Lincoln 85353 Parts list manual

Performance Curve.................................................................................................. 2
Dimensions: withEncapsulated Muffler .................................................................... 3
MetricDimensions:with EncapsulatedMuffler ......................................................... 4
PrincipleofPump Operation .................................................................................... 5
InstallationandStart-up ........................................................................................... 5
AirSupply ................................................................................................................ 5
AirValveLubrication ................................................................................................ 5
AirLineMoisture ...................................................................................................... 5
Air Inletand Priming ................................................................................................. 5
Between Uses ......................................................................................................... 5
Troubleshooting........................................................................................................ 6
Warranty .................................................................................................................. 6
Important Safety Information .................................................................................... 7
CompositeRepairParts Drawing............................................................................. 8
OverlayOptionDrawing .......................................................................................... 8
Available Service and Conversion Kits ................................................................ 8
CompositeRepairParts List .................................................................................... 9
Air DistributionValve Assembly Drawing ................................................................10
Air DistributionValve Assembly Parts List...............................................................10
AirDistributionValve Servicing ...............................................................................11
PilotValve Assembly Drawing.................................................................................12
PilotValve Assembly Parts List...............................................................................12
PilotValve Servicing ...............................................................................................13
Intermediate Assembly Drawing &Repair Parts List ...............................................14
IntermediateAssemblyServicing............................................................................15
Modular CheckValve Drawing ................................................................................16
Modular CheckValve Servicing ..............................................................................17
DiaphragmServiceDrawing,Non-Overlay .............................................................18
DiaphragmServiceDrawing,with Overlay..............................................................18
DiaphragmServicing ..............................................................................................19
OverlayDiaphragmServicing .................................................................................19
ExhaustPort orAuxiliary Muffler Setup...................................................................20
Models 85353, 85354
½" Air-Powered Diaphragm Pump
LINCOLN • One Lincoln Way, St Louis, MO 63120-1578 • Customer Service [phone] Form #402975 520-280-000 5/00 Page 1
Table of Contents
SERVICE & OPERATING MANUAL
Section - B5
Page - 22
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 2
345678910111213141516
2
1
0
Capacity
U.S.Gallons per minute
Liters per minute
100
90
2 (3.5)
4 (7)
80
70
60
50
40
30
20
10
10 20 30 40 50 60
0
0
BAR PSI
Head
1
2
3
4
5
6
7
0
30
20
25
10
15
5
9.1
6
7.6
3
4.5
1.5
NPSHR
FEET METERS
6 (10)
8 (13.5)
10 (17)
12 (20)
14 (24)
16 (27)
100 PSI (6.8 Bar)
80 PSI (5.44 Bar)
60 PSI (4.08 Bar)
40 PSI (2.72 Bar)
20 PSI (1.36 Bar)
Air Inlet Pressure
.
Performance Curve, Models 85353,85354
Displacement per Stroke: .026 U.S. gallons
.098 liters
Flow Capacity: 0 to 14 U.S. gallons per minute
0 to 52 liters per minute
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 3
Dimensions: with
Encapsulated Muffler
Dimensionsin Inches
Dimensionaltolerance:±1/8"
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 4
Dimensions: with
Encapsulated Muffler
Dimensionsin millimeters
Dimensionaltolerance:±3mm
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 5
PRINCIPLE OF PUMP OPERATION
This ball type check valve pump is
poweredbycompressedairandisa1:1
ratio design. The inner side of one
diaphragm chamber is alternately
pressurized while simultaneously
exhaustingtheotherinnerchamber.This
causes the diaphragms, which are
connected by a common rod secured
by plates to the centers of the
diaphragms,to move inareciprocating
action.(Asonediaphragmperformsthe
discharge stroke the other diaphragm
is pulled to perform the suction stroke
in the opposite chamber.) Air pressure
is applied over the entire inner surface
of the diaphragm while liquid is
dischargedfromtheoppositesideof the
diaphragm.Thediaphragm operates in
a balanced condition during the
dischargestrokewhichallowsthepump
tobeoperated at discharge headsover
200feet (61 meters)ofwater.
For maximum diaphragm life, keep
the pump as close to the liquid being
pumped as possible. Positive suction
headinexcessof10feetofliquid(3.048
meters) may require a back pressure
regulating device to maximize
diaphragmlife.
Alternate pressurizing and
exhausting of the diaphragm chamber
isperformedby an externallymounted,
pilot operated, four way spool type air
distributionvalve.Whenthespoolshifts
to one end of the valve body, inlet
pressure is applied to one diaphragm
chamber and the other diaphragm
chamber exhausts. When the spool
shifts to the opposite end of the valve
body, the pressure to the chambers is
reversed.Theairdistributionvalvespool
is moved by a internal pilot valve which
alternately pressurizes one end of the
air distribution valve spool while
exhaustingtheotherend.Thepilotvalve
is shifted at each end of the diaphragm
stroke when a actuator plunger is
contacted by the diaphragm plate. This
actuatorplungerthenpushesthe end of
the pilot valve spool into position to
activatetheairdistribution valve.
The chambers are connected with
manifolds with a suction and discharge
check valve for each chamber,
maintainingflowinonedirectionthrough
thepump.
INSTALLATION AND START-UP
Locate the pump as close to the
productbeingpumpedaspossible.Keep
the suction line length and number of
fittingstoa minimum. Do notreducethe
suctionline diameter.
For installations of rigid piping, short
sectionsofflexiblehoseshouldbeinstalled
between the pump and the piping. The
flexible hose reduces vibration and strain
to the pumping system. A surge
suppressor is recommended to further
reducepulsationinflow.
AIR SUPPLY
Air supply pressure cannot exceed
100 psi (7 bar). Connect the pump air
inlettoanairsupplyofsufficient capacity
and pressure required for desired
performance. When the air supply line
is solid piping, use a short length of
flexible hose not less than ½" (13mm)
in diameter between the pump and the
pipingtoreducestraintothepiping.The
weight of the air supply line, regulators
and filters must be supported by some
meansotherthantheairinletcap.Failure
to provide support for the piping may
resultindamagetothepump.Apressure
regulating valve should be installed to
insure air supply pressure does not
exceedrecommended limits.
AIRVALVE LUBRICATION
Theairdistributionvalveandthepilot
valvearedesignedtooperateWITHOUT
lubrication.Thisisthepreferredmodeof
operation. There may be instances of
personal preference or poor quality air
supplies when lubrication of the
compressed air supply is required. The
pump air system will operate with
properly lubricated compressed air
supply. Proper lubrication requires the
useof an airlinelubricatorsetto deliver
onedropofSAE10non-detergentoilfor
every20SCFM(9.4liters/sec.)ofairthe
pumpconsumesatthepointofoperation.
Consult the pump’s published
PerformanceCurvetodetermine this.
AIR LINE MOISTURE
Water in the compressed air supply
can create problems such as icing or
freezing of the exhaust air, causing the
pump to cycle erratically or stop
operating. Water in the air supply can
be reduced by using a point-of-use air
dryertosupplementtheuser’sairdrying
equipment. This device removes water
from the compressed air supply and
alleviatestheicingorfreezingproblems.
AIR INLET AND PRIMING
To start thepump,opentheair valve
approximately ½ to ¾ turn. After the
pumpprimes,theairvalvecanbeopened
toincreaseairflowasdesired. Ifopening
thevalveincreasescyclingrate,butdoes
not increase the rate of flow, cavitation
hasoccurred.Thevalveshouldbeclosed
slightly to obtain the most efficient air
flowto pump flowratio.
BETWEEN USES
Whenthepumpisusedformaterials
that tend to settle out or solidify when
notinmotion,thepumpshouldbeflushed
after each use to prevent damage.
(Productremaininginthepumpbetween
uses could dry out or settle out. This
could cause problems with the
diaphragmsandcheckvalvesat restart.)
Infreezingtemperaturesthepumpmust
becompletely drainedbetweenuses in
all cases.
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 6
TROUBLESHOOTING
PossibleSymptoms:
•Pump will not cycle.
•Pump cycles, but produces no flow.
•Pump cycles, but flow rate is
unsatisfactory.
•Pump cycle seems unbalanced.
•Pump cycle seems to produce
excessivevibration.
What to Check: Excessive suction lift
in system.
Corrective Action: For lifts exceeding
20 feet (6 meters), filling the pumping
chamberswithliquidwillprimethepump
in most cases.
What to Check: Excessive flooded
suction in system.
Corrective Action: For flooded
conditionsexceeding10 feet (3meters)
ofliquid, install abackpressure device.
What to Check: System head exceeds
airsupply pressure.
CorrectiveAction:Increasetheinletair
pressure to the pump. Most diaphragm
pumps are designed for 1:1 pressure
ratioat zeroflow.
What to Check: Air supply pressure or
volumeexceeds system head.
Corrective Action: Decrease inlet air
pressure and volume to the pump as
calculated on the published
PERFORMANCE CURVE. Pump is
cavitating the fluid by fast cycling.
What to Check: Undersized suction
line.
Corrective Action: Meet or exceed
pump connection recommendations
shownontheDIMENSIONALDRAWING.
What to Check: Restricted or
undersizedair line.
Corrective Action: Install a larger air
line and connection. Refer to air inlet
recommendationsshowninyourpump’s
SERVICEMANUAL.
What to Check: Check ESADS, the
Externally Serviceable Air Distribution
System of the pump.
Corrective Action: Disassemble and
inspect the main air distribution valve,
pilotvalveandpilotvalveactuators.Refer
tothepartsdrawingand airvalvesection
of the SERVICE MANUAL. Check for
cloggeddischargeorclosedvalvebefore
reassembly.
What to Check: Rigidpipeconnections
topump.
Corrective Action: Install flexible
connectorsand a surgesuppressor.
What to Check: Blocked air exhaust
muffler.
Corrective Action: Remove muffler
screen, clean or de-ice and reinstall.
Referto theAirExhaust sectionofyour
pumpSERVICEMANUAL.
What to Check: Pumped fluid in air
exhaustmuffler.
Corrective Action: Disassemblepump
chambers.Inspectfordiaphragmrupture
orloosediaphragmplateassembly.Refer
tothe Diaphragm Replacementsection
ofyour pump SERVICEMANUAL.
What to Check: Suction side air
leakage or air in product.
Corrective Action: Visually inspect all
suction side gaskets and pipe
connections.
What to Check: Obstructed check
valve.
CorrectiveAction:Disassemblethewet
endof the pumpandmanuallydislodge
obstruction in the check valve pocket.
Refer to the Check Valve section of the
pump SERVICE MANUAL for
disassembly instructions.
What to Check: Worn or misaligned
checkvalveor check valveseat.
CorrectiveAction:Inspectcheckvalves
and seats for wear and proper seating.
Replace if necessary. Refer to Check
Valve section of the pump SERVICE
MANUALfor disassemblyinstructions.
What to Check: Blocked suction line.
Corrective Action: Remove or flush
obstruction.Check and clearallsuction
screensand strainers.
What to Check: Blockeddischargeline.
Corrective Action: Check for
obstruction or closed discharge line
valves.
What to Check: Blocked pumping
chamber.
Corrective Action: Disassemble and
inspect the wetted chambers of the
pump.Removeorflushanyobstructions.
Refer to the pump SERVICE MANUAL
for disassembly instructions.
What to Check: Entrained air or vapor
lock in one or both pumping chambers.
Corrective Action: Purge chambers
through tapped chamber vent plugs.
PURGING THE CHAMBERS OF AIR
CAN BE DANGEROUS! Contact the
Technical Services Department before
performingthisprocedure.Amodelwith
top-ported discharge will reduce or
eliminateproblemswith entrained air.
If your pump continues to perform
below your expectations, contact your
local distributor or factory Technical
ServicesGroupforaserviceevaluation.
WARRANTY
This pump is warranted for a period
of five years against defective material
andworkmanship.
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 7
IMPORTANT SAFETY INFORMATION
Read these safety warnings and instructions in this manual
COMPLETELY, before installation and start-up of the pump. It is the
responsibility of the purchaser to retain this manual for reference. Failure to
comply with the recommendations stated in this manual will damage the
pump,and void factory warranty.
WARNING!
Take action to prevent static
sparking. Fire or explosion can
result, especially when handling flammable
liquids.The pump, piping, valves, containers
or other miscellaneous equipment must be
grounded.
IMPORTANT!
This pump is pressurized internally
with air pressure during operation.
Always make certain that all bolting is in
good condition and that all of the correct
bolting is reinstalled during assembly.
CAUTION!
In the event of diaphragm rupture,
pumped material may enter the air
end of the pump, and be discharged into
the atmosphere. If pumping a product
which is hazardous or toxic, the air exhaust
must be piped to an appropriate area for
safe disposition.
DANGER!
Before doing any maintenance on
the pump, be certain all pressure is
completely vented from the pump, suction,
discharge, piping, and all other openings
and connections. Be certain the air supply
is locked out or made non-operational, so
that it cannot be started while work is being
done on the pump. Be certain that approved
eye protection and protective clothing are
worn all times in the vicinity of the pump.
Failure to follow these recommendations
may result in serious injury or death.
BEFORE OPERATION
Before pump operation, inspect all
gasketed fasteners for looseness
caused by gasket creep. Re-torque loose
fasteners to prevent leakage. Follow
recommended torques stated in this
manual.
CAUTION!
Before maintenance or repair, shut
off the compressed air line, bleed
the pressure, and disconnect the air line
from the pump. The discharge line may be
pressurized and must be bled of its
pressure.When used for toxic or aggressive
fluids, the pump should always be flushed
clean prior to disassembly.
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 8
Composite Repair
Parts Drawing
Available Service and Conversion Kits
PART NO. DESCRIPTION
252891 AIR END KIT
Seals, O-rings, Gaskets,
Retaining Rings, Air Valve
Spool and Pilot Valve Assembly.
252892 WETTED END KIT
SantopreneDiaphragms, Nitrile
SpacerGaskets, Santoprene
Check Balls andTFE Seals.
252893 WETTED END KIT
Santoprene Diaphragms, TFE
Overlay Diaphragm, TFE
Check Balls and TFE Seals.
MUFFLER
OPTION
OVERLAY
OPTION
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 9
Composite Repair Parts List Model Model
85353 85354
ITEM DESCRIPTION QTY PART NO. PART NO.
1 AirValve Assembly 1 252894 252894
2 Ball, Check 4 252895 252896
3 PilotValve Assembly 1 252897 252897
4 IntermediateAssembly 1 252898 252898
5 Bracket,Mounting 2 252899 252899
Bracket,FreeStanding(Optional) 2 252939 252939
6 Bumper,Diaphragm 2 252900 252900
8 Cap, AirInlet 1 252902 252902
9 Capscrew, Hex HD 5/16-18 X 1.25 48 252903 252903
Capscrew, Hex HD 5/16-18 X 1.75 8 252940 252940
(usewithFreeStanding Option)
10 Capscrew, Hex HD 1/4-20 X 1.62 4 252904 252904
11 Capscrew, Soc HD 1/4-20 X 1.50 4 252905 252905
12 Chamber, Outer 2 252906 252906
13 Diaphragm 2 252907 252907
14 Diaphragm, Overlay 2 252908
15 Elbow 4 252909 252909
16 Gasket, Spacer 2 252910 252910
17 Gasket, Air Inlet 1 252911 252911
18 Gasket, PilotValve 1 252912 252912
19 Gasket, Air Valve 1 252913 252913
20 Manifold 2 252914 252914
23 Nut, Hex5/16-18" 24 252916 252916
25 Plate, OuterDiaphragm 2 240768 240768
26 Plate, InnerDiaphragm 2 252917 252917
27 Plunger, Actuator 2 252918 252918
28 Retainer, Ball 4 252919 252919
30 Rod, Diaphragm 1 252920 252920
31 Seal, DiaphragmRod 2 252921 252921
32 Seal,Manifold 4 252922 252922
33 Seal, Check Valve 8 252923 252923
34 Seat, CheckValve 4 252924 252924
35 Washer, Flat1/4" 8 240783 240783
36 Washer, Flat5/16" 72 240659 240659
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 10
Air Distribution Valve Assembly Drawing
MAIN AIRVALVE ASSEMBLY PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
1 252894 Main Air Valve Assembly 1
1-A 252925 Body, Air Valve 1
1-B 252926 Cap, End with o-ring 2
1-C 252927 O-Ring 8
1-D 252928 Ring, Retaining 2
1-E 252929 Sleeve and Spool Set w/o-rings 1
1-F 252930 Muffler 1
1-G 252931 Cap, Muffler 1
1-H 252932 Screws, Self-Tapping 4
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 11
AIR DISTRIBUTIONVALVE
SERVICING
To service the air valve first shut off
thecompressedair,bleedpressurefrom
thepump,anddisconnectthe air supply
linefrom the pump.
STEP#1:SeeCOMPOSITEREPAIR
PARTSDRAWING.
Using a 3/16" Allen wrench, remove
thefourhex socket capscrews (item11)
andfourflatwashers(item36).Remove
theair valve assemblyfromthepump.
Removeandinspectgasket(item19)
forcracksor damage. Replace gasketif
needed.
STEP #2: Disassembly of the air
valve.
To access the internal air valve
componentsfirstremovethetworetaining
rings (item 1-D) from each end of the air
valveassemblyusingclipringpliers.
Nextremove the twoendcaps(item
1-B).Inspecttheo-ring(item1-C)forcuts
orwear.Replacetheo-ringsifnecessary.
Remove the spool (part of item 1-E)
fromthesleeve.Becareful nottoscratch
or damage the outer diameter of the
spool. Wipe spool with a soft cloth and
inspect for scratches or wear.
Inspect the inner diameter of the
sleeve (part of item 1-E for dirt,
scratches, or other contaminants.
Remove the sleeve if needed and
replacewitha new sleeve andspoolset
(item1-E).
STEP#3:Reassemblyoftheairvalve.
Install one end cap (item 1-B) with
an o-ring (item 1-C) into one end of the
air valve body (item 1-A). Install one
retainingring (item 1-D)intothe groove
on the same end.
Removethenewsleeveandspoolset
(item1-E)fromtheplasticbag.Carefully
removethespoolfromthesleeve.Install
the six o-rings (item 1-C) into the six
grooves on the sleeve. Apply a light
coating of grease to the o-rings before
installingthe sleeveintothe valve body
(item 1-A). align the slots in the sleeve
with the slots in the valve body. Insert
thespool into thesleeve.Be careful not
to scratch or damage the spool during
installation. Push the spool in until
touches the end cap on the opposite
end.
Install the remaining end cap with
o-ringandretainingring.
Fasten the air valve assembly (item
1) and gasket (item 19) to the pump.
Connect the compressed air line to
the pump. The pump is now ready for
operation.
IMPORTANT
Read these instructions completely, before
installation and start-up. It is the
responsibility of the purchaser to retain this
manual for reference. Failure to comply with
the recommendations stated in this manual
will damage the pump, and void factory
warranty.
WARNING
Take action to prevent static sparking. Fire
or explosion can result, especially when
handling flammable liquids. The pump,
piping, valves, containers or other
miscellaneous equipment must be
grounded.
IMPORTANT
This pump is pressurized internally with air
pressure during operation. Always make
certain that all bolting is in good condition
and that all of the correct bolting is
reinstalled during assembly.
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 12
Pilot Valve Assembly Drawing PILOTVALVE ASSEMBLY PARTS LIST
ITEM PARTNUMBER DESCRIPTION QTY
3 252897 Pilot Valve Assembly
3-A 252933 Body, Pilot Valve 1
3-B 252934 Bushing, Pilot Valve 2
3-C 252935 Ring, Spiral Retaining 2
3-D 252936 Spacer 5
3-E 252937 Spool, Pilot Valve 1
3-F 252938 Wiper 6
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 13
PILOTVALVE SERVICING
Toservicethepilotvalve first shutoff
the compressed air supply, bleed the
pressurefromthepump,anddisconnect
theairsupplylinefromthepump.Insert
the safety clip (item 1-G from Air
Distribution Valve assembly drawing)
intothesmallerunthreadedholesinthe
end cap (item 1-F from air distribution
valveassemblydrawing).
Step #1: See PUMP ASSEMBLY
DRAWING.
Using a 7/16" wrench or socket,
remove the four capscrews (items 10)
andfourflatwashers(items36).Remove
the air inlet cap (item 8) and air inlet
gasket (item 17). The pilot valve
assembly(item3)cannowberemoved
forinspectionor service.
Step #2: Disassembly of the pilot
valve.
Remove the pilot valve spool (item
3-E). Wipe clean, and inspect for dirt,
scratchesor wear.Replace the spoolif
necessary.
Removethetwospiralretainingrings
(items 3-C) from each end of the pilot
valvebodybyinsertingthetipofasmall
flat screw driver under the notch in the
retaining ring. Lift and push the ring
clockwise in a circular motion.
Removethetwopilotvalvebushings
(items 3-B), five spacers (items 3-D),
and six spool wipers (items 3-F) by
pushing gently from other end of the
pilotvalvebody. Inspectthewipersand
spacers for cuts and/or wear. Replace
wipers and/or spacers as necessary.
Step #3: Re-assembly of the pilot
valve.
First install a spiral retaining ring to
one end of the pilot valve body. Spread
the spiral and insert one end into the
groove in the pilot valve body. Twist the
ring in a clockwise motion until the full
ring is snapped into the groove. Install
one bushing making sure the step side
faces toward the wiper. Apply a light
coatingofgreasetotheoutsidediameter
of each wiper. Next, gently push in the
wipersandspacersuntilthey areagainst
theinstalledretainingringin theopposite
end of the pilot valve body. Install the
remainingbushingmakingsurethestep
sidefacesthewiper.Installtheremaining
spiral retaining ring using the same
methoddescribed.
Apply a light coating of grease to the
innerdiameterofeachwiper.Alsoapply
a light coating of grease to the outer
diameterofthepilotvalvespoolandgently
pushthespoolthrougheachwiper.
Step #4: Inspect the actuator
plungers.
SeePUMPASSEMBLY DRAWING.
Theactuatorplungers(items27)can
be reached through the stem cavity of
the pilot valve in the intermediate
assembly(item4). Toservicebushings,
o-rings and retaining rings, see
IntermediateAssemblyDrawing.
Removetheplungers(items27)from
thebushings(item4-B)ineachendofthe
intermediate cavity. Apply a light coating
of grease to each o-ring and re-install
the plungers in to the bushings. Push
the plungers in as far as they will go.
IMPORTANT
Read these instructions completely, before
installation and start-up. It is the
responsibility of the purchaser to retain this
manual for reference. Failure to comply with
the recommendations stated in this manual
will damage the pump, and void factory
warranty.
WARNING
Take action to prevent static sparking. Fire
or explosion can result, especially when
handling flammable liquids. The pump,
piping, valves, containers or other
miscellaneous equipment must be
grounded.
IMPORTANT
This pump is pressurized internally with air
pressure during operation. Always make
certain that all bolting is in good condition
and that all of the correct bolting is
reinstalled during assembly.
Step #5: Re-install the pilot valve
assembly into the intermediate
assembly.
Be careful to align the ends of the
stem between the plungers when
inserting the stem of the pilot valve into
thecavity of theintermediate.
Re-install the gasket (item 17), air
inlet cap (item 8), capscrews and
washers(items 10and36).
Connect the air supply to the pump.
Remove the safety clip (item 1-G) from
theendcap(item1-F).Thepumpisnow
readyforoperation.
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 14
INTERMEDIATE ASSEMBLY REPAIR PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
4 252898 Intermediate Assembly 1
4-A 270960 Bearing 2
4-B 252901 Bushing,Plunger 2
4-C 270961 Housing 2
4-D 240655 O-Ring 2
4-E 240717 Ring,Retaining* 2
*NOTE: It is recommended that when plunger components are
serviced, new retaining rings be installed.
Intermediate Assembly Drawing
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 15
PLUNGER BUSHING, O-RING, AND
RETAINING RING SERVICING
To service the plunger bushing
components first remove the two
retaining rings (items 4-E) using a
small flat screwdriver. *Note: It is
recommendedthat new retainingrings
beinstalled.
Next remove the two plunger
bushings (items 4-B). Inspect the
bushingsforwearorscratches.Replace
the bushings as necessary.
Inspectthetwoo-rings(4-D)forcuts
and/orwear.
IMPORTANT
Read these instructions completely, before
installation and start-up. It is the
responsibility of the purchaser to retain this
manual for reference. Failure to comply with
the recommendations stated in this manual
will damage the pump, and void factory
warranty.
WARNING
Take action to prevent static sparking. Fire
or explosion can result, especially when
handling flammable liquids. The pump,
piping, valves, containers or other
miscellaneous equipment must be
grounded.
IMPORTANT
This pump is pressurized internally with air
pressure during operation. Always make
certain that all bolting is in good condition
and that all of the correct bolting is
reinstalled during assembly.
INTERMEDIATE ASSEMBLY SERVICING
SERVICING THE DIAPHRAGM ROD
BEARINGS
To inspect the bearings, first remove
thediaphragm rod (item30).Checkfor
wearorscratches.Replaceasneeded.
Thetwobearings(items4-A)canbe
removedby inserting aflatscrewdriver
through the center bore of the
intermediateassemblyand tapping the
back of the bearings. Care should be
taken when removing the bearing
throughthe housings (items4-C).
Toreinstallthebearingsuseanarbor
press to push the bearings flush to the
edgeof the throughboreeachend.
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 16
Modular Check Ball Valve Drawing
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 17
MODULAR CHECK BALLVALVE
SERVICING
Beforeservicingthecheckvalves,first
shut off the suction line and then the
discharge line to the pump. Next, shut
offthecompressed air supply,bleed air
pressurefromthepump,anddisconnect
theair supply linefromthe pump.Drain
anyremaining fluid fromthepump. The
pumpcannowberemoved for service.
To access the modular check valve,
removetheelbows(items15frompump
composite repair parts drawing). Use a
½" wrench or socket to remove the
fasteners.Oncetheelbowsareremoved,
the modular check valves can be seen
in the cavities of the outer chamber
(items12).
Next remove the check valve seal
(item 33). Inspect the seal for cuts or
pinchedareas.Replacesealasneeded.
Disassemblethecomponentpartsof
each modular check valve. Inspect the
check valve retainer (item 28) for cuts,
abrasivewear,or embeddedmaterials.
Replaceasneeded.
Inspect the check balls (items 2) for
wear,abrasion,or cutsonthe spherical
surface. The check valve seats (items
34)shouldbeinspectedforcuts,abrasive
wear, or embedded material on the
surfacesofboththeexternal andinternal
chamfers. The spherical surface of the
check balls must seat flush to the
surfaceoftheinnerchamferonthecheck
valve seats for the pump to operate to
peak efficiency. Replace any worn or
damagedparts asnecessary.
Remove the check valve seal (item
33).Inspect the sealforcuts or pinched
areas.Replace seal asneeded.
RE-ASSEMBLETHE MODULAR
CHECK VALVE
Place a check valve seal (item 33)
intothecavityoftheouterchamber (item
12). Make sure the chamfer side of the
sealfacesout.Insertthe modular check
valve into the outer chamber with the
retainer facing up. Install a check valve
seal (item 33). Make sure the chamfer
side of the seals face the chamfer on
the check valve seat or retainer.
Thepumpcannowbereassembled,
reconnectedandreturnedto operation.
IMPORTANT
Read these instructions completely, before
installation and start-up. It is the
responsibility of the purchaser to retain this
manual for reference. Failure to comply with
the recommendations stated in this manual
will damage the pump, and void factory
warranty.
WARNING
Take action to prevent static sparking. Fire
or explosion can result, especially when
handling flammable liquids. The pump,
piping, valves, containers or other
miscellaneous equipment must be
grounded.
IMPORTANT
This pump is pressurized internally with air
pressure during operation. Always make
certain that all bolting is in good condition
and that all of the correct bolting is
reinstalled during assembly.
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 18
Diaphragm Service Drawing,
Non-Overlay Diaphragm Service Drawing, with Overlay
THE DIAPHRAGMS FOR BOTH CONFIGURATIONS
SHOWN ABOVE ARE TO BE INSTALLED WITH
CONVOLUTIONS FACING TOWARDS CENTER OF
PUMP
Cross Section of Diaphragm
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 19
DIAPHRAGMSERVICING
To service the diaphragms first shut
off the suction, then shut off the
dischargelinestothepump.Shutoffthe
compressed air supply, bleed the
pressurefromthepump,anddisconnect
theair supply linefromthe pump.Drain
anyremaining liquid fromthepump.
Step #1: See the pump composite
repairpartsdrawing,andthediaphragm
servicingillustration.
Usinga½"wrenchorsocket,remove
the 16 capscrews (items 9), hex nuts
and washers that fasten the elbows
(items15) to theouterchambers(items
12). Remove the elbows with the
manifoldsand spacers attached.
Step #2: Removing the outer
chambers.
Usinga½"wrenchorsocket,remove
the 16 capscrews (items 9), hex nuts
and washers that fasten the outer
chambers,diaphragms,andintermediate
(items4) together.
Step #3: Removing the diaphragm
assemblies.
Use a ¾" (19mm) wrench or six
pointedsockettoremovethediaphragm
assemblies(outerplate,diaphragm,and
innerplate)fromthediaphragmrod(item
30)by turning counterclockwise.
Insert a 6-32 set screw into the
smaller tapped hole in the inner
diaphragm plate (item 26). Insert the
protruding stud and the 6-32 fastener
loosely into a vise. Use a ¾" wrench or
socket to remove the outer diaphragm
plate (item 25) by turning
counterclockwise. Inspect the
diaphragm(item13)forcuts,punctures,
abrasive wear or chemical attack.
Replacethe diaphragms ifnecessary.
Step #4: Installing thediaphragms.
Push the threaded stud of the outer
diaphragmplatethroughthecenterhole
ofthediaphragm.Threadtheinnerplate
clockwiseontothestud.Inserttheloose
assembly with the above 6-32 fastener
backinto the vise.Useatorque wrench
to tighten the diaphragm assembly
together to 7.5 ft. Lbs. (10.17 Newton
meters).Allowaminimumof15minutes
to elapse after torquing, then re-torque
the assembly to compensate for stress
relaxation in the clamped assembly.
Step #5: Installing the diaphragm
assemblies to the pump.
Make sure the bumper (item 6) is
installedoverthediaphragm rod.
Threadthestudoftheonediaphragm
assemblyclockwiseintothetappedhole
at the end of the diaphragm rod (item
30)untiltheinnerdiaphragmplateisflush
totheendoftherod.Insertrodintopump.
Aligntheboltholes in the diaphragm
with the bolt pattern in the intermediate
(item4).
Fasten the outer chamber (item 12)
tothepump,usingthecapscrews(items
9), hex nuts and flat washers.
On the opposite side of the pump,
pull the diaphragm rod out as far as
possible. Make sure the bumper (item
6)is installed overthediaphragmrod.
Thread the stud of the remaining
diaphragmassembly clockwise intothe
tappedholeattheend of the diaphragm
rod (item 30) as far as possible and still
allow for alignment of the bolt holes in
the diaphragm with the bolt pattern in
the inner chamber. Install diaphragms
withconvolutionsfacing towards center
ofpump.Seesectionalviewonprevious
page.
Fastentheremainingouterchamber
(item 12) to the pump, using the
capscrews (items 9), hex nuts and flat
washers.
Step#6:Re-installtheelbow/spacer/
manifoldassembliestothe pump, using
the capscrews (items 9), hex nuts and
flatwashers.
The pump is now ready to be
re-installed, connected and returned to
operation.
OVERLAY DIAPHRAGM SERVICING
The overlay diaphragm (item 14)
isdesignedtofitsnuglyovertheexterior
of the standard TPE diaphragm (item
13).
Follow the same procedures
described for the standard diaphragm
forremovaland installation.
IMPORTANT
Read these instructions completely, before
installation and start-up. It is the
responsibility of the purchaser to retain this
manual for reference. Failure to comply with
the recommendations stated in this manual
will damage the pump, and void factory
warranty.
WARNING
Take action to prevent static sparking. Fire
or explosion can result, especially when
handling flammable liquids. The pump,
piping, valves, containers or other
miscellaneous equipment must be
grounded.
IMPORTANT
This pump is pressurized internally with air
pressure during operation. Always make
certain that all bolting is in good condition
and that all of the correct bolting is
reinstalled during assembly.
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-280-000 5/00 Form #402975 Page 20
SAFE AIR
EXHAUST
DISPOSAL
AREA
PUMP INSTALLATION AREA
1" DIAMETER AIR
EXHAUST PIPING
1" DIAMETER AIR
EXHAUST PIPING
1" DIAMETER AIR
EXHAUST PIPING
MUFFLER
LIQUID
LEVEL
SUCTION
LINE
LIQUID
LEVEL
SUCTION
LINE
MUFFLER
MUFFLER
PUMPINGHAZARDOUSLIQUIDS
Whenadiaphragmfails,thepumped
liquid or fumes enter the air end of the
pump. Fumes are exhausted into the
surroundingenvironment.Whenpumping
hazardous or toxic materials, the
exhaust air must be piped to an
appropriate area for safe disposal. See
illustration #1 at right.
This pump can be submerged if the
pump materials of construction are
compatiblewiththeliquidbeingpumped.
Theairexhaustmustbe pipedabovethe
liquid level. See illustration #2 at right.
Pipingusedfor the airexhaustmustnot
be smaller than ½" (1.27 cm) diameter.
Reducing the pipe size will restrict air
flow and reduce pump performance.
When the pumped product source is at
a higher level than the pump (flooded
suction condition), pipe the exhaust
higher than the product source to
preventsiphoningspills. See illustration
#3 at right.
CONVERTINGTHE PUMP FOR
PIPINGTHE EXHAUST AIR
Thefollowingstepsarenecessaryto
convertthepumptopipetheexhaustair
awayfrom the pump.
UseaPhillipsscrewdrivertoremove
the six self-tapping screws (item 1-H).
Removethe muffler capandmuffler
(items1-Gand1-F).The3/8"NPTmolded
threadsinthe air distribution valvebody
(item1-A).
Pipingorhosemaynowbeinstalled.
IMPORTANT INSTALLATION
NOTE: The manufacturer
recommends installing a flexible hose or
connection between the pump and any
rigid plumbing. This reduces stresses on
the molded plastic threads of the air
exhaust port. Failure to do so may result
indamagetotheairdistributionvalvebody.
Anypiping or hoseconnectedto the
pump’s air exhaust port must be
physicallysupported.Failure to support
these connections could also result in
damagetotheairdistributionvalvebody.
CONVERTEDEXHAUSTILLUSTRATION
Illustration #1
Illustration #2
Illustration #3
Exhaust Conversion Drawing
½"
½"
½"
To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]