Graco Husky 715 Datasheet

308–445
Rev. R
Supersedes Rev
. P
First choice when
quality counts. 
04050
INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Husky 715 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. D63–_______ Aluminum Pumps, Series E
*Model No. D64–_______ Stainless Steel Pumps, Series E
*NOTE: Refer to the Pump Matrix on page 24 to
determine the Model No. of your pump.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Graco Inc. is registered to I.S. EN ISO 9001

 
Table of Contents
Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety W arnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service
Replacing
the Air V alve 14. . . . . . . . . . . . . . . . . . . . .
Repairing the Air V alve 17. . . . . . . . . . . . . . . . . . . . . .
Ball Check V alves 20. . . . . . . . . . . . . . . . . . . . . . . . . .
Diaphragm Repair 21. . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Matrix 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Kit Matrix 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layouts 32. . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data and Performance Chart 33. . . . . . . . . .
Warranty 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco T oll-Free Phone Number 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.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury .
D
This equipment is for professional use only .
D
Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor .
D
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D Check equipment daily . Repair or replace worn or damaged parts immediately .
D Do 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.
D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer ’ s warnings.
D Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in aluminum pumps. Such use could result in a serious chemical
reaction, with the possibility of explosion.
D Do not use hoses to pull equipment.
D 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).
DW
ear hearing protection when operating this equipment.
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

 
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.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container . Dispose of hazardous fluid according to all local,
state and national guidelines.
D Always wear protective eyewear , gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer .
D 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 V entilation on
page 9.
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
.
D Ground the equipment. Refer to Grounding on page 4.
D If there is any static sparking or you feel an electric shock while using this equipment, stop pump-
ing immediately . Do not use the equipment until you identify and correct the problem.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being pumped.
D 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 V entilation on page 9.
D Keep the work area free of debris, including solvent, rags, and gasoline.
D Electrically disconnect all equipment in the work area.
D Extinguish all open flames or pilot lights in the work area.
D Do not smoke in the work area.
D Do not turn on or of f any light switch in the work area while operating or if fumes are present.
D Do not operate a gasoline engine in the work area.

 
Installation
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before
operating the pump, ground the system
as explained below. Also read the sec -
tion FIRE OR EXPLOSION HAZARD on
page 3.
T o 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.
D Pump : attach a ground wire (Y) to the grounding
strip (1 1 1) with the screw (121), lockwasher (122)
and nut (123), as shown in Fig. 1. Connect the
clamp end of the ground wire to a true earth
ground. Order Part No. 222–01 1 Ground Wire and
Clamp.
04051B
Fig. 1
Y
111
121
122
123
D Air and fluid hoses : use only electrically conductive
hoses.
D
Air compressor : follow the manufacturer ’ s recom -
mendations.
D
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 .
D
Fluid supply container: follow your local code.

 
Installation
General Information
DThe T ypical Installations in Figs. 2 and 3 are only
guides for selecting and installing system compo
-
nents. Contact your Graco distributor for assistance
in planning a system to suit your needs.
D Always use Genuine Graco Parts and Accessories.
D Use a compatible, liquid thread sealant on all male
threads. T ighten all connections firmly to avoid air
or fluid leaks.
D Reference numbers and letters in parentheses refer
to the callouts in the Figures and the parts lists on
pages 26–30.
WARNING
T OXIC 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 T
OXIC FLUID HAZARD on page 3.
2. Use fluids and solvents which are compatible
with the equipment wetted parts. Refer to the
T echnical Data section of all equipment manu -
als. Read the fluid and solvent manufacturer ’s
warnings.
Tightening Threaded Fasteners Before
First Use
After unpacking the pump, and before using it for the
first time, check and retorque all external fasteners.
See the Service section for torque specifications.
After the first day of operation, retorque the fasteners
again. Although the recommended frequency for
retorquing fasteners varies with pump usage, a general
guideline is to retorque fasteners every two months.
Mountings
1. Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as
well as the stress caused during operation.
2. The Husky 715 Pump can be used in a variety of
installations. See Figs. 2 and 3 for some exam -
ples.
3.
Secure the pump with screws and nuts.
Pumping High Density or Abrasive Fluids
High density fluids prevent the lightweight and
buna-N check valve balls from seating properly
, which
reduces pump performance significantly . Use stainless
steel balls for such applications (see page 30). Refer
to page 20 to change the balls.
PTFE

6 308-445
Installation
04052
Fig. 2
KEY
A Husky
715 Pump
B Bleed-T ype Master Air V alve
(required for pump)
C Electrically Conductive
Air Supply Line
D Air Line Quick Disconnect
E Master Air V alve (for accessories)
F Air Line Filter
G Pump Air Regulator
H Fluid Drain V alve (required)
J Fluid Regulator (optional)
K Electrically Conductive
Fluid Supply Hose
L Fluid Suction Line
M Underground Storage T ank
NW
all Mounting Bracket
Y Ground Wire (required; see page 4
for installation instructions)
H
J
ABOVE-GROUND
TRANSFER
INST ALLATION
A
CDG K
L
M
N
Y
F BE
04053
Fig. 3
KEY
A Husky
715 Pump
C Electrically Conductive Air Supply Line
D Air Line Quick Disconnect
H Fluid Drain V alve (required)
K Electrically Conductive
Fluid Supply Hose
L Suction T ube
P
Bung Plug
R Elbow
Y
Ground Wire (required; see page 4
for installation instructions)
55-GALLON BUNG PUMP INST ALLATION
See Fig. 2 for air line accessories
H
A
CD
K
L
Y
P
R

308-445 7
Installation
Air Line
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. 2. 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 contamina -
tion from hazardous fluids.
CAUTION
The pump exhaust air may contain contaminants.
V entilate to a remote area if the contaminants could
af fect your fluid supply . See Air Exhaust V entilation
on page 9.
1. Install the air line accessories as shown in Fig. 2.
Mount these accessories on the wall or on a
bracket. Be sure the air line supplying the acces -
sories is electrically conductive.
a. The fluid pressure can be controlled in either
of two ways. T o control it on the air side, install
an air regulator (G). T o control it on the fluid
side, install a fluid regulator (J) near the pump
fluid outlet (see Fig. 2).
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. 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
DUse electrically conductive fluid hoses. The pump
fluid inlet is 3/4 npt(f). Screw the fluid fitting into the
pump inlet snugly
.
D
If the inlet pressure to the pump is more than 25%
of the outlet working pressure, the ball check valves
will not close fast enough, resulting in inef ficient
pump operation.
D At inlet fluid pressures greater than 15 psi (100
kPa, 1.0 bar), diaphragm life will be shortened.
D See the T echnical Data on page 33 for maximum
suction lift and flow rate loss at various lift dis -
tances.
Fluid Outlet Line
WARNING
A fluid drain valve (H) is required in your system to
relieve pressure in the hose if it is plugged. See
Figs. 2 and 3. 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.
1. Use electrically conductive fluid hoses (K). The
pump fluid outlet is 3/4 npt(f). Screw the fluid fitting
into the pump outlet snugly
. Do not overtighten.
2.
Install a fluid regulator (J) at the pump fluid outlet
to control fluid pressure, if desired (see Fig. 2).
See Air Line, step 1a, for another method of
controlling pressure.
3. Install a fluid drain valve (H) near the fluid outlet.
See the WARNING above.

 
Installation
Changing the Orientation of the Fluid Inlet
and Outlet Ports
You can change the direction of the fluid inlet and
outlet manifolds (102), if desired. As shipped, the fluid
inlet manifold points away from the air valve (A) and
the fluid outlet manifold points toward the air valve.
See Fig. 4.
1. Remove the bolts (105) holding the manifold (102)
to the covers (101). Save the attaching hardware.
2. T urn the manifold to the desired position, and
reinstall the hardware. T orque the bolts (105) to
3–6 ft-lb (4–8 N.m).
04050
Fig. 4
T
orque to 3–6 ft–lb (4–8 N.m).

102
102
105
A
21
Fluid Pressure Relief Valve
CAUTION
Some systems may require installation of a pressure
relief valve at the pump outlet to prevent overpres -
surization and rupture of the pump or hose. See Fig.
5.
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.
Pressure Relief Kit 238–428 is available for use on
aluminum Husky 715 pumps and may be purchased
separately.
04333
Fig. 5
KEY
A 3/4
npt(f) Fluid Inlet Manifold
B 3/4 npt(f) Fluid Outlet Manifold
C Pressure Relief V alve
Part No. 1 10–134 (Aluminum)
Part No. 1 12–1 19 (Stainless Steel)


Connect
fluid inlet line here.
Install valve between fluid inlet and outlet ports.
Rotate fluid inlet manifold 180
_ (see Fig. 4).
C
A
B




Connect fluid outlet line here.


308-445 9
Installation
Air Exhaust Ventilation
WARNING
FIRE AND EXPLOSION HAZARD
Be sure to read FIRE OR EXPLOSION
HAZARD and T OXIC FLUID HAZARD
on page 3, before operating this pump.
Be sure the system is properly ventilated
for your type of installation. Y ou must
vent the exhaust to a safe place, away from peo -
ple, 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. 6.
The air exhaust port is 3/8 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
erratic pump operation.
T o exhaust to a remote location:
1. Remove the muf fler (W) from the pump air exhaust
port.
2.
Install an electrically conductive air exhaust hose
(X) and connect the muf fler 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.
A void 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.
See Fig. 6.
Fig. 6
VENTING EXHAUST AIR
See Fig. 2 for accessories
All wetted and non-wetted pump parts must be compatible with the
fluid being pumped.
KEY
W Muffler
X Electrically
Conductive Air Exhaust Hose
Z Container for Remote Air Exhaust
W
X
Z


10 308-445
Operation
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of serious
injury from pressurized fluid, accidental spray from
the gun or splashing fluid, follow this procedure
whenever you:
D Are instructed to relieve pressure,
D Stop pumping,
D Check, clean or service any system equipment,
D Install or clean fluid nozzles.
1. Shut of f 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 air , to eliminate possible
contamination of the fluid you are pumping by test
fluids such as water . Prior to use, flush the pump
thoroughly with a compatible solvent. Follow the steps
under Starting and Adjusting the Pump.
Starting and Adjusting the Pump
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.
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. Use a
compatible liquid thread sealant on all male
threads. T ighten 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.
NOTE:
If the inlet pressure to the pump is more than
25% of the outlet working pressure, the ball check
valves will not close fast enough, resulting in inef ficient
pump operation.
4. Place the end of the fluid hose (K) into an appro -
priate container .
5.
Close the fluid drain valve (H).
6. With the pump air regulator (G) closed, open all
bleed-type master air valves (B, E).
7. If the fluid hose has a dispensing device, hold it
open while continuing with the following step.
Slowly open the air regulator (G) 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.
NOTE: If the pump does not start, turn the reset shaft
(21) on the air valve (A). See Fig. 4 on page 8.
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.

308-445 11
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 muf fler , which could contaminate your
fluid supply or other equipment. Excessive lubrication
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 10.
Flush the pump often enough to prevent the fluid you
are pumping from drying or freezing in the pump and
damaging it. Use a compatible solvent.
Always flush the pump and relieve the pressure
before storing it for any length of time.
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.
The recommended frequency for retorquing of fasten -
ers varies with pump usage; a general guideline is to
retorque every two months.
Tightening the Clamps
When tightening the clamps (109), apply thread lubri -
cant to the bolts and be sure to torque the nuts (1 10)
to 75–85 in-lb (8.5–9.6 N.m). See Fig. 7.
04056
Fig. 7

Apply thread lube to bolts and
torque nuts to 75–85 In-lb
(8.5–9.6 N.m).

109
110
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.

12 308-445
Troubleshooting
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
Relieve the pressure.
Check all possible problems and causes before disas -
sembling the pump.
PROBLEM CAUSE SOLUTION
Pump will not cycle, or cycles once
and stops.
Air valve is stuck or dirty . T urn reset shaft (21).
Disassemble and clean air valve.
See pages 17, 18.
Use filtered air .
W orn or broken detent link (22). Replace detent link (22) and ball (8).
See pages 17, 18.
Broken or damaged springs (3, 6)
and/or valve cup (5) and plate (13).
Replace. See pages 17, 18.
Bent or broken pilot pins (26). Replace. See pages 14, 16. When
reinstalling the air valve, be sure to
follow the instructions on page 16,
to avoid damaging the pins.
Pump cycles at stall or fails to hold
pressure at stall.
Leaky check valves or o-rings (1 13). Replace. See page 20.
W orn check balls (301) or guide
(201).
Replace. See page 20.
Check ball (301) wedged in guide
(201).
Repair or replace.
See page 20.
Excessive air leakage from exhaust
port.
W orn air valve cup (5) or plate (13). Replace. See pages 17, 18.
W orn shaft seals (31‡). Replace. See page 21.
Pump operates erratically . Clogged suction line. Inspect; clear .
Loose manifolds (102). T ighten manifold screws (105).
Refer to page 20.
Sticky or leaking check valve balls
(301).
Clean or replace. See page 20.
Diaphragm (401, 404) ruptured. Replace. See page 21.

308-445 13
Troubleshooting
PROBLEM CAUSE SOLUTION
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm (401, 404) ruptured. Replace. See page 21.
Loose manifolds (102) or damaged
o-rings (113).
T ighten manifold screws (105);
replace o-rings (1 13). See page 20.
Loose fluid side diaphragm plates
(116).
T ighten screw (1 14). See page 21.
Fluid in exhaust air . Diaphragm (401, 404) ruptured. Replace. See page 21.
Loose fluid side diaphragm plates
(116).
T ighten screw (1 14). See page 21.
Pump exhausts air at stall. W orn air valve cup (5) or plate (13). Replace. See pages 17, 18.
W orn shaft seals (31‡). Replace. See page 21.
Pump exhausts air from clamps. Loose clamps (109). T ighten clamp nuts (1 10).
See page 1 1.
Pump exhausts air near air valve. Air valve screws (10) are loose. T ighten screws. See page 14.
Air valve o-ring (19) is damaged. Inspect; replace. See pages 17, 18.
Pump leaks fluid from check valves. Worn or damaged o-rings (113). Inspect; replace. See page 20.
Loose manifolds (102). T ighten manifold screws (105).
Refer to page 20.

14 308-445
Service
Tools Required
DTorque wrench
D Phillips screwdriver
D O-ring pick
D 1/8” EZY -OUT bearing extractor
D Rubber mallet
Replacing the Air Valve
NOTE: Air V alve Kit 239–952 is available. Parts
included in the kit are marked with a symbol, for exam -
ple (2 { ). A tube of general purpose grease (25 { ) is
supplied in the kit. Install the kit as follows.
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
1. Relieve the pressure.
2. Unscrew the six mounting screws (10) and remove
the air valve (A) from the pump. See Fig. 8.
04345
Fig. 8
1
2
T orque oppositely and evenly to 20–25 in-lb (2.3–2.8 N.m).
Apply grease (25 {).
110
A
{21
19{
GREASE APPLICA TION
2
2
2
2
{14
21{
{16
03412A

308-445 15
Service
3. Refer to Fig. 9. Use an o-ring pick to remove the
bearings (9 and 24).
4. Remove the two screws (23) holding the valve
plate (13) to the pump. Use an o-ring pick to
remove the valve plate and seal (12). Clean and
inspect the parts. Replace any worn ones.
5. If the pilot pins (26) are accessible from the inside
of the pump housing (1), pull them out. If not
accessible, disassemble the fluid section as ex -
plained on page 21.
NOTE: Inspect the pilot pin o-rings (28) and bearings
(27) in place. Removal will destroy the bearings and is
not required unless they are damaged. T o service the
bearings, first perform steps 2–5 on page 21.
6. Use a 1/8 in. EZY -OUT to remove the bearings
(27) from the housing (1). See Fig. 17 on page 21
for an illustration of how to use an EZY -OUT.
Remove the o-rings (28). Clean and inspect the
parts. Replace any worn ones.
NOTE: If the pilot pin o-rings (28) and bearings (27)
were not removed, go to step 8.
7. Grease the o-rings (28) and install them in the
bearings (27). Press the bearings and o-rings in
place so the bearings are flush with the surface of
the housing (1). See Fig. 9.
8. Grease the pilot pins (26) and install them from the
inside of the housing (1).
9. Install the seal (12) in the pump housing (1). Install
the valve plate (13) and secure with the two
screws (23). (The heads of the screws overlap the
top and bottom edges of the plate to hold it in
place.) T orque the screws to 5–7 in-lb (0.6–0.8
N.m).
10.
Apply grease (25 { ) to the bearings (9 { and 24).
Install the bearing (9 { ) in the pump housing (1).
Install the other bearing (24).
11. Make certain the o-ring (19 { ) is in place on the air
valve (A). See Fig. 8.
12. Apply grease (25 { ) where shown in Fig. 8.
Fig. 9
3
2627
28
Press-fit flush with surface of housing (1).
04233
1
12
1
23
13
T orque to 5–7 in-lb (0.6–0.8 N.m).
24
2
Apply grease (25 {).
1
2
2
2
2
3
{9

 
Service
CAUTION
If you are replacing the diaphragms, you must rein -
stall the air valve before installing the diaphragms, as
the diaphragms will force the pilot pins into the air
valve area.
The pilot pins (26) must give clearance for the actua -
tor link (16 { ), to prevent damage to the pins. Follow
steps 13–15 carefully .
13. Check if either of the two pilot pins (26) are pro -
truding out into the air valve cavity . Push them
back in as far as possible.
14. If one of the pins is still protruding, make sure the
air valve is shifted away from that pin’s side of the
cavity. T o shift the valve, push down on the detent
link (22) and slide it to the other side with your
fingers (see Fig. 1 1).
15.
Align the air valve assembly (A) so the reset shaft
(21) is at the top and the valve is angled away
from a protruding pilot pin (26), then slip it into
position. See Fig. 10. Do not force the air valve
down onto the pin. If the pin is interfering with
the actuator link (16), make sure the valve is
shifted away from the pin (see step 14), then
reposition the valve.
16. Install the six screws (10) and torque oppositely
and evenly to 20–25 in-lb (2.3–2.8 N.m). See
Fig. 8.
05111
26
21
A
Fig. 10
1Top
end of the air valve.
1
NOTE: This example shows how to shift the air valve when a pilot pin (26) is protruding as shown in Fig. 10. If the
pin on the other side of the air valve is protruding, the valve should be shifted in the reverse of this example.
Fig. 11
05109 05109
22{
16{
21{
{22
{16
{21
1
Push
down and slide to the other side.
2
T op end of the air valve.
1 1
2
05110A

 
Service
Tools Required
DTorque wrench
D Phillips screwdriver
D O-ring pick
D Rubber mallet
Repairing the Air Valve
Disassembly
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
1. Relieve the pressure.
2. Remove the air valve (A) from the pump (see page
14).
3.
Remove the screw (15) and shift saddle (14). See
Fig. 12.
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 18.
Fig. 12
NOTE: ALL P AR TS SHOWN ARE
INCLUDED IN AIR V AL VE KIT
239–952.
01431A
{2
7{
{4
{18
{16
{20
{21
{22
{17
{14
{15
{3
5{
8{
6{19{

18 308-445
Service
Reassembly
1.
If the detent collar (7) was removed, carefully
install a new collar in a new cover (2). Using a
rubber mallet, carefully press fit the detent collar
(7) into the cover (2). See Fig. 13.
2. Grease the detent 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. 13. Slide the washer (18)
onto the blunt end of the reset shaft (21). Insert
the shaft through the cover (2) until it seats.
03414
Fig. 13
1
2
18
2
6
8
7
21
Apply grease (25).
Press fit.
20
1
1
1
2
1
H
4.
Grease the spring (3). Place the link stop (4) inside
the spring. See Fig. 14.
5. Grease the detent link (22) and link spacer (17).
Assemble the detent link, link spacer , and actuator
link (16) as shown in Fig. 14. The raised bumps on
the links (16 and 22) 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 onto the air valve 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 in the detent
link (22). Make certain the bumps on the detent
link (22) engage the detent ball (8).
Fig. 14
{17
{3
1
3
2
{16
2{
4{8{
5{
{22
Apply grease (25 {).
Bumps face up.
Reset shaft square must
engage with square hole.
2
3
1
1
1
2
7505A
1

 
Service
8. Grease the inside surfaces of the shift saddle (14)
and install it as shown in Fig. 15. Hold the link
assembly firmly in place and install the screw (15).
T orque 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. 15
{2


{22
{5
19{
{14
15{
21{
Apply grease (25 {).
T
orque to 7 to 9 in-lb (0.8 to 1.0 N.m).





7506A

 
Service
Tools Required
DTorque wrench
D 9/16” socket wrench
D O-ring pick
Ball Check Valves
NOTE: A Fluid Section Repair Kit is available. See
page 25 for the correct kit. Parts included in the kit are
marked with an asterisk, for example (301*). Use all
the parts in the kit for the best results. Always replace
the o-rings (1 13) with new ones whenever they are
removed for any reason.
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
1. Relieve the pressure. Disconnect all hoses.
2. Remove the pump from its mounting.
3. Unscrew the four bolts (105), washers (107), and
nuts (106) holding the top manifold (102) to the
covers (101). Lift the manifold of f the pump. See
Fig. 16.
4. Remove the outer o-ring (1 13), ball stop (202), ball
(301), ball guide (201), and inner o-ring (1 13) from
each of the covers (101).
5. T urn the pump over . Remove the bolts (105), nuts
(106), feet (108), and bottom manifold (102).
6. Remove the outer o-ring (1 13), ball guide (201),
ball (301), ball stop (202), and inner o-ring (1 13)
from each of the covers (101).
7. Clean all parts. Inspect parts and replace worn or
damaged ones.
8. Reassemble. Follow all notes in Fig. 16. Be sure
the ball checks are assembled exactly as shown.
04057
Fig. 16
202*
Torque to 3–6 ft–lb (4–8 N.m)
105
105
201*



113*
201*
301*
113*
107
102
113*
106
101
106
113*
202*
102
108
301*