Graco Husky 715 User manual

308–444
Rev. R
Supersedes Rev. P
First choice when
quality counts. t
04025
INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
ACETAL AND POLYPROPYLENE
Huskyt715 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. D61–_____ Acetal Pumps, Series E
*Model No. D62–_____ Polypropylene Pumps, Series E
*Model No. D6A–_____ Acetal BSPT Pumps, Series E
*Model No. D6B–_____ Polypropylene BSPT Pumps, Series E
*NOTE: Refer to the Pump Matrix on page 26 to
determine the Model No. of your pump.
US Patent Nos. 4,789,131 and 4,867,653
Other US and Foreign Patents Pending
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1995, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

2 308-444
Table of Contents
Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Matrix 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Kit Matrix 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layouts 33. . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data and Performance Chart 34. . . . . . . . . . .
Graco Standard Warranty 36. . . . . . . . . . . . . . . . . . . . . .
Graco 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.
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 Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DDo not 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).
DWear hearing protection when operating this equipment.
DDo not lift pressurized equipment.
DComply 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.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas. If
the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page
11.
 Never use an acetal pump to pump acids. 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.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
Ground the equipment. Refer to Grounding on page 5.
 Never use a polypropylene pump with non-conductive flammable fluids as specified by your local
fire protection code. Refer to Grounding on page 5 for additional information. Consult your fluid
supplier to determine the conductivity or resistivity of your fluid.
If there is any static sparking or you feel an electric shock while using this equipment, stop pump-
ing immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being pumped.
Pipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm fails,
the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 11.
Keep the work area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the work area.
Extinguish all open flames or pilot lights in the work area.
Do not smoke in the work area.
Do not turn on or off any light switch in the work area while operating or if fumes are present.
Do not operate a gasoline engine in the work area.

 
Installation
General Information
DThe Typical Installations in Figs. 3 to 5 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.
DUse a compatible, liquid thread sealant on all male
threads. Tighten all connections firmly to avoid air
or fluid leaks.
DReference numbers and letters in parentheses refer
to the callouts in the Figures and the parts lists on
pages 28 to 31.
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.
WARNING
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can
cause serious injury or death if splashed
in the eyes or on the skin, inhaled, or
swallowed.
1. Read TOXIC FLUID HAZARD on page 3.
2. Use fluids and solvents which are compatible
with the equipment wetted parts. Refer to the
Technical Data section of all equipment manu-
als. Read the fluid and solvent manufacturer’s
warnings.
CAUTION
Safe Operating Temperature
Minimum: 40 _ F (4.4 _ C); Maximum: 150 _ F (66 _ C).
These temperatures are based upon mechanical
stress only and may be significantly altered by
pumping certain chemicals. Consult engineering
guides for chemical compatibilities and temperature
limits, or contact your Graco distributor.
Mountings
DBe sure the mounting surface can support the
weight of the pump, hoses, and accessories, as
well as the stress caused during operation.
DThe Husky 715 Pump can be used in a variety of
installations. See Figs. 3 to 5 for some examples.
DWhen installed on a drum (see Fig. 4), slide the
pump’s feet securely under the rim of the drum.
DOn all other installations, mount the pump using
screws and nuts.
Pumping High Density or Abrasive Fluids
High density fluids prevent the lightweight PTFE and
buna-N check valve balls from seating properly, which
reduces pump performance significantly. Use stainless
steel balls for such applications (see page 31). Refer
to page 21 to change the balls.
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. 237–633 for acetal pumps and
Part No. 237–632 for polypropylene pumps.

308-444 5
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 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.
Attaching the ground wire to the grounding strip
grounds only the air motor.
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. 2). Never use a
polypropylene pump with non-conductive
flammable fluids as specified by your local fire
protection code.
US Code (NFPA 77 Static Electricity) recommends
a conductivity greater than 50 x 10–12
Siemans/meter (mhos/meter) over your operating
temperature range to reduce the hazard of fire.
Consult your fluid supplier to determine the
conductivity or resistivity of your fluid. The
resistivity must be less than 2 x 1012
ohm-centimeters.
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:
 Pump : Attach a ground wire (Y) to the grounding
strip (107) with the screw (117), lockwasher (118)
and nut (119), as shown in Fig. 1. Connect the
clamp end of the ground wire to a true earth
ground. To order a ground wire and clamp, order
Part No. 222–011.
NOTE: When pumping conductive flammable fluids
with a polypropylene pump, always ground the fluid
system. See the WARNING at left. Fig. 2 shows a
recommended method of grounding flammable fluid
containers during filling.
04031A
Fig. 1
Y
107
117
118
119
 Air and fluid hoses : Use only electrically conductive
hoses.
 Air compressor : Follow the manufacturer’s recom-
mendations.
 Solvent pails used when flushing : Follow the local
code. Use only grounded metal pails, which are
conductive. Do not place the pail on a non-conduc-
tive surface, such as paper or cardboard, which
interrupts the grounding continuity.
 Fluid supply container: Follow the local code.

6 308-444
Installation
05104
KEY
A Husky 715 pump
H Fluiddrainvalve(required)
S Dispensevalve
T Fluiddrainline
Y Airmotor groundwire(required;
seepage 5for installationinstructions)
Z Containergroundwire(required)
Fig. 2
2
GROUNDING A PUMP
Dispensevalve nozzle must be in contact with container.
A
H
S
T
Y
Z
1
2
1Hose must be conductive.

308-444 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. 3. 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.
Ventilate to a remote area if the contaminants could
affect your fluid supply. See Air Exhaust Ventilation
on page 11.
1. Install the air line accessories as shown in Fig. 3.
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. To control it on the air side, install
an air regulator (G). To control it on the fluid
side, install a fluid regulator (J) near the pump
fluid outlet (see Fig. 3).
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
If using a conductive (acetal) pump, use conductive
hoses. If using a non-conductive (polypropylene)
pump, ground the fluid system. See Grounding on
page 5. The pump fluid inlet is 3/4 npt(f). See
Fig. 6. Screw the fluid fitting into the pump inlet
snugly.
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 inefficient
pump operation.
At inlet fluid pressures greater than 15 psi
(0.1 MPa, 1 bar), diaphragm life will be shortened.
See the Technical Data on page 34 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. 3 to 5. 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). See Fig. 6. 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. 3).
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
04032A
Fig. 3
KEY
A Husky 715 pump
B Bleed-typemaster airvalve
(requiredforpump)
C Electricallyconductive
airsupply line
D Air line quick disconnect
E Master air valve (for accessories)
F Airline filter
G Pumpairregulator
H Fluiddrainvalve(required)
J Fluidregulator(optional)
K Electricallyconductive
fluidsupply hose
L Fluidsuctionline
M Undergroundstoragetank
N Wallmountingbracket
Y Groundwire (required; see page 5
forinstallationinstructions)
H
JABOVE-GROUND
TRANSFER INSTALLATION
A
CDG
K
L
M
N
Y
F BE
04034A
04033
Fig. 4
KEY
A Husky 715 pump
C Electricallyconductive airsupply line
D Air line quick disconnect
H Fluiddrainvalve(required)
K Electricallyconductive fluidsupply hose
L 55-gallonbungkit221–094
Y Groundwire (required; see page 5
forinstallationinstructions)
H
55-GALLON BUNG PUMP INSTALLATION
See Fig. 3 for air line accessories
A
CD
K
L
YA
1Slidepump feet securely
underdrumrim.
1

308-444 9
Installation
05112A
Fig. 5
AIR SPRAY INSTALLATION
A
F E
KEY
A Husky 715 pump
C Electricallyconductive air lineto pump
E Gun air line shutoff valve
F Airline filter
G Gunairregulator
H Fluiddrainvalve(required)
K Electricallyconductive fluidsupply hose
P Circulatingvalve
R Electricallyconductive air line to gun
S Air spray gun
T Electricallyconductivefluidreturnline
U 5-gallonpailmountkit221–095
V Agitatorkit221–096
Y Groundwire (required; see page 5
forinstallationinstructions)
G
K
P
R
S
T
U
V
Y
H
C

10 308-444
Installation
Changing the Orientation of the Fluid Inlet
and Outlet Ports
You can rotate the fluid inlet and outlet manifolds (102)
to three positions. As shipped, the fluid inlet manifold
points down and the fluid outlet manifold points toward
from the air valve (A). See Fig. 6.
1. Remove the four nuts (105) and bolts (104) from
each end of the manifold (102).
2. Turn the manifold to the desired position, and
reinstall the bolts and nuts. Torque to 20 to 25 in-lb
(2.3 to 2.8 N-m).
NOTE: If the manifold is difficult to rotate, loosen the
nuts (114) holding the clamps (113). After turning the
manifold, torque the nuts to 75 to 85 in-lb (8.5 to
9.6 N-m).
04025
Fig. 6
1
3
4
2
Torqueto 20 to 25 in-lb (2.3 to 2.8 N-m).
3/4npt(f)Fluid Inlet
3/4npt(f)Fluid Outlet
1
2
3
4
102
102
104,
105
Torque to 75 to 85 in-lb (8.5 to 9.6 N-m).
A
114
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. 7.
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.
04234
Fig. 7
KEY
A 3/4npt(f)Fluid InletManifold
B 3/4npt(f)FluidOutletManifold
C Pressure Relief Valve
Part No. 110–134(Aluminum)
Part No. 112–119 (StainlessSteel)
1
3
2Connectfluidinletline here.
Installvalve betweenfluid inletand outlet ports.
Rotatefluidinletmanifold90(see Fig. 6).
C
A
B
1
2
3
4Connectfluidoutletlinehere. 4

308-444 11
Installation
Air Exhaust Ventilation
WARNING
FIRE AND EXPLOSION HAZARD
Be sure to read FIRE AND EXPLOSION
HAZARD and TOXIC FLUID HAZARD
on page 3, before operating this pump.
Be sure the system is properly ventilated
for your type of installation. You must
vent the exhaust to a safe place, away from 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. 8.
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 (W) from the pump air exhaust
port.
2. Install an electrically conductive air exhaust hose
(X) and connect the muffler to the other end of the
hose. The minimum size for the air exhaust hose
is 3/8 in. (10 mm) ID. If a hose longer than 15 ft
(4.57 m) is required, use a larger diameter hose.
Avoid sharp bends or kinks in the hose.
3. Place a container (Z) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures.
See Fig. 8.
04035A
Fig. 8
VENTING EXHAUST AIR (Submerged Installation Shown)
See Fig. 3 for accessories
In a submerged installation (as shown), all wetted and non-wetted
pump parts must be compatible with the fluid being pumped.
KEY
W Muffler
X ElectricallyConductive Air Exhaust Hose
Z Containerfor RemoteAir Exhaust
W
X
Z

12 308-444
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
Are instructed to relieve pressure
Stop pumping
Check, clean or service any system equipment
Install or clean fluid nozzles
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 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 fol-
low the Pressure Relief Procedure above before
lifting the pump.
1. Be sure the pump is properly grounded. Read
FIRE AND EXPLOSION HAZARD on page 3.
2. Check all fittings to be sure they are tight. Use a
compatible liquid thread sealant 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.
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 inefficient
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. 6 on page 10.
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.

308-444 13
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 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 12.
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.
Check and retorque all threaded connections, including
manifold screws, clamps, and air valve screws, at least
every two months. Although the recommended fre-
quency for retorquing of fasteners varies with pump
usage, a general guideline is to retorque every two
months.
Tightening the Clamps
When tightening the clamps (113), apply thread lubri-
cant to the bolts and be sure to torque the nuts (114)
to 75 to 85 in-lb (8.5 to 9.6 N-m). See Fig. 9.
Fig. 9
1Applythread lube to bolts and
torque nuts to 75 to 85 in-lb (8.5 to 9.6 N-m).
1
113
114
04037
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.

14 308-444
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
1. Relieve the pressure before checking or servicing
the equipment.
2. Check all possible problems and causes before
disassembling the pump.
PROBLEM CAUSE SOLUTION
Pump will not cycle, or cycles once
and stops. Air valve is stuck or dirty. Turn reset shaft (21).
Disassemble and clean air valve.
See pages 19, 20.
Use filtered air.
Worn or broken detent link (22). Replace detent link (22) and ball (8).
See pages 19, 20.
Broken or damaged springs (3, 6)
and/or valve cup (5) and plate (13). Replace. See pages 19, 20.
Bent or broken pilot pins (26). Replace. See pages 16, 18. When
reinstalling the air valve, be sure to
follow the instructions on page 18,
to avoid damaging the pins.
Pump cycles at stall or fails to hold
pressure at stall. Leaky check valves or o-rings (111). Replace. See page 21.
Worn check balls (301) or guide
(201). Replace. See page 21.
Check ball (301) wedged in guide
(201). Repair or replace. See page 21.
Excessive air leakage from exhaust
port. Worn air valve cup (5) or plate (13). Replace. See pages 19, 20.
Worn shaft seals (30). Replace. See page 23.
Pump operates erratically. Clogged suction line. Inspect; clear.
Check valve plug (106) is loose. Tighten. Refer to page 21.
Sticky or leaking check valve balls
(301). Clean or replace. See page 21.
Diaphragm (401 or 404) ruptured. Replace. See page 23.

308-444 15
Troubleshooting
PROBLEM CAUSE SOLUTION
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm (401 or 404) ruptured. Replace. See page 23.
Loose manifolds (102) or damaged
o-rings (109). Tighten manifold bolts (104) or nuts (105); replace o-rings (109).
See page 23.
Loose fluid side diaphragm plates
(112). Tighten. See page 23.
Fluid in exhaust air. Diaphragm (401 or 404) ruptured. Replace. See page 23.
Loose fluid side diaphragm plates
(112). Tighten. See page 23.
Pump exhausts air from muffler at
stall. Worn air valve cup (5) or plate (13). Replace. See pages 19, 20.
Worn shaft seals (30). Replace. See page 23.
Pump exhausts air from clamps. Loose clamps (113). Tighten clamp nuts (114).
See page 13.
Pump exhausts air near air valve. Air valve screws (10) are loose. Tighten screws. See page 16.
Air valve o-ring (19) is damaged. Inspect; replace. See pages 19, 20.
Pump leaks fluid from check valves. Worn or damaged o-rings (109). Inspect; replace. See page 23.
Check valve plug (106) is loose. Tighten. Refer to page 21.

16 308-444
Service
Tools Required
DTorque wrench
DPhillips screwdriver
DO-ring pick
D1/8” EZY-OUT bearing extractor
DRubber mallet
Replacing the Air Valve
NOTE: Air Valve Kit 239–952 is available. Parts
included in the kit are marked with a dagger, for exam-
ple (2{). A tube of general purpose grease (25{) 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 12.
1. Relieve the pressure.
2. Unscrew the six mounting screws (10) and remove
the air valve (A) from the pump. See Fig. 10.
04026
Fig. 10
1
2
Torqueoppositely and evenly to 20 to 25 in-lb (2.3 to 2.8 N-m).
Applygrease (25{).
1
19{
{21
A
10
GREASE APPLICATION
2
2
2
2
{14 21{
{16
03412A

308-444 17
Service
3. See Fig. 11. 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 23.
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. To service the
bearings, first perform steps 3 to 5 on page 23.
6. Use a 1/8 in. EZY-OUT to remove the bearings
(27) from the housing (1). See Fig. 22 on page 25
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. 11.
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.) Torque the screws to 5 to 7 in-lb (0.6 to 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. 10.
12. Apply grease (25) where shown in Fig. 10.
Fig. 11
3Press-fitflush with surface of housing (1).
04233
1
1
Torque to 5 to 7 in-lb (0.6 to 0.8 N-m).
2Applygrease (25). 1
2
2
2
2
3
27
28
26
12
23
9
13
24

18 308-444
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 to 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. To shift the valve, push down on the detent
link (22) and slide it to the other side with your
fingers (see Fig. 13).
15. Align the air valve assembly (A) so the reset shaft
(21) is at the top and the valve is angled away
from the protruding pilot pin (26), then slip it into
position. See Fig. 12. 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 to 25 in-lb (2.3 to 2.8 N-m). See
Fig. 10.
05111
Fig. 12
26
21
A
Fig. 13
NOTE: This example shows how to shift the air valve when a pilot pin (26) is protruding as shown in Fig. 12. If the
pin on the other side of the air valve is protruding, the valve should be shifted in the reverse of this example.
05109 05109
22
16
21
22
16
21
1
Push down and slide to the other side.
2
Top end of the air valve.
1 1
2
05110A

 
Service
Tools Required
DTorque wrench
DPhillips screwdriver
DO-ring pick
DRubber 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 12.
1. Relieve the pressure.
2. Remove the air valve (A) from the pump (see
page 16).
3. Remove the screw (15) and shift saddle (14). See
Fig. 14.
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 20.
Fig. 14
NOTE: All parts shown are included
in Air Valve Kit 239–952.
01431A
{2
7{
{4
{18
{16
{20
{21
{22
{17
{14
{15
{35{
8{
6{19{

20 308-444
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
into the cover. See Fig. 15.
03414
Fig. 15
1
2
18
2
6
8
7
21
Applygrease (25).
Press fit.
20
1
1
1
2
1
H
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. 15. Slide the washer (18)
onto the blunt end of the reset shaft (21). Insert
the shaft through the cover (2) until it seats.
Fig. 16
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
4. Grease the spring (3). Place the link stop (4) inside
the spring. See Fig. 16.
5. Grease the detent link (22) and link spacer (17).
Assemble the detent link, link spacer, and actuator
link (16) as shown in Fig. 16. 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).
8. Grease the inside surfaces of the shift saddle (14)
and install it as shown in Fig. 17. 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 18.
Fig. 17
2
1
2
22
5
19
14
15
21
Apply grease (25).
Torque to 7 to 9 in-lb (0.8
to 1.0 N.m).
1
1
1
1
2
7506A