PowerWise 4061 Parts list manual

PerformanceCurve, Non-MetallicBallValve,Design Level1 ................................... 2
Performance Curve,Trihedral Model Non-Metallic DesignLevel 1............................ 3
Dimensions: with EncapsulatedMuffler .................................................................... 4
MetricDimensions:withEncapsulated Muffler ......................................................... 5
Dimensions:withMeshMuffler................................................................................. 6
MetricDimensions:withMesh Muffler ...................................................................... 7
Dimensions:withSoundDampeningMuffler ............................................................ 8
MetricDimensions: withSoundDampeningMuffler .................................................... 9
PrincipleofPump Operation ...................................................................................10
InstallationandStart-up ..........................................................................................10
AirSupply ...............................................................................................................10
AirValveLubrication ...............................................................................................10
AirLine Moisture .....................................................................................................10
Air Inletand Priming ................................................................................................10
Between Uses ........................................................................................................10
Troubleshooting.......................................................................................................11
Warranty .................................................................................................................11
ImportantSafetyInformation ...................................................................................12
MaterialCodes........................................................................................................13
CompositeRepair Parts Drawing............................................................................14
OverlayOption Drawing .........................................................................................14
Available Service and Conversion Kits ............................................................... 14
CompositeRepair Parts List ...................................................................................15
Air DistributionValve Assembly Drawing ................................................................16
Main AirValve Assembly Parts List.........................................................................16
AirDistributionValveServicing ...............................................................................17
Air DistributionValve Assembly Drawing w/Stroke Indicator Option........................18
Air DistributionValve w/Stroke Indicator Parts List ..................................................18
AirDistributionValvewith StrokeIndicator Servicing ..............................................19
SolenoidShifted AirValveDrawingand Parts List ...................................................20
Intermediate AssemblyDrawing forSolenoid Shifted Option ...................................20
Intermediate Assembly for SolenoidShifted OptionParts List .................................20
SolenoidShifted Air DistributionValveOption .........................................................21
PilotValve Assembly Drawing and Parts List ..........................................................22
PilotValveServicing ...............................................................................................23
Intermediate Assembly Drawing and Parts List .......................................................24
IntermediateAssemblyServicing............................................................................25
Modular Check BallValve Drawing .........................................................................26
ModularCheckBallValveServicing........................................................................27
ModularTrihedral CheckValve Option Drawing and Parts List ................................28
ModularTrihedralCheckValveServicing ................................................................29
DiaphragmService Drawing, Non-Overlay .............................................................30
Diaphragm Servicing Drawing with Overlay ............................................................30
DiaphragmServicing, Overlay Diaphragm Servicing ..............................................31
PumpingHazardousLiquids ...................................................................................32
Converting the Pump for Piping the Exhaust Air .....................................................32
ExhaustConversion Drawing .................................................................................32
Converted ExhaustIllustration ................................................................................32
Grounding thePump ...............................................................................................33
520-259-000 6/00
CE
Models 4061, 4063
Non-Metallic Design Level 1
SERSER
SERSER
SERVICE & OPERAVICE & OPERA
VICE & OPERAVICE & OPERA
VICE & OPERATING MANUALTING MANUAL
TING MANUALTING MANUAL
TING MANUAL
Powerwise Ink Pumps • 2700West 21st Street • Erie, PA 16506 • [phone] • FAX [phone]
Table of Contents

520-259-000 6/00 Powerwise Models 4061, 4063 Page 2
100
80
90
70
50
30
10
60
40
20
00 2 4 6 8 101214161820222426
Head NPSHR
CAPACITY
METERS FEET
BAR PSI
7
6
5
4
3
2
1
0
U.S.Gallons per minute
Liters per minute
10 20 30 40 50 60 70 80 90 1000
4 (7)
8 (13.5)
12 (20)
16 (27)
20 (34)
30
20
25
15
10
5
9.1
6
7.6
4.5
3
1.5
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 Non-Metallic BallValve, Design Level 1
Displacement per Stroke: .026 U.S. gallons
.098 liters
Flow Capacity: 0 to 23 U.S. gallons per minute
0 to 87 liters per minute
CAUTION!
Operating temperature limitations
are as follows:
PVDF – 200
o
F(93
o
C) Max to 10
o
F(-13
o
C) Min.
Polypro – 150
o
F(65
o
C) Max to 40
o
F(5
o
C) Min.
Nylon – 120
o
F(48
o
C) Max to 32
o
F(0
o
C) Min.
Acetal – 180
o
F(82
o
C) Max to -20
o
F(-28
o
C) Min.

520-259-000 6/00 Powerwise Models 4061, 4063 Page 3
100
80
90
70
50
30
10
60
40
20
00 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Head
NPSHR
CAPACITY
METERS FEET
BAR PSI
7
6
5
4
3
2
1
0
U.S.Gallons per minute
Liters per minute
5 101520253035404550550
2 (3.5)
6(10)
30
20
25
15
10
5
9.1
6
7.6
4.5
3
1.5
S07Trihedral Performance Curve
4(7)
100 PSI (6.8 Bar)
8(13.5)
12(20)
14(24)
10 (17)
16(27)18(30.4)
80 PSI (5.44 Bar)
60 PSI
(4.08 Bar)
(2.72 Bar)
40 PSI
Air Inlet Pressure
20 PSI (1.36 Bar)
Performance Curve,Trihedral Model Non-Metallic, Design Level 1
Displacement per Stroke: .016 U.S. gallons
.059 liters
Flow Capacity: 0 to 13 U.S. gallons per minute
0 to 48.8 liters per minute

520-259-000 6/00 Powerwise Models 4061, 4063 Page 4
Dimensions: with
Encapsulated Muffler
Dimensionsin Inches
Dimensionaltolerance: ±1/8"

520-259-000 6/00 Powerwise Models 4061, 4063 Page 5
Dimensions: with
Encapsulated Muffler
Dimensionsin millimeters
Dimensionaltolerance: ±3mm

520-259-000 6/00 Powerwise Models 4061, 4063 Page 6
Dimensions: with Mesh Muffler
Dimensionsin Inches
Dimensionaltolerance: ±1/8"

520-259-000 6/00 Powerwise Models 4061, 4063 Page 7
Dimensions: with Mesh Muffler
Dimensionsin millimeters
Dimensionaltolerance: ±3mm

520-259-000 6/00 Powerwise Models 4061, 4063 Page 8
Dimensions: with
Sound Dampening Muffler
Dimensionsin Inches
Dimensionaltolerance: ±1/8"

520-259-000 6/00 Powerwise Models 4061, 4063 Page 9
Dimensions: with
Sound Dampening Muffler
Dimensionsin millimeters
Dimensionaltolerance: ±3mm

520-259-000 6/00 Powerwise Models 4061, 4063 Page 10
PRINCIPLE OF PUMP OPERATION
This ball type check valve pump is
poweredbycompressedair andis 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 in 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
dischargedfromthe oppositeside ofthe
diaphragm.The diaphragm operates in
a balanced condition during the
dischargestrokewhich allowsthe pump
tobe operated atdischarge heads over
200feet (61 meters) of water.
For maximum diaphragm life, keep
the pump as close to the liquid being
pumped as possible. Positive suction
headinexcess of10 feetof liquid(3.048
meters) may require a back pressure
regulating device to maximize
diaphragmlife.
Alternate pressurizing and
exhausting of the diaphragm chamber
isperformed by an externallymounted,
pilot operated, four way spool type air
distributionvalve. Whenthe spoolshifts
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.Theair distributionvalve spool
is moved by a internal pilot valve which
alternately pressurizes one end of the
air distribution valve spool while
exhaustingtheother end.The pilotvalve
is shifted at each end of the diaphragm
stroke when a actuator plunger is
contacted by the diaphragm plate. This
actuatorplunger thenpushesthe end of
the pilot valve spool into position to
activatethe air distributionvalve.
The chambers are connected with
manifolds with a suction and discharge
check valve for each chamber,
maintainingflowin onedirection through
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 not reduce the
suctionline diameter.
Forinstallations of 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
recommended to further reduce
pulsationin flow.
AIR SUPPLY
Air supply pressure cannot exceed
100 psi (7 bar). Connect the pump air
inlettoan airsupply 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 reducestrain to thepiping. The
weight of the air supply line, regulators
and filters must be supported by some
meansotherthantheairinletcap.Failure
to provide support for the piping may
resultindamagetothe pump.Apressure
regulating valve should be installed to
insure air supply pressure does not
exceedrecommended limits.
AIRVALVE LUBRICATION
Theairdistribution valveand thepilot
valvearedesignedtooperate WITHOUT
lubrication.Thisisthe preferredmode 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 air line lubricatorsetto deliver
one drop of SAE 10 non-detergent oil
for every 20 SCFM (9.4 liters/sec.) of
air the pump consumes at the point of
operation.Consultthe pump’spublished
Performance Curve to determine 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
dryerto supplementthe user’sair drying
equipment. This device removes water
from the compressed air supply and
alleviatestheicingor freezingproblems.
AIR INLET AND PRIMING
To startthe pump, open theairvalve
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
flowto pump flow ratio.
BETWEEN USES
Whenthe pumpis used 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
diaphragmsandcheck valvesatrestart.)
Infreezing temperaturesthe pumpmust
becompletely drained between uses in
all cases.

520-259-000 6/00 Powerwise Models 4061, 4063 Page 11
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
chamberswithliquid willprime thepump
in most cases.
What to Check: Excessive flooded
suction in system.
Corrective Action: For flooded
conditionsexceeding 10 feet (3meters)
ofliquid, install a back pressure device.
What to Check: System headexceeds
airsupply pressure.
CorrectiveAction: Increase theinlet air
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
totheparts drawingandair valvesection
of the SERVICE MANUAL. Check for
cloggeddischargeorclosedvalvebefore
reassembly.
What to Check: Rigidpipe connections
topump.
Corrective Action: Install flexible
connectors and a surge suppressor.
What to Check: Blocked air exhaust
muffler.
Corrective Action: Remove muffler
screen, clean or de-ice and reinstall.
RefertotheAirExhaustsectionofyour
pumpSERVICE MANUAL.
What to Check: Pumped fluid in air
exhaustmuffler.
Corrective Action: Disassemblepump
chambers.Inspectfordiaphragmrupture
orloosediaphragmplateassembly.Refer
tothe Diaphragm Replacement section
of your pump SERVICE MANUAL.
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 pump and manually 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 or check valveseat.
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.Check and clear all suction
screensand strainers.
What to Check: Blocked discharge
line.
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
MarathonTechnicalServicesDepartment
before performing this procedure. A
model with top-ported discharge will
reduce or eliminate problems with
entrained air.
WARRANTY
This pump is warranted for a period
of five years against defective material
andworkmanship.

520-259-000 6/00 Powerwise Models 4061, 4063 Page 12
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.
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.
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.

520-259-000 6/00 Powerwise Models 4061, 4063 Page 13
The Last 3 Digits of Part Number
000 .....Assembly, sub-assembly; and some
purchased items
010 .....Cast Iron
012 .....Powered Metal
015 .....Ductile Iron
020 .....Ferritic Malleable Iron
025 .....Music Wire
080 .....Carbon Steel, AISI B-1112
100 .....Alloy 20
110 .....Alloy Type 316 Stainless Steel
111 .....Alloy Type 316 Stainless Steel (Electro
Polished)
112 .....Alloy “C” (Hastelloy equivalent)
113 .....Alloy Type 316 Stainless Steel (Hand
Polished)
114 .....303 Stainless Steel
115 .....302/304 Stainless Steel
117 .....440-C Stainless Steel (Martensitic)
120 .....416 Stainless Steel (Wrought
Martensitic)
123 .....410 Stainless Steel (Wrought
Martensitic)
148 .....Hardcoat Anodized Aluminum
149 .....2024-T4 Aluminum
150 .....6061-T6 Aluminum
151 .....6063-T6 Aluminum
152 .....2024-T4 Aluminum (2023-T351)
154 .....Almag 35 Aluminum
155 .....356-T6 Aluminum
156 .....356-T6 Aluminum
157 .....Die Cast Aluminum Alloy #380
158 .....Aluminum Alloy SR-319
159 .....Anodized Aluminum
162 .....Brass, Yellow, Screw Machine Stock
165 .....Cast Bronze, 85-5-5-5
166 .....Bronze, SAE 660
170 .....Bronze, Bearing Type, Oil Impregnated
175 .....Die Cast Zinc
180 .....Copper Alloy
305 .....Carbon Steel,Gray Epoxy Coated
306 .....Carbon Steel, Black Teflon®Coated
307 .....Aluminum, GrayEpoxy Coated
308 .....Stainless Steel, Black Teflon Coated
309 .....Aluminum, Black Teflon Coated
310 .....Kynar Coated
330 .....Zinc Plated Steel
331 .....Chrome Plated Steel
332 .....Aluminum, Electroless Nickel Plated
333 .....Carbon Steel, Electroless Nickel
Plated
335 .....Galvanized Steel
336 .....Zinc Plated Yellow Brass
337 .....Silver Plated Steel
340 .....Nickel Plated
342 .....Filled Nylon
353 .....Geolast; Color: Black
354 .....Injection Molded #203-40 Santoprene -
Duro 40D +/-5; Color: RED
355 .....Thermal Plastic
356 .....Hytrel
357 .....Injection Molded Polyurethane
358 .....Rupplon (Urethane Rubber). Color
coded: PURPLE (Some Applications)
(Compression Mold)
359 .....Urethane Rubber
360 .....Buna-N Rubber. Color coded: RED
361 .....Buna-N
363 .....Viton (Flurorel). Color coded: YELLOW
364 .....E.P.D.M. Rubber. Color coded: BLUE
MATERIAL CODES
365 .....Neoprene Rubber. Color coded:
GREEN
366 .....Food Grade Nitrile
368 .....Food Grade EPDM
370 .....Butyl Rubber. Color coded: BROWN
371 .....Philthane (Tuftane)
374 .....Carboxylated Nitrile
375 .....Fluorinated Nitrile
378 .....High Density Polypropylene
405 .....Cellulose Fibre
408 .....Cork and Neoprene
425 .....Compressed Fibre
426 .....Blue Gard
440 .....Vegetable Fibre
465 .....Fibre
500 .....Delrin 500
501 .....Delrin 570
502 .....Conductive Acetal, ESD-800
503 .....Conductive Acetal, Glass-Filled
505 .....Acrylic Resin Plastic
506 .....Delrin 150
520 .....Injection Molded PVDF Natural color
540 .....Nylon
541 .....Nylon
542 .....Nylon
544 .....Nylon Injection Molded
550 .....Polyethylene
551 .....Glass Filled Polypropylene
552 .....Unfilled Polypropylene
553 .....Unfilled Polypropylene
555 .....Polyvinyl Chloride
556 .....Black Vinyl
570 .....Rulon II
580 .....Ryton
590 .....Valox
591 .....Nylatron G-S
592 .....Nylatron NSB
600 .....Teflon (virgin material)
Tetrafluorocarbon (TFE)
601 .....Teflon (Bronze and moly filled)
602 .....Filled Teflon
603 .....Blue Gylon
604 .....Teflon
607 .....Envelon
606 .....Teflon
610 .....Teflon Encapsulated Silicon
611 .....Teflon Encapsulated Viton
632 .....Neoprene/Hytrel
633 .....Viton/Teflon
634 .....EPDM/Teflon
637 .....Teflon, Viton/Teflon
638 .....Teflon, Hytrel/Teflon
639 .....Buna-N/TFE
643 .....Santoprene®/EPDM
644 .....Santoprene®/Teflon
Delrin, Teflon, Viton and Hytrel are registered
tradenames of E.I. DuPont.
Gylon is a registered tradename of Garlock, Inc.
Nylatron is a registered tradename of Polymer Corp.
Santoprene is a registered tradename of
MonsantoCorp.
Rulon II is a registered tradename of
Dixion Industries Corp.
Hastelloy-C is a registered tradename of Cabot Corp.
Ryton is a registered tradename of
PhillipsChemicalCo.
Valox is a registered tradename of
General Electric Co.

520-259-000 6/00 Powerwise Models 4061, 4063 Page 14
Composite Repair
Parts Drawing
Available Service and Conversion Kits
PART NO. DESCRIPTION
476-160-000 AIR END KIT
Seals, O-rings, Gaskets,
Retaining Rings, Air Valve
Spool and Pilot Valve
Assembly.
476-161-000 AIR END KIT for pumps
equipped with Stroke Indicator
(same components as above,
except Spool Assembly with
pins replaces Air Valve Spool)
476-163-000 AIR END KIT for standard
Conductive Acetal pumps
(same components as
475-160-000 above)
476-164-000 AIR END KIT for Conductive
Acetal pumps equipped with
Stroke Indicator
(same components as
475-161-000 above)
476-166-354 WETTEDEND KIT
Santoprene Diaphragms,
Nitrile Spacer Gaskets,
Santoprene Check Balls and
TFE Seals.
476-166-654 WETTEDEND KIT
Santoprene Diaphragms, TFE
Overlay Diaphragm, TFE
Check Balls and TFE Seals.
476-180-657 WETTED END KIT (Trihedral)
Santoprene Diaphragms,
Buna Trihedral Valve
Components, Buna Spacer
Gaskets and TFE Manifold
Seals.
476-180-658 WETTED END KIT (Trihedral)
Santoprene Backup
Diaphragms, TFE Overlay
Diaphragms, Viton Trihedral
Valve Components, and TFE
Manifold Seals.
NOTE: ForTrihedral Parts, see ModularTrihedral CheckValve page.
Muffler
Option
Overlay
Option

520-259-000 6/00 Powerwise Models 4061, 4063 Page 15
Composite Repair Parts List
ITEM PARTNUMBER DESCRIPTION QTY
1 031-115-000 AirValve Assembly 1
031-115-001 AirValveAssembly(ConductiveAcetal) 1
031-115-002 AirValveAssembly(w/Teflon coated hardware) 1
031-116-000 AirValve Assembly 1
031-116-001 AirValveAssembly(ConductiveAcetal) 1
031-116-002 AirValveAssembly(w/Teflon coated hardware) 1
031-122-000 AirValve Assembly 1
031-122-001 AirValveAssembly(ConductiveAcetal) 1
031-123-000 AirValve Assembly 1
031-123-001 AirValveAssembly(ConductiveAcetal) 1
2 050-028-354 Ball,Check 4
050-028-600 Ball,Check 4
3 095-091-000 PilotValveAssembly 1
095-091-001 PilotValveAssembly 1
4 114-023-157 IntermediateAssembly 1
114-023-157S IntermediateAssembly (Solenoid OptionOnly) 1
114-023-307 IntermediateAssembly 1
114-023-307S IntermediateAssembly (Solenoid OptionOnly) 1
114-023-309 IntermediateAssembly 1
114-023-309S IntermediateAssembly (Solenoid OptionOnly) 1
114-023-332 IntermediateAssembly 1
114-023-332S IntermediateAssembly (Solenoid OptionOnly) 1
5 115-141-080 Bracket, Mounting 2
115-141-305 Bracket, Mounting 2
115-141-306 Bracket, Mounting 2
115-141-333 Bracket, Mounting 2
6 132-034-360 Bumper, Diaphragm 2
8 165-110-157 Cap, Air Inlet 1
165-110-307 Cap, Air Inlet 1
165-110-309 Cap, Air Inlet 1
165-110-332 Cap, Air Inlet 1
9 170-045-115 Capscrew, Hex HD 5/16-18 X 1.25 48
170-045-308 Capscrew, Hex HD 5/16-18 X 1.25 48
10 170-116-115 Capscrew,HexHD1/4-20X 1.62 4
170-116-308 Capscrew, Hex HD 1/4-20 X 1.62 4
12 171-058-115 Capscrew, Soc HD 1/4-20 X 1.50 4
171-058-308 Capscrew, Soc HD 1/4-20 X 1.50 4
13 196-162-502 Chamber, Outer 2
196-162-520 Chamber, Outer 2
196-162-542 Chamber, Outer 2
196-162-552 Chamber, Outer 2
14 286-095-354 Diaphragm 2
15 286-096-600 Diaphragm, Overlay 2
16 312-107-502 Elbow 4
312-107-520 Elbow 4
312-107-542 Elbow 4
312-107-552 Elbow 4
17 360-099-360 Gasket, Spacer 2
18 360-100-360 Gasket, Air Inlet 1
19 360-101-360 Gasket, PilotValve 1
20 360-102-360 Gasket, Air Valve 1
21 518-139-502 Manifold 2
518-139-502E Manifold (BSP) 2
518-139-520 Manifold 2
518-139-520E Manifold (BSP) 2
518-139-542 Manifold 2
518-139-542E Manifold (BSP) 2
518-139-552 Manifold 2
518-139-552E Manifold (BSP) 2
22 530-024-000 Muffler 1
530-023-000 Muffler (not shown) 1
24 545-004-115 Nut, Hex 5/16-18" 24
545-004-308 Nut, Hex 5/16-18" 24
26 612-091-502 Plate, Outer Diaphragm 2
612-091-520 Plate, Outer Diaphragm 2
612-091-542 Plate, Outer Diaphragm 2
612-091-552 Plate, Outer Diaphragm 2
27 612-177-150 Plate, Inner Diaphragm 2
28 620-019-115 Plunger, Actuator 2
29 670-050-502 Retainer, Ball 4
670-050-520 Retainer, Ball 4
670-050-542 Retainer, Ball 4
670-050-552 Retainer, Ball 4
31 685-056-120 Rod, Diaphragm 1
32 720-012-360 Seal, Diaphragm Rod 2
33 720-046-600 Seal, Manifold 4
34 720-051-600 Seal, CheckValve 8
35 722-081-506 Seat, Check Valve 4
722-081-520 Seat, Check Valve 4
722-081-542 Seat, Check Valve 4
722-081-552 Seat, Check Valve 4
36 901-037-115 Washer, Flat 1/4" 8
901-037-308 Washer,Flat 1/4" 8
37 901-038-115 Washer,Flat 5/16" 72
901-038-308 Washer,Flat 5/16" 72
52 920-025-000 Ground Strap (Conductive Acetal Only) 1
ITEM PARTNUMBER DESCRIPTION QTY

520-259-000 6/00 Powerwise Models 4061, 4063 Page 16
Air Distribution Valve Assembly Drawing
MAIN AIRVALVE ASSEMBLY PARTS LIST
ITEM PARTNUMBER DESCRIPTION QTY
1 031-115-000 Main Air Valve Assembly 1
1-A 095-086-551 Body, Air Valve 1
1-B 165-074-551 Cap, End with O-Ring 2
1-C 560-101-360 O-Ring 8
1-D 675-051-115 Ring, Retaining 2
1-E 031-132-000 Sleeve and Spool Set with O-Ring 1
1-F 530-031-550 Muffler 1
1-G 165-109-551 Cap, Muffler 1
1-H 710-011-115 Screws, Self-Tapping 4

520-259-000 6/00 Powerwise Models 4061, 4063 Page 17
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.
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
thefour hex socketcapscrews (item 11)
andfour flatwashers (item36). Remove
theair valve assembly from thepump.
Removeandinspectgasket (item19)
forcracks or damage.Replace gasket if
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
valveassemblyusingclip ringpliers.
Nextremove the two end caps (item
1-B).Inspecttheo-ring(item 1-C)forcuts
orwear.Replacetheo-ringsifnecessary.
Remove the spool (part of item 1-E)
fromthesleeve. Becarefulnot toscratch
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
replacewith a newsleeve and spool set
(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) into the groove
on the same end.
Removethenewsleeveandspoolset
(item1-E)fromthe plasticbag. 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
installingthesleeve into the valve body
(item 1-A). align the slots in the sleeve
with the slots in the valve body. Insert
thespool into the sleeve. Be careful not
to scratch or damage the spool during
installation. Push the spool in until
touches the end cap on the opposite
end.
Installthe remaining end cap with o-
ringand retaining ring.
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.

520-259-000 6/00 Powerwise Models 4061, 4063 Page 18
Air Distribution Valve Assembly Drawing
with Stroke Indicator Option
MAIN AIRVALVE ASSEMBLY PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
1 031-116-000 Main Air Valve Assembly 1
1-A 095-086-551 Body, Air Valve 1
1-B 165-101-147 Cap, End 2
1-C 560-101-360 O-Ring 8
1-D 679-051-115 Ring, Retaining 2
1-E 031-134-000 Sleeve & Spool Set 1
with Pins and O-Rings
1-F 530-031-550 Muffler 1
1-G 165-109-551 Cap, Muffler 1
1-H 710-011-115 Screws, Self-Tapping 4
1-J 132-030-552 Bumper 2
1-K 560-029-360 O-Ring 2
1-L 210-008-330 Clip, Safety 1

520-259-000 6/00 Powerwise Models 4061, 4063 Page 19
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.
AIR DISTRIBUTIONVALVEWITH
STROKEINDICATOR OPTION
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
thefour hex socketcapscrews (item 11)
andfour flatwashers (item36). Remove
theair valve assembly from thepump.
Removeandinspectgasket (item19)
forcracks or damage.Replace gasket if
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
valveassemblyusingclip ringpliers.
Nextremove the two end caps (item
1-B). Inspect the o-ring (items 1-C and
1-K)forcuts orwear.Replacethe o-rings
if necessary.
Removethe twobumpers (item 1-J).
Inspect the bumpers for cut, wear or
abrasion.Replace if necessary.
Remove the spool (part of item 1-E)
fromthesleeve. Becarefulnot toscratch
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
replacewith a newsleeve and spool set
(item1-E).
STEP#3: Reassemblyoftheairvalve.
Installonebumper(item1-J)and one
end cap (item 1-B) with o-rings (item 1-
K and 1-C) into one end of the air valve
body(item1-A). Installone retainingring
(item 1-D) into the groove on the same
end. Insert the safety clip (item 1-L)
through the smaller unthreaded hole in
theendcap.
Removethenewsleeveandspoolset
(item1-E)fromthe plasticbag. 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
installingthesleeve into the valve body
(item 1-A). Align the slots in the sleeve
with the slots in the valve body. Insert
thespool into the sleeve. Be careful not
to scratch or damage the spool during
installation. Push the spool in until
the pin touches the safety clip on the
oppositeend.
Installtheremainingbumper,endcap
witho-rings and retaining ring.
Fasten the air valve assembly (item
1) and gasket (item 19) to the pump.
Connect the compressed air line to
the pump. Remove the safety clip. The
pumpis now ready for operation.

520-259-000 6/00 Powerwise Models 4061, 4063 Page 20
Solenoid Shifted Air Valve Drawing
INTERMEDIATE ASSEMBLY FOR
SOLENOID SHIFTED OPTION PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
4 114-023-157S Intermediate Assembly 1
4-A 070-029-170 Bearing 2
4-B 618-050-150 Plug 2
4-C 430-047-150 Housing 2
4-D 560-001-360 O-Ring 2
4-E 675-042-115 Ring, Retaining* 2
*NOTE: It is recommended that when plunger components are
serviced, new retaining rings be installed.
For Epoxy Coated Mid-Sections:
4 114-023-307S Intermediate Assembly 1
(Includes all other items used on 114-023-157S above)
For Teflon Coated Mid-Sections:
4 114-023-309S Intermediate Assembly 1
(Includes all other items used on 114-023-157S above)
For Electroless Nickel Plated Mid-Sections:
4 114-023-332S Intermediate Assembly 1
(Includes all other items used on 114-023-157S above)
SOLENOID SHIFTED AIRVALVE PARTS LIST
(Includes all items used on Composite Repair Parts List except as shown)
ITEM PART NUMBER DESCRIPTION QTY
4 114-023-157S Intermediate Assembly 1
114-023-307S Intermediate Assembly 1
114-023-309S Intermediate Assembly 1
114-023-332S Intermediate Assembly 1
47 893-093-000 Solenoid Valve, NEMA4 1
48 219-001-000 Solenoid Coil, 24VDC 1
219-004-000 Solenoid Coil, 24VAC/12VDC 1
219-002-000 Solenoid Coil, 120VAC 1
219-003-000 Solenoid Coil, 240VAC 1
49 241-001-000 Connector, Conduit 1
50 170-051-115 Capscrew, Hex HD ¼-20 x 1.25 4
For Explosion Proof Solenoid Valve
(Connector not required for explosion proof coil; coil is integral with valve)
47 893-094-001 Solenoid Valve, NEMA 7/9, 24VDC 1
893-094-002 Solenoid Valve, NEMA 7/9, 24VAC/12VDC 1
893-094-003 Solenoid Valve, NEMA 7/9, 120VAC 1
893-094-004 Solenoid Valve, NEMA 7/9, 240VAC 1
Intermediate Assembly Drawing
for Solenoid Shifted Option