Graco saniforce 1590 Use and care manual

Repair/Parts
SaniForce® SaniForce®
SaniForce®1590 1590 1590Air Air Air- - -Operated Operated OperatedHigh High High
Sanitation Sanitation
SanitationDiaphragm Diaphragm DiaphragmPump Pump Pump3A6781D
EN
For For
Fortransfer transfer transferof of of󰘱uids 󰘱uids 󰘱uidsin in insanitary 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
Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandrelated
manualsbeforeusingtheequipment.Save Save
Saveall all allinstructions. instructions. instructions.
120psi(0.8MPa,8bar)MaximumFluid
WorkingPressure
120psi(0.8MPa,8bar)MaximumAir
InputPressure
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..................................19
LeakDetectors............................................21
Parts..................................................................22
Diaphragms.................................................26
TechnicalSpeci󰘰cations......................................29
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
3A5999SaniForceHighSanitationDiaphragmPumps,Operation
3A6976LeakDetectionSystem,Instructions/Parts
23A6781D

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,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.
•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.
•Check󰘱uidlines,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
3A6781D3

Warnings
WARNING
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.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Routeexhaustawayfromworkarea.Ifdiaphragmruptures,󰘱uidmaybeexhaustedinto
theair.
•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.
43A6781D

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 SectionMaterial Material MaterialDrive Drive
DriveType Type TypeCenter Center
CenterSection Section Sectionand and andAir Air Air
Valve Valve
ValveMaterial Material Material
Manifolds Manifolds
Manifolds
1590 1590
15903A 3A 3A3-AcompliantP P
PPneumatic
S01A S01A
S01A
StainlessSteel,for
allbut2-piecePS
diaphragms
SSA SSA
SSAStainlesssteel,TriClamp,
horizontal
HS HS
HSHighSanitationS02A S02A S02AStainlessSteel,3-ASSB SSB SSBStainlesssteel,DIN,
horizontal
PH PH
PHPharmaceuticalS03A S03A
S03AStainlessSteel,PH,
forallbut2-piecePS
diaphragms
SSC SSC
SSCStainlesssteel,TriClamp,
SDU,STUuse
SP1A SP1A
SP1A
StainlessSteel,
PSdiaphragms,
for2-piecePS
diaphragmsonly
SSD SSD
SSDStainlesssteel,DIN,SDU,
STUuse
SP3A SP3A
SP3AStainlessSteel,PH,
PSdiaphragms,
for2-piecePS
diaphragmsonly
Seat Seat
SeatMaterial Material MaterialChecks Checks ChecksDiaphragm Diaphragm
DiaphragmMaterial Material MaterialSeals Seals
SealsCerti󰘰cation Certi󰘰cation Certi󰘰cation
FL FL
FL316Stainless
Steel,Flapper
— —
—FlapperBN BN
BNBuna-NBN BN BNBuna-N21 21
21EN10204Type
2.1
SS SS
SS316Stainless
Steel,BallBN BN
BNBuna-NEO EO
EOEPDMOvermoldEP EP
EPEPDM31 31
31EN10204Type
3.1
CW CW
CWPolychloroprene
WeightedBallFK FK
FKFKM
FluoroelastomerFK FK
FKFKM
EP EP
EPEPDMPO PO
POPTFE/EPDM
Overmold
FK FK
FKFKM
Fluoroelastomer
Ball
PS PS
PSPTFE/
Santoprene,2
piece
PT PT
PTPTFEBallSP SP
SPSantoprene
SP SP
SPSantopreneBall
3A6781D5

OrderingInformation
Approvals Approvals
Approvals
Exceptfor3-Apumps,allpumpsareapprovedto:
II2GD
ExhIIAT6...T3Gb
ExhIIIBT160°CDb
DiaphragmmaterialscodedEO,PO,orPS
combinedwith󰘱apperorPTballcheckscomply
with:
EC1935/2004
DiaphragmmaterialscodedEOorPScombined
with󰘱apperorPTballcheckscomplywith:
ClassVI
Allmodelsareapprovedto:
All󰘱uidcontactmaterialsareFDAcompliant
andmeettheUnitedStatesCodeofFederal
Regulations(CFR)
ATEXT-coderatingisdependentonthetemperatureofthe󰘱uidbeingpumped.Fluidtemperatureislimited
bythematerialsofthepumpinteriorwettedparts.SeeTechnicalSpeci󰘰cations,page29,forthemaximum
󰘱uidoperatingtemperatureforyourspeci󰘰cpumpmodel.
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.
63A6781D

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
overmoldeddiaphragmrepair
procedure.
Reducedpump
performance.
Restrictedexhaust.Removerestriction.
Loosesuctionline.Tighten.
Ruptureddiaphragm.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Airbubblesin󰘱uid.
Looseinletmanifold,damagedseal
betweenmanifoldand󰘱uidcover,or
damagedgaskets.
Tightenmanifoldclampsorreplace
gasketsorseatingcomponents.
Loosesanitaryclamp.Tightenclamp.
Damagedorworngasket.Replacegasket.
Leakininletoroutlet
sanitary󰘰tting.
Misalignmentofinlet/outlet󰘱uidline
orpipe.
Use󰘱exible󰘱uidlinesatpumpinlet
andoutlet.
3A6781D7

Troubleshooting
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Manifoldsdonot󰘰tfor
installationonto󰘱uid
covers.
Useofincorrectaircovergaskets
resultsinmisalignment.
Installcorrectaircovergasketsfor
thetypeofdiaphragmsinuse.See
Partslistforcorrectgasket.
Diaphragmruptured.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Fluidinexhaustair.
Loosediaphragmplate.Tightenorreplace.Seestandard
orovermoldeddiaphragmrepair
procedure.
Wornairvalveblock,plate,pilot
block,u-cups,orpilotpino-rings.
Repairorreplace. Pumpexhaustsexcessive
airatstall.
Wornshaftseals.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
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.
83A6781D

Repair
Repair Repair
Repair
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressureis
manuallyrelieved.Tohelppreventseriousinjury
frompressurized󰘱uid,suchassplashing󰘱uid,
followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyou
stopdispensingandbeforecleaning,checking,or
servicingtheequipment.
1.Closethemasterairvalve(A)toshutofftheair
tothepump.
2.Openoutbound󰘱uidvalvetorelieve󰘱uid
pressurefromthepump.
3.If󰘱uidisstillintheoutbound󰘱uidlines,isolate
this󰘱uidasfollows:
a.For For
Forsimple simple simpletransfer transfer transferapplications, applications, applications,openeither
the󰘱uidshutoffvalve(J)orthe󰘱uiddrain
valve(K).
b.For For
Forcirculating circulating circulatingapplications, applications, applications,ensurethatthe
󰘱uidshutoffvalve(J)isclosedandopenthe
󰘱uiddrainvalve(K).
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.
3A6781D9

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,page19.
7.Cleanallpartsandinspectforwearordamage.
Replaceasneeded.
Reassemble Reassemble
ReassembleAir Air AirValve Valve Valve
NOTE: NOTE:
NOTE:Ifrepairsinvolveremoving
󰘱uidcovers,performthestepsin
ReassembletheOvermoldedDiaphragms,page17,
priortoreassemblyoftheairvalve.Theairvalve
con󰘰gurationwillbemodi󰘰edtoaid󰘱uidcover
installation.
1.Ifthecentersectionwasdisassembledto
replacethebearings(113,115),complete
theCenterSectionRepair,page19,before
continuingwiththeairvalvereassembly.
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).
103A6781D

Repair
9.Alignthevalvegasket(118)andcover(109)
withthesixholesinthecenterhousing(101).
Securewithsixscrews(107),usingaTorx(T20)
screwdriveror7mm(9/32in.)socketwrench.
Torqueto50-60in-lb(5.7-6.8N•m).
3A6781D11

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.
Disconnectall󰘱uidandairlines.
2.Todrainthepump,pulltheframequick-release
pins(207)androtatethepump.
NOTE: NOTE:
NOTE:Afterdraining,rotatethepumpto
positionswhichwillaiddisassembly.
3.Removetheclamps(23)ontheoutletmanifold
(17)andremovethemanifold.
NOTE: NOTE:
NOTE:Usecarewhileremovingmanifoldsto
avoiddamagetocheckvalvecomponents.
4.Removeremainingclamps(23),manifolds(16,
17),gaskets(18),andcheckvalves(19,20).
5.Cleanandinspectgaskets,balls,ballstops,and
seatingsurfacesforanydamageandreplaceas
necessary.
6.Tocontinuewithdiaphragmdisassembly,see
DisassembletheStandardDiaphragms,page14.
123A6781D

Repair
Disassemble Disassemble
DisassembleFlapper Flapper FlapperCheck Check CheckValves Valves Valves
1.FollowthePressureReliefProcedure,page9.
Disconnectall󰘱uidandairlines.
2.Todrainthepump,pulltheframequick-release
pins(207)androtatethepump.
NOTE: NOTE:
NOTE:Afterdraining,rotatethepumpto
positionswhichwillaiddisassembly.
3.Removetheclamps(23)ontheoutletmanifold
(17)andremovethemanifold.
NOTE: NOTE:
NOTE:Usecarewhileremovingmanifoldsto
avoiddamagetocheckvalvecomponents.
4.Removeremainingclamps(23),manifolds(16,
17),gaskets(18),andcheckvalves(8).
5.Cleanandinspectgaskets,󰘱appers,and
seatingsurfacesforanydamageandreplaceas
necessary.
6.Tocontinuewithdiaphragmdisassembly,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.Looselyttachthemanifoldstothe󰘱uidcovers.
Onceallcomponentsareproperlyaligned,
tightenclampshandtight.
3A6781D13

Repair
Standard Standard
StandardDiaphragm Diaphragm DiaphragmRepair Repair Repair
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,
itmaybenecessarytoalsoreplacethecenter
sectionaircovergaskets.SeeParts,page22,for
affectedaircovergaskets.
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󰘱atsontheplates(Y)
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,page19.
9.Reachintothecenterhousing(101)withan
o-ringpickandhooktheu-cups(106),thenpull
themoutofthehousing.Thiscanbedonewith
thebearings(111)inplace.
10.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
143A6781D

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,followCenterSectionRepair,page19,
beforereplacingdiaphragms.
1.Lubricateandinstalltheshaftu-cups(106)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.
NOTE: NOTE:
NOTE:Toensureproperspacingandalignment
ofmanifolds,installclamps(21)looseenoughto
allowfor󰘱uidcovermovementbeforesecuring
thecoversandclampsinplace.
7.Alignthe󰘱uidcovers(15)andthecenterhousing.
Securethecoverswiththeclamps(21)andhand
tighten.
NOTE: NOTE:
NOTE:Useafoodgradeanti-seizelubricanton
theclampthreadstoaidassembly.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12.
3A6781D15

Repair
Overmolded Overmolded
OvermoldedDiaphragm Diaphragm DiaphragmRepair Repair Repair
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,page19.
8.Reachintothecenterhousing(101)withan
o-ringpickandhooktheu-cups(110),thenpull
themoutofthehousing.Thiscanbedonewith
thebearings(111)inplace.
9.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
163A6781D

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,followCenterSectionRepair,page19,
beforereplacingdiaphragms.
1.Lubricateandinstalltheshaftu-cups(106)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.
NOTE: NOTE:
NOTE:Toensureproperspacingandalignment
ofmanifolds,installclamps(21)looseenoughto
allowfor󰘱uidcovermovementbeforesecuring
thecoversandclampsinplace.
NOTE: NOTE:
NOTE:Useafoodgradeanti-seizelubricanton
theclampthreadstoaidinassembly.
7.Alignthe󰘱uidcovers(15)andthecenterhousing.
Securethecoverswiththeclamps(21)andhand
tighten.If,afterinstallingthe󰘰rst󰘱uidcover,the
opposingdiaphragmprotrudesawayfromthe
centerhousing,leavingagapbetweenthecenter
housingandthesecond󰘱uidcover,donottry
toforcethediaphragmintoposition.Instead,
completethefollowingproceduresinsteps7a–7i
toattachthesecond󰘱uidcover.
a.Removetheairvalvecover(B),thegasket
(C),andthepilotcup(D).Seetheimagein
stepi.
b.Withinthedrive,shiftthemainairvalve
carriage(E)awayfromtheinstalled󰘱uid
cover.Thiswillexposetheairpassagethat
feedstheassembledside.
c.Reinstallthegasket(C)andtheairvalve
cover(B).Torqueallboltsaccordingto
instructionsinyourpumpmanual.
d.Supplythepumpwith10–20psi(0.07–0.14
MPa,0.7–1.4bar)airpressure,justenough
tomovethediaphragm.Thediaphragm
willshiftsothesecond󰘱uidcoverwillseat
properly.Keeptheairpressureonwhileair
󰘱owsoutoftheexhaust.
NOTE: NOTE:
NOTE:Toomuchairpressuremaycausethe
diaphragmtodeformandseatincorrectly.
e.Installtheremaining󰘱uidcover.
f.Followthe
PressureReliefProcedure,page9.
Disconnecttheairsupplyfromthepump.
g.Removetheairvalvecover(B)andthe
gasket(C).
h.Lubricateandreinstallthepilotcup(D).
3A6781D17

Repair
i.Reinstallthegasket(C)andtheairvalve
cover(B).Torqueallboltsaccordingto
instructionsinyourpumpmanual.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12.
183A6781D

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.
Disconnectall󰘱uidandairlines.
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.
3A6781D19

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,page10
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,page26.
7.SeeReassembletheCheckValves,page13.
203A6781D