Lincoln B Series Parts list manual

LINCOLN®• One Lincoln Way, St. Louis, MO 63120-1578 • Customer Service [phone]
520-357-000 7/03 Revision A Form # 403315
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, with Overlay ........................................................14
Diaphragm Service Drawing, Non-Overlay .......................................................14
Diaphragm Servicing ..........................................................................................15
Overlay 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
Models 85627, 85628, 85629 Series BModels 85627, 85628, 85629 Series B
Models 85627, 85628, 85629 Series BModels 85627, 85628, 85629 Series B
Models 85627, 85628, 85629 Series B
Table of Contents
Section - B5Section - B5
Section - B5Section - B5
Section - B5
Page - 28APage - 28A
Page - 28APage - 28A
Page - 28A
1" Aluminum Air-P1" Aluminum Air-P
1" Aluminum Air-P1" Aluminum Air-P
1" Aluminum Air-Powered Diaphragm Pumpowered Diaphragm Pump
owered Diaphragm Pumpowered Diaphragm Pump
owered Diaphragm Pump
CE
U.S. Patent #
5,996,627
6,241,487
Other U.S. Patents
Applied for
II 2GD b T5

520-357-000 7/03 Page 1
Models 85627,Models 85627,
Models 85627,Models 85627,
Models 85627,
85628, 8562985628, 85629
85628, 8562985628, 85629
85628, 85629
Series BSeries B
Series BSeries B
Series B
1" Aluminum Air-Powered
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
Neoprene All purpose. Resistant to vegetable oil. Generally not affected by moderate chemicals,
fats, greases and many oils and solvents. Generally attacked by strong oxidizing acids, ketones, 170°F -10°F 50° to 130°F
esters, nitro hydrocarbons and chlorinated aromatic hydrocarbons. 77°C -23°C 10°C to 54°C
Santoprene® Injection molded thermoplastic elastomer with no fabric layer. Long mechanical flex 212°F -10°F 50° to 212°F
life. Excellent abrasion resistance. 100°C -23°C 10°C to 100°C
Virgin PTFE Chemically inert, virtually impervious. Very few chemicals are known to react chemically with
PTFE: molten alkali metals, turbulent liquid or gaseous fluorine and a few fluoro-chemicals such as 212°F -35°F 50°F to 212°F
chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures. 100°C -37°C 10°C to 100°C
Polypropylene 150°F -40°F
65°C -40°C
Polyethylene 180°F -40°F 50°F to 140°F
82°C -40°C 10°C to 60°C
Hytrel®190°F -10°F 50°F to 140°F
88°C -23°C 10°C to 60°C
Materials Maximum* Minimum* Optimum**
Operating Temperatures
INTAKE/DISCHARGE PIPE SIZE
1" NPT(internal)
CAPACITY
0 to 45 gallons per minute
(0 to 170 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
.11 Gallon / .42 liter
CAUTION! Operating temperature limitations are as follows:
Air Inlet Side View Air Exhaust Side View
II 2GD b T5

520-357-000 7/03 Page 2
Performance Curve
Capacity
Liters per minute
Head
5(00)
15(00) 20(34)
U.S. Gallons per minute
25(00)
0 5 10 15 20 25 30 35 40 45
160140120100806040200
BAR
PSI
100
80
60
40
20
0
0
1
2
3
4
5
6
7
30
20
25
10
15
5
9.1
6
7.6
3
4.5
1.5
NPSHR
METERS FEET
100 PSI (6.8 Bar)
60 PSI (4.08 Bar)
20 PSI (1.36 Bar) Air Inlet Pressure
40 PSI (2.72 Bar)
80 PSI (5.44 Bar)
10(17)
30(51)
35(00)
40(68)

520-357-000 7/03 Page 3
1" NPT Exhaust Port For Metal
Muffler or Piping Exhaust Air In
Submerged Applications.
Air Inlet
1/2" NPT
Suction Port
1" NPT
Discharge Po
rt
1" NPT
Dimensions:
DimensionsinInches
DimensionalTolerance:±1/8"
DIMENSION A
Metal Muffler 12 1/2"

520-357-000 7/03 Page 4
Metric Dimensions:
1" NPT Exhaust Port For Metal
Muffler or Piping Exhaust Air In
Submerged Applications.
Air Inlet
1/2" NPT
Suction Port
1" NPT
Discharge Po
rt
1" NPT
DimensionsinMillimeters
DimensionalTolerance:± 3mm
DIMENSION A
Metal Muffler 319mm

520-357-000 7/03 Page 5
PRINCIPLE OF PUMP OPERATION
This ball type check valve pump is
poweredbycompressed airandis a1:1
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 ina reciprocating
action.(Asone diaphragmperformsthe
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 diaphragmoperates in
a balanced condition during the
dischargestrokewhichallows thepump
tobe operatedat discharge headsover
200feet (61 meters)of water.
For maximum diaphragm life, keep
the pump as close to the liquid being
pumped as possible. Positive suction
headinexcessof 10feetofliquid(3.048
meters) may require a back pressure
regulating device to maximize
diaphragmlife.
Alternate pressurizing and
exhausting of the diaphragm chamber
isperformed byanexternally mounted,
pilot operated, four way spool type air
distributionvalve.When thespool 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.Theairdistribution valvespool
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 thenpushes theend of
the pilot valve spool into position to
activatethe airdistribution valve.
The chambers are connected with
manifolds with a suction and discharge
check valve for each chamber,
maintainingflowinone directionthrough
thepump.
INSTALLATION AND START-UP
Locate the pump as close to the
productbeingpumpedaspossible.Keep
the suction line length and number of
fittingsto aminimum. Do notreduce the
suctionline diameter.
Forinstallations of rigidpiping, 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.
Insystemswherea closeddischarge
mayoccur,thermalexpansionofthefluid
can cause a hazardous, high-pressure
condition. To prevent damage to
equipment and or personnel, place a
pressurerelief valve in thesystem.The
pressure relief valve should be set to
relievepressure inthe systemat150psi
andthereliefvalveshouldbelocatednear
outletof the pump. (Seerecommended
installationdrawing onpage#6.)
AIR SUPPLY
Air supply pressure cannot exceed
125psi (8.6 bar). Connect the pump air
inlettoanairsupplyofsufficientcapacity
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.
AIR VALVE LUBRICATION
Theairdistributionvalve andthepilot
valvearedesignedtooperateWITHOUT
lubrication.Thisis thepreferredmode of
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 airline lubricator setto deliver
onedropof SAE10non-detergent oilfor
every20SCFM (9.4liters/sec.)ofairthe
pumpconsumesatthepointofoperation.
Consult the pump’s published
PerformanceCurve todetermine 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
dryertosupplement theuser’s airdrying
equipment. This device removes water
from the compressed air supply and
alleviatestheicing orfreezingproblems.
AIR INLET AND PRIMING
To startthe pump,openthe airvalve
approximately ½ to ¾ turn. After the
pumpprimes,theairvalvecanbeopened
toincreaseairflowas desired.Ifopening
thevalveincreasescyclingrate,butdoes
not increase the rate of flow, cavitation
hasoccurred.Thevalveshouldbeclosed
slightly to obtain the most efficient air
flowto pump flow ratio.
BETWEEN USES
Whenthepumpisused formaterials
that tend to settle out or solidify when
notinmotion,thepumpshouldbeflushed

520-357-000 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

520-357-000 7/03 Page 7
after each use to prevent damage.
(Productremaininginthepumpbetween
uses could dry out or settle out. This
could cause problems with the
diaphragmsandcheckvalvesatrestart.)
Infreezingtemperatures thepump must
becompletely drained between uses in
all cases.
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
chamberswithliquidwill primethepump
in most cases.
What to Check: Excessive flooded
suction in system.
Corrective Action: For flooded
conditionsexceeding 10feet (3 meters)
ofliquid, install a backpressuredevice.
What to Check: Systemhead exceeds
airsupply pressure.
CorrectiveAction: Increasetheinletair
pressure to the pump. Most diaphragm
pumps are designed for 1:1 pressure
ratioat zero flow.
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
shown on the DIMENSIONAL
DRAWING.
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
tothepartsdrawingandairvalvesection
of the SERVICE MANUAL. Check for
cloggeddischargeorclosedvalvebefore
reassembly.
What to Check: Rigidpipe connections
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.
Refertothe Air Exhaust section of your
pumpSERVICE MANUAL.
What to Check: Pumped fluid in air
exhaustmuffler.
Corrective Action: Disassemblepump
chambers.Inspectfordiaphragmrupture
orloosediaphragmplateassembly.Refer
tothe Diaphragm Replacement section
ofyour pump SERVICEMANUAL.
What to Check: Suction side air
leakageor air in product.
Corrective Action: Visually inspect all
suction side gaskets and pipe
connections.
What to Check: Obstructed check
valve.
CorrectiveAction:Disassemblethewet
endof the pumpandmanually dislodge
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 orcheckvalve seat.
CorrectiveAction:Inspectcheckvalves
and seats for wear and proper seating.
Replace if necessary. Refer to Check
Valve section of the pump SERVICE
MANUALfordisassemblyinstructions.
What to Check: Blocked suction line.
Corrective Action: Remove or flush
obstruction.Check and clearallsuction
screensand strainers.
Whatto 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
Customer Service Department before
performing this procedure. Any model
withtop-ported discharge willreduceor
eliminateproblems with entrainedair.
If your pump continues to perform
below your expectations, contact your
local Distributor or factory Customer
Service Department for a service
evaluation.
Warranty
This pump is warranted for a period
of five years against defective material
andworkmanship.

520-357-000 7/03 Page 8
RECYCLING
Many components of LINCOLN
AODD pumps are made of recyclable
materials (see chart on page 10 for
materialspecifications). We encourage
pump users to recycle worn out parts
andpumpswheneverpossible,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

520-357-000 7/03 Page 9

520-357-000 7/03 Page 10
Composite Repair Parts Drawing
AVAILABLESERVICEAND CONVERSION KITS
273039 AIR END KIT
Seals, O-rings, Gaskets, Retaining
Rings,Air ValveAssembly, and Pilot
ValveAssembly
271811 WET END KIT
BunaDiaphragms, Buna Balls, and
UHMW Polyethylene Seats.
(ForModel85627)
271813 WET END KIT
HytrelDiaphragms, Hytrel Balls and
UHMW Polyethylene Seats.
(ForModel85629)
271812 WET END KIT
NeopreneDiaphragms,PTFE
OverlayDiaphragms, PTFEBalls and
PTFESeats. (For Model85628)

520-357-000 7/03 Page 11
Composite Repair Parts List
ITEM DESCRIPTION QTY MODEL 85627 MODEL 85628 MODEL 85629
1 Air Valve Assembly 1 273013 273013 273013
2 Ball, Check 4 271814 271815 271816
3 Bearing, Sleeve 2 240720 240720 240720
4 Pilot Valve Assembly 1 273014 273014 273014
5 Bracket, Intermediate 1 271817 271817 271817
6 Bumper 2 240727 240727 240727
7 Bushing, Plunger 2 252901 252901 252901
8 Cap, Air Inlet 1 271818 271818 271818
9 Capscrew, Hex Head 5/16-18UNC x .88 16 271819 271819 271819
10 Capscrew, Hex Head 5/16-18 x 1.25 16 240731 240731 240731
11 Capscrew, Hex Head 5/16-18UNC x 1.75 4 271820 271820 271820
12 Capscrew, Hex Head 3/8-16UNC x 1.00 4 273015 273015 273015
13 Chamber, Outer 2 271822 271822 271822
14 Diaphragm 2 240983 240873 240730
15 Diaphragm, Overlay 2 240749
16 Gasket, Air Valve 1 273016 273016 273016
17 Gasket, Pilot Valve 1 273017 273017 273017
18 Gasket, Air Inlet 1 273018 273018 273018
19 Manifold, Suction 1 271823 271823 271823
20 Manifold, Discharge 1 271824 271824 271824
21 O-Ring 2 240655 240655 240655
23 Plate, Inner Diaphragm 2 240729 240729 240729
24 Plate, Outer Diaphragm 2 240728 240728 240728
25 Plunger, Actuator 2 271825 271825 271825
26 Ring, Retaining 2 240717 240717 240717
27 Rod, Diaphragm 1 271826 271826 271826
28 Seal, U-Cup 2 240721 240721 240721
29 Seat, Check Valve 4 271827 271827 271827
30 Washer, Flat 4 271810 271810 271810
31 Muffler 1 273020 273020 273020

520-357-000 7/03 Page 12
#273013 From Pages 10 & 11
Item Part Number Description Qty
1-A 273041 Body, Air Valve 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 8
Air Valve Assembly Drawing, Parts List and Servicing
1-E
1-F
1-D
1-C
1-A
1-B
1-B
1-C
1-D
1-E
1-F
1-D
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 16)
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
o-rings 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

520-357-000 7/03 Page 13
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 18).The pilot valve
assembly (item 4) can now be removed.
Step #2: Inspect the actuator
plungers.
See ILLUSTRATION AT RIGHT.
The actuator plungers (items 25) can
be reached through the pilot valve cavity
in the intermediate assembly (item 5).
Remove the plungers (item 25) from
the bushings (item 7) in each end of
the cavity. Inspect the installed o-ring
(items 21) 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 26)
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 18), 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
25
21 7
26
5
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

520-357-000 7/03 Page 14
Diaphragm Service Drawing,
Non-Overlay
Diaphragm Service Drawing,
with Overlay

520-357-000 7/03 Page 15
DIAPHRAGMSERVICING
To service the diaphragms first shut off
the suction, then shut off the discharge
lines to the pump. Shut off the
compressed air supply, bleed the
pressurefrom thepump anddisconnect
theair supplyline from thepump. Drain
anyremaining liquid fromthepump.
Step #1: See the pump assembly
drawing and the diaphragm servicing
illustration.
Using a 1/2” wrench or socket,
remove the 16 capscrews (item 9) that
fasten the manifolds (items 19 & 20) to
theouter chambers (item 13).
Step #2: Removing outer
chambers.
Using a 1/2” wrench or socket,
removethe16 capscrews(item10),that
fasten the outer chambers (item 13),
diaphragms (item 14) and intermediate
(item 5) together.
Step#3: Removingthediaphragms
anddiaphragm plates.
Use a 7/8” wrench or six point
socket to remove the outer diaphragm
plateassemblies (item24), diaphragms
(item 14) and inner diaphragm plates
(item 23) from the diaphragm rod (item
27)byturningcounterclockwise. Inspect
the diaphragm for cuts, punctures,
abrasive wear or chemical attack.
Replace the diaphragms if necessary.
DO NOT USE A WRENCH ON THE
DIAPHRAGM ROD. FLAWS ON THE
SURFACE MAY DAMAGE BEARINGS
AND SEALS.
Step #4: Assembling the
diaphragmand diaphragm platesto the
diaphragmrod.
Pushthethreadedstudofoneouter
diaphragm plate assembly through the
centerofonediaphragmandthroughone
inner diaphragm plate. Install the
diaphragmwith the naturalbulge facing
awayfrom thediaphragm rodand make
sure the radius on the inner diaphragm
plate is towards the diaphragm, as
indicated on the diaphragm servicing
illustration. Thread the assembly onto
thediaphragm rod,leaving loose.
Step #5: Installing the diaphragm
and rod assembly to the pump.
Make sure the bumper (item 6) is
installedover thediaphragm rod. Insert
rodinto pump.
On the opposite side of the pump,
pull the diaphragm rod out as far as
possible. Makesurethesecondbumper
isinstalled over thediaphragm rod.
Pushthethreaded studoftheother
outerdiaphragmplateassemblythrough
the center of the other diaphragm and
throughtheotherinnerdiaphragmplate.
Make sure the radius on the inner
diaphragm plate is towards the
diaphragm. Thread the assembly onto
the diaphragm rod. Use a 7/8” wrench
or socket to hold one outer diaphragm
plate. Then, use a torque wrench to
tighten the other outer diaphragm plate
tothediaphragm rodto500in.lbs. (56.5
Newtonmeters).
Align one diaphragm with the
intermediate and install the outer
chamber to the pump using the 8
capscrews. Tighten the opposite
diaphragm plate until the holes in the
diaphragm align with the holes in the
intermediate. Then,installtheotherouter
chamber using the 8 capscrews.
Step #6: Reinstall the manifolds
to the pump using the 16 capscrews.
The pump is now ready to be
reinstalled, connected and returned to
operation.
OVERLAYDIAPHRAGMSERVICING
The overlay diaphragm (item 15)
isdesigned to fit over theexteriorof the
standarddiaphragm (item14).
Follow the same procedures
described for the standard diaphragm
for removal and installation, except
tighten the outer diaphragm plate
assembly, diaphragms and inner
diaphragmplateto thediaphragm rodto
500 in. lbs. (56.5 Newton meters).
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

520-357-000 7/03 Page 16
Check Valve Drawing
CHECK VALVE SERVICING
Before servicing the check valve
components,firstshutoffthesuctionline
andthenthedischargeline tothe pump.
Next,shutoffthecompressed airsupply,
bleed air pressure from the pump, and
disconnect the air supply line from the
pump.Drainanyremainingfluidfromthe
pump. The pump can now be removed
forservice.
To access the check valve
components, remove the manifold
(item 20 or item 19 not shown). Use a
1/2" 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 cuts onthe spherical
surface.Thecheckvalve seats(item29)
should be inspected for cuts, abrasive
wear, or embedded material on the
surfacesofboththeexternaland internal
chambers.The spherical surface of the
check balls must seat flush to the
surface of the check valve seats for the
pump to operate to peak efficiency.
Replaceany worn ordamagedparts as
necessary.
Re-assemble the check valve
components.Theseatshouldfitintothe
counterbore of theouter chamber.
Thepumpcannowbe reassembled,
reconnectedand returnedto operation.
20
9
2
29

520-357-000 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.
Theairexhaustmustbepipedabovethe
liquid level. See illustration #2 at right.
Pipingused fortheair exhaustmustnot
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
Thefollowingstepsarenecessary to
convertthepumptopipe theexhaust air
awayfrom the pump.
Remove the muffler. The air valve
assembly (item 1) has 1" NPT threads
forpiped exhaust.
IMPORTANT INSTALLATION
NOTE: Themanufacturerrecommends
installing a conductive flexible hose or
connection between the pump and any
rigidplumbing.Thisreduces stresseson
the molded plastic threads of the air
exhaustport.Failuretodo somay result
in damage to the air distribution valve
body.
Anypiping or hose connectedtothe
pump’s air exhaust port must be
conductive and physically supported.
Failure to support these connections
could also result in damage to the air
distributionvalvebody.
CONVERTED EXHAUST ILLUSTRATION
Illustration #1
Illustration #2
Illustration #3
Air Valve Assembly
On ATEX compliant units the
pump comes equipped with a
standard metal muffler
1
36

520-357-000 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