Graco Hydra-Clean 1040 User manual

Instructions - Parts List
SaniForce™
Diaphragm Pumps
1040, 1590, and 2150 Models 311879ZAC
EN
For use in sanitary applications. For professional use only.
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Refer to the appropriate Pump Matrix on page 26, 34,
or 42 to determine the model number of your pump.
See page 3 for approval information.
1590 Models TI8926a
TI8924a
TI8928a
2150 Models
1040 Models

2311879ZAC
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pump and Repair Kit Matrix - 1040 Models . . . . . 26
Available 1040 Configurations . . . . . . . . . . . . . 27
Parts - 1040 Models . . . . . . . . . . . . . . . . . . . . . . . . 28
Dimensional Drawing - 1040 Models . . . . . . . . . . 31
Technical Data - 1040 Models . . . . . . . . . . . . . . . . 32
Performance Chart - 1040 Models . . . . . . . . . . . . 33
Pump and Repair Kit Matrix - 1590 Models . . . . . 34
Available 1590 Configurations . . . . . . . . . . . . . 35
Parts - 1590 Models . . . . . . . . . . . . . . . . . . . . . . . . 36
Dimensional Drawing - 1590 Models . . . . . . . . . . 39
Technical Data - 1590 Models . . . . . . . . . . . . . . . . 40
Performance Chart - 1590 Models . . . . . . . . . . . . 41
Pump and Repair Kit Matrix - 2150 Models . . . . . 42
Available 2150 Configurations . . . . . . . . . . . . . . 43
Options for Ram Mounting . . . . . . . . . . . . . . . . . 43
Parts - 2150 Models . . . . . . . . . . . . . . . . . . . . . . . . 44
Parts - 2150 Models for Ram Mounting . . . . . . . . 48
Dimensional Drawing - 2150 Models . . . . . . . . . . 50
Technical Data - 2150 Models . . . . . . . . . . . . . . . . 52
Performance Chart - 2150 Models . . . . . . . . . . . . 53
Graco Warranties . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 54

Models
311879ZAC 3
Models
* FA pumps have painted aluminum center sections that may exhibit signs of corrosion depending on cleaning
solutions used.
Model Connections Description Approvals
FD1___ Flange
1040 AODD Pump
FD7___ DIN
*FA1___ Flange
*FA7___ DIN
FD2___ Flange
1590 AODD Pump
FD8___ DIN
*FA2___ Flange
*FA8___ DIN
FD3___ Flange
2150 AODD Pump
FD9___ DIN
*FA3___ Flange
*FA9___ DIN
24G743 Flange
2150 AODD Pump
for Ram Mounting
24G744 Flange
*FA1111 Flange
1040 AODD Pump
*FA7111 DIN
FD1111 Flange
FD7111 DIN
FD1211 Flange
*FA2111 Flange
1590 AODD Pump
*FA8111 DIN
FD2111 Flange
FD2113 Flange
FD8111 DIN
FD2211 Flange
*FA3111 Flange
2150 AODD Pump
*FA9111 DIN
FD3111 Flange
FD9111 DIN
FD3211 Flange
II 2 G
II 2 G

Models
4311879ZAC
Material Certification
Reference: SaniForce Product Family
Issue Date: November 1, 2011
All fluid contact materials in the SaniForce product family are FDA-Compliant and meet the United States
Code of Federal Regulations (CFR) Title 21, Section 177 or are of a corrosion resistant grade Stainless
Steel. This includes the below product groups:
1. SaniForce 515, 1040, 1590, 2150 Air-Operated Double Diaphragm Pumps
2. SaniForce 1590, 3150 HS Air-0perated Double Diaphragm Pumps
3. SaniForce 1590, 3150 HS 3-A Certified Air-Operated Double Diaphragm Pumps
4. SaniForce 5:1, 6:1 and 12:1 Air-Operated Piston Pumps
5. SaniForce Diaphragm Pump and Piston Pump Drum Unloaders
6. SaniForce Diaphragm Pump and Piston Pump Bin Evacuation Systems
Bradley A. Byron
Quality Manager
Graco Inc.

Warnings
311879ZAC 5
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. When
these symbols appear in the body of this manual, refer back to these Warnings. Additional, product-specific warnings
may be found throughout the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

Warnings
6311879ZAC
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into the air.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, hearing loss,
inhalation of toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNING

Installation
311879ZAC 7
Installation
General Information
• FA pumps have painted aluminum center sections
that may exhibit signs of corrosion depending on
cleaning solutions used.
• The typical installations shown in Figs. 2-4 are only
guides for selecting and installing system compo-
nents. Contact your Graco distributor for assistance
in planning a system to suit your needs.
• Always use genuine Graco parts and accessories.
• Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 28-30, 36-38, and 44-46.
Tightening Clamps Before First Use
After you unpack the pump, and before you use it for the
first time, check all clamps and tighten as necessary.
Grounding
•Pump: Connect a ground wire and clamp as shown
in Fig. 1. Loosen the grounding screw (W). Insert
one end of a 12 ga (1.5 mm²) minimum ground wire
(Y) behind the grounding screw and tighten the
screw securely. Connect the clamp end of the
ground wire to a true earth ground. Order Part No.
238909 Ground Wire and Clamp.
FIG. 1
•Fluid hoses: Use only grounded hoses with a maxi-
mum of 500 ft. (150 m) combined hose length to
ensure grounding continuity.
•Air compressor: Follow the manufacturer’s recom-
mendations.
•All solvent pails used when flushing:Follow the local
code. Use only metal pails, which are conductive.
Do not place the pail on a non-conductive surface,
such as paper or cardboard, which interrupts the
grounding continuity.
•Fluid supply container: Follow the local code.
The pump is very heavy (see Technical Data on pages
32, 40, and 51 for specific weights). If the pump must
be moved, follow the pressure relief procedure on
page 12 and have two people to lift the pump by grasp-
ing the outlet manifold securely or use appropriate lift-
ing equipment.
To reduce the risk of serious injury due to burns, insu-
late and/or label the pump before pumping hot fluids.
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
"
Y
W

Installation
8311879ZAC
Mountings
• Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as well
as the stress caused during operation.
• For all mountings, be sure the pump is bolted
directly to the mounting surface.
• For ease of operation and service, mount the pump
so the air valve cover (2), air inlet, and fluid inlet and
outlet ports are easily accessible.
Air Line
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 accesso-
ries is grounded.
a. Install an air regulator (C) and gauge to control
the fluid pressure. The fluid outlet pressure will
be the same as the setting of the air regulator.
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 a grounded, flexible air hose (A) between the
accessories and the 1/2 npt(f) pump air inlet (N).
See Fig. 5. Use a minimum 3/8 in. (9.5 mm) ID air
hose. Screw an air line quick disconnect coupler (D)
onto the end of the air hose (A), and screw the mat-
ing fitting into the pump air inlet snugly.
Fluid Suction Line
1. Use flexible, grounded fluid hoses.
2. For best sealing results, use a standard tri-clamp or
DIN style sanitary gasket of a flexible material such
as EPDM, Buna-N, fluoroelastomer, or silicon.
3. If the fluid 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 ineffi-
cient pump operation.
4. At inlet fluid pressures greater than 15 psi (0.1 MPa,
1 bar), diaphragm life will be shortened.
5. See the Technical Data on pages 32, 40, and 51
for maximum suction lift (wet and dry).
NOTICE
The pump exhaust air may contain contaminants. Ven-
tilate to a remote area if the contaminants could affect
your fluid supply. See Air Exhaust Ventilation on
page 11.
A bleed-type master air valve (B) is required in the sys-
tem to relieve air trapped between this valve and the
pump. Trapped air can cause the pump to cycle unex-
pectedly, which could result in serious injury, including
splashing in the eyes or on the skin, injury from moving
parts, or contamination from hazardous fluids. See
FIG. 2.
In the step below, do not connect the quick-disconnect
coupler (D) on the air hose to the mating fitting on the
pump until you are ready to operate the pump. Con-
necting the coupler too early can result in unintentional
operation of the pump, leading to serious injury from
moving parts, splashing fluid in the eyes or on the skin,
and contact with hazardous fluids.

Installation
311879ZAC 9
Fluid Outlet Line
1. Use flexible grounded fluid hoses (L).
2. For best sealing results, use a standard tri-clamp or
DIN style sanitary gasket of a flexible material such
as EPDM, Buna-N, fluoroelastomer, or silicon
3. Install a fluid drain valve (J) near the fluid outlet. See
the WARNING above, and FIG. 2.
4. Install a shutoff valve (K) in the fluid outlet line.
FIG. 2 Typical Floor-Mount Installation
A fluid drain valve (J) is required to relieve pressure in
the hose if it is plugged. 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. See FIG. 2.
TI8930a
Key:
A Air supply line
B Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
G Flexible fluid suction line
J Fluid drain valve (required)
K Fluid shutoff valve
L Flexible fluid line
Y Ground wire (required; see page
7 for installation instructions)
E
F
CB
A
K
L
J
G
Y
D

Installation
10 311879ZAC
Changing the Orientation of the Fluid Inlet
and Outlet Ports
The pump is shipped with the ports facing the same
direction. To reverse the orientation of the ports:
1. Remove the clamps holding the inlet and/or outlet
manifold to the covers.
2. Reverse the manifold and reattach. Install and
tighten clamps snugly.
FIG. 3
Key:
N 1/2 npt(f) air inlet port
P Muffler (air exhaust
port is 3/4 npt(f)
R Fluid inlet port
S Fluid outlet port
113 Manifold clamps
3 Air valve screws
Torque to
28-30 in-lb
(3.2-3.7 N•m)
1
1
N
3 113 S
R
P
106 TI8926a

Installation
311879ZAC 11
Air Exhaust Ventilation
The air exhaust port is 3/4 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
erratic pump operation.
To provide a remote exhaust:
1. Remove the muffler (P) from the pump air exhaust
port.
2. Install a grounded air exhaust hose (T) and connect
the muffler (P) to the other end of the hose. The
minimum size for the air exhaust hose is 3/4 in. (19
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 (U) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures. See
FIG. 4.
FIG. 4 Venting Exhaust Air
Be sure the system is properly ventilated for your type
of installation. When pumping flammable or hazardous
fluids, you must vent the exhaust to a safe place, away
from people, animals, food handling areas, and all
sources of ignition.
Diaphragm failure will cause the fluid being pumped to
exhaust with the air. Place an appropriate container at
the end of the air exhaust line to catch the fluid. See
FIG. 4.
Key:
A Air supply line
B Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
PMuffler
T Grounded air exhaust hose
U Container for remote air exhaust
P
U
TD
A
B
C
F
E
TI8931a

Operation
12 311879ZAC
Operation
Pressure Relief Procedure
1. Shut off the air to the pump.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve fluid pressure,
having a container ready to catch the drainage.
Sanitize the Pump Before First Use
It is the user’s responsibility to properly sanitize the
pump before first use. It is up to the user whether this
will include disassembling and cleaning individual parts
or simply flushing pump with a sanitizing solution. As
necessary, follow the steps under Starting and Adjust-
ing the Pump below, under the Service section on
page 16, or under Flushing on page 13.
Starting and Adjusting the Pump
1. Be sure the pump is properly grounded. Refer to
Grounding on page 4.
2. Check connections to be sure they are tight. Tighten
fluid inlet and outlet connections securely.
3. Place the suction tube (if used) in fluid to be
pumped.
NOTE: If fluid inlet pressure to the pump is more than
25% of outlet working pressure, the ball check valves
will not close fast enough, resulting in inefficient pump
operation.
4. Place the end of fluid hose (L) into an appropriate
container.
5. Close the fluid drain valve (J).
6. Back out the air regulator (C) knob, and 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.
8. Slowly increase air pressure with the air regulator
(C) 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.
Pump Shutdown
At the end of the work shift, relieve pressure.
The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of serious injury
from pressurized fluid or splashing fluid, follow this
procedure whenever you stop pumping and before
cleaning, checking, or servicing equipment.
Never move or lift apump under pressure. If dropped,
the fluid section may rupture. Always follow the Pres-
sure Relief Procedure before lifting the pump.

Maintenance
311879ZAC 13
Maintenance
Lubrication
The air valve is designed to operate unlubricated, how-
ever if lubrication is desired, every 500 hours of opera-
tion (or monthly) remove the hose from the pump air
inlet and add two drops of machine oil to the air inlet.
Flushing
Insert suction tube into cleaning solution. Open air regu-
lator to supply low pressure air to the pump. Run the
pump long enough to thoroughly clean the pump and
hoses. Close the air regulator. Remove the suction tube
from the cleaning solution and drain pump. Place suc-
tion tube in the fluid to be pumped.
Flush the pump often enough to prevent the fluid you
are pumping from drying or freezing in the pump and
damaging it. Flushing schedule will be based on what
the pump is being used for. Use a compatible cleaning
solution and always cycle the pump during the entire
flushing process.
Always flush the pump and relieve the pressure before
storing it for any length of time.
Tightening Connections
Before each use, check all hoses for wear or damage,
and replace as necessary. Check to be sure all connec-
tions are tight and leak-free.
Preventive Maintenance Schedule
Establish a preventive maintenance schedule, based on
the pump’s service history. This is especially important
for prevention of spills or leakage due to diaphragm fail-
ure.
NOTICE
Do not over-lubricate the pump. Oil is exhausted
through the muffler and could contaminate your fluid
supply or other equipment. Excessive lubrication can
also cause the pump to malfunction.

Troubleshooting
14 311879ZAC
Troubleshooting
• Relieve the pressure before checking or servicing
the equipment.
• Check all possible problems and causes before dis-
assembling the pump.
To reduce the risk of serious injury, whenever you are
instructed to relieve pressure, always follow the Pres-
sure Relief Procedure on page 12.
PROBLEM CAUSE SOLUTION
Pump cycles at stall or fails to hold
pressure at stall. Worncheckvalve balls(301),seats (201) or o-rings (202). Replace. See 18.
Pump will not cycle, or cycles once
and stops. Air valve is stuck or dirty. Disassemble and clean air valve. See page 16. Use filtered air.
Check valve ball (301) severely
worn and wedged in seat (201) or
manifold (102 or 103).
Replace ball and seat. See page 18.
Check valve ball (301) is wedged
into seat (201), due to overpressur-
ization.
Install Pressure Relief Valve
(see page 10).
Dispensing valve clogged. Relieve pressure and clear valve.
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking balls (301). Clean or replace. See page 18.
Diaphragm ruptured. Replace. See pages 19-21.
Restricted exhaust. Remove restriction.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace. See pages 19-21.
Loose inlet manifold (102), dam-
aged seal between manifold and
seat (201), damaged o-rings (202).
Tighten manifold clamps (113), or
replace seats (201) or o-rings (202).
See page 18.
Loose diaphragm shaft bolt (107). Tighten or replace (pages 19-21).
Damaged o-ring (108). Replace. See pages 19-21.
Chattering - noisy operation. Check valve balls do not seat prop-
erly/cleanly due to imbalance
between fluid inlet and outlet line
sizing. Noise is accentuated with
light viscosity fluids.
Reduce size/diameter of inlet line rela-
tive to outline line. Outlet line size
should not exceed pump size.

Troubleshooting
311879ZAC 15
Leak in inlet or outlet sanitary fit-
ting. Loose sanitary clamp. Tighten clamp.
Damaged or worn gasket. Replace gasket.
Misalignment of inlet/outlet hose or
pipe. Use flexible hoses at pump inlet and outlet.
Gasket does not seal. Use a standard sanitary gasket of flexi-
ble material such as EPDM, Buna-N,
fluoroelastomer, or silicon.
Fluid in exhaust air. Diaphragm ruptured. Replace. See pages 19-21.
Loose diaphragm shaft bolt (107). Tighten or replace. See pages 19-21.
Damaged o-ring (108). Replace. See pages 19-21.
Pump exhausts excessive air at
stall. Worn air valve block (7), o-ring (6), plate (8), pilot block (18), u-cups
(10), or pilot pin o-rings (17).
Repair or replace. See page 16.
Worn shaft seals (402). Replace. See pages 19-21.
Pump leaks air externally. Air valve cover (2) or air valve
cover screws (3) are loose. Tighten screws. See page 16.
Air valve gasket (4) or air cover
gasket (22) is damaged. Inspect; replace. See pages 16, 22-23.
Air cover screws (25) are loose. Tighten screws. See pages 22-23.
Pump leaks fluid externally from
ball check valves. Loose manifolds (102, 103), dam- aged seal between manifold and
seat (201), damaged o-rings (202).
Tighten manifold clamps (113), or
replace seats (201) or o-rings (202).
See page 18.
PROBLEM CAUSE SOLUTION

Service
16 311879ZAC
Service
Repairing the Air Valve
Tool Required
• Torque wrench
• Torx (T20) screwdriver or 7 mm (9/32 in.) socket
wrench
• Needle-nose pliers
• O-ring pick
• Lithium base grease
NOTE: Air Valve Repair Kits are available. Order Kit
255061 for models with stainless steel center housing.
Order Kit 236273 for models with aluminum center
housing. Parts included in Kit 255061 are marked with †,
and parts included in Kit 236273 are marked with .
Use all the parts in the kit for the best results.
Disassembly
1. Relieve the pressure.
2. With a Torx (T20) screwdriver or 7 mm (9/32 in.)
socket wrench, remove the six screws (3), air valve
cover (2), and gasket (4). See FIG. 5.
3. Move the valve carriage (5) to the center position
and pull it out of the cavity. Remove the valve block
(7) and o-ring (6) from the carriage. Using a nee-
dle-nose pliers, pull the pilot block (18) straight up
and out of the cavity. See FIG. 6.
4. Pull the two actuator pistons (11) out of the bearings
(12). Remove the u-cup packings (10) from the pis-
tons. Pull the pilot pins (16) out of the bearings (15).
Remove the o-rings (17) from the pilot pins. See
FIG. 7.
5. Inspect the valve plate (8) in place. If damaged, use
a Torx (T20) screwdriver or 7 mm (9/32 in.) socket
wrench to remove the three screws (3). Remove the
valve plate (8). See FIG. 8.
6. Inspect the bearings (12, 15) in place. See FIG. 7.
The bearings are tapered and, if damaged, must be
removed from the outside. This requires disassem-
bly of the fluid section. See page 24.
7. Clean all parts and inspect for wear or damage.
Replace as needed. Reassemble.
Reassembly
1. If you replaced the bearings (12, 15), reinstall as
explained on page 24. Reassemble the fluid sec-
tion.
2. On models with aluminum center housing, install the
valve plate seal (55) into the groove at the bottom
of the valve cavity. The rounded side of the seal
must face down into the groove. See FIG. 8.
3. Install the valve plate (8†) in the cavity, seal down.
Install the three screws (3), using a Torx (T20)
screwdriver or 7 mm (9/32 in.) socket wrench.
Tighten until the screws bottom out on the housing.
See FIG. 8.
4. Install an o-ring (17†) on each pilot pin (16).
Grease the pins and o-rings. Insert the pins into the
bearings (15), narrow end first. See FIG. 7.
5. Install a u-cup packing (10†) on each actuator pis-
ton (11), so the lips of the packings face the narrow
end of the pistons. See FIG. 7.
6. Lubricate the u-cup packings (10†) and actuator
pistons (11). Insert the actuator pistons in the bear-
ings (12), wide end first. Leave the narrow end of
the pistons exposed. See FIG. 7.
7. Grease the lower face of the pilot block (18†) and
install so its tabs snap into the grooves on the ends
of the pilot pins (16). See FIG. 6.
8. Grease the o-ring (6†) and install it in the valve
block (7†). Push the block onto the valve carriage
(5). Grease the lower face of the valve block. See
FIG. 6.
9. Install the valve carriage (5) so its tabs slip into the
grooves on the narrow end of the actuator pistons
(11). See FIG. 6.
10. Align the valve gasket (4†) and cover (2) with the
six holes in the center housing (1). Secure with six
screws (3), using a Torx (T20) screwdriver or 7 mm
(9/32 in.) socket wrench. Torque to 52-60 in-lb
(5.6-6.8 N•m). See FIG. 5.

Service
311879ZAC 17
FIG. 5
FIG. 6
FIG. 7
FIG. 8
TI9086A
2
2
2
4† 
3
Torque to 52-60 in-lb
(5.6-6.8 N•m)
TI9087A
Detail
5
 †6
 †7
2
1
32
3
See detail at right.
Grease.
Grease lower face.
18† 
5
31
TI9088A
TI9089A
2
1
3
4
11
12
17† 
15 16
4
1
2
Insert narrow end first
Grease
Install with lips facing narrow end of piston (11)
Insert wide end first
10† 
23
TI9090A
1
Tighten screws until they bottom out on the housing.
3
8 †
1
2
Rounded side of seal must face down. (Seal is used
only on models with aluminum center housing).
55 
2

Service
18 311879ZAC
Ball Check Valve Repair
Tools Required
• O-ring pick
Disassembly
NOTE:
• A Fluid Section Repair Kit is available. Refer to the
Repair Kit Matrix parts section for the appropriate
pump size so that the correct kit for your pump is
ordered. Parts included in the kit are marked with an
asterisk, for example (202*). Use all the parts in the
kit for the best results.
• To ensure proper seating of the balls (301), always
inspect the seats (201) when replacing the balls.
Replace seats as necessary if seating surface
shows evidence of wear. Also, replace the o-rings
(202) as necessary. PTFE o-rings should be
replaced every time manifolds are removed.
1. Relieve the pressure. Disconnect all hoses.
2. Remove the pump from its mounting.
3. Remove the clamps (106) holding the outlet mani-
fold (103) to the fluid covers (101). See FIG. 9.
4. Remove the o-rings (202), seats (201), and balls
(301) from the manifold (103).
5. Turn the pump over and remove the inlet manifold
(102). Remove the o-rings (202), seats (201), and
balls (301) from the fluid covers (101).
Reassembly
1. Clean all parts and inspect for wear or damage.
Replace parts as needed.
2. Reassemble in the reverse order, following all notes
in FIG. 9. Be sure the ball checks and manifolds are
assembled exactly as shown. The arrows (A) on
the fluid covers (101) must point toward the outlet
manifold (103).
FIG. 9
TI8932a
2
1
Arrow (A) must point toward outlet manifold (103)
Radiused seating surface must face the ball (301).
Large chamfer on O.D. must face o-ring.
103
301*
201
202*
101
A
301*
201
202*
102
1
2
2
113
113

Service
311879ZAC 19
Standard Diaphragm Repair
NOTE: If your pump uses overmolded diaphragms, see
page 22.
Tools Required
• Torque wrench
• 15 mm socket wrench
• 19 mm open end wrench
• O-ring pick
• Lithium-base grease
Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to
page 27, 35, or 43 to order the correct kit for your pump.
Parts included in the kit are marked with an asterisk, for
example (401*). Use all the parts in the kit for the best
results.
1. Relieve the pressure.
2. Remove the manifolds and disassemble the ball
check valves as explained on page 18.
3. Remove the clamps (106) holding the fluid covers
(101) to the air covers (23). Pull the fluid covers
(101) off the pump. See FIG. 10.
FIG. 10
TI9091A
1
Arrow (A) must point toward air valve.
B23
101
A
1
1
106
106

Service
20 311879ZAC
4. Loosen but do not remove the diaphragm shaft bolts
(107), using a 15 mm socket wrench on both bolts.
See FIG. 11.
5. Unscrew one bolt from the diaphragm shaft (24) and
remove the o-ring (108), fluid side diaphragm plate
(105), diaphragm (403), backer (401) used only on
PTFE models, and air side diaphragm plate (104).
See FIG. 11.
6. Pull the other diaphragm assembly and the dia-
phragm shaft (24) out of the center housing (1).
Hold the shaft flats with a 19 mm open end wrench,
and remove the bolt (107) from the shaft. Disassem-
ble the remaining diaphragm assembly.
7. Inspect the diaphragm shaft (24) for wear or
scratches. If it is damaged, inspect the bearings (19)
in place. If the bearings are damaged, refer to page
24.
8. Reach into the center housing (1) with an o-ring pick
and hook the u-cup packings (402), then pull them
out of the housing. This can be done with the bear-
ings (19) in place.
9. Clean all parts and inspect for wear or damage.
Replace parts as needed.
Reassembly
1. Install the shaft u-cup packings (402*) so the lips
face out of the housing (1). Lubricate the packings.
See FIG. 11.
2. Install the diaphragm assembly on one end of the
shaft (24) as follows:
a. Install the o-ring (108*) on the shaft bolt (107).
b. Install the fluid side diaphragm plate (105) on
the bolt so the rounded side faces the dia-
phragm (401).
NOTE: The fluid side diaphragm plate (105) is stainless
steel. This plate is not stamped with its part number. Be
sure to install this plate on the fluid side of the dia-
phragm.
c. Install the diaphragm (403*). Make certain the
side marked AIR SIDE faces the center
housing (1).
d. On PTFE models only, install the backer (401*)
on the bolt. Make certain the side marked AIR
SIDE faces the center housing (1).
e. Install the air side diaphragm plate (104) so the
rounded side faces the diaphragm (401). This
plate is stamped with its part number.
f. Apply medium-strength (blue) Loctite®or equiv-
alent to the bolt (107) threads. Screw the bolt
into the shaft (24) hand tight.
3. Grease the length and ends of the diaphragm shaft
(24), and slide it through the housing (1).
4. Assemble the other diaphragm assembly to the
shaft as explained in step 2.
5. Hold one shaft bolt (107) with a wrench and torque
the other bolt to 60-70 ft-lb (81-95 N•m) at 100 rpm
maximum.
6. Align the fluid covers (101) and the center housing
(1) so the arrows (A) on the covers face the same
direction as the air valve (B). Secure covers with the
clamps. See FIG. 10.
7. Reassemble the ball check valves and manifolds as
explained on page 18.