Graco TRITON 1030HP Operation manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
309476B
Instructions/Parts List
TRITON™1030HP
Diaphragm Pump
Part No. 233750, Series A
3:1 Ratio Air-Operated Double Diaphragm Pump, with BSPP Fittings
Part No. 233751, Series A
3:1 Ratio Air-Operated Double Diaphragm Pump, with npt Fittings
0.6 MPa, 6 bar (88 psi) Maximum Air Input Pressure
1.8 MPa, 18 bar (260 psi) Maximum Fluid Working Pressure
Read warnings and instructions.
TI1962A
II 2 G

2309476B
Contents
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Information . . . . . . . . . . . . . . . . . . . . . . 5
Mounting the Pump . . . . . . . . . . . . . . . . . . . . . . . 5
Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fluid Suction Line . . . . . . . . . . . . . . . . . . . . . . . . 6
Fluid Outlet Line . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 9
Flush the Pump Before First Use . . . . . . . . . . . . 9
Starting and Adjusting the Pump . . . . . . . . . . . . 9
Pump Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Flushing and Storage . . . . . . . . . . . . . . . . . . . . 10
Tighten Threaded Connections . . . . . . . . . . . . . 10
Preventive Maintenance Schedule . . . . . . . . . . 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Prepare the Pump for Repair . . . . . . . . . . . . . . . 15
General Repair Notes . . . . . . . . . . . . . . . . . . . . 15
Fault Indications . . . . . . . . . . . . . . . . . . . . . . . . 15
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replace the Diaphragms . . . . . . . . . . . . . . . . . . 16
Repair the Air Valve . . . . . . . . . . . . . . . . . . . . . . 18
Replace the Ball Check Valves . . . . . . . . . . . . . 20
Replace the Cylinder and Piston Seals . . . . . . . 22
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 27
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Wall Mount Hole Pattern . . . . . . . . . . . . . . . . . . . . 29
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 30
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 30
Manual Conventions
Warning Caution
Note
WARNING
A warning alerts you to the possibility of serious injury
or death if you do not follow the instructions.
Symbols, such as fire and explosion (shown above),
alert you to a specific hazard and direct you to read
the indicated hazard warnings (pages 3-4) for detailed
information.
CAUTION
A caution alerts you to the possibility of damage to or
destruction of equipment if you do not follow the
instructions.
A note calls attention to additional helpful informa-
tion.

Warning
309476B 3
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
• This equipment is for professional use only.
• Read all instruction manuals, tags, and labels before operating the equipment.
• Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
• Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 26 for the maximum working pressure of this equipment.
• Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Techni-
cal Data section of all equipment manuals. Read the fluid and solvent manufacturer's warnings.
• Do not use hoses to pull equipment.
• Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82°C (180°F) or below -40°C (-40°F).
• Wear hearing protection when operating this equipment.
• Comply with all applicable local, state, and national fire, electrical, and safety regulations.
PRESSURIZED EQUIPMENT HAZARD
Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin and
cause serious injury.
• Do not point the gun at anyone or at any part of the body.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
•FollowthePressure Relief Procedure on page 9 whenever you are instructed to relieve pressure;
stop spraying; clean, check, or repair the equipment; and install or clean the spray nozzle.
• Tighten all fluid connections before operating the equipment.
• Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.

Warning
4309476B
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result
in a fire or explosion and serious injury.
• Ground the equipment and the object being sprayed. Refer to Grounding on page 8.
• If there is any static sparking or you feel an electric shock while using this equipment, stop the
equipment immediately. Do not use the equipment until you identify and correct the problem.
• Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being
sprayed.
• Keep the spray area free of debris, including solvent, rags, and gasoline.
• Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop cloths.
Do not plug in or unplug power cords or turn lights on or off in the spray area.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
• Know the specific hazards of the fluid you are using.
• Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
• Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
• If a diaphragm fails, fluid is exhausted along with the air. When pumping hazardous fluids, place the
pump in an appropriate container to catch the fluid if a diaphragm ruptures.
MOVING PARTS HAZARD
Moving parts, such as the diaphragm shaft, can pinch or amputate your fingers.
• Keep clear of all moving parts when starting or operating the pump.
• Before servicing the equipment, follow the Pressure Relief Procedure on page 9 to prevent the
equipment from starting unexpectedly.
WARNING

Installation
309476B 5
Installation
General Information
•F
IG. 3 on page 7 is only a guide for installing system
components and accessories. It is not an actual sys-
tem design. Contact your Graco distributor for assis-
tance in designing a system to suit your particular
needs.
• Always use Genuine Graco Parts and Accessories,
available from your Graco distributor. If you supply
your own accessories, be sure they are adequately
sized and pressure-rated for your system.
• Reference numbers and letters in parentheses refer
to the reference numbers in the figures and the
parts list on page 24.
Mounting the Pump
For ease of operation and service, mount the pump so
the air inlet, fluid inlet, and fluid outlet ports are easily
accessible. The inlet port must point down and the outlet
port must point up.
Use 5/8 in. lag screws or bolts for mounting.
Wall Mount Installation
1. Wall Mount Kit 245875 is available. See FIG. 1.
2. Be sure the wall can support the weight of the
pump, bracket, hoses and accessories, as well as
the stress caused during operation.
3. Using the wall bracket (B) as a template, drill 5/8 in.
mounting holes in the wall. See page 29 for a wall
mounting diagram. Mount the bracket 1.2-1.5 m (4-5
ft) above the floor.
4. Attach the bracket (B) to the pump (A) with the
screws (C) and washers (D) provided in the kit.
5. Attach the bracket to the wall. Use screws (E) that
are long enough to keep the pump from vibrating
during operation. Be sure the pump is level.
Floor Stand Installation
Floor Stand Kit 245874 is available. See FIG. 2 to
assemble.
To ensure proper operation, mount the pump in a
horizontal position.
FIG. 1: Wall Mount Kit
FIG. 2: Floor Stand Installation
TI2079B
C
D
B
A
E
TI20798

Installation
6309476B
Air Line
1. Install the air line accessories as shown in FIG. 3.
Mount these accessories on the wall or on a
bracket. Be sure the air line supplying the accesso-
ries is grounded.
a. Install an air regulator (C) and gauge to control
the fluid pressure. The fluid outlet pressure will
be three times the setting of the air regulator.
b. A bleed-type master air valve (B) is required in
your system to relieve air trapped between it
and the pump when the valve is closed. Trapped
air can cause the pump to cycle unexpectedly
which could result in serious injury including
splashing in the eyes or on the skin, or injury
from moving parts. Be sure the bleed valve is
easily accessible from the pump, and is located
downstream from the air regulator.
c. The air line filter (D) removes harmful dirt and
moisture from the compressed air supply.
d. A second bleed-type air valve (T) isolates the air
line accessories for servicing. Locate upstream
from all other air line accessories.
2. Install a grounded, flexible air hose (A) between the
accessories and the pump air inlet. See Technical
Data on page 26 to determine the air inlet size of
your pump. Use a minimum 13 mm (1/2 in.) ID air
hose.
3. Screw an air line quick disconnect coupler (N) onto
the end of the air hose (A), and screw the mating fit-
ting into the pump air inlet snugly. Do not connect
the coupler to the fitting until you are ready to oper-
ate the pump.
Fluid Suction Line
• Use conductive hoses (E). See FIG. 3.
•See
Technical Data on page 26 to determine the
fluid inlet size of your pump.
•
Do not
pressure feed the pump; diaphragm life will
be shortened.
• For maximum suction lift (wet and dry) information,
see Technical Data on page 26.
Fluid Outlet Line
1. Use conductive fluid hoses (J). See FIG. 3. See
Technical Data on page 26 to determine the fluid
outlet size of your pump.
2. Install a fluid drain valve (G) near the fluid outlet.
The fluid drain valve is required to relieve pressure
in the hose and gun. The drain valve reduces the
risk of serious injury, including splashing in the eyes
or on the skin, or injury from toxic fluids.
3. Install a shutoff valve (H) in the fluid outlet line.

Installation
309476B 7
Key:
A Air Supply Line
B Bleed-Type Master Air Valve
C Air Regulator
D Air Line Filter
E Fluid Suction Line
F Fluid Supply
G Fluid Drain Valve
H Fluid Shutoff Valve
J Fluid Line
K Mounting Bracket
L Internal Air Relief Valve
M Muffler
N Air Line Quick Disconnect Coupler
P Pump Air Piston
R Pump Diaphragms
S Pump Ball Checks
T Air Shutoff Valve
Y Pump Ground Wire
FIG. 3. Typical Installation
A
BC
D
E
F
G
H
J
K
L
M
N
Y
T
P
R
RS
S
S
S
TI1961B

Installation
8309476B
Grounding
Ground all of this equipment:
•
Pump: use a ground wire and clamp. See FIG. 4.
Loosen the grounding screw (X). Insert one end of a
1.5 mm2(12 ga) minimum ground wire (Y) into the
pump’s grounding clamp (8) and tighten the screw
(X) securely. Connect the other end of the wire to a
true earth ground. For a ground wire and clamp,
order Part No. 238909.
•
Air and fluid hoses: Use only electrically conductive
hoses.
•
Air compressor: Follow manufacturer’s recommen-
dations.
•
Fluid supply drum: Follow your local code.
•
All solvent pails used when flushing: Follow your
local code. Use only metal pails, which are conduc-
tive, placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continu-
ity.
FIG. 4. Grounding the Pump
WARNING
Before operating the pump, ground the system as
explained below. Read the warnings on page 4.
Y
X
TI2085A

Operation
309476B 9
Operation
Pressure Relief Procedure
1. Shut off the air to the pump.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve all fluid pres-
sure, having a container ready to catch the drain-
age.
Flush the Pump Before First
Use
The pump was tested in water. If the water could con-
taminate the fluid you are pumping, flush the pump thor-
oughly with a compatible solvent. Follow the steps under
Starting and Adjusting the Pump.
Starting and Adjusting the
Pump
1. Be sure the pump is properly grounded. Refer to
Grounding on page 8.
2. Check all fittings to be sure they are tight. Be sure to
use a compatible liquid thread sealant on all male
threads. Tighten the fluid inlet and outlet fittings
securely.
3. Re-torque all screws and fasteners before startup.
Re-torque the fluid cover screws first, followed by
the manifold screws.
4. Place the suction tube (E) in the fluid to be pumped.
5. Place the end of the fluid hose (J), see FIG. 3, into
an appropriate container.
6. Close the fluid drain valve (G). Open the fluid shutoff
valve (H).
7. With the pump air regulator (C) closed, open the
bleed-type master air valve (B).
8. If the fluid hose has a dispensing device, hold it
open while continuing with the following step.
9. Slowly open the air regulator (C) until the pump
starts to cycle. Allow the pump to cycle slowly until
all air is pushed out of the lines and the pump is
primed.
If you are flushing, run the pump long enough to thor-
oughly clean the pump and hoses. Close the air regula-
tor. Remove the suction tube (E) from solvent and place
it in the fluid to be pumped.
Pump Shutdown
Short Term Shutdown
For a short term shutdown, relieve the pressure (see at
left).
Long Term Shutdown
For a long term shutdown, such as several hours or
overnight:
1. Flush the pump thoroughly.
2. Leave compatible solvent in the pump.
3. Relieve the pressure (see at left).
WARNING
Read the warnings on page 3, and follow the Pressure
Relief Procedure below whenever you:
• are instructed to relieve pressure
• stop spraying
• check or service any of the equipment
• install or clean the fluid nozzle.
Operating the pump beyond the maximum air
input pressure will decrease diaphragm life.
Do not operate the pump dry for long periods of
time to avoid reducing diaphragm life.

Maintenance
10 309476B
Maintenance
Lubrication
Flushing and Storage
Flush the pump with a compatible solvent often enough
to prevent the fluid you are pumping from drying in the
pump and damaging it. Follow the Pressure Relief Pro-
cedure on page 9 before storing it for any length of time.
Tighten Threaded
Connections
1. Before each use, check all hoses for wear or dam-
age, and replace as necessary.
2. Check to be sure all threaded connections are tight
and leak-free.
3. Check and re-torque all screws and fasteners at
least every two months. Re-torque the fluid cover
screws first, followed by the manifold screws.
Preventive Maintenance
Schedule
Establish a preventive maintenance schedule, based on
the service history of the pump. This is especially impor-
tant for prevention of spills or leakage due to diaphragm
failure.
CAUTION
Lubrication of the pump is not required. Oil is
exhausted through the muffler, which could contami-
nate the fluid supply or other equipment. Excessive
lubrication can also cause the pump to malfunction.

Maintenance
309476B 11

Troubleshooting
12 309476B
Troubleshooting
Relieve the pressure (page 9) before checking or
servicing the equipment.
Check all possible problems and causes before
disassembling the pump.
Problem Cause Solution
Pump cycles at stall or fails to hold
pressure at stall.
Worn check valve balls (56), seats
(53), or ball guides (57).
Replace. See page 20.
Pump will not cycle, or cycles once
and stops.
Stuck or dirty air valve. Disassemble and clean air valve. See
page 18. Use filtered air.
Check valve ball (56) severely worn
and wedged in seat (53).
Replace ball and seat. See page 20.
Check valve ball (56) wedged in seat
(53) due to overpressurization.
Replace. See page 20. Do not
exceed the maximum fluid working
pressure, see page 26.
Clogged fluid dispensing valve. Relieve pressure and clear valve.
Pinched hose line. Check lines.
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking check valves. Clean or replace balls (56) and seats
(53). See page 20.
Ruptured diaphragm (14). Replace. See page 16. Do not
exceed maximum air input pressure.
Restricted exhaust. Remove restriction.
Air bubbles in fluid. Loose suction line. Tighten.
Ruptured diaphragm (14). Replace. See page 16.
Pump running irregularly. Stroke fre-
quency dropping, coming to stand-
still.
Worn parts. Replace worn parts. Check com-
pressed air supply.
Icing caused by: compressed air too
moist, stroke frequency too high,
local temperature too low.
Remove ice by changing operating
conditions.
Air escapes continually from muffler. Damaged air valve cup (47) or seat
(33).
Replace damaged parts. See page
18.
Foreign matter inside pump. Check air filter.
Pump does not start, or pressure
fluctuates.
Worn check valve seats (53). Replace. See page 20.
Inlet strainer blocked, maximum suc-
tion exceeded, hose or seal defec-
tive.
Clean strainer. Replace defective
parts.
Contaminated fluid. Pump installed or
operated incorrectly.
Check fluid supply. Follow installa-
tion and operation instructions in this
manual.

Troubleshooting
309476B 13
FIG. 5. Cutaway Views of Pump and Air Valve
Fluid Outlet
Outlet Ball Check
Diaphragm
Air Piston
Inlet Ball Check
Outlet Manifold Tube
Fluid Inlet
Inlet Manifold Tube
Outlet Ball Check
Diaphragm
Inlet Ball Check
Diaphragm Shaft
Optional Fluid Outlet
Air Valve
Air Valve Gasket
Diaphragm Shaft
Air Valve Cup
Carriage
Driver Carriage
Air Inlet
Carriage

Troubleshooting
14 309476B

Repair
309476B 15
Repair
Prepare the Pump for Repair
1. Flush the pump if possible, page 10.
2. Relieve the pressure, page 9.
3. Disconnect the air and fluid hoses.
4. Remove the pump from its mounting and take it to
the work bench.
General Repair Notes
Fault Indications
During operation, check for indications of worn or dam-
aged parts, such as:
• major pressure fluctuations
• change in the pump’s operating sound
• irregular operation.
Always replace worn or damaged parts immediately to
prevent additional damage.
Tools Required
• 4, 5, 6, 8 and 10 mm allen wrenches
• 13 mm open end wrench
• 28 mm open end wrench, or adjustable wrench
• two flat blade screwdrivers
• #2 Phillips screwdriver
• internal snap ring pliers
• dowel rod (wood or plastic)
•o-ringpick
• A qualified technician should make all repairs.
• Inspect and clean all parts thoroughly before
reassembly.
• Use only genuine Graco replacement parts,
available from your Graco distributor.
• Be careful not to damage sealing surfaces.
• Replace all o-rings removed from the pump.
• Follow all lubrication, torque, and repair notes
in the repair procedures.
• Do not use silicone or silicone-based grease.

Repair
16 309476B
Replace the Diaphragms
Disassembly
1. Prepare the pump for repair, page 15.
2. Remove the screws (31) from one fluid cover (1).
Pull the cover assembly off, separating it from the
fluid tubes (12). See FIG. 6.
3. Remove the fluid tubes (12) from the other cover
assembly.
4. Remove the screws (31) and the remaining fluid
cover (1).
5. Push on one diaphragm (14) to force the shaft all
the way to one side.
6. Unscrew the diaphragms (14) from the shaft by turn-
ing them counterclockwise, by hand.
Reassembly
1. Screw the new diaphragms (14*) into the shaft by
hand.
2. Remove the o-rings (13) from the fluid tubes (12)
and replace with new o-rings (13*) from the kit.
3. Install the cover assembly that has the tube hous-
ings (4) attached. The arrow must point toward the
top of the pump and the air inlet (40) must be to the
right of the cover (1). Torque the screws (31) to 20
N•m (15 ft-lb).
4. Lubricate the o-rings (13*) and ends of the fluid
tubes (12) and push the tubes into the tube hous-
ings (4) so they are securely seated.
5. Install the cover assembly that has the fluid inlet (3)
and outlet (2) housings attached. The arrow must
point toward the top of the pump. Seat the cover
securely on the fluid tubes (12). Torque the screws
(31) oppositely and evenly to 20 N•m (15 ft-lb).
Diaphragm Repair Kit 243152 is available. Parts
included in the kit are marked, for example (14*).
For the best results, replace both diaphragms and
all o-rings (13*).
Operating the pump beyond the maximum air
input pressure will decrease diaphragm life.
Do not operate the pump dry for long periods of
time to avoid reducing diaphragm life.

Repair
309476B 17
FIG. 6. Replace the Diaphragms
13*
12
13*
14*
13*
12
13*
14*
31
31
1
40
1
2
3
Lubricate.
Torque to 12 N•m (8.8 ft-lb)
1
2
2
1
1
1
1
2
TI1959A
4
4

Repair
18 309476B
Repair the Air Valve
Disassembly
1. Prepare the pump for repair, page 15.
2. Remove the screws (31) from one fluid cover (1).
Pull the cover assembly off, separating it from the
fluid tubes (12). See FIG. 7.
3. Remove the screws (31) and the other fluid cover
(1) assembly, keeping the fluid tubes (12) attached.
4. Remove the air inlet fitting (40).
5. Remove the screws (68) and the top (67) and bot-
tom (66) covers.
6. Remove the diaphragms (14), page 16.
7. Remove the four screws (38) and washers (37), air
valve cover (36), and gasket (35).
8. Pry the air valve seat (33) out of the housing (5),
using two screwdrivers inserted in the recesses on
the seat. Remove the o-rings (43, 44) from the seat.
9. Remove the cup (47) from the center housing.
10. Remove the two clips (46) from the shaft (17).
11. Remove the screws (30), cylinder outer cover (11),
and cylinder (7). Do not lose the o-rings (22).
12. Pull out the piston (16) and shaft assembly.
13. Remove the screws (29) and inner cover (6).
14. Remove the clips (50) from the air valve plugs (51).
Thread a screw (38) partially into each plug and pull
the plugs out. Remove the o-rings (52).
15. Push the driver carriage (48) out of its bore.
Remove the o-rings (49).
16. Remove the clips (21) and push the bearings (18)
out of the center housing (5), inner cover (6), and
outer cover (11). Remove the o-rings (19, 20) from
the bearings.
17. Remove the carriage (45).
Reassembly
1. Install the o-rings (19†, 20†) on the three bearings
(18). Install the bearings in the center housing (5),
cylinder inner cover (6), and cylinder outer cover
(11). Secure with the clips (21).
2. Install the carriage (45) in the center housing (5),
oriented as shown.
3. Install the o-rings (49†) on the driver carriage
(48†).Push the driver carriage into its bore, oriented
as shown.
4. Install the o-rings (52†) on the air valve plugs (51).
Install the plugs and secure with clips (50).
5. Check that the o-rings (42 and 28) are in place in
the center housing (5).
6. Check that the o-rings (22 and 25) are in place on
the cylinder inner cover (6).
7. Check that the o-ring (23), packing (26), and quad
ring (32) are in place on the piston (16).
8. Insert the air valve tube (24) through the cylinder
inner cover (6). Install the cover on the center hous-
ing (5). Seat the air valve tube securely in the center
housing, oriented with the spring pin (27). Torque
the screws (29) to 8 N•m (5.9 ft-lb).
9. Lubricate the diaphragm shaft (17), then slide it into
the center housing (5), guiding the air valve tube
(24) through the hole in the piston. Install the two
clips (46) on the shaft.
10. Liberally grease the inside of the cylinder (7) and
the piston o-ring (23). Install the cylinder, making
sure it is seated on the inner cover (6).
11. Install the o-ring (22) on the cylinder outer cover
(11). Install the outer cover. Torque the screws (30)
to 15 N•m (11 ft-lb).
Air Valve Repair Kit 243153 is available. Parts
included in the kit are marked, for example (33†).
For the best results, use all parts in the kit.
Lubricate all o-rings when reassembling the
pump.

Repair
309476B 19
12. Install the cup (47†) in the center housing.
13. Install the o-rings (43†, 44†) on the air valve seat
(33†). Lubricate the o-rings. Install the seat in the
center housing (5), oriented with the spring pin (34).
14. Install the gasket (35†), cover (36), and screws and
washers (38, 37). Torque to 6 N•m (4.4 ft-lb).
15. Reinstall the diaphragms (14), page 16.
16. Install the fluid covers (1). The arrows must point up.
Torque the screws (31) to 20 N•m (15 ft-lb).
17. Check that the felt strips (71) are in place on the
inside of the top (67) and bottom (66) covers. Install
the covers. The hole for the air inlet fitting must align
with the port in the center housing (5). Tighten the
screws (68).
18. Install the air inlet fitting (40).
FIG. 7. Repair the Air Valve
38 37 36 35†
†33
†43
†44 †47 45
67
5
12
31
12
68
66
68
7
22
22
11
20†
18
19†
21
14
31
21
19† 18
20†
29
30
17
46
28
6
25
24
42
†52
50
40
26
32
21
19†
18
20†
48†
†49
†52
51
50
14
15 23
51
Lubricate.
Torque to 8 N•m (5.9 ft-lb)
Torque to 15 N•m (11 ft-lb)
Torque to 6 N•m (4.4 ft-lb)
Torque to 20 N•m (15 ft-lb)
1
2
3
4
5
1
2
3
4
5
5
1
1
1
1
1
1
1
1
1
TI1958A
27
34
1
1
71
71
16

Repair
20 309476B
Replace the Ball Check
Valves
Disassembly
1. Prepare the pump for repair, page 15.
2. Remove the screws (38) and take the tube assem-
blies off the pump. See FIG. 8.
3. Remove the springs (65), ball guides (57), and balls
(56) from the outlet (top) check valves.
4. Insert a dowel through the outlet seats (53) and
push the inlet (bottom) valve parts (65, 57, 56, 53,
58) out of the pump. Remove the flat seal (59).
5. Insert a dowel through the inlet ports and push the
outlet valve seats (53) and sleeves (54) out of the
pump. Remove the flat seals (55, 59).
Reassembly
1. Install the outlet check valves into the fluid covers
(1): a flat seal (59★), seat (53‡), seal (59★), sleeve
(54), ball (56‡), ball guide (57‡), spring (65‡), and
seal (55★).
2. Install the outlet tube assembly. Torque the screws
(38) to 10 N•m (7.4 ft-lb).
3. Install the inlet check valves into the fluid covers (1):
a spring (65‡), ball guide (57‡), ball (56‡), seat
(53‡), flat seal (59★), and seal (58).
4. Install the inlet tube assembly. Torque the screws
(38) to 10 N•m (7.4 ft-lb).
Ball Check Valve Repair Kit 243154 is available.
Parts included in the kit are marked, for example
(56‡). For the best results, use all parts in the kit.
Sealing Ring Repair Kit 243156 is available. Parts
included in the kit are marked, for example (55★).
For the best results, use all parts in the kit.
If the ball is stuck in the seat, pry it loose with a
screwdriver.
Some parts will be reused, so be careful not to
drop or lose parts.
CAUTION
The outlet ball check valves must be installed exactly
as shown in FIG. 8:
• beveled side of seat (53) must face the ball (56)
• beveled end of sleeve (54) must face the seat (53)
• open end of ball guide (57) must face the ball (56)
• turned down end of spring (65) must face the ball
guide (57)
CAUTION
The inlet ball check valves must be installed exactly
as shown in FIG. 8:
• turned down end of spring (65) must face the ball
guide (57)
• open end of ball guide (57) must face the ball (56)
• beveled side of seat (53) must face the ball (56)
• wide end of seal (58) must face the seat (53)