Lincoln B Series Parts list manual

LINCOLN® • One Lincoln Way, St. Louis, MO 63120-1578 • Customer Service [phone]
520-359-000 7/03 Revision A Form # 403291
Engineering Data and Temperature Limitations .................................................. 1
Performance Curve ............................................................................................... 2
Dimensions ........................................................................................................... 3
Metric Dimensions ................................................................................................ 4
Principle of Pump Operation ................................................................................ 5
Installation and Start-Up ....................................................................................... 5
Air Supply ............................................................................................................. 5
Air Valve Lubrication ............................................................................................. 5
Air Line Moisture .................................................................................................. 5
Air Inlet and Priming ............................................................................................. 5
Between Uses ...................................................................................................... 5
Installation Guide .................................................................................................. 6
Troubleshooting .................................................................................................... 7
Warranty ............................................................................................................... 7
Recycling .............................................................................................................. 8
Important Safety Information ................................................................................ 8
Composite Repair Parts Drawing ...................................................................... 10
Available Service and Conversion Kits .............................................................. 10
Composite Repair Parts List ..............................................................................11
Air Distribution Valve Assembly Drawing, Parts List and Servicing ................... 12
Actuator Plunger Servicing ................................................................................. 13
Diaphragm Service Drawing ..............................................................................14
Diaphragm Servicing ..........................................................................................15
Check Valve Servicing ........................................................................................ 16
Check Valve Drawing .........................................................................................16
Pumping Hazardous Liquids .............................................................................. 17
Converting Pump for Piping Exhaust Air ............................................................17
Converted Exhaust Illustration ........................................................................... 17
Grounding the Pump .......................................................................................... 18
ATEX Declaration of Conformity .........................................................................19
SERVICE & OPERATING MANUAL
Model 85624 Series BModel 85624 Series B
Model 85624 Series BModel 85624 Series B
Model 85624 Series B
Table of Contents
CE
U.S. Patent #
5,996,627 &
6,241,487
Other U.S. Patents
Applied for
Section - B5Section - B5
Section - B5Section - B5
Section - B5
Page - 27APage - 27A
Page - 27APage - 27A
Page - 27A
2" Aluminum Air-P2" Aluminum Air-P
2" Aluminum Air-P2" Aluminum Air-P
2" Aluminum Air-Powered Diaphragm Pumpowered Diaphragm Pump
owered Diaphragm Pumpowered Diaphragm Pump
owered Diaphragm Pump
II 2GD b T5

520-359-000 7/03 Page 1
Model 85624Model 85624
Model 85624Model 85624
Model 85624
Series BSeries B
Series BSeries B
Series B
Aluminum Air-PoweredAluminum Air-Powered
Aluminum Air-PoweredAluminum Air-Powered
Aluminum Air-Powered
Diaphragm PumpDiaphragm Pump
Diaphragm PumpDiaphragm Pump
Diaphragm Pump
ENGINEERING, PERFORMANCE
& CONSTRUCTION DATA
CE
U.S. Patent #
5,996,627 &
6,241,487
Other U.S. Patents
Applied for
Buna General purpose, oil-resistant. Shows good solvent, oil, water and hydraulic fluid resistance.
Should not be used with highly polar solvents like acetone and MEK, ozone, chlorinated 190°F -10°F 50° to 140°F
hydrocarbons and nitro hyrdrocarbons. 88°C -23°C 10°C to 60°C
Polypropylene 150°F -40°F
65°C -40°C
Polyethylene 180°F -40°F 50° to 140°F
82°C -40°C 10° to 60°C
Materials Maximum* Minimum* Optimum**
Operating Temperatures
INTAKE/DISCHARGE PIPE SIZE
2" NPT(internal)
CAPACITY
0 to 150 gallons per minute
(0 to 567 liters per minute)
AIR VALVE
No-lube, no-stall
design
SOLIDS-HANDLING
Up to .25 in. (6mm)
HEADS UP TO
125 psi or 289 ft. of water
(8.6 Kg/cm2or 86 meters)
DISPLACEMENT/STROKE
.42 Gallon / 1.59 liter
CAUTION! Operating temperature limitations are as follows:
Air Inlet Side View
Air Exhaust Side View
II 2GD b T5

520-359-000 7/03 Page 2
Performance Curve
0 20 40 60 80 100 120 140 160
20 (34)
40 (68)
60 (102)
80 (136)
100 (170)
600500400300200100
Capacity
U.S. Gallons per minute
Liters per minute
100
90
80
70
60
50
40
30
20
10
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
METERS FEET
40 PSI (2.72 Bar)
20 PSI (1.36 Bar)
Air Inlet Pressure
60 PSI (4.08 Bar)
80 PSI
(5.44 Bar)
100 PSI
(6.8 Bar)
Displacement per Stroke: .42 gallons
1.59 liters
Flow Capacity: 0 to150 gallon per minute
0 to 567 liters per minute

520-359-000 7/03 Page 3
Dimensions:
DimensionsinInches
DimensionalTolerance:±1/8"
A
STANDARD METAL MUFFLER
1" NPT EXHAUST PORT
FOR PIPING EXHAUST
AIR IN SUBMERGED
APPLICATIONS.
SUCTION PORT
2" NPT
DISCHARGE PORT
2" NPT
DIMENSION A
Metal Muffler 14 11/16

520-359-000 7/03 Page 4
Metric Dimensions:
A
STANDARD METAL MUFFLER
1" NPT EXHAUST PORT
FOR PIPING EXHAUST
AIR IN SUBMERGED
APPLICATIONS.
SUCTION PORT
2" NPT
DISCHARGE PORT
2" NPT
DimensionsinMillimeters
DimensionalTolerance:± 3mm
Metal Muffler
A
373
DIMENSION

520-359-000 7/03 Page 5
PRINCIPLE OF PUMP OPERATION
This ball type check valve pump is
poweredbycompressedair andisa1:1
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,tomovein a reciprocating
action.(As onediaphragm performsthe
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
dischargedfromtheoppositeside ofthe
diaphragm.The diaphragm operates in
a balanced condition during the
dischargestrokewhichallowsthepump
tobe operated at discharge headsover
200feet(61meters)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
isperformed by an externally mounted,
pilot operated, four way spool type air
distributionvalve. Whenthespool shifts
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
actuatorplunger then pushestheendof
the pilot valve spool into position to
activatethe air distribution 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
fittingsto a minimum. Do notreducethe
suctionlinediameter.
Forinstallationsof rigid piping, short
sections of flexible hose should be
installed between the pump and the
piping. The flexible hose reduces
vibration and strain to the pumping
system. A surge suppressor is
recommendedtofurtherreducepulsation
inflow.
Insystemswhereacloseddischarge
mayoccur,thermalexpansionofthefluid
can cause a hazardous, high-pressure
condition. To prevent damage to
equipment and or personnel, place a
pressurerelief valve in the system. The
pressure relief valve should be set to
relievepressure inthesystem at150psi
and the pressure relief valve should be
locatedneartheoutletofthepumpwith
provision for return to tank. (See
recommended installation drawing on
page6).
AIR SUPPLY
Air supply pressure cannot exceed
125psi (8.6 bar). Connect the pumpair
inlettoanairsupply ofsufficient 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
pipingto reducestrainto the piping.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
exceedrecommendedlimits.
AIR VALVE LUBRICATION
Theairdistributionvalveandthepilot
valvearedesignedtooperateWITHOUT
lubrication.Thisisthe preferredmodeof
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
useofan air line lubricator set to deliver
onedropofSAE 10non-detergentoilfor
every20SCFM(9.4 liters/sec.)ofair the
pumpconsumesatthepointofoperation.
Consult the pump’s published
PerformanceCurve to determinethis.
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
dryerto supplementtheuser’s airdrying
equipment. This device removes water
from the compressed air supply and
alleviatestheicingor freezingproblems.
AIR INLET AND PRIMING
To startthepump,opentheair valve
approximately ½ to ¾ turn. After the
pumpprimes,theairvalvecanbeopened
toincreaseair flowasdesired.Ifopening
thevalveincreasescyclingrate,butdoes
not increase the rate of flow, cavitation
hasoccurred.Thevalveshouldbeclosed
slightly to obtain the most efficient air
flowtopumpflowratio.
BETWEEN USES
Whenthe pumpisused formaterials
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
diaphragmsandcheckvalvesatrestart.)
Infreezing temperaturesthepump must
becompletelydrained between uses in
all cases.

520-359-000 7/03 Page 6
1
1
2
Surge Suppressor
Filter/Regulator
CAUTION
The air exhaust should be
piped to an area for safe
disposition of the product
being pumped, in the event
of a diaphragm failure.
INSTALLATION GUIDE
Top Discharge Ball Valve Unit
2
150 PSI Pressure
Relief Valve
Provision For Return
To Tank

520-359-000 7/03 Page 7
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
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
conditionsexceeding 10 feet (3 meters)
ofliquid,installa back pressure device.
What to Check: Systemheadexceeds
airsupplypressure.
CorrectiveAction: Increasetheinletair
pressure to the pump. Most diaphragm
pumps are designed for 1:1 pressure
ratioatzero flow.
What to Check: Air supply pressure or
volumeexceedssystemhead.
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
shown on the DIMENSIONAL
DRAWING.
What to Check: Restricted or
undersizedairline.
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
totheparts drawingandairvalvesection
of the SERVICE MANUAL. Check for
cloggeddischargeorclosedvalvebefore
reassembly.
What to Check: Rigidpipe connections
topump.
Corrective Action: Install flexible
connectorsanda surge suppressor.
What to Check: Blocked air exhaust
muffler.
Corrective Action: Remove muffler
screen, clean or de-ice and reinstall.
Refer to theAir Exhaust section of your
pumpSERVICE MANUAL.
What to Check: Pumped fluid in air
exhaustmuffler.
Corrective Action: Disassemblepump
chambers.Inspectfordiaphragmrupture
orloosediaphragmplateassembly.Refer
totheDiaphragmReplacementsection
ofyourpumpSERVICEMANUAL.
What to Check: Suction side air
leakageorair in product.
Corrective Action: Visually inspect all
suction side gaskets and pipe
connections.
What to Check: Obstructed check
valve.
CorrectiveAction:Disassemblethewet
endofthepumpandmanuallydislodge
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
checkvalve or check valve seat.
CorrectiveAction:Inspectcheckvalves
and seats for wear and proper seating.
Replace if necessary. Refer to Check
Valve section of the pump SERVICE
MANUALfor disassembly instructions.
What to Check: Blocked suction line.
Corrective Action: Remove or flush
obstruction.Checkandclearallsuction
screensandstrainers.
Whatto Check: Blocked dischargeline.
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
performing this procedure. Any model
withtop-porteddischargewillreduceor
eliminateproblemswith entrained air.
If your pump continues to perform
below your expectations, contact your
local Distributor or factory Technical
ServicesGroup foraservice evaluation.
WARRANTY
This pump is warranted for a period
of five years for defective material and
workmanship.

520-359-000 7/03 Page 8
RECYCLING
Many components of LINCOLN
AODD pumps are made of recyclable
materials (see chart on page 10 for
materialspecifications).Weencourage
pump users to recycle worn out parts
andpumpswhenever possible,afterany
hazardouspumpedfluidsarethoroughly
flushed.
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.
WARNING
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
When used for toxic or
aggressive fluids, the pump
should always be flushed
clean prior to disassembly.
WARNING
Before maintenance or
repair, shut off the com-
pressed 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.
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. (See page 18)
WARNING
IMPORTANT
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
Airborne particles and loud
noise hazards.
Wear ear and eye protection.
Before doing any main-
tenance 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.
WARNING
WARNING
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.
IMPORTANT SAFETY
INFORMATION
In systems where a closed
discharge may occur,
thermal expansion of the fluid
can cause hazardous,
high-pressure conditions.
Follow instrutions in the Installation and
Start-Up section of this manual.
CAUTION
CE
Pump complies with EN809 Pumping
Directive and Directive 98/37/EC Safety of
Machinery, and ATEX 100a Directive
94/9/EC Equipment for use in Potentially
Explosive Environments.
II 2GD b T5

520-359-000 7/03 Page 9

520-359-000 7/03 Page 10
Composite Repair Parts Drawing
AVAILABLE SERVICEAND CONVERSION KITS
271770 WETENDKIT
Buna Diaphragms, Balls, and Seats.
273040 AIRENDKIT
Seals, O-rings, Gaskets, Retaining Rings, Air Valve
Assembly, and Pilot Valve Assembly

520-359-000 7/03 Page 11
Composite Repair Parts List
ITEM DESCRIPTION QTY MODEL 85624 Series B
1 Air Valve Assembly 1 273013
2 Ball, Check 4 240903
3 Bearing, Sleeve 2 240922
4 Pilot Valve Assembly 1 273014
5 Bracket, Intermediate 1 271785
6 Bumper 2 271786
7 Bushing, Plunger 2 271787
8 Cap, Air Inlet 1 271788
9 Capscrew, Hex Head 7/16UNC x 2.00 long 16 271754
10 Capscrew, Hex Head 3/8-16UNC x 2.25 long 16 271789
11 Capscrew, Hex Head 5/16-18UNC x 2.00 long 4 271790
12 Capscrew, Socket Head 3/8-16UNC x 2.50 long 4 273015
13 Capscrew, Flat Socket Head 7/16-14UNC x 1.25 8 271792
14 Chamber, Outer 2 271793
15 Chamber, Inner 2 271794
16 Diaphragm 2 240900
18 Gasket, Air Valve 1 273016
19 Gasket, Pilot Valve 1 273017
20 Gasket, Air Inlet 1 273018
21 Gasket, Inner Chamber 2 273019
22 Manifold, Suction 1 271799
23 Manifold, Discharge 1 271800
24 Nut, Hex 3/8-16UNC 16 271801
25 Nut, Hex 7/16-14UNC 16 240911
26 O-Ring 2 240655
28 Plate, Inner Diaphragm 2 271804
29 Plate, Outer Diaphragm 2 240805
30 Plunger, Actuator 2 271806
31 Ring, Retaining 2 240717
32 Rod, Diaphragm 1 271807
33 Seal, U-Cup 2 243134
34 Seat, Check Valve 4 271767
35 Washer, Lock 16 271808
36 Washer, Flat 5/16 4 271809
37 Muffler 1 273020

520-359-000 7/03 Page 12
Air Valve Assembly Drawing, Parts List and Servicing
1-H
1-G
1-E
1-F
1-D
1-C
1-A
1-B
1-B
1-C
1-F
1-E
1-D
1-D
1-J
#273013 From Pages 10 & 11
Item Part Number Description Qty
1-A 273041 Air Valve Body 1
1-B 271774 Sleeve and Spool Set 1
1-C 273042 Bumper 2
1-D 240932 O-Ring 10
1-E 273043 End Cap 2
1-F 273044 Hex Head Capscrew 1/4-20 x .75 Long 8
AIR DISTRIBUTION VALVE SERVICING
To service the air valve first shut off the
compressed air, bleed pressure from the
pump, and disconnect the air supply line
from the pump.
Step #1: See COMPOSITE REPAIR PARTS
DRAWING.
Using a 9/16" wrench or socket, remove
the four hex capscrews (items 12). Remove
the air valve assembly from the pump.
Remove and inspect gasket (item 18)
for cracks or damage. Replace gasket if
needed.
Step #2: Disassembly of the air valve.
Using a 7/16" wrench or socket, remove
the eight hex capscrews (items 1-F) that
fasten the end caps to the valve body. Next
remove the two end caps (items 1-E).
Inspect the two o-rings (items 1-D) on each
end cap for damage or wear. Replace the
bumpers as needed.
Remove the bumpers (items 1-C).
Inspect the bumpers for damage or wear.
Replace the bumpers as needed.
Remove the spool (part of item 1-B) from
the sleeve. Be careful not to scratch 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-B) for dirt, scratches, or other
contaminants. Remove the sleeve if needed
and replace with a new sleeve and spool
set (item 1-B).
Step #3: Reassembly of the air valve.
Install one bumper (item 1-C) and one
end cap (item 1-E), with two o-rings (items
1-D), and fasten with four hex capscrews
(items 1-F) to the valve body (item 1-A).
Remove the new sleeve an spool set
(item 1-B) from the plastic bag. Carefully
remove the spool from the sleeve. Install
the six o-rings (item 1-D) into the six
grooves on the sleeve. Apply a light coating
of grease to the o-rings before installing
the sleeve into the valve body (item 1-A),
align the slots in the sleeve with the slots in
the valve body. Insert the spool into the
sleeve. Be careful not to scratch or damage
the spool during installation. Carefully
insert the sleeve into the bumper and end
cap (with o-rings) and fasten with the
remaining hex capscrews.
Fasten the air valve assembly (item 1)
and gasket to the pump.Connect the
compressed air line to the pump. The pump
is now ready for operation.
Read these instructions
completely, before in-
stallation 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.
IMPORTANT

520-359-000 7/03 Page 13
Read these instructions
completely, before in-
stallation 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.
IMPORTANT
ACTUATOR PLUNGER SERVICING
To service the actuator plunger first
shut off the compressed air supply,
bleed the pressure from the pump, and
disconnect the air supply line from the
pump.
Step #1: See PUMP ASSEMBLY
DRAWING.
Using a 1/2" wrench or socket,
remove the four capscrews (items 11).
Remove the air inlet cap (item 8) and
air inlet gasket (item 20).The pilot valve
assembly (item 4) can now be removed.
Step #2: Inspect the actuator
plungers.
See ILLUSTRATION AT RIGHT.
The actuator plungers (items 30) can
be reached through the pilot valve cavity
in the intermediate assembly (item 5).
Remove the plungers (item 30) from
the bushings (item 7) in each end of
the cavity. Inspect the installed o-ring
(items 26) for cuts and/or wear. Replace
the o-rings if necessary. 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.
To remove the bushings (item 7),
first remove the retaining rings (item 31)
by using a flat screwdriver.
NOTE: It is recommended that new
retaining rings be installed.
Step #3: 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
the cavity of the intermediate.
Re-install the gasket (item 20), air
inlet cap (item 8) and capscrews (item
11).
Connect the air supply to the pump.
The pump is now ready for operation.
ACTUATOR PLUNGER SERVICING
26
7
31
30
5

520-359-000 7/03 Page 14
Diaphragm Service Drawing

520-359-000 7/03 Page 15
DIAPHRAGM SERVICING
To service the diaphragms first shut
off the suction, then shut off the
dischargelines tothepump. Shutoffthe
compressed air supply, bleed the
pressurefromthepump,anddisconnect
theairsupplyline from the pump. Drain
anyremainingliquidfromthepump.
Step #1: See the pump assembly
drawing, and the diaphragm servicing
illustration.
Usinga9/16"wrenchorsocket,remove
the16 capscrews(item 10),hexnuts, and
lockwashers that fasten the manifolds
(items22&23)totheouterchambers(item
14).
Step #2: Removing the outer
chambers.
Using a 11/16" and a 5/8" wrench or
socket,removethe16capscrews(items
9), and hex nuts that fasten the outer
chambers, diaphragms, and inner
chambers(items15) together.
Step #3: Removing the diaphragm
assemblies.
Use a 11/16" (27mm) wrench or six
pointedsockettoremovethediaphragm
assemblies(outerplate,diaphragm,and
inner plate) from the diaphragm rod
(item32)by turning counterclockwise.
Inserta1/4-20capscreworset screw
intothesmallertappedholeintheinner
diaphragm plate (item 28). Insert the
protrudingstudand the 1/4-20 fastener
loosely into a vise. Use a 11/16" wrench
orsockettoremovethe outerdiaphragm
plate (item 29) by turning counter-
clockwise. Inspect the diaphragm
(item 16) for cuts, punctures, abrasive
wear or chemical attack. Replace the
diaphragmsifnecessary.
Step #4: Installing the diaphragms.
Push the threaded stud of the outer
diaphragmplate throughthecenter hole
ofthe diaphragm.Threadtheinnerplate
clockwiseonto the stud.Insertthe loose
assemblywiththe above1/4-20fastener
backintothevise.Useatorquewrench
to tighten the diaphragm assembly
together to 480 in. lbs. (54.23 Newton
meters).Allow aminimumof 15minutes
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
installedover the diaphragm rod.
Threadthestudoftheonediaphragm
assemblyclockwiseintothetappedhole
at the end of the diaphragm rod (item
32)untiltheinnerdiaphragmplateisflush
totheendoftherod.Insertrodintopump.
Alignthe bolt holes inthediaphragm
withtheboltpatternin theinner chamber
(item15).
Fasten the outer chamber (item 14)
tothepump,using the capscrews (item
9), and hex nuts.
On the opposite side of the pump,
pull the diaphragm rod out as far as
possible. Make sure the bumper (item
6)isinstalledoverthediaphragmrod.
Thread the stud of the remaining
diaphragmassemblyclockwiseintothe
tappedhole at theendofthe diaphragm
rod (item 32) as far as possible and still
allow for alignment of the bolt holes in
the diaphragm with the bolt pattern in
theinnerchamber(item15).
Fastenthe remainingouterchamber
(item 14) to the pump, using the
capscrews (items 9), hex nuts, and
lockwashers.
Step #6: Re-install the manifolds to
thepump,usingthecapscrews(item10),
hex nuts and flat washers.
The pump is now ready to be re-
installed, connected and returned to
operation.
Read these instructions
completely, before in-
stallation 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.
IMPORTANT

520-359-000 7/03 Page 16
Check Valve Drawing
CHECK VALVE SERVICING
Before servicing the check valve
components,firstshut offthesuctionline
andthen thedischargeline tothepump.
Next,shutoffthecompressed airsupply,
bleed air pressure from the pump, and
disconnect the air supply line from the
pump.Drainany remainingfluidfromthe
pump. The pump can now be removed
forservice.
To access the check valve
components, remove the manifold
(item 23 or item 22 not shown). Use a
9/16" wrench or socket to remove the
fasteners.Oncethemanifoldisremoved,
the check valve components can be
seen.
Inspect the check balls (items 2) for
wear,abrasion, or cutsonthe spherical
surface.Thecheckvalveseats(item34)
should be inspected for cuts, abrasive
wear, or embedded material on the
surfacesofboththeexternalandinternal
chambers.Thespherical surface of the
check balls must seat flush to the
surface of the check valve seats for the
pump to operate to peak efficiency.
Replaceanywornordamagedpartsas
necessary.
Re-assemble the check valve
components.The seatshouldfitinto the
counterboreof the outer chamber.
Thepump cannowbe reassembled,
reconnectedand returned to operation.

520-359-000 7/03 Page 17
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
PUMPING HAZARDOUS LIQUIDS
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.
Theairexhaust mustbepipedabovethe
liquid level. See illustration #2 at right.
Pipingused for the air exhaust must not
be smaller than 1" (2.54 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
higherthantheproductsourcetoprevent
siphoning spills. See illustration #3 at
right.
CONVERTINGTHE PUMP FOR
PIPING THE EXHAUST AIR
Thefollowing stepsarenecessary to
convertthe pumptopipe theexhaustair
awayfromthepump.
Theairvalveassembly(item1)has
1"NPTthreadsforpiped exhaust.
IMPORTANT INSTALLATION
NOTE: Themanufacturer recommends
installing a conductive flexible hose or
connection between the pump and any
rigidplumbing.Thisreducesstresseson
the molded plastic threads of the air
exhaustport. Failuretodo so mayresult
in damage to the air distribution valve
body.
Anypipingorhoseconnected to the
pump’s air exhaust port must
beconductiveand physically supported.
Failure to support these connections
could also result in damage to the air
distributionvalve body.
CONVERTED EXHAUST ILLUSTRATION
Illustration #1
Illustration #2
Illustration #3
1
Air Valve Assembly
37
On ATEX compliant units the pump
comes equipped with a standard
metal muffler

520-359-000 7/03 Page 18
The eyelet end is fastened to the pump hardware.
The clamp end is installed
to a true earth ground.
This 8 foot long (244 centimeters) Ground Strap, part number 920-025-000,
can be ordered as a service item.
To reduce the risk of static electrical sparking, this pump must be grounded.
Check the local electrical code for detailed grounding instruction and the
type of equipment required.
Grounding The Pump
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.
WARNING