Graco saniforce 1590 Manual

Repair/PartsList
SaniForce®1590Air-Operated
HighSanitationDiaphragmPump3A6781C
EN
For For
Foruse use usein in insanitary sanitary sanitaryapplications. applications. applications.
For For
Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandrelated
manualsbeforeusingtheequipment.Save Save
Saveall all allinstructions. instructions. instructions.
Maximumworkingpressure:120psi
(0.8MPa,8bar)
Seepage6forapprovals.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals................................................2
Warnings...........................................................3
Con󰘰gurationNumberMatrix...............................5
OrderingInformation...........................................6
Troubleshooting..................................................7
Repair................................................................9
PressureReliefProcedure............................9
AirValveRepair...........................................9
CheckValveRepair.....................................12
StandardDiaphragmRepair.........................14
OvermoldedDiaphragmRepair.....................16
CenterSectionRepair..................................18
LeakDetectors............................................20
Parts..................................................................22
TechnicalData...................................................28
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
3A5999SaniForceHighSanitationDiaphragmPumps,Operation
3A6976LeakDetectionSystem,Instructions/Parts
23A6781C

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reand
explosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
•Routeexhaustawayfromallignitionsources.Ifdiaphragmruptures,󰘱uidmaybeexhausted
withair.
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
3A6781C3

Warnings
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestSafetyDataSheet(SDS)fromdistributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
43A6781C

CongurationNumberMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrix
Checktheidenti󰘰cationplate(ID)forthe
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Whenyoureceiveyourpump,recordthe9character
partnumberfoundontheshippingbox(e.g.,
SP15.0023):_____________
Alsorecordthecon󰘰gurationnumberonthepumpID
platetoassistyouwhenorderingreplacementparts:
_____________________________________
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:1590HS.PSP1ASSASSPTPSEP21 1590HS.PSP1ASSASSPTPSEP21
1590HS.PSP1ASSASSPTPSEP21
1590 1590
1590HS HS HSP P
PSP1A SP1A
SP1ASSA SSA SSASS SS SSPT PT
PTPS PS
PSEP EP
EP21 21
21
Pump
Model
WettedSection
Material
DriveCenterSectionandAir
ValveMaterial
ManifoldsSeatsChecksDiaphragmsSealsCerti󰘰ca-
tion
NOTE: NOTE:
NOTE:Somecombinationsarenotpossible.Pleasecheckwithyourlocalsupplier.
Pump Pump
PumpWetted Wetted
WettedSection Section Section
Material Material
Material
Drive Drive
DriveType Type TypeCenter Center
CenterSection Section Sectionand and and
Air Air
AirValve Valve ValveMaterial Material Material
Manifolds Manifolds
Manifolds
1590 1590
15903A 3A 3A3-AcompliantP P
PPneumaticS01A S01A
S01AStainlessSteelSSA SSA
SSAStainlesssteel,
TriClamp,horizontal
HS HS
HSHighSanitationS02A S02A S02AStainlessSteel,3-ASSB SSB SSBStainlesssteel,DIN,
horizontal
PH PH
PHPharmaceuticalS03A S03A
S03AStainlessSteel,PHSSC SSC
SSCStainlesssteel,
TriClamp,SDU,STU
use
SP1A SP1A
SP1AStainlessSteel,PS
diaphragmsSSD SSD
SSDStainlesssteel,DIN,
SDU,STUuse
SP3A SP3A
SP3AStainlessSteel,PH,
PSdiaphragms
Seat Seat
SeatMaterial Material MaterialChecks Checks ChecksDiaphragm Diaphragm
DiaphragmMaterial Material MaterialSeals Seals
SealsCerti󰘰cation Certi󰘰cation Certi󰘰cation
FL FL
FL316Stainless
Steel,Flapper
— —
—FlapperEO EO
EOEPDM
OvermoldEP EP
EPEPDM21 21
21Type2.1
SS SS
SS316Stainless
Steel,BallCW CW
CWPolychloroprene
WeightedBallFK FK
FKFKM
Fluoroelastomer31 31
31Type3.1
FK FK
FKFKM
Fluoroelastomer
Ball
PO PO
POPTFE/EPDM
Overmold
PT PT
PTPTFEBallPS PS
PSPTFE/
Santoprene,2
piece
SP SP
SPSantopreneBallSP SP SPSantoprene
3A6781C5

OrderingInformation
Approvals Approvals
Approvals
Exceptfor3-Apumps,allpumpsarecerti󰘰ed
to:
II2GD
ExhIIAT6...T3GbX
ExhIIIBT160°CDb
DiaphragmmaterialscodedEO,PO,orPS
combinedwith󰘱apperorPTballchecksare
certi󰘰edto:
EC1935
AllModelsarecerti󰘰edtoFDAstandardsand
Ordering Ordering
OrderingInformation Information Information
To To
ToFind Find FindYour Your YourNearest Nearest NearestDistributor Distributor Distributor
1.Visitwww.graco.com.
2.ClickonWhere Where
Whereto to toBuy Buy BuyandusetheDistributor Distributor DistributorLocator. Locator. Locator.
To To
ToSpecify Specify Specifythe the theCon󰘰guration Con󰘰guration Con󰘰gurationof of ofa a aNew New NewPump Pump Pump
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
OR OR
OR
UsetheOnline Online
OnlineDiaphragm Diaphragm DiaphragmPump Pump PumpSelector Selector Selectorat at atwww.graco.com www.graco.com www.graco.com. . .Tolocate,searchonselector selector selector.
To To
ToOrder Order OrderReplacement Replacement ReplacementParts Parts Parts
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
63A6781C

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
•FollowthePressureReliefProcedure,page9,
beforecheckingorservicingtheequipment.
•Checkallpossibleproblemsandcausesbefore
disassembly.
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Pumpcyclesatstallor
failstoholdpressureat
stall.
Wornchecksorseats.Replace.
Airvalveisstuckordirty.Disassembleandcleanairvalve.
Use󰘰lteredair.
Checkballisseverelywornand
wedgedinseatormanifold.
Replaceballandseatcomponent.
Checkvalveballisseverelywedged
intoseatduetooverpressurization.
Follow
PressureReliefProcedure,page9.
Disassembleballcheckassembly
andinspectfordamage.
Cloggeddispensingvalve.Follow
PressureReliefProcedure,page9.
Clearvalve.
Pumpwillnotcycle,or
cyclesonceandstops.
Leakdetectorhasactivatedashut-
downsolenoid.
Investigatefailureandresetleak
detector.
Cloggedsuctionline.Inspect;clear.
Stickyorleakingcheckballsor
󰘱apperchecks.
Cleanorreplace.
Flapvalvesinstalledupside-down.Installthe󰘱appervalvewiththetext
sidefacingtheseat.
Ruptureddiaphragm.Replace.Seestandardor
overmoldedrepairprocedure.
Pumpoperates
erratically.
Restrictedexhaust.Removerestriction.
Loosesuctionline.Tighten.
Ruptureddiaphragm.Replace.Seestandardor
overmoldedrepairprocedure.
Airbubblesin󰘱uid.
Looseinletmanifold,damagedseal
betweenmanifoldand󰘱uidcover,or
damagedgaskets.
Tightenmanifoldclampsorreplace
gasketsorseatingcomponents.
Loosesanitaryclamp.Tightenclamp.
Damagedorworngasket.Replacegasket.
Leakininletoroutlet
sanitary󰘰tting.
Misalignmentofinlet/outlethoseor
pipe.
Use󰘱exiblehosesatpumpinletand
outlet.
Manifoldsdonot󰘰tfor
installationonto󰘱uid
covers.
Useofincorrectaircovergaskets
resultsinmisalignment.
Installcorrectaircovergasketsfor
thetypeofdiaphragmsinuse.See
Partslistforcorrectgasket.
3A6781C7

Troubleshooting
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Diaphragmruptured.Replace.Seestandardor
overmoldedrepairprocedure.
Fluidinexhaustair.
Loosediaphragmplate.Tightenorreplace.Seestandardor
overmoldedrepairprocedure.
Wornairvalveblock,plate,pilot
block,u-cups,orpilotpino-rings.
Repairorreplace. Pumpexhaustsexcessive
airatstall.
Wornshaftseals.Replace.Seestandardor
overmoldedrepairprocedure.
Looseairvalvecover.Tightenscrews.
Airvalvegasketoraircovergasket
isdamaged.
Inspect;replace.
Pumpleaksairexternally.
LooseaircoverclampsTightenclamps.
Pumpleaks󰘱uid
externallyfromballcheck
valves.
Loosemanifolds,damagedseal
betweenmanifoldand󰘱uidcover,or
damagedgaskets.
Tightenmanifoldclampsorreplace
seatsorclamps.
Chattering.Checkvalveballsnotseating
properly/cleanlyduetoimbalance
between󰘱uidinletandoutletline
sizing.Noiseisaccentuatedwith
lightviscosity󰘱uids.
Reducesize/diameterofinletline
relativetooutletline.Outletlinesize
shouldnotexceedpumpsize.
83A6781C

Repair
Repair Repair
Repair
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Trappedaircancausethepumptocycle
unexpectedly,whichcouldresultinserious
injuryfromsplashing.FollowthePressure Pressure
PressureRelief Relief Relief
Procedure Procedure
Procedurewhenyoustoppumpingandbefore
cleaning,checking,orservicingequipment.
1.Shutofftheairtothepump.
2.Openanyavailableoutbound󰘱uidvalveto
relieve󰘱uidpressurefromthepump.
3.If󰘱uidisstillintheoutbound󰘱uidlines,isolate
this󰘱uidasfollows:
a.Closetheoutbound󰘱uidvalves.
b.Slowlyremovethe󰘱uidconnectionsfromthe
pump,andhaveacontainerreadytocatch
any󰘱uidthatrunsout.
Air Air
AirValve Valve ValveRepair Repair Repair
ToolsRequired
•Torquewrench
•Torx(T20)screwdriveror7mm(9/32in.)socket
wrench
•Needle-nosepliers
•O-ringpick
•Lithiumbasegrease
Airvalverepairkit255122isavailable.Useallparts
inthekitforbestresults.
Disassemble Disassemble
DisassembleAir Air AirValve Valve Valve
1.FollowthePressureReliefProcedure,page9.
2.WithaTorx(T20)screwdriveror7mm(9/32in.)
socketwrench,removethesixscrews(107),air
valvecover(109),andgasket(118).
3.Movethevalvecarriage(105)tothecenter
positionandpullitoutofthecavity.Usinga
needle-nosepliers,pullthepilotblock(116)
straightupandoutofthecavity.
4.Pullthetwoactuatorpistons(114).Removethe
u-cups(106)fromthepistons.Pullthepilotpins
(112).Removetheo-rings(108)fromthepilot
pins.
3A6781C9

Repair
5.Inspectthevalveplate(110)inplace.If
damaged,useaTorx(T20)screwdriveror7mm
(9/32)in.)socketwrenchtoremovethethree
screws(107).Removethevalveplate(110).
6.Inspectthebearings(113,115)inplace.See
Parts,page22.Thebearingsaretaperedand,
ifdamaged,mustberemovedfromtheoutside.
Thisrequiresdisassemblyofthe󰘱uidsection.
SeeCenterSectionRepair,page18.
7.Cleanallpartsandinspectforwearordamage.
Replaceasneeded.
Using
Using
Using Diaphragm
Diaphragm
Diaphragm Install
Install
Install Tool
Tool
Tool
If repairs involve removal of 󰘱uid covers, these steps
will ease installation of 󰘱uid c overs. These steps
should be performed prior to reassembly of the air
valve because the air valve con󰘰guration will be
modi󰘰ed to aid 󰘱uid cover installation.
The diaphragm install tool kit 24V543 is available
separately.
1.Iftheairvalveassemblyhasnotbeen
disassembled:
a.Removetheairvalvecover(109)andgasket
(118).
b.Removethevalvecartridge(105)andboth
pistons(114).
c.Insertthetravelrestrictors(2)fromthe
diaphragminstalltoolkitintotheactuator
pistons(E).Lubricatetheu-cupsandinsert
theactuatorpistonsinthebearings(115),
wide wide
wide
end󰘰rst.Leavethenarrowendofthe
pistonsexposed.
d.Proceedtostep4below.
2.Iftheairvalveassemblyhasbeendisassembled,
performstep1throughstep4oftheairvalve
reassemblyprocedure.
3.Installtheu-cups(106)ontotheactuatorpistons
(E)andinsertthetravelrestrictors(2)fromthe
diaphragminstalltoolkitintotheactuatorpistons
(E).Lubricatetheu-cupsandinserttheactuator
pistonsinthebearings(115),
wide wide
wide
end󰘰rst.
Leavethenarrowendofthepistonsexposed.
4.Installthesupplieddiaphragminstalltool(1)so
thatthearrow(A)pointstowardthesideofthe
pumpwiththediaphragmagainsttheaircover.
Installtheairvalvegasket(C)andcover(B).
Snugtheairvalvecoverscrews.
5.Lubricatetheinnersurfaceofbothcoverclamps
withwaterproofsanitarylubricant.Installthe
coverandclamponthesideofthepumpwith
thediaphragmagainsttheaircover.Leavethe
clampslightlytightenedbutlooseenoughto
allowminorcoverrotationtoallowforalignment
withtheinletandoutletmanifolds.
6.Supplythepumpwithlowpressureair,just
enoughtomovethediaphragm.Useabout10to
20psi(0.07MPa,0.7to1.4bar).Shopairmay
beused.Thediaphragmwillshiftsothesecond
󰘱uidcoverwillseatproperly.Keepairpressure
on.
7.Installtheremaining󰘱uidcoverandclamp.
8.Removeairsupplyfrompump.
9.Removetheairvalvecover(B),gasket(C)and
thetool(1).
10.Removethepistons(E)andthetravelrestrictors
(2).
11.Lubricateandinstallthepistons(E).
12.Tocompleteassemblyoftheair
valveassembly,proceedtostep6of
ReassembleAirValve,page11.
103A6781C

Repair
Reassemble Reassemble
ReassembleAir Air AirValve Valve Valve
1.Ifthecentersectionwasdisassembledtoreplace
thebearings(113,115),completethecenter
sectionrepairbeforecontinuingwiththeairvalve
reassembly.
2.Installthevalveplate(110)inthecavity,seal
down.Installthethreescrews(107),usinga
Torx(T20)screwdriveror7mm(9/32in.)socket
wrench.Tightenuntilthescrewsbottomouton
thehousing.
3.Installano-ring(108)oneachpilotpin(112).
Greasethepinsando-rings.Insertthepinsinto
thebearings,
narrow narrow
narrow
end󰘰rst.
4.Installu-cups(106)oneachactuatorpiston
(114),sothelipsofthepackingsfacethe narrow narrow
narrow
endofthepistons.
5.Lubricatetheu-cups(106)andactuatorpistons
(114).Inserttheactuatorpistonsinthebearings
(115), wide wide
wide
end󰘰rst.Leavethenarrowendof
thepistonsexposed.
6.Greasethelowerfaceofthepilotblock(116)and
installsoitstabssnapintothegroovesonthe
endsofthepilotpins(112).
7.Greasethelowerfaceofthevalvecarriage(105).
8.Installthevalvecarriage(105)soitstabsslipinto
thegroovesonthenarrowendoftheactuator
pistons(114).
9.Alignthevalvegasket(118)andcover(109)
withthesixholesinthecenterhousing(101).
Securewithsixscrews(107),usingaTorx(T20)
screwdriveror7mm(9/32in.)socketwrench.
Torqueto50-60in-lb(5.7-6.8N•m).
3A6781C11

Repair
Check Check
CheckValve Valve ValveRepair Repair Repair
NOTE: NOTE:
NOTE:Kitsareavailablefornewcheckvalve
󰘱appers,orcheckvalveballsinarangeofmaterials.
Gasketkitsalsoareavailable.
Disassemble Disassemble
DisassembleBall Ball BallCheck Check CheckValves Valves Valves
1.FollowthePressureReliefProcedure,page9.
Disconnectallhoses.
2.Todrainthepump,pulltheframequick-release
pins(207)androtatethepump.
NOTE: NOTE:
NOTE:Afterdraining,rotatethepumpto
positionswhichwillaiddisassembly.
3.Removetheclamps(23)ontheoutletmanifold
(17)andremovethemanifold.
NOTE: NOTE:
NOTE:Usecarewhileremovingmanifoldsto
safelyremovecheckvalvecomponents.
4.Removeremainingclamps,manifolds,gaskets
andcheckvalves.
5.Cleanandinspectgaskets,balls,ballstops,and
seatingsurfacesforanydamageandreplaceas
necessary.
6.Tocontinuedisassembly,see
DisassembletheStandardDiaphragms,page14.
123A6781C

Repair
Disassemble Disassemble
DisassembleFlapper Flapper FlapperCheck Check CheckValves Valves Valves
1.FollowthePressureReliefProcedure,page9.
Disconnectallhoses.
2.Todrainthepump,pulltheframequick-release
pins(207)androtatethepump.
NOTE: NOTE:
NOTE:Afterdraining,rotatethepumpto
positionswhichwillaiddisassembly.
3.Removetheclamps(23)ontheoutletmanifold
(17)andremovethemanifold.
NOTE:Usecarewhileremovingmanifoldsto
safelyremovecheckvalvecomponents.
4.Removeremainingclamps,manifolds,gaskets
andcheckvalves.
5.Cleanandinspectgaskets,󰘱appers,and
seatingsurfacesforanydamageandreplaceas
necessary.
6.Tocontinuedisassembly,see
DisassembletheStandardDiaphragms,page14.
Reassemble Reassemble
Reassemblethe the theCheck Check CheckValves Valves Valves
NOTE: NOTE:
NOTE:Lubricateclamps,clampingsurfaces,and
gasketswithwaterproof,sanitarylubricant.
1.Reassemblecheckassemblyinreverseorder.
NOTE: NOTE:
NOTE:Installthe󰘱appervalve(8)withthetext
sidefacingtheseat.
2.Attachthemanifoldstothe󰘱uidcovers.Tighten
clampshandtight.
3A6781C13

Repair
Standard Standard
StandardDiaphragm Diaphragm DiaphragmRepair Repair Repair
ThisappliestoFK,PS,andSPdiaphragms.
NOTE: NOTE:
NOTE:Overmoldeddiaphragmsarecoveredin
OvermoldedDiaphragmRepair,page16.
Tools Tools
ToolsRequired Required Required
•Torquewrench
•5/8in.wrench
•19mmopenendwrench
•O-ringpick
•Lithiumbasegrease
NOTE: NOTE:
NOTE:Centersectiongasketisdependenton
diaphragmmaterial.Ifchangingdiaphragmmaterial,
itmaybenecessarytoalsoreplacethecentersection
aircovergaskets.SeeParts,page22foraffected
diaphragm/gasketconcerns.
Disassemble Disassemble
Disassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page9.
2.Removethemanifoldsanddisassemble
thecheckvalvesasexplainedin
CheckValveRepair,page12.
3.Removetheclamps(21)fromthe󰘱uidcovers
(15),thenpullthe󰘱uidcoversoffofthepump.
4.Withboth󰘱uidcoversremoved,usingtwo5/8in.
wrenches,holdthewrench󰘱ats(Y)ontheplates
ofeachdiaphragmassemblyandloosen.One
diaphragmassemblywillcomefreeandtheother
willremainattachedtotheshaft.
5.Disassemblethefreediaphragmassembly.
6.Removeplate(12)withbolt(14)installed,
diaphragm(10),backer(11)ifpresent,andplate
(9).
7.Pulltheotherdiaphragmassemblyandthe
diaphragmshaft(24)outofthecenterhousing
(101).Holdtheshaft󰘱atswitha19mmopenend
wrench,andremovethediaphragmassembly
fromtheshaft.Disassembletheremaining
diaphragmassembly.
8.Inspectthediaphragmshaft(24)forwearor
scratches.Ifitisdamaged,inspectthebearings
(111)inplace.Ifthebearingsaredamaged,refer
toCenterSectionRepair,page18.
9.Reachintothecenterhousing(101)withan
o-ringpickandhooktheu-cups(106),thenpull
themoutofthehousing.Thiscanbedonewith
thebearings(111)inplace.
10.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
143A6781C

Repair
Reassemble Reassemble
Reassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthecenter
section,seeCenterSectionRepair,page18,before
youputthediaphragmsbackon.
1.Lubricateandinstalltheshaftu-cups(110)so
thelipsface
out out
out
ofthehousing(101).
2.Assemblediaphragm(10),backer(11)ifpresent,
andplate(9)ontoplate(12)withscrew(14).
Roundedsideofplate(9)shouldfacediaphragm.
MakesurethesidemarkedAIRSIDEfacesthe
centerhousing.
NOTE: NOTE:
NOTE:Threadlockermustbeappliedtoscrew
(14)asshownforalldiaphragmassemblies.
1
Applyahigh-strengththreadlockerto
attachthescrewtothediaphragmplate,
ifneeded.
2
Applyamedium-strengththreadlocker
totheshaftsideofthescrew.
3.Screwassembleddiaphragmassemblyintoshaft
(24)andhandtighten.
4.Greasethelengthofthediaphragmshaft(24),
andslideitthroughthehousing(101).
5.Assembletheotherdiaphragmassemblytothe
shaftasexplainedinstep2.
6.Usinga5/8in.wrenchholdthewrench󰘱atsof
onediaphragmassemblyandtorquetheother
diaphragmto60-70ft-lb(81-94N•m).
NOTE: NOTE:
NOTE:Applywaterproof,sanitarylubricanttothe
clamp(21)andclampingsurfaceofthecover
(15)toeaseassembly.
7.Alignthe󰘱uidcovers(15)andthecenter
housing.Securethecoverswiththeclamps
(21)andhandtighten.Theopposingdiaphragm
mayprotrudeawayfromthecenterhousing
afterthe󰘰rst󰘱uidcoverissecured,leaving
agapbetweenthecenterhousingandthe
second󰘱uidcover.Donottrytoforcethe
diaphragmintoposition.Instead,usethe
diaphragminstalltooltopositionthediaphragm
andallow󰘱uidcoverinstallation.Referto
UsingDiaphragmInstallTool,page10foruse
ofthediaphragminstalltooltopositionthe
diaphragmandallow󰘱uidcoverinstallation.
NOTE: NOTE:
NOTE:Useafoodgradeanti-seizelubricanton
theclampthreadstoaidassembly.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12
3A6781C15

Repair
Overmolded Overmolded
OvermoldedDiaphragm Diaphragm DiaphragmRepair Repair Repair
ForusewithPOandEOdiaphragms.
Tools Tools
ToolsRequired Required Required
•Torquewrench
•19mmopenendwrench
•O-ringpick
•Lithiumbasegrease
Disassemble Disassemble
Disassemblethe the theOvermolded Overmolded OvermoldedDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page9.
2.Removethemanifoldsanddisassemble
thecheckvalvesasexplainedin
CheckValveRepair,page12.
3.Removetheclamps(21)fromthe󰘱uidcovers
(15),thenpullthe󰘱uidcoversoffofthepump.
4.Oncethe󰘱uidcoversareremoved,the
diaphragmonthesideofthepumpwhichwas
lastpressurizedwithairwillbeseparatedfrom
thecentersection/aircover.Thisallowsyouto
gripthediaphragms.
5.Toloosen,gripbothdiaphragmssecurelyaround
theouteredgeandrotatecounterclockwise.One
diaphragmassemblywillcomefreeandtheother
willremainattachedtotheshaft.Removethe
freeddiaphragm(10)withscrew(14)andairside
plate(9).
6.Pulltheoppositediaphragmassemblyandshaft
(24)outofthecenterhousing(101).Holdthe
shaft󰘱atswitha19mmopenendwrenchand
removethediaphragmandairsideplatefrom
theshaft.
7.Inspectthediaphragmshaft(24)forwearor
scratches.Ifitisdamaged,inspectthebearings
(111)inplace.Ifthebearingsaredamaged,refer
toCenterSectionRepair,page18.
8.Reachintothecenterhousing(101)withan
o-ringpickandhooktheu-cups(110),thenpull
themoutofthehousing.Thiscanbedonewith
thebearings(111)inplace.
9.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
163A6781C

Repair
Reassemble Reassemble
Reassemblethe the theOvermolded Overmolded OvermoldedDiaphragms Diaphragms Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthecenter
section,seeCenterSectionRepair,page18,before
youputthediaphragmsbackon.
1.Lubricateandinstalltheshaftu-cups(110)so
thelipsface
out out
out
ofthehousing(101).
2.Assembleplate(9)ontodiaphragm(10)with
screw(14).Roundedsideofplate(9)should
facediaphragm.MakesurethesidemarkedAIR
SIDEfacesthecenterhousing.
NOTE: NOTE:
NOTE:Threadlockermustbeappliedtoscrew
(14)foralldiaphragmassemblies.
1
Applyahigh-strengththreadlockerto
attachthescrewtothediaphragm.
2
Applyamedium-strengththreadlocker
totheshaftsideofthescrew.
3.Screwassembleddiaphragmassemblyintoshaft
(24)andhandtighten.
4.Greasethelengthofthediaphragmshaft(24),
andslideitthroughthehousing(101).
5.Assembletheotherdiaphragmassemblytothe
shaftasexplainedinstep2.
6.Gripbothdiaphragmssecurelyaroundtheirouter
edgeandrotateclockwiseuntilbottomedonthe
shaft.
NOTE: NOTE:
NOTE:Applywaterproof,sanitarylubricanttothe
clamp(21)andclampingsurfaceofthecover
(15)toeaseassembly.
7.Alignthe󰘱uidcovers(15)andthecenter
housing.Securethecoverswiththeclamps
(21)andhandtighten.Theopposingdiaphragm
mayprotrudeawayfromthecenterhousing
afterthe󰘰rst󰘱uidcoverissecured,leaving
agapbetweenthecenterhousingandthe
second󰘱uidcover.Donottrytoforcethe
diaphragmintoposition.Instead,usethe
diaphragminstalltooltopositionthediaphragm
andallow󰘱uidcoverinstallation.Referto
UsingDiaphragmInstallTool,page10foruse
ofthediaphragminstalltooltopositionthe
diaphragmandallow󰘱uidcoverinstallation.
NOTE: NOTE:
NOTE:Useafoodgradeanti-seizelubricanton
theclampthreadstoaidassembly.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12
3A6781C17

Repair
Center Center
CenterSection Section SectionRepair Repair Repair
Tools Tools
ToolsRequired Required Required
•Torquewrench
•10mmsocketwrench
•9/16in.socketwrench
•Bearingpuller
•O-ringpick
•Press,orblockandmallet
Disassemble Disassemble
Disassemblethe the theCenter Center CenterSection Section Section
NOTE: NOTE:
NOTE:Donotremoveundamagedbearings.
1.FollowthePressureReliefProcedure,page9.
Removepowerfromthemotor.Disconnectall
hoses.
2.Removethemanifoldsand
checkvalvepartsasdirectedin
DisassembleBallCheckValves,page12.
3.Removethe󰘱uidcoversanddiaphragms
asdirectedinDisassembletheStandard
Diaphragms,page14orDisassemblethe
OvermoldedDiaphragms,page16.
NOTE:Ifyouareremovingonlythediaphragm
shaftbearing(111),skipstep4.
4.Disassembletheairvalveasexplainedin
AirValveRepair,page9.
5.Usea9/16in.socketwrenchtoremovethe
screws(3)andnuts(105)holdingtheaircovers
totheframe.
6.Usea10mmsocketwrenchtoremovethe
screws(104)holdingtheaircovers(103)tothe
centerhousing(101).
7.Removetheaircovergaskets(102).Always
replacethegasketswithnewones.
NOTE: NOTE:
NOTE:Ifremovingthediaphragmshaftbearings
(111),useano-ringpicktoremovetheu-cups
(106)󰘰rst.
8.Useabearingpullertoremovethediaphragm
shaftbearings(111),airvalvebearings(115)
orpilotpinbearings(113).Donotremove
undamagedbearings.
9.Inspecttheu-cups.Replaceasneeded.
183A6781C

Repair
Reassemble Reassemble
Reassemblethe the theCenter Center CenterSection Section Section
1.Installtheshaftu-cups(106)sothelipsface
out out
out
ofthehousing.
2.Insertnewbearings(111,113,and115)intothe
centerhousing(101),
tapered tapered
taperedend end end󰘰rst 󰘰rst 󰘰rst
.Using
apressorablockandrubbermallet,press-󰘰t
thebearingsoitis󰘱ushwiththesurfaceofthe
centerhousing.
3.Reassembletheairvalveasexplainedin
ReassembleAirValve,page11
4.Alignthenewaircovergasket(102)sothepilot
pin(112)protrudingfromthecenterhousing
(101)󰘰tsthroughtheproperholeinthegasket.
5.Aligntheaircover(103)sothepilotpin(112)󰘰ts
inthemiddlehole(M)ofthethreesmallholes
nearthecenterofthecover.
6.Applyamedium-strengththreadlockertothe
threadsofthescrews(106).Installthescrews
(106),handtight.Usinga10mmsocketwrench,
torquethescrewsoppositelyandevenlyto
130-150in-lb(15-17N•m).Installthediaphragm
assembliesand󰘱uidcoversasexplainedin
Diaphragms
.
7.SeeReassembletheCheckValves,page13.
3A6781C19

Repair
Leak Leak
LeakDetectors Detectors Detectors
Leakdetectorsaresensorsthataremountedinthe
aircoversofthepumptomonitorfor󰘱uidleakage
causedbyadiaphragmrupture.Leakdetectors
areprovidedwith3-Apumpsandcanbeordered
separatelyforotherpumps.Forleaksensorelectrical
andcon󰘰gurationinformation,refertotheleak
detectionsystemmanual(3A6976).
Availableleakdetectionkits:
Kit Kit
KitDescription Description Description
17Z666Kit,Standard,non-ATEX,2sensors,2
bushings;providedwith3-Apumps
17Z667Kit,ATEX,2sensors,2bushings,2
o-rings
25P303Kit,Leakdetectioncontrolbox;
notapprovedforuseinanATEX
environment
25P305Kit,Leakdetectioncontrolboxmounting
bracketandmountinghardware
Leak Leak
LeakDetector Detector DetectorTesting Testing Testing
1.Obtainasmallcontaineroftheproductbeing
pumpedtotesttheleakdetectors.
2.PerformthePressureReliefProcedure,page9.
3.Unscrewtheleakdetectorbushingfromtheair
sidecover.
4.Dipthebushing,withtheleakdetectorstill
installedinit,intotheproductcontainerinan
orientationthatmimicshowitwouldbeoriented
intheairsidediaphragmcover.Observewhether
theleakdetectorsensesthepresenceofthe
product.
5.Iftheleakdetectorsuccessfullydetectedthe
product,cleanthebushingandleakdetectorand
re-installtheleakdetectorandbushingintothe
airsidediaphragmcover.
NOTE: NOTE:
NOTE:Iftheleakdetectorfailstosensethe
product,troubleshoottheleakdetectortoseeif
theleaksensorhasfailedortheleakdetectoris
unabletodetecttheproduct.
6.Toreturnthecurrentleakdetectortothepump:
a.Iftheleakdetectorneedstobeinstalledin
thebushing,simplyscrewtheleakdetector
injustpast󰘰ngertight.
NOTE: NOTE:
NOTE:IfusingtheATEXleakdetector,
installtheo-ringontotheleakdetectorbefore
installationintothebushing.
b.Ifthebushingisnotinstalledintheairside
diaphragmcover,screwthebushingintothe
airsidediaphragmcover.
c.Iftheleakdetectorwasdisconnectedfrom
themonitoringdevice,re-attachtheleak
detectorwirestothemonitoringdevice.
7.Repeatsteps3–6fortheotherleakdetector.
Leak Leak
LeakDetector Detector DetectorRemoval Removal Removal
1.FollowthePressureReliefProcedure,page9.
2.Notetheconnectionlocationsoftheleak
detectorwireswithinthemonitoringdevice,then
disconnecttheleakdetectorwires.
3.Removetheleakdetectorfromthebushinginthe
airsidediaphragmcover.
4.Ifdesired,repeattoremovetheotherleak
detectorfromtheotherairsidediaphragmcover.
Leak Leak
LeakDetector Detector DetectorInstallation Installation Installation
1.Iftheleakdetectorneedstobeinstalledinthe
bushing,simplyscrewtheleakdetectorinjust
past󰘰ngertight.
NOTE: NOTE:
NOTE:IfusingtheATEXleakdetector,installthe
o-ringontotheleakdetectorbeforeinstallation
intothebushing.
2.Ifthebushingisnotinstalledintheairside
diaphragmcover,screwthebushingintotheair
sidediaphragmcover.
3.Wiretheleakdetectortothemonitoringdevice.
203A6781C