwrenchtoremove4
bolts(111).Pullthealignmenthousingoffthe
gearbox(118).
12.Leavethegearboxcoupler(118a)attachedtothe
gearboxshaft(118)unlessitisdamaged.Ifyou
needtoremoveit,abearingpullermustbeused.
3A7037G15
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Repair
Reassemble Reassemble
Reassemblethe the theCenter Center CenterSection Section Section
1.Cleananddrythecenterhousing(101),the
centerofthepiston(105)andthedriveshaft
(109).
2.Inspectthepistonandcentersectionbearings
forexcessivewearandreplaceifneeded.Install
thepistoninthecentersectionwiththesloton
thetop,inlinewiththealignmentmarkingsinthe
centersection.
3.Installtheo-ring(113)andapplymedium-strength
(blue)threadlockertothebearingbolt(114)
andscrewintothecentersection.Besurethat
thebearing(112)isintheslotonthepiston,as
shown.Besurethatthepistonmovesfreely.
Torquethebolt(114)to15–25ft-lb(20–34N•m).
4.Besurethesealingsurfaceofthedriveshaft
(109)isclean.Installthesealcartridge(106)and
theradialseal(107)onthedriveshaft.Thelips
ontheradialseal(107)mustfaceIN IN
INtowardthe
center.Inspectseallipfordamage.Replace
ifnecessary.
5.Installo-ring(108)tothecenterhousing(101).
6.Applyanti-seizelubricantonthematingedges
ofthedriveshaft,asshownintheillustrationon
page17.
7.ApplyLoctite®Primer7471andRetaining
Compound641tothebearingboreandouter
race.Assembleimmediately.Allowtocurefora
minimumof12hoursbeforerunningthepump.
8.Centerthepistoninthehousingandinstall
thedriveshaftassembly(109)intothecenter
housing(101)withthegroovefacingup.
9.Inspecttheshaftcoupler(115)forwearand
replaceifneeded.Installonthedriveshaft.
10.Ifremoved,installthealignmenthousingtothe
centersection.Applymedium-strength(blue)
threadlockerandinstallthehousingscrews
(111).Torqueto130–160in-lb(15–18N•m).
11.Ifremoved,installthegearboxcoupler(4)onthe
gearboxshaft.UseanM12x30boltandalarge
washerinsertedintotheholeintheshafttopress
thecouplerintoposition.Thecouplerisinproper
positionwhenitis󰘱ushwiththeendoftheshaft.
12.Besurethegearboxcoupler(4)isaligned
properly.Turnbyhandifneeded.Connectthe
pumptothegearboxassembly,engagingthe
couplers.
13.Applymedium-strength(blue)threadlocker
andinstallthegearboxscrews(3).Torqueto
130–160in-lb(15–18N•m).
14.Besureo-ring(127)isontheplug(124).Install
theplugandtorqueto15–25ft-lb(20–34N•m).
15.SeeReassembletheStandardDiaphragms,page
14,andReassembletheCheckValve,page11.
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Repair
1
Applymedium-strength(blue)thread
lockertothreads.
2
Torqueto15–25ft-lb(20–34N•m).
3
LipsmustfaceIN IN
INtowardthecenter.
4
ApplyLoctite®Primer7471and
RetainingCompound641tothe
bearingboreandouterrace.
Assembleimmediately.Allowtocure
foraminimumof12hoursbefore
runningthepump.
5
Installthedriveshaftassemblywith
thegroovefacingup.
6
Tightenscrewsinacrisscross
pattern,5turnsatatime,toengage
thecouplerevenly.Torqueto
130–160in-lb(15–18N•m).
7
Applylubricanttoinnermating
surface.
8
Applyanti-seizelubricantliberallyon
thisradialsurfaceofthedriveshaft
assembly.
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Repair
Disconnect Disconnect
Disconnectthe the theMotor Motor Motorand and andGearbox Gearbox Gearbox
NOTE: NOTE:
NOTE:Normally,themotorremainsconnectedtothe
gearbox.Disconnectthemotoronlyifyoususpect
thatthemotororgearboxmustbereplaced.
TIP: TIP:
TIP:Clampthegearboxbrackettothebench.
Startatstep1forATEXorFlameproofmotors.
StandardACmotors(04A,05A,or06A)areofone
piecewiththegearbox,sobeginwithstep3.
NOTE: NOTE:
NOTE:Useahoistandslingtoremovemotorweight
fromthegearboxduringremoval.
1.Usea3/4in.socketwrenchtoremove4screws
(122).
2.Pullthemotor(121)straightoffofthegearbox
(118).
3.Usea3/4in.socketwrenchtoremove4bolts(7)
andnuts(11,ifpresent).Liftthegearboxoffof
thebracket.NOTE: NOTE:
NOTE:IfyouhaveanACmotorwith
gearbox,liftthewholeunitoffofthebracket.
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Repair
Leak Leak
LeakSensor Sensor SensorRepair Repair Repair
Theleaksensorcanbereplacedorre-positioned.
Whenproperlypositioned,thetwoarrowsimprinted
ontwoofthe󰘱atsurfacesoftheleaksensorhex
headareverticalandpointingdown.
Leak Leak
LeakSensor Sensor SensorTesting Testing Testing
Testingthecontinuityoftheleaksensorispossible
toensureproperoperation.Ifcontinuitytesting
indicatesthattheleaksensorisnotfunctional,a
replacementkit,25B435,canbeorderedseparately.
1.FollowthePressureReliefProcedure,page11.
RemovepowertothemotorandVFD.
2.Totesttheleaksensorwithoutremovingfrom
thepump:
a.Notetheconnectionlocationsoftheleak
sensorwireswithintheVFDorother
monitoringdevice,thendisconnecttheleak
sensorwires.
b.Useanohmmeterattachedtotheleak
sensorleadstotesttheconductivityofthe
leaksensor.Continuityisaf󰘰rmedbya
readingof0-5ohms.
c.Loosentheleaksensorbushing1/2turn
(leaksensorarrowspointup).
d.Useanohmmeterattachedtotheleaksensor
leadstotesttheconductivityoftheleak
sensor.Anopencircuitshouldbeindicated.
Normaloperationpositionshownbydark
󰘱oat.Lighter󰘱oatlineindicatestheopen
circuitposition.
e.Ifthecontinuitytestresultindicatesthat
theleaksensorisnotfunctioningproperly,
proceedtostep3.Otherwise,tightenthe
bushingtoitsoriginalpositionsothatthe
arrowsontheleaksensorpointdown.Attach
theremovedleaksensorwirestothepoint
wheretheyweredisconnectedfromtheVFD
orothermonitoringdevice.
f.Applyairpressuretothepumpandusea
soapysolutionaroundthebushingtoensure
anairtightseal.Ifairbubblesappear,itwill
benecessarytoreturntothestepsabovefor
airpressurereliefandremovingthebushing
fromthepump.Applynewthreadsealer
onthebushingandinstallinthepumpso
thattheleaksensorisproperlypositioned.
Repeatthissteptotestforairleakagearound
thebushing.
3.Removeandreplacetheleaksensoratthe
pump:
a.Notetheconnectionlocationsoftheleak
sensorwireswithintheVFDorother
monitoringdevice,thendisconnecttheleak
sensorwires.
b.Removetheleaksensorandbushingfrom
thepumpcentersection.
c.Applythreadtapeorpastetothebushing
threadsandscrew󰘰ngertightintothepump.
d.Toensureawatertightseal,applyLoctite®
425Assure™threadlockersuppliedwiththe
leaksensorkittotheleaksensorthreads
andscrewtheleaksensorintothebushing.
e.Verifythattheleaksensorwasproperly
orientedinthepumpsothatthearrows
imprintedontheleaksensorhexheadare
verticalpositionedwiththearrowspointing
down.Itmaybenecessarytofurthertighten
boththebushingandleaksensortoachieve
properpositioning.
f.Useanohmmeterattachedtotheleak
sensorleadstotesttheconductivityofthe
leaksensor.Continuityisaf󰘰rmedbya
readingof0-5ohms.Attachtheleaksensor
wirestotheVFDorothermonitoringdevice.
g.Applyairpressuretothepumpandusea
soapysolutionaroundthebushingtoensure
anairtightseal.Ifairbubblesappear,itwill
benecessarytoreturntothestepsabovefor
airpressurereliefandremovingthebushing
fromthepump.Applynewthreadsealer
onthebushingandinstallinthepumpso
thattheleaksensorisproperlypositioned.
Repeatthissteptotestforairleakagearound
thebushing.
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Repair
Replace Replace
Replacethe the theCompressor Compressor Compressor
Toavoidinjuryfrom󰘰re,explosion,orelectric
shock,allelectricalwiringmustbedonebya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
1.FollowthePressureReliefProcedure,page11.
2.Removeelectricalpowertothepump.
3.Removethe8boltsholdingthepumptothe
mountingsurface.
4.Tipthepumponitssidetoprovideaccesstothe
compressorbox.
5.Removeriserbracket(8).
6.Removetheairline(A1)fromthecompressor.
Disconnectthecompressorwiresattheterminal
block(L1,L2,andground).Removethefour
bolts,andcarefullypullthecompressoroutof
thebox.
7.Usethefourboltstoinstallthenewcompressor.
ConnecttheairlinefromA1toA1,asshown.
8.Connectthewiresfromthenewcompressorto
theterminalblock,asshown.
9.Replaceriserbracket.
10.Returnthepumptoitsmountinglocation.Secure
itwiththe8bolts.
11.Returnpowertothepump.
L1
L2
A
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