Graco SaniForce 1040e Use and care manual

Repair/Parts
SaniForce® SaniForce®
SaniForce®1040e 1040e 1040eElectric Electric Electric- - -Operated Operated Operated
Diaphragm Diaphragm
DiaphragmPump Pump Pump3A3168N
EN
For For
For󰘱uid 󰘱uid 󰘱uidtransfer transfer transferin in inindoor indoor indoorsanitary sanitary sanitaryapplications. applications. applications.Not Not Notapproved approved approvedfor for foruse use usein in inexplosive explosive explosiveatmospheres atmospheres atmospheresor or or
hazardous hazardous
hazardous(classi󰘰ed) (classi󰘰ed) (classi󰘰ed)locations locations locationsunless unless unlessotherwise otherwise otherwisestated. stated. stated.See See SeeApprovals Approvals Approvalspage page pagefor for formore more moreinformation. information. information.For For For
professional professional
professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandinyour
SaniForce1040eOperationmanualbeforeusingtheequipment.
Save Save
Savethese these theseinstructions. instructions. instructions.
Formaximumoperatingpressures,
seethePerformanceChartsinyour
Operationmanual.
Seepages6–8formodelinformation,
includingapprovals.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals................................................2
Warnings...........................................................3
Con󰘰gurationNumberMatrixforFG
Pumps..................................................6
Con󰘰gurationNumberMatrixforHSandPH
Pumps..................................................7
Approvals...........................................................8
Overview............................................................9
Troubleshooting..................................................10
Repair................................................................12
PressureReliefProcedure............................12
CheckValveRepair.....................................12
DiaphragmRepair........................................14
CenterSectionRepair..................................17
ReplaceCenterBearing...............................20
ReplacetheCompressor..............................22
Parts..................................................................23
Cart-MountedModels...................................29
Cart.............................................................31
KitsandAccessories....................................35
TechnicalSpeci󰘰cations......................................36
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
3A3167SaniForce1040eElectric-OperatedDiaphragmPump,Operation
23A3168N

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
DANGER
SEVERE SEVERE
SEVEREELECTRIC ELECTRIC ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentcanbepoweredbymorethan240V.Contactwiththisvoltagewill
causedeathorseriousinjury.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesand
beforeservicingequipment.
•Thisequipmentmustbegrounded.Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocal
codesandregulations.
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolvent,inwork work
workarea area areacanigniteorexplode.Solvent󰘱owingthrough
theequipmentcancausestaticsparking.Tohelpprevent󰘰reandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygrounded󰘱uidlines.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
3A3168N3

Warnings
WARNING
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checklines,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Speci󰘰cations Speci󰘰cations
Speci󰘰cationsinallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.
Forcompleteinformationaboutyourmaterial,requestSafetyDataSheet(SDS)from
distributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Route󰘱uidlinesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhot
surfaces.
•Donotkinkoroverbend󰘱uidlinesoruse󰘱uidlinestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
PRESSURIZED PRESSURIZED
PRESSURIZEDALUMINUM ALUMINUM ALUMINUMPARTS PARTS PARTSHAZARD HAZARD HAZARD
Useof󰘱uidsthatareincompatiblewithaluminuminpressurizedequipmentcancauseserious
chemicalreactionandequipmentrupture.Failuretofollowthiswarningcanresultindeath,
seriousinjury,orpropertydamage.
•Donotuse1,1,1-trichloroethane,methylenechloride,otherhalogenatedhydrocarbon
solventsor󰘱uidscontainingsuchsolvents.
•Donotusechlorinebleach.
•Manyother󰘱uidsmaycontainchemicalsthatcanreactwithaluminum.Contactyourmaterial
supplierforcompatibility.
43A3168N

Warnings
WARNING
THERMAL THERMAL
THERMALEXPANSION EXPANSION EXPANSIONHAZARD HAZARD HAZARD
Fluidssubjectedtoheatincon󰘰nedspaces,includinglines,cancreatearapidriseinpressure
duetothethermalexpansion.Over-pressurizationcanresultinequipmentruptureandserious
injury.
•Openavalvetorelievethe󰘱uidexpansionduringheating.
•Replacelinesproactivelyatregularintervalsbasedonyouroperatingconditions.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheets(SDSs)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
3A3168N5

CongurationNumberMatrixforFGPumps
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrixfor for forFG FG FGPumps Pumps Pumps
Checktheidenti󰘰cationplate(ID)forthe
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Whenyoureceiveyourpump,recordthe9character
partnumberfoundontheshippingbox(e.g.,
SP1B.0014):
_____________
Alsorecordthecon󰘰gurationnumberonthepumpID
platetoassistyouwhenorderingreplacementparts:
_____________________________________
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:1040FG 1040FG
1040FG- - -EA04AS13SSPTPOPT21 EA04AS13SSPTPOPT21 EA04AS13SSPTPOPT21
1040 1040
1040FG FG FGE E
EA A A04A 04A
04AS13 S13 S13SS SS SSPT PT
PTPO PO
POPT PT
PT21 21
21
Pump
Model
Wetted
Section
Material
DriveCenter
Section
Material
GearBox
andMotor
Fluid
Coversand
Manifolds
SeatsBallsDiaphragmsManifold
O-rings
Certi󰘰ca-
tion
Pump Pump
PumpWetted Wetted
WettedSection Section Section
Material Material
Material
Drive Drive
DriveType Type TypeCenter Center
CenterSection Section SectionMaterial Material MaterialMotor Motor Motorand and andGearbox Gearbox Gearbox
1040 1040
1040FG FG FGFoodGradeE E
EElectricA A
AAluminum04A 04A
04AStandardACInductionMotorwith
Gearbox
S S
SStainlessSteel04B 04B 04BBrushlessDCMotor
04E 04E
04ENEMA56CGearbox‡
04F 04F
04FIEC90B5FlangeGearbox‡
04G 04G
04GNomotor,Nogearbox
05C 05C
05CBrushlessDCMotor(con󰘰gured
forcart-mountedsystems)
Fluid Fluid
FluidCovers Covers Coversand and and
Manifolds Manifolds
Manifolds
Seat Seat
SeatMaterial Material MaterialBall Ball
BallMaterial Material MaterialDiaphragm Diaphragm DiaphragmMaterial Material MaterialManifold Manifold
Manifold
Gaskets Gaskets
Gaskets
Certi󰘰cation Certi󰘰cation
Certi󰘰cation
S13 S13
S13TriClamp,
FGSS SS
SS316Stainless
SteelCW CW
CWPolychloro-
prene
Weighted
PO PO
POPTFE/EPDM
OvermoldPT PT
PTPTFE21 21
21EN10204
type2.1
S14 S14
S14DIN,FGPT PT
PTPTFEPT PT PTPTFE/EPDM
2-PieceEP EP
EPEPDM31 31
31EN10204
type3.1
SP SP
SPSantopreneSP SP SPSantoprene
63A3168N

CongurationNumberMatrixforHSandPHPumps
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrixfor for forHS HS HSand and andPH PH PHPumps Pumps Pumps
Checktheidenti󰘰cationplate(ID)fortheCon󰘰guration
Numberofyourpump.Usethefollowingmatrixtode󰘰ne
thecomponentsofyourpump.
Whenyoureceiveyourpump,recordthe9characterpart
numberfoundontheshippingbox(e.g.,SP1B.0014):
_____________
Alsorecordthecon󰘰gurationnumberonthepumpIDplate
toassistyouwhenorderingreplacementparts:
_____________________________________
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:1040HS.ES04ASSASSPTPOPT21 1040HS.ES04ASSASSPTPOPT21
1040HS.ES04ASSASSPTPOPT21
1040 1040
1040HS HS HSE E
ES S
S04A 04A 04ASSA SSA SSASS SS SSPT PT
PTPO PO
POPT PT
PT21 21
21
Pump
Model
Wetted
Section
Material
DriveCenter
Section
Material
GearBox
andMotor
Fluid
Coversand
Manifolds
SeatsBallsDiaphragmsManifold
Gaskets
Certi󰘰ca-
tion
Pump Pump
PumpWetted Wetted
WettedSection Section SectionMaterial Material MaterialDrive Drive
DriveType Type TypeCenter Center
CenterSection Section SectionMaterial Material MaterialMotor Motor Motorand and andGearbox Gearbox Gearbox
1040 1040
1040HS HS HSHighSanitationE E
EElectricS S
SStainlessSteel04A 04A 04AStandardACInductionMotor
withGearbox
PH PH
PHPharmaceutical04B 04B
04BBrushlessDCMotor
04E 04E
04ENEMA56CGearbox‡
04F 04F
04FIEC90B5FlangeGearbox‡
04G 04G
04GNomotor,Nogearbox
05C 05C
05CBrushlessDCMotor(con󰘰gured
forcart-mountedsystems)
Fluid Fluid
FluidCovers Covers Coversand and and
Manifolds Manifolds
Manifolds
Seat Seat
SeatMaterial Material MaterialBall Ball
BallMaterial Material MaterialDiaphragm Diaphragm DiaphragmMaterial Material MaterialManifold Manifold
Manifold
Gaskets Gaskets
Gaskets
Certi󰘰cation Certi󰘰cation
Certi󰘰cation
SSA SSA
SSATriClamp,
HSorPHSS SS
SS316Stainless
SteelBN BN
BNBuna-NBN BN BNBuna-NBN BN BNBuna-N21 21
21EN
10204
type2.1
SSB SSB
SSBDIN,HSor
PHCW CW
CWPolychloro-
prene
Weighted
PO PO
POPTFE/EPDM
OvermoldEP EP
EPEPDM31 31
31EN
10204
type3.1
FK FK
FKFKMPS PS
PSPTFE2-Piece
Santoprene
PT PT
PTPTFESP SP
SPSantoprene
SP SP
SPSantoprene
3A3168N7

Approvals
Approvals Approvals
Approvals
Approvals Approvals
Approvals
Allmodelsareapprovedto:
*DiaphragmmaterialscodedPO,PT,or
PScombinedwithballmaterialscodedPT
complywith:
EC1935/2004
‡Pumpswithcode04Eor04Fareapproved
to:
II2G
ExhIIBT3Gb
DiaphragmmaterialscodedPTorPS
combinedwithballmaterialscodedPT
complywith:
ClassVI
All󰘱uidcontactmaterialsareFDAcompliant
andmeettheUnitedStatesCodeofFederal
Regulations(CFR).
*EC1935/2004compliantpumpsmaybesubjecttoindividualnationalprovisionsinadditiontothose
speci󰘰edintheECregulation.Itistheusersresponsibilitytoknowandfollowlocallaws.
83A3168N

Overview
Overview Overview
Overview
Theproductlineofferselectric-powereddiaphragmpumpsinawiderangeofmodels.Thissectionshows
thebasicstructureofavailablemodels.
Food Food
FoodGrade Grade GradePump Pump PumpModels Models Models
Center Center
Center
Section Section
Section
Motor Motor
MotorType Type TypeController Controller
ControllerGearbox Gearbox GearboxCompressor Compressor CompressorApproval Approval
Approval
Options Options
Options
Cart Cart
Cart
Yes-120VNoneNo*
Yes-240VNo*AC
VFD—notincluded.
VFDKits16K911(240V)
and16K912(480V)are
available.
Yes–part
ofmotor
No†CENo*
Yes-120VNoneYes
Yes-240VYesBrushless
DC
GracoMotorControl–
includedNEMA
No†CENo*
NEMA
Aluminum
or
Stainless
Steel
NoneNoneIECNoneATEX&CENo*
*CartKit24Y923isavailable.
†CompressorKits24Y921(120V)and24Y922(240V)areavailable
High High
HighSanitation Sanitation Sanitationor or orPharmaceutical Pharmaceutical PharmaceuticalPump Pump PumpModels Models Models
Center Center
CenterSection Section SectionMotor Motor
Motor
Type Type
Type
Controller Controller
ControllerGearbox Gearbox GearboxCompressor Compressor CompressorApproval Approval
Approval
Options Options
Options
Cart Cart
Cart
AC
VFD—notincluded.
VFDKits16K911(240V)
and16K912(480V)are
available.
Yes–
partof
motor
Brushless
DC
GracoMotorControl–
includedNEMA
No†CE
NEMA
StainlessSteel
NoneNoneIECNoneATEX&CE
No*
*CartKit24Y923isavailable.
†CompressorKits24Y921(120V)and24Y922(240V)areavailable
Key Key
KeyPoints: Points: Points:
•PumpsareavailablewithanACorBrushless
DC(BLDC)motor,orwithjustagearbox(for
applicationswhereamotorisalreadyavailable).
•Gracorecommendstheuseofamotorsoft
starteroraVFD(PN16K911or16K912)inthe
electricalcircuitforallinstallations.Seethe
motormanufacturer’srecommendationsforproper
installationwhenusingeitherofthesecomponents.
Inallcases,makesureallproductsareinstalledin
accordancewithlocalcodesandregulations.
•BLDCmotorsarecontrolledbytheGracoMotor
Controlthatissuppliedwiththepump.
3A3168N9

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
•FollowthePressureReliefProcedure,page12,
beforecheckingorservicingtheequipment.
•Checkallpossibleproblemsandcausesbefore
disassembly.
SeetheOperationManual(3A3167)fortroubleshootingorerrorinformationontheGracoMotorControl.
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Pumpisrunningtoofast,causing
cavitationbeforeprime.
Slowdownthemotorcontroller(VFD
orGracoMotorControl)
Centersectionhasnoairpressure,
orairpressureistoolow.
Applyairpressuretocentersection
peryourapplicationrequirements.
Checkvalveballisseverelywornor
wedgedinseatormanifold.
Replacetheballandseat.
Insuf󰘰cientsuctionpressureIncreasesuctionpressure.See
manual3A3167.
Seatisseverelyworn.Replacetheballandseat.
Outletorinletisrestricted.Removetherestriction.
Inlet󰘰ttingsormanifoldsareloose.Tighten.
Pumpcyclesbutwillnot
primeand/orpump.
Manifoldo-ringsaredamaged.Replaceo-rings.
Thecentersectionis
excessivelyhot.
Thedriveshaftisbroken.Replace.
Checkvalveballs,seats,oro-rings
areworn.
Replace.
Manifoldclampsor󰘱uidcover
clampsareloose.
Tighten.
Pumpfailstohold󰘱uid
pressureatstall.
DiaphragmshaftboltislooseTighten.
Motororcontrolleriswired
improperly.
Wirepermanual. Pumpwillnotcycle.
Theleakdetector(ifinstalled)has
tripped.
Checkdiaphragmforruptureor
incorrectinstallation.Repairor
replace.
Suctionlineisclogged.Inspect;clear.
Checkballsarestickyorleaking.Cleanorreplace.
Pump󰘱owrateiserratic.
Diaphragm(orbackup)ruptured.Replace.
Pumpmakesunusualnoises.Pumpisoperatingnearoratstall
pressure.
Adjustairpressureorslowthepump
speed.
A󰘰ttingisloose.Tighten.Inspectthreadsealant.
Looseordamagedo-ringsorshaft
seal.
Replace.
Airconsumptionishigher
thanexpected.
Diaphragm(orbackup)ruptured.Replace.
103A3168N

Troubleshooting
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Suctionlineisloose.Tighten.
Diaphragm(orbackup)ruptured.Replace.
Loosemanifolds,damagedseatsor
o-rings.
Tightenmanifoldboltsorreplace
seatsoro-rings.
Airbubblesin󰘱uid.
Loosediaphragmshaftbolt.Tighten.
Loosemanifoldclampsor󰘱uidcover
clamps.
Tighten.
Pumpleaks󰘱uidexternally
fromjoints.
Manifoldo-ringswornout.Replaceo-rings.
AGFCIhastripped.RemovethecontrollerfromtheGFCI
circuit.
Supplypowerispoor.Determineand󰘰xthesourceofthe
powerproblem.
Thecontrollerfaultsorshuts
down.
Operationalparametersare
exceeded.
Seemanual3A3167foreventcodes.
NOTE: NOTE:
NOTE:ForproblemswithaVariableFrequencyDevice(VFD),seeyourVFDmanual.Forproblemswiththe
GracoMotorControl,seeyourOperationManual.
3A3168N11

Repair
Repair Repair
Repair
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressureis
manuallyrelieved.Tohelppreventseriousinjury
frompressurized󰘱uid,suchassplashing󰘱uid,
followthePressureReliefProcedurewhenyou
stopdispensingandbeforecleaning,checking,or
servicingtheequipment.
1.Turnoffthepumpanddisconnectpowertothe
system.
2.Closethemasterairvalve(J)toshutofftheair
tothepump.
3.Openthe󰘱uiddrainvalve(L)torelieve󰘱uid
pressure.Haveacontainerreadytocatchthe
drainage.
4.Closethepumpairinletvalve(E)onthe
pneumaticenclosure.
5.Units Units
Unitswith with witha a acompressor: compressor: compressor:Cyclethevalveto
bleedanyremainingair.
Check Check
CheckValve Valve ValveRepair Repair Repair
NOTE: NOTE:
NOTE:Kitsareavailablefornewcheckvalveballs,
diaphragms,andmanifoldo-ringsinarangeof
materials.Aseatandmanifoldo-ringkitisalso
available.
NOTE: NOTE:
NOTE:Toensureproperseatingofthecheckballs,
alwaysinspecttheseatswhenreplacingtheballs.
Replaceseatsasnecessaryifseatingsurfaceshows
evidenceofwear.
Disassemble Disassemble
Disassemblethe the theCheck Check CheckValves Valves Valves
1.FollowthePressureReliefProcedure,page12.
Removepowerfromthemotor.Disconnectall
󰘱uidandairlines.
2.Removethemanifoldclamps(6),thenremove
theoutletmanifold(3).
3.Removetheballcheckassemblies:
a.Onthe1040FG,removetheo-rings(9),
seats(7),andballs(8).
b.Onthe1040HSand1040PH,removethe
ballstops(8),gaskets(9),andballs(8).
4.Repeatfortheinletmanifold(4),o-rings(9),
seats(7),andballs(8).
5.Tocontinuedisassembly,see
DisassembletheDiaphragms,page14.
Reassemble Reassemble
Reassemblethe the theCheck Check CheckValves Valves Valves
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
2.Reassembleinthereverseorder,followingall
notesintheillustration.Puttheinletmanifoldon
󰘰rst.Besuretheballchecks(7–9)andmanifolds
(3,4)areassembledexactly exactly
exactlyasshown.The
arrowsonthe󰘱uidcovers(2)must must
mustpointtoward
theoutletmanifold(3).
123A3168N

Repair
1040FG 1040FG
1040FG
1
Arrowonbothcoversmustpointtoward
outletmanifold
1040HS 1040HS
1040HSor or or1040PH 1040PH 1040PH
3A3168N13

Repair
Diaphragm Diaphragm
DiaphragmRepair Repair Repair
Disassemble Disassemble
Disassemblethe the theDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page12.
Removepowerfromthemotor.Disconnectall
hoses.
2.Removethemanifoldsanddisassemble
theballcheckvalvesasexplainedin
CheckValveRepair,page12.
3.Removetheclamps(5)fromthe󰘱uidcovers,
thenpullthe󰘱uidcoversoffofthepump.
4.Loosenthescrewsandremovethemotorfan
cover.Turnthemotorfanbyhandtomovethe
pistonfullytooneside.
NOTE: NOTE:
NOTE:Ifthepumpisstillattachedtothemotor,
removetheplug(124)ando-ring(134).Usea
10mmsockettorotatetheshaftclockwiseto
shiftthepistontooneside.Socketshouldmove
easily[nomorethan15in-lb(1.7N•m)oftorque].
Ifmoretorqueisrequired,stop.Removethe
motor.SeeCenterSectionRepair,page17
5.Overmolded Overmolded
OvermoldedDiaphragms Diaphragms Diaphragms( ( (PO PO POmodels) models) models)
a.Holda5/8in.wrenchonthewrench󰘱atsof
theexposedpistonshaft.Thediaphragm
(12)willscrewoffbyhand.Removetheair
sidediaphragmplate(11).
b.Movethepistonfullytoonesidebyrotating
thedriveshaft.OnACModels,movethe
pistonbyhandturningthemotorfan.(See
instructionsinstep4).Repeatstep5a.
6.All All
AllOther Other OtherDiaphragms Diaphragms Diaphragms
a.Holda5/8in.wrenchonthewrench󰘱ats
oftheexposedpistonshaft.Usea15mm
wrenchontheshaftbolt(15)toremoveit.
Thenremoveallpartsofthediaphragm
assembly.
b.Movethepistonfullytoonesidebyrotating
thedriveshaft.OnACModels,movethe
pistonbyhandturningthemotorfan.(See
instructionsinstep4).Repeatstep6a.
7.Tocontinuewithcentersectiondisassembly,see
DisassembletheCenterSection,page17.
143A3168N

Repair
Reassemble Reassemble
Reassemblethe the theDiaphragms Diaphragms Diaphragms
Followallnotesintheillustrationsonthefollowing
page.Thesenotescontainimportant important
importantinformation.
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthe
centersection(driveshaft,piston,etc.),follow
CenterSectionRepair,page17,beforereplacing
diaphragms.
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.Besurethecenter
sectioniscleananddry.
2.Overmolded Overmolded
OvermoldedDiaphragms Diaphragms Diaphragms(PO) (PO) (PO)
a.Ifadiaphragmsetscrewcomeslooseor
isreplaced,applypermanent(red)thread
lockertodiaphragmsidethreads.Screwinto
diaphragmuntiltight.
b.Assembletheairsideplate(11)ontothe
diaphragm.Theroundedsideoftheplate
mustfacethediaphragm.
c.Cleanthefemalethreadsofthepiston
shaftwithawirebrushdippedinsolventto
removeanyresidualthreadlocker.Apply
thread-lockingprimerandallowittodry.
d.Thoroughlyclean,thenapply
medium-strength(blue)threadlocker
tothethreadsofthediaphragmassembly.
e.Holda5/8in.wrenchonthewrench󰘱atsof
thepistonshaft.Screwtheassemblyintothe
shaftastightaspossiblebyhand.
f.Movethepistonfullytoonesideby
rotatingthedriveshaft.OnACmodels,
movethepistonbyhandturningthe
motorfan.Seeinstructionsinstep4of
DisassembletheDiaphragms,page14.
g.Repeattoinstalltheotherdiaphragm
assembly.
3.All All
AllOther Other OtherDiaphragms-Metal Diaphragms-Metal Diaphragms-MetalPumps Pumps Pumps
a.Thoroughlycleanorreplacethediaphragm
bolt(14).Installtheo-ring(15).
b.Assemblethe󰘱uidsideplate(10),the
diaphragm(12),thebackupdiaphragm(13,
ifpresent),andtheairsidediaphragmplate
(11)ontheboltexactlyasshown.
c.Cleanthefemalethreadsofthepiston
shaftwithawirebrushdippedinsolventto
removeanyresidualthreadlocker.Apply
thread-lockingprimerandallowittodry.
d.Applymedium-strength(blue)threadlocker
tothethreadsofthebolt.
e.Holda5/8in.wrenchonthewrench󰘱ats
ofthepistonshaft.Screwtheboltontothe
shaftandtorqueto60–70ft-lb(81–95N•m).
f.Movethepistonfullytoonesideby
rotatingthedriveshaft.OnACmodels,
movethepistonbyhandturningthe
motorfan.Seeinstructionsinstep4of
DisassembletheDiaphragms,page14.
g.Repeattoinstalltheotherdiaphragm
assembly.
4.Attachthe󰘱uidcovers.Thearrowoneach󰘱uid
covermustpointtowardtheoutletmanifold.
Tightenthemountingclamp(5).
NOTE: NOTE:
NOTE:Afoodgradeanti-seizelubricantcanbe
usedontheclampthreadstoaidassembly.
5.Reassemblethecheckvalvesandmanifolds.
SeeReassembletheCheckValves,page12.
3A3168N15

Repair
1
Roundedsidefacesdiaphragm.2 2
2- - -Piece Piece Piece( ( (PT PT PTand and andPS PS PS) ) )Models Models Models
2
Applymedium-strength(blue)thread
lockertothethreads.
3
AIRSIDEmarkingsondiaphragmmust
facethecenterhousing.
4
Ifthescrewcomeslooseorisreplaced,
applypermanent(red)threadlocker
todiaphragmsidethreads.Apply
medium-strength(blue)threadlockerto
shaftsidethreads.
5
Torqueto60–70ft-lb(81–95N•m)at
100rpmmaximum.
6
Applyprimertothefemalethreads.
Allowtodry.
Overmolded Overmolded
Overmolded( ( (PO PO PO) ) )Models Models ModelsStandard Standard Standard( ( (SP SP SP) ) )Models Models Models
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
163A3168N

Repair
Center Center
CenterSection Section SectionRepair Repair Repair
Disassemble Disassemble
Disassemblethe the theCenter Center CenterSection Section Section
Seetheillustrationsonthefollowingpage.
1.FollowthePressureReliefProcedure,page12.
Disconnectall󰘱uidandairlines.
2.Removethemanifoldsand
checkvalvepartsasdirectedin
DisassembletheCheckValves,page12.
3.Removethe󰘱uidcoversand
diaphragmsasdirectedin
DisassembletheDiaphragms,page14.
TIP: TIP:
TIP:Clampthegearboxbracket(27)tothe
bench.Leavethepumpconnectedtothemotor.
4.Usea5mmhexwrenchtoremove4bolts(117).
Pullthepumpoffofthealignmenthousing(116).
TIP: TIP:
TIP:Itmaybenecessarytotapthepumpwitha
rubbermallettodisengagethecoupler.
5.Usea5/16hexwrenchtoremovetheplug(124).
Usea30mmsocketwrenchtoremovethe
bearingbolt(106)andtheo-ring(108)fromthe
top.
6.Turntheshaftsothegroove(G)onthedrive
shaft(112)isatthetop,inlinewiththealignment
mark(A)onthecenterhousing.
7.Usea3/4–16bolt,screwedintotheholeforplug
(124),topushoutthedriveshaft(112).Youcan
alsousethebearingbolt(106),butremovethe
bearing(107)󰘰rst.Besurethatthegrooveon
thedriveshaftremainsalignedwiththemarkings
inthecentersection.
NOTICE NOTICE
NOTICE
Properalignmentisessential.Donotapply
morethanabout10in-lb(1.1N•m)oftorque.
Excessivetorquecouldstripthehousing
thread.Ifyouencounterresistance,check
driveshaftalignmentorcontactyourdistributor.
8.Removethesealcartridge(110),theo-ring(109)
andtheradialseal(111)witho-ring(111a).
9.Slidethepistonassembly(102)outofthecenter.
10.Leavethegearboxcoupler(114)attachedtothe
gearbox(118)shaftunlessitisdamaged.Ifyou
needtoremoveit,󰘰rstremovethealignment
housing(116).Usean8mmhexwrenchto
loosenthescrew(115),thenremovethegearbox
coupler(114).
NOTE: NOTE:
NOTE:Ifthecouplerdoesnotcomeofffreely,
useabearingpullertoremoveit.Donotuseany
pryingtools,asdamagetothemounting󰘱ange
onthegearboxcouldoccur.
3A3168N17

Repair
1
Applymedium-strength(blue)thread
lockertothreads.
2
Torqueto15–25ft-lb(20–34N•m).
3
LipsmustfaceIN IN
INtowardthecenter.
4
Applyanti-seizelubricantliberally
onthesurfacesofthedriveshaft
assembly.
5
Installthedriveshaftassemblywith
thegroovefacingup.
6
Tightenscrewsinacrisscross
pattern,5turnsatatime,toengage
thecouplerevenly.Torqueto
130–160in-lb(15–18N•m).
7
Applylubricanttoinnermating
surface.
183A3168N

Repair
Reassemble Reassemble
Reassemblethe the theCenter Center CenterSection Section Section
Seetheillustrationsonthepreviouspage.
1.Cleananddrythecenterhousing(101),the
centerofthepiston(102)andthedriveshaft
(112).
2.Inspectthepistonforexcessivewearandreplace
ifneeded.Greasethepistonasshownonpage
18andinstallitinthecentersectionwiththe
grooveonthetop,inlinewiththebearingbolt
(106)holeinthecentersection.
3.Installthebearing(107[ifremovedfromthe
bearingbolt]),o-ring(108),andthebearingbolt
(106).Applymedium-strength(blue)thread
lockertothebearingbolt.Besurethatthe
bearing(107)isinthegrooveonthepiston,as
shown.Besurethatthepistonmovesfreely.
Torquetheboltto15–25ft-lb(20–34N•m).
4.Besurethesealingsurfaceofthedriveshaft
(112)isclean.Installthesealcartridge(110†)
andtheradialseal(111†)onthedriveshaft.Be
suretheo-ring(111a†)isontheradialseal.The
lipsontheradialseal(111†)mustfaceIN IN
INtoward
thecenter.
5.Installo-ring(109†).
6.Applyanti-seizelubricantonthematingsurfaces
ofthedriveshaft,asshownintheillustration,
page18.
7.Centerthepistoninthehousingandinstallthe
driveshaftassembly(112),withthegroove(G)
facingup,intothecenterhousing(101).
8.Inspecttheshaftcoupler(114)forwearand
replaceifneeded.Installonthedriveshaft.
9.Ifremoved,installthegearboxcoupler(114)
ontheshaft.Applymediumstrength(blue)
threadlockerandinstallthescrew(115).Torque
to35–45ft-lb(47–61N•m).Theninstallthe
alignmenthousing(116)andliftingbracket(139)
onthegearboxusingthescrews(120,122),
washers(119).Torqueto130–160in-lb(15–18
N•m).
10.Installthealignmenthousingo-ring(130)onthe
housing(101).
11.Besurethegearboxcoupler(114)isaligned
properly.Turnbyhandifneeded.Connectthe
pumptothegearboxassembly,engagingthe
couplers.
12.Applymedium-strength(blue)threadlockerand
installthehousingscrews(117).Tighteneach
screwabout5turnsatatime,inacrisscross
pattern,tofullyengagethecoupler.Torqueto
130–160in-lb(15–18N•m).
13.Besureo-ring(134)isontheplug(124).Install
theplugandtorqueto15–25ft-lb(20–34N•m).
14.SeeReassembletheDiaphragms,page15,and
ReassembletheCheckValves,page12.
3A3168N19

Repair
Replace Replace
ReplaceCenter Center CenterBearing Bearing Bearing
NOTE: NOTE:
NOTE:Followthisprocedureonlyifyoususpectthat
thecenterbearingisdamaged.Itisnotnecessaryto
replacethebearingfornormalpumpservice.Youwill
needCenterSectionRepairToolKit24Y627.You
alsowillneedBearingPullerKit17J718.Thetool(A)
wasdesignedtoworkwiththisbearingpuller.
1.Followallstepsin
DisassembletheCenterSection,page17.
2.Clampthecenterhousing(101)inavise,with
oneofthebushingsfacingup.
3.Placetherepairtool(A)onthehousingwiththe
groovedsidedown.
4.Removethebushing(C).Usetheupperholes
onthemedium-sizedjaw,andtheinnerholes
onthepuller.Besurethatthejawsengagethe
bottomrimofthebushing.Whenonebushing
isout,turnthehousingoverandrepeatforthe
otherbushing.
5.Placethecenterhousing(101)inthevisewith
thebearing(D)sideonthebottom.
6.Placetherepairtool(A)onthehousingwiththe
steppedsidedown.
7.Removethebearing(D).Usethelowerholeson
themedium-sizedjaw,andtheouterholeson
thepuller.
8.Useanarborpresstoinstallthenewbearing(D)
intothecenterhousing(101).Pressthebearing
totheshoulderinthecenterhousing.
203A3168N