Graco saniforce 2150 Manual

Repair/PartsList
SaniForce® SaniForce®
SaniForce®Air Air Air- - -Operated Operated OperatedHigh High High
Sanitation Sanitation
SanitationDiaphragm Diaphragm DiaphragmPumps, Pumps, Pumps,Models Models Models
2150, 2150,
2150,3150, 3150, 3150,4150 4150 4150
3A6782E
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..................................................................21
TechnicalData...................................................30
GracoStandardWarranty....................................32
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
3A5999SaniForceHighSanitationDiaphragmPumps,Operation
3A6976LeakDetectionSystem,Instructions/Parts
23A6782D

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.
3A6782D3

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.
43A6782D

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.,
SP3F.0018):_____________
Alsorecordthecon󰘰gurationnumberonthepumpID
platetoassistyouwhenorderingreplacementparts:
_____________________________________
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:2150HS.PSP1ASSASSPTPSEP21 2150HS.PSP1ASSASSPTPSEP21
2150HS.PSP1ASSASSPTPSEP21
2150 2150
2150HS 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 SectionDrive Drive
DriveType Type TypeCenter Center
CenterSection Section Sectionand and andAir Air Air
Valve Valve
Valve
Manifolds Manifolds
Manifolds
2150 2150
21503A 3A 3A3-AcompliantP P
PPneumaticS01A S01A
S01AStainlessSteelSSA SSA
SSAStainlesssteel,
TriClamp,centerport
3150 3150
3150HS HS HSHighSanitationS02A S02A S02AStainlessSteel,
leakdetector,
3-A
SSB SSB
SSBStainlesssteel,DIN,
centerport
4150 4150
4150PH PH
PHPharmaceuticalS03A S03A
S03AStainlessSteel,
PHSSC SSC
SSCStainlesssteel,
TriClamp,unloader
SP1A SP1A
SP1AStainlessSteel,
PSdiaphragmsSSD SSD
SSDStainlesssteel,DIN,
unloader
SP2A SP2A
SP2AStainlessSteel,
leakdetector,PS
diaphragms,3-A
SSE SSE
SSEStainlesssteel,
TriClamp,horizontal,
WYEmanifold
SP3A SP3A
SP3AStainless
Steel,PH,PS
diaphragms
SSF SSF
SSFStainlesssteel,DIN,
horizontal,WYE
manifold
SSG SSG
SSGHorizontal,nomanifolds
Seat Seat
SeatMaterial Material MaterialChecks Checks ChecksDiaphragm Diaphragm
DiaphragmMaterial Material MaterialSeals Seals
SealsCerti󰘰cation Certi󰘰cation Certi󰘰cation
FL FL
FL316Stainless
Steel,Flapper
— —
—StainlessSteel
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
SP SP
SPSantopreneBallSP SP SPSantoprene
3A6782D5

OrderingInformation
Approvals Approvals
Approvals
Exceptfor3-Apumps,allpumpsarecerti󰘰ed
to:
II2GD
ExhIIAT6...T3GbX
ExhIIIBT160°CDb
DiaphragmmaterialscodedEO,POorPS
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 BuyanduseFind Find Finda a aDistributor. Distributor. Distributor.
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. . .SearchforSelector Selector Selector
To To
ToOrder Order OrderReplacement Replacement ReplacementParts Parts Parts
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
63A6782D

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󰘱ap
valves.
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,
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.
3A6782D7

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.
Airvalvecoverisloose.Tightenscrews.
Airvalvegasketoraircovergasket
isdamaged.
Inspect;replace.
Pumpleaksairexternally.
AircoverclampsarelooseTightenclamps.
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.
83A6782D

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.
3A6782D9

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,page21.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.
103A6782D

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.Greasethelowerfaceofthepilotblock(116)and
installsoitstabssnapintothegroovesonthe
endsofthepilotpins(112).
6.Lubricatetheu-cups(106)andactuatorpistons
(114).Inserttheactuatorpistonsinthebearings
(115),
wide wide
wide
end󰘰rst.Leavethenarrowendof
thepistonsexposed.
7.Greasethelowerfaceofthevalvecarriage(119).
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).
3A6782D11

Repair
Check Check
CheckValve Valve ValveRepair Repair Repair
NOTE: NOTE:
NOTE:Kitsareavailablefornewcheckvalve
󰘱appers,orcheckvalveballsinarangeofmaterials.
Gasketkitsalsoareavailable.
Disassemble Disassemble
Disassemblethe the theCheck Check CheckValve Valve Valve
1.FollowthePressureReliefProcedure,page9.
Disconnectallhoses.
2.Drainthepump
a.Onrotatablestand,pulltheframe
quick-releasepins(207)androtatethe
pump.
NOTE: NOTE:
NOTE:Afterdraining,rotatethepumpto
positionswhichwillaiddisassembly.
b.Onnon-rotatablestand,partiallydisassemble
the󰘱uidsectionasnotedbelow.
NOTE: NOTE:
NOTE:Theverticalpumpscanbedrained
byremovingtheinletmanifoldandmanually
raisingtheinlet󰘱appers.Horizontalpumps
willrequireremovalofthe󰘱uidcovers.
3.Removetheclamps(23)ontheoutletmanifold
(17)andremovethemanifold.
NOTE: NOTE:
NOTE:Usecarewhileremovingmanifoldto
safelyremovecheckvalvecomponents.
4.Removeremainingclamps,manifolds,gaskets
andcheckvalves.
NOTE NOTE
NOTE:Inspectallcomponentsforanydamage
andreplaceasnecessary.
5.Tocontinuedisassembly,see
DisassembletheStandardDiaphragms,page14.
Ball Ball
Ballpump pump pumpshown shown shown
123A6782D

Repair
Vertical Vertical
Vertical󰘱apper 󰘱apper 󰘱apperpump pump pumpshown shown shown
Horizontal Horizontal
Horizontal󰘱apper 󰘱apper 󰘱apperpump pump pumpshown shown shown
Reassemble Reassemble
Reassemblethe the theCheck Check CheckValves Valves Valves
NOTE: NOTE:
NOTE:Lubricateclampsandclampingsurfaceswith
waterproof,sanitarylubricant.
1.Reassembleballor󰘱appercheckassemblyin
reverseorder.
2.Attachthemanifoldstothe󰘱uidcovers.Tighten
clampshandtight.
NOTE: NOTE:
NOTE:Installthe󰘱appervalve(8)withthetext
sidefacingtheseat.
NOTE: NOTE:
NOTE:Flapper󰘱uidcoversarenot
interchangeableandtheirorientationis
criticalonhorizontalpumps.Horizontalpump
󰘱uidcoversmustbepositionedsothatthe
󰘱appershangdownfromthehingepinwhen
placedinthe󰘱uidcover.Installthe󰘱appervalves
(8)withthetextsidefacingtheseat.
3A6782D13

Repair
Standard Standard
StandardDiaphragm Diaphragm DiaphragmRepair Repair Repair
NOTE: NOTE:
NOTE:Overmoldeddiaphragmsarecoveredin
OvermoldedDiaphragmRepair,page16.
Tools Tools
ToolsRequired Required Required
•Torquewrench
•5/8in.wrench
•19mmopenendwrench
•Diaphragminstalltool(optional),kit24V543
•O-ringpick
•Lithiumbasegrease
NOTE: NOTE:
NOTE:Centersectiongasketisdependenton
diaphragmmaterial.Ifchangingdiaphragmmaterial,
itmaybenecessarytoalsoreplacethecentersection
aircovergaskets.SeeDiaphragms
foraffecteddiaphragm/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(4,
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.
143A6782D

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.Assembleplate(9)ontodiaphragm(10),with
screw(14).Roundedsideofplate(9)should
facediaphragm.MakesurethesidemarkedAIR
SIDEfacesthecenterhousing.
NOTE: NOTE:
NOTE:Threadlockermustbeappliedtoscrew
(14)asshownforalldiaphragmassemblies.
Applyahigh-strengththreadlockertoattach
thescrewtothediaphragmplate,ifneeded.
Applyamedium-strengththreadlockertothe
shaftsideofthescrew.
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(4,
15)toeaseassembly.
7.Alignthe󰘱uidcovers(4,15)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:Applyafoodgradeanti-seizelubricanton
theclampthreadstoaidassembly.
a.Ballpump󰘱uidcoversareinterchangeable.
b.Flapper󰘱uidcoversarenotinterchangeable
andtheirorientationiscriticalonhorizontal
pumps.Horizontalpump󰘱uidcoversmust
bepositionedsothatthe󰘱appershangdown
fromthehingepinwhenplacedinthe󰘱uid
cover.Installthe󰘱appervalves(8)withthe
textsidefacingtheseat.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12
3A6782D15

Repair
Overmolded Overmolded
OvermoldedDiaphragm Diaphragm DiaphragmRepair Repair Repair
Tools Tools
ToolsRequired Required Required
•Torquewrench
•19mmopenendwrench
•O-ringpick
•Diaphragminstalltool,kit24V543
•Lithiumbasegrease
NOTE: NOTE:
NOTE:Centersectiongasketisdependenton
diaphragmmaterial.Ifchangingdiaphragmmaterial,
itmaybenecessarytoalsoreplacethecentersection
aircovergaskets.SeeDiaphragms
foraffecteddiaphragm/gasketconcerns.
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(4,
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.
163A6782D

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)asshownforalldiaphragmassemblies.
Applyahigh-strengththreadlockertoattach
thescrewtothediaphragmplate.
Applyamedium-strengththreadlockertothe
shaftsideofthescrew.
3.Screwassembleddiaphragmassemblyintoshaft
(24)andhandtighten.
4.Greasethelengthofthediaphragmshaft(24),
andslideitthroughthehousing(101).
5.Assembletheotherdiaphragmassemblytothe
shaftasexplainedinstep2.
6.Gripbothdiaphragmssecurelyaroundtheirouter
edgesandrotateclockwiseuntilbottomedonthe
shaft.
NOTE: NOTE:
NOTE:Applywaterproof,sanitarylubricanttothe
clamp(21)andclampingsurfaceofthecover(4,
15)toeaseassembly.
7.Alignthe󰘱uidcovers(4,15)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.
a.Ballpump󰘱uidcoversareinterchangeable.
b.Flapper󰘱uidcoversarenotinterchangeable
andtheirorientationiscriticalonhorizontal
pumps.Horizontalpump󰘱uidcoversmust
bepositionedsothatthe󰘱appershangdown
fromthehingepinwhenplacedinthe󰘱uid
cover.Installthe󰘱appervalves(8)withthe
textsidefacingtheseat.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12
3A6782D17

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
DisassembletheCheckValve,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.
183A6782D

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.
3A6782D19

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.Repeatsteps3–5fortheotherleakdetector.
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.
203A6782D