VERDER HI-CLEAN VA-2H40 Use and care manual

Repair/Parts
Verder Verder
VerderHI HI HI- - -CLEAN CLEAN CLEANDiaphragm Diaphragm Diaphragm
Pump, Pump,
Pump,Model Model ModelVA VA VA- - -2H40 2H40 2H40812.0064
Rev.A
EN
For For
Fortransfer transfer transferof of of󰘱uids 󰘱uids 󰘱uidsin in insanitary sanitary sanitaryapplications. applications. applications.Not Not Notapproved approved approvedfor for foruse use usein in inexplosive explosive explosiveatmospheres atmospheres atmospheresor or or
hazardous hazardous
hazardous(classi󰘰ed) (classi󰘰ed) (classi󰘰ed)locations locations locationsunless unless unlessotherwise otherwise otherwisestated. stated. stated.See See SeeApprovals Approvals Approvalspage page pagefor for formore more moreinformation. information. information.
For For
Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandinyour
Operationmanualbeforeusingthisequipment.Save Save
Savethese these these
instructions. instructions.
instructions.
8bar(0.8MPa,120psi)MaximumFluid
WorkingPressure
8bar(0.8MPa,120psi)MaximumAit
InputPressure
Seepage6forapprovals.

Contents Contents
Contents
RelatedManuals................................................2
Warnings...........................................................3
Con󰘰gurationNumberMatrix...............................5
Troubleshooting..................................................7
Repair................................................................9
PressureReliefProcedure............................9
AirValveRepair...........................................9
CheckValveRepair.....................................12
StandardDiaphragmRepair.........................14
OvermoldedDiaphragmRepair.....................16
CenterSectionRepair..................................19
LeakDetectors............................................21
Parts..................................................................22
Diaphragms.................................................26
TechnicalData...................................................29
CustomerServices/Guarantee.............................31
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualNumber Number NumberTitle Title Title
812.0061VerderHI-CLEANDiaphragmPumps,Operation
812.0254LeakDetectionSystem,Instructions/Parts
2812.0064

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolvent,inwork work
workarea area areacanigniteorexplode.Solvent󰘱owingthrough
theequipmentcancausestaticsparking.Tohelpprevent󰘰reandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygrounded󰘱uidlines.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
•Routeexhaustawayfromallignitionsources.Ifdiaphragmruptures,󰘱uidmaybeexhausted
withair.
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Check󰘱uidlines,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
812.00643

Warnings
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestSafetyDataSheet(SDS)fromdistributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Route󰘱uidlinesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhot
surfaces.
•Donotkinkoroverbend󰘱uidlinesoruse󰘱uidlinestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Routeexhaustawayfromworkarea.Ifdiaphragmruptures,󰘱uidmaybeexhaustedinto
theair.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
4812.0064

CongurationNumberMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrix
Checktheidenti󰘰cationplate(ID)forthe
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Whenyoureceiveyourpump,recordthe8character
partnumberfoundontheshippingbox(e.g.,
811.0018):
_____________
Alsorecordthecon󰘰gurationnumberonthepumpID
platetoassistyouwhenorderingreplacementparts:
_____________________________________
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:VA VA
VA- - -2H40XS 2H40XS 2H40XS- - -STTFTSD4SB21 STTFTSD4SB21 STTFTSD4SB21
VA VA
VA- - -2H 2H 2H40 40 40X X
XS S
SST ST STTF TF
TFTS TS
TSD4 D4
D4SB SB
SB21 21 21
Pump
Model
Pump
Size
Wetted
Parts
Air
Section
SeatsBallsDiaphragmsConnectionsOptionsCerti󰘰cations
NOTE: NOTE:
NOTE:Somecombinationsarenotpossible.Pleasecheckwithyourlocalsupplier.
Pump Pump
PumpPump Pump
PumpSize Size SizeWetted Wetted
WettedParts Parts PartsAir Air
AirSection Section SectionSeat Seat
SeatMaterial Material Material
VA VA
VA- - -2H 2H 2H40 40 4040mmX X
XHighSanitation,
3-A0.8μmE E
EPolishedStainless
SteelSB SB
SBStainlessSteel,
Buna-Ngasket
Y Y
YPharmaceutical,
0.5μmS S
SStainlessSteelSE SE SEStainlessSteel,
EPDMgasket
ST ST
STStainlessSteel,
EP-TFgasket
SV SV
SVStainlessSteel,
FKMgasket
Ball Ball
BallMaterial Material MaterialDiaphragm Diaphragm DiaphragmMaterial Material MaterialConnections Connections
ConnectionsOptions Options OptionsCerti󰘰cation Certi󰘰cation Certi󰘰cation
BN BN
BNBuna-NBN BN BNBuna-ND4 D4 D4DIN11851
(DN40)3A 3A
3A3-A21 21 21EN10204
type2.1
EP EP
EPEPDMEO EO
EOEPDM
OvermoldedT4 T4
T4TRI-CLAMP
1.5”SB SB
SBSanitary
ball31 31
31EN10204
type3.1
FL FL
FLStainlessSteel
󰘱apperSP SP
SPSantopreneSF SF SFSanitary
󰘱apper
NW NW
NWPolychloroprene
weightedTO TO
TOPTFE
Overmolded
SP SP
SPSantopreneTS TS TSPTFE/San-
toprene,
2-piece
TF TF
TFPTFEVT VT VTFKM
VT VT
VTFKM
812.00645

CongurationNumberMatrix
Approvals Approvals
Approvals
Exceptfor3-Apumps,allpumpsareapprovedto:
II2GD
ExhIIAT6...T3Gb
ExhIIIBT160°CDb
DiaphragmmaterialscodedEO,TO,orTS
combinedwith󰘱apperorTFballcheckscomply
with:
EC1935/2004
DiaphragmmaterialscodedEOorTScombined
with󰘱apperorTFballcheckscomplywith:
ClassVI
Allmodelsareapprovedto:
All󰘱uidcontactmaterialsareFDAcompliant
andmeettheUnitedStatesCodeofFederal
Regulations(CFR)
ATEXT-coderatingisdependentonthetemperatureofthe󰘱uidbeingpumped.Fluidtemperatureislimited
bythematerialsofthepumpinteriorwettedparts.SeeTechnicalData,page29,forthemaximum󰘱uid
operatingtemperatureforyourspeci󰘰cpumpmodel.
6812.0064

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
•FollowthePressureReliefProcedure,page9,
beforecheckingorservicingtheequipment.
•Checkallpossibleproblemsandcausesbefore
disassembly.
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Pumpcyclesatstallor
failstoholdpressureat
stall.
Wornchecksorseats.Replace.
Airvalveisstuckordirty.Disassembleandcleanairvalve.
Use󰘰lteredair.
Checkballisseverelywornand
wedgedinseatormanifold.
Replaceballandseatcomponent.
Checkvalveballisseverelywedged
intoseatduetooverpressurization.
Follow
PressureReliefProcedure,page9.
Disassembleballcheckassembly
andinspectfordamage.
Cloggeddispensingvalve.Follow
PressureReliefProcedure,page9.
Clearvalve.
Pumpwillnotcycle,or
cyclesonceandstops.
Leakdetectorhasactivatedashut-
downsolenoid.
Investigatefailureandresetleak
detector.
Cloggedsuctionline.Inspect;clear.
Stickyorleakingcheckballsor
󰘱apperchecks.
Cleanorreplace.
Ruptureddiaphragm.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Reducedpump
performance.
Restrictedexhaust.Removerestriction.
Loosesuctionline.Tighten.
Ruptureddiaphragm.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Airbubblesin󰘱uid.
Looseinletmanifold,damagedseal
betweenmanifoldand󰘱uidcover,or
damagedgaskets.
Tightenmanifoldclampsorreplace
gasketsorseatingcomponents.
Loosesanitaryclamp.Tightenclamp.
Damagedorworngasket.Replacegasket.
Leakininletoroutlet
sanitary󰘰tting.
Misalignmentofinlet/outlet󰘱uidline
orpipe.
Use󰘱exible󰘱uidlinesatpumpinlet
andoutlet.
Manifoldsdonot󰘰tfor
installationonto󰘱uid
covers.
Useofincorrectaircovergaskets
resultsinmisalignment.
Installcorrectaircovergasketsfor
thetypeofdiaphragmsinuse.See
Partslistforcorrectgasket.
812.00647

Troubleshooting
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Diaphragmruptured.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Fluidinexhaustair.
Loosediaphragmplate.Tightenorreplace.Seestandard
orovermoldeddiaphragmrepair
procedure.
Wornairvalveblock,plate,pilot
block,u-cups,orpilotpino-rings.
Repairorreplace. Pumpexhaustsexcessive
airatstall.
Wornshaftseals.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Looseairvalvecover.Tightenscrews.
Airvalvegasketoraircovergasket
isdamaged.
Inspect;replace.
Pumpleaksairexternally.
LooseaircoverclampsTightenclamps.
Pumpleaks󰘱uid
externallyfromballcheck
valves.
Loosemanifolds,damagedseal
betweenmanifoldand󰘱uidcover,or
damagedgaskets.
Tightenmanifoldclampsorreplace
seatsorclamps.
Chattering.Checkvalveballsnotseating
properly/cleanlyduetoimbalance
between󰘱uidinletandoutletline
sizing.Noiseisaccentuatedwith
lightviscosity󰘱uids.
Reducesize/diameterofinletline
relativetooutletline.Outletlinesize
shouldnotexceedpumpsize.
8812.0064

Repair
Repair Repair
Repair
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressureis
manuallyrelieved.Tohelppreventseriousinjury
frompressurized󰘱uid,suchassplashing󰘱uid,
followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyou
stopdispensingandbeforecleaning,checking,or
servicingtheequipment.
1.Closethemasterairvalve(A)toshutofftheair
tothepump.
2.Openoutbound󰘱uidvalvetorelieve󰘱uid
pressurefromthepump.
3.If󰘱uidisstillintheoutbound󰘱uidlines,isolate
this󰘱uidasfollows:
a.For For
Forsimple simple simpletransfer transfer transferapplications, applications, applications,openeither
the󰘱uidshutoffvalve(J)orthe󰘱uiddrain
valve(K).
b.For For
Forcirculating circulating circulatingapplications, applications, applications,ensurethatthe
󰘱uidshutoffvalve(J)isclosedandopenthe
󰘱uiddrainvalve(K).
Air Air
AirValve Valve ValveRepair Repair Repair
Tools Tools
ToolsRequired: Required: Required:
•Torquewrench
•Torx(T20)screwdriveror7mm(9/32in.)socket
wrench
•Needle-nosepliers
•O-ringpick
•Lithiumbasegrease
Airvalverepairkit819.0664isavailable.Useall
partsinthekitforbestresults.
Disassemble Disassemble
DisassembleAir Air AirValve Valve Valve
1.FollowthePressureReliefProcedure,page9.
2.WithaTorx(T20)screwdriveror7mm(9/32in.)
socketwrench,removethesixscrews(107),air
valvecover(109),andgasket(118).
3.Movethevalvecarriage(105)tothecenter
positionandpullitoutofthecavity.Usinga
needle-nosepliers,pullthepilotblock(116)
straightupandoutofthecavity.
4.Pullthetwoactuatorpistons(114).Removethe
u-cups(106)fromthepistons.Pullthepilotpins
(112).Removetheo-rings(108)fromthepilot
pins.
812.00649

Repair
5.Inspectthevalveplate(110)inplace.If
damaged,useaTorx(T20)screwdriveror7mm
(9/32)in.)socketwrenchtoremovethethree
screws(107).Removethevalveplate(110).
6.Inspectthebearings(113,115)inplace.See
Parts,page22.Thebearingsaretaperedand,
ifdamaged,mustberemovedfromtheoutside.
Thisrequiresdisassemblyofthe󰘱uidsection.
SeeCenterSectionRepair,page19.
7.Cleanallpartsandinspectforwearordamage.
Replaceasneeded.
10812.0064

Repair
Reassemble Reassemble
ReassembleAir Air AirValve Valve Valve
NOTE: NOTE:
NOTE:Ifrepairsinvolveremoving
󰘱uidcovers,performthestepsin
ReassembletheOvermoldedDiaphragms,page17,
priortoreassemblyoftheairvalve.Theairvalve
con󰘰gurationwillbemodi󰘰edtoaid󰘱uidcover
installation.
1.Ifthecentersectionwasdisassembledto
replacethebearings(113,115),complete
theCenterSectionRepair,page19,before
continuingwiththeairvalvereassembly.
2.Installthevalveplate(110)inthecavity,seal
down.Installthethreescrews(107),usinga
Torx(T20)screwdriveror7mm(9/32in.)socket
wrench.Tightenuntilthescrewsbottomouton
thehousing.
3.Installano-ring(108)oneachpilotpin(112).
Greasethepinsando-rings.Insertthepinsinto
thebearings,
narrow narrow
narrow
end󰘰rst.
4.Installu-cups(106)oneachactuatorpiston
(114),sothelipsofthepackingsfacethe
narrow narrow
narrow
endofthepistons.
5.Lubricatetheu-cups(106)andactuatorpistons
(114).Inserttheactuatorpistonsinthebearings
(115), wide wide
wide
end󰘰rst.Leavethenarrowendof
thepistonsexposed.
6.Greasethelowerfaceofthepilotblock(116)and
installsoitstabssnapintothegroovesonthe
endsofthepilotpins(112).
7.Greasethelowerfaceofthevalvecarriage(105).
8.Installthevalvecarriage(105)soitstabsslipinto
thegroovesonthenarrowendoftheactuator
pistons(114).
9.Alignthevalvegasket(118)andcover(109)
withthesixholesinthecenterhousing(101).
Securewithsixscrews(107),usingaTorx(T20)
screwdriveror7mm(9/32in.)socketwrench.
Torqueto5.7-6.8N•m(50-60in-lb).
812.006411

Repair
Check Check
CheckValve Valve ValveRepair Repair Repair
NOTE: NOTE:
NOTE:Kitsareavailablefornewcheckvalve
󰘱appers,orcheckvalveballsinarangeofmaterials.
Gasketkitsalsoareavailable.
Disassemble Disassemble
DisassembleBall Ball BallCheck Check CheckValves Valves Valves
1.FollowthePressureReliefProcedure,page9.
Disconnectall󰘱uidandairlines.
2.Todrainthepump,pulltheframequick-release
pins(207)androtatethepump.
NOTE: NOTE:
NOTE:Afterdraining,rotatethepumpto
positionswhichwillaiddisassembly.
3.Removetheclamps(23)ontheoutletmanifold
(17)andremovethemanifold.
NOTE: NOTE:
NOTE:Usecarewhileremovingmanifoldsto
avoiddamagetocheckvalvecomponents.
4.Removeremainingclamps(23),manifolds(17),
gaskets(18),andcheckvalves(19).
5.Cleanandinspectgaskets,balls,ballstops,and
seatingsurfacesforanydamageandreplaceas
necessary.
6.Tocontinuewithdiaphragmdisassembly,see
DisassembletheStandardDiaphragms,page14.
12812.0064

Repair
Disassemble Disassemble
DisassembleFlapper Flapper FlapperCheck Check CheckValves Valves Valves
1.FollowthePressureReliefProcedure,page9.
Disconnectall󰘱uidandairlines.
2.Todrainthepump,pulltheframequick-release
pins(207)androtatethepump.
NOTE: NOTE:
NOTE:Afterdraining,rotatethepumpto
positionswhichwillaiddisassembly.
3.Removetheclamps(23)ontheoutletmanifold
(17)andremovethemanifold.
NOTE: NOTE:
NOTE:Usecarewhileremovingmanifoldsto
avoiddamagetocheckvalvecomponents.
4.Removeremainingclamps(23),manifolds(16
and17),gaskets(18),andcheckvalves(8).
5.Cleanandinspectgaskets,󰘱appers,and
seatingsurfacesforanydamageandreplaceas
necessary.
6.Tocontinuewithdiaphragmdisassembly,see
DisassembletheStandardDiaphragms,page14.
Reassemble Reassemble
Reassemblethe the theCheck Check CheckValves Valves Valves
NOTE: NOTE:
NOTE:Lubricateclamps,clampingsurfaces,and
gasketswithwaterproof,sanitarylubricant.
1.Reassemblecheckassemblyinreverseorder.
2.Attachthemanifoldstothe󰘱uidcovers.Tighten
clampshandtight.
812.006413

Repair
Standard Standard
StandardDiaphragm Diaphragm DiaphragmRepair Repair Repair
Tools Tools
ToolsRequired: Required: Required:
•Torquewrench
•5/8in.wrench
•19mmopenendwrench
•O-ringpick
•Lithiumbasegrease
NOTE: NOTE:
NOTE:Centersectiongasketisdependenton
diaphragmmaterial.Ifchangingdiaphragmmaterial,
itmaybenecessarytoalsoreplacethecentersection
aircovergaskets.SeeParts,page22,foraffected
aircovergaskets.
Disassemble Disassemble
Disassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page9.
2.Removethemanifoldsanddisassemble
thecheckvalvesasexplainedin
CheckValveRepair,page12.
3.Removetheclamps(21)fromthe󰘱uidcovers
(15),thenpullthe󰘱uidcoversoffofthepump.
4.Withboth󰘱uidcoversremoved,usingtwo5/8in.
wrenches,holdthewrench󰘱atsontheplates(Y)
ofeachdiaphragmassemblyandloosen.One
diaphragmassemblywillcomefreeandtheother
willremainattachedtotheshaft.
5.Disassemblethefreediaphragmassembly.
6.Removeplate(12)withbolt(14)installed,
diaphragm(10),backer(11)ifpresent,andplate
(9).
7.Pulltheotherdiaphragmassemblyandthe
diaphragmshaft(24)outofthecenterhousing
(101).Holdtheshaft󰘱atswitha19mmopenend
wrench,andremovethediaphragmassembly
fromtheshaft.Disassembletheremaining
diaphragmassembly.
8.Inspectthediaphragmshaft(24)forwearor
scratches.Ifitisdamaged,inspectthebearings
(111)inplace.Ifthebearingsaredamaged,refer
toCenterSectionRepair,page19.
9.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
14812.0064

Repair
Reassemble Reassemble
Reassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthecenter
section,followCenterSectionRepair,page19,
beforereplacingdiaphragms.
1.Lubricateandinstalltheshaftu-cups(106)so
thelipsface
out out
out
ofthehousing(101).
2.Assemblediaphragm(10),backer(11)ifpresent,
andplate(9)ontoplate(12)withscrew(14).
Roundedsideofplate(9)shouldfacediaphragm.
MakesurethesidemarkedAIRSIDEfacesthe
centerhousing.
NOTE: NOTE:
NOTE:Threadlockermustbeappliedtoscrew
(14)asshownforalldiaphragmassemblies.
1
Applyahigh-strengththreadlockerto
attachthescrewtothediaphragmplate,
ifneeded.
2
Applyamedium-strengththreadlocker
totheshaftsideofthescrew.
3.Screwassembleddiaphragmassemblyintoshaft
(24)andhandtighten.
4.Greasethelengthofthediaphragmshaft(24),
andslideitthroughthehousing(101).
5.Assembletheotherdiaphragmassemblytothe
shaftasexplainedinstep2.
6.Usinga5/8in.wrench,holdthewrench󰘱atsof
onediaphragmassemblyandtorquetheother
diaphragmto81-94N•m(60-70ft-lb).
NOTE: NOTE:
NOTE:Applywaterproof,sanitarylubricanttothe
clamp(21)andclampingsurfaceofthecover
(15)toeaseassembly.
7.Alignthe󰘱uidcovers(15)andthecenterhousing.
Securethecoverswiththeclamps(21)andhand
tighten.
NOTE: NOTE:
NOTE:Useafoodgradeanti-seizelubricanton
theclampthreadstoaidassembly.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12
812.006415

Repair
Overmolded Overmolded
OvermoldedDiaphragm Diaphragm DiaphragmRepair Repair Repair
Tools Tools
ToolsRequired: Required: Required:
•Torquewrench
•19mmopenendwrench
•O-ringpick
•Lithiumbasegrease
Disassemble Disassemble
Disassemblethe the theOvermolded Overmolded OvermoldedDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page9.
2.Removethemanifoldsanddisassemble
thecheckvalvesasexplainedin
CheckValveRepair,page12.
3.Removetheclamps(21)fromthe󰘱uidcovers
(15),thenpullthe󰘱uidcoversoffofthepump.
4.Oncethe󰘱uidcoversareremoved,the
diaphragmonthesideofthepumpwhichwas
lastpressurizedwithairwillbeseparatedfrom
thecentersection/aircover.Thisallowsyouto
gripthediaphragms.
5.Toloosen,gripbothdiaphragmssecurelyaround
theouteredgeandrotatecounterclockwise.One
diaphragmassemblywillcomefreeandtheother
willremainattachedtotheshaft.Removethe
freeddiaphragm(10)withscrew(14)andairside
plate(9).
6.Pulltheoppositediaphragmassemblyandshaft
(24)outofthecenterhousing(101).Holdthe
shaft󰘱atswitha19mmopenendwrenchand
removethediaphragmandairsideplatefrom
theshaft.
7.Inspectthediaphragmshaft(24)forwearor
scratches.Ifitisdamaged,inspectthebearings
(111)inplace.Ifthebearingsaredamaged,refer
toCenterSectionRepair,page19.
8.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
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Repair
Reassemble Reassemble
Reassemblethe the theOvermolded Overmolded OvermoldedDiaphragms Diaphragms Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthecenter
section,followCenterSectionRepair,page19,
beforereplacingdiaphragms.
1.Lubricateandinstalltheshaftu-cups(106)so
thelipsface
out out
out
ofthehousing(101).
2.Assembleplate(9)ontodiaphragm(10)with
screw(14).Roundedsideofplate(9)should
facediaphragm.MakesurethesidemarkedAIR
SIDEfacesthecenterhousing.
NOTE: NOTE:
NOTE:Threadlockermustbeappliedtoscrew
(14)foralldiaphragmassemblies.
1
Applyahigh-strengththreadlockerto
attachthescrewtothediaphragm.
2
Applyamedium-strengththreadlocker
totheshaftsideofthescrew.
3.Screwassembleddiaphragmassemblyintoshaft
(24)andhandtighten.
4.Greasethelengthofthediaphragmshaft(24),
andslideitthroughthehousing(101).
5.Assembletheotherdiaphragmassemblytothe
shaftasexplainedinstep2.
6.Gripbothdiaphragmssecurelyaroundtheirouter
edgeandrotateclockwiseuntilbottomedonthe
shaft.
NOTE: NOTE:
NOTE:Applywaterproof,sanitarylubricanttothe
clamp(21)andclampingsurfaceofthecover
(15)toeaseassembly.
NOTE: NOTE:
NOTE:Useafoodgradeanti-seizelubricanton
theclampthreadstoaidassembly.
7.Alignthe󰘱uidcovers(15)andthecenterhousing.
Securethecoverswiththeclamps(21)andhand
tighten.If,afterinstallingthe󰘰rst󰘱uidcover,the
opposingdiaphragmprotrudesawayfromthe
centerhousing,leavingagapbetweenthecenter
housingandthesecond󰘱uidcover,donottry
toforcethediaphragmintoposition.Instead,
completethefollowingproceduresinsteps7a–7i
toattachthesecond󰘱uidcover.
a.Removetheairvalvecover(B),thegasket
(C),andthepilotcup(D).Seetheimagein
stepi.
b.Withinthedrive,shiftthemainairvalve
carriage(E)awayfromtheinstalled󰘱uid
cover.Thiswillexposetheairpassagethat
feedstheassembledside.
c.Reinstallthegasket(C)andtheairvalve
cover(B).Torqueallboltsaccordingto
instructionsinyourpumpmanual.
d.Supplythepumpwith0.7–1.4bar(0.07–0.14
MPa,10–20psi)airpressure,justenough
tomovethediaphragm.Thediaphragm
willshiftsothesecond󰘱uidcoverwillseat
properly.Keeptheairpressureonwhileair
󰘱owsoutoftheexhaust.
NOTE: NOTE:
NOTE:Toomuchairpressuremaycausethe
diaphragmtodeformandseatincorrectly.
e.Installtheremaining󰘱uidcover.
f.Followthe
PressureReliefProcedure,page9.
Disconnecttheairsupplyfromthepump.
g.Removetheairvalvecover(B)andthe
gasket(C).
h.Lubricateandreinstallthepilotcup(D).
812.006417

Repair
i.Reinstallthegasket(C)andtheairvalve
cover(B).Torqueallboltsaccordingto
instructionsinyourpumpmanual.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12.
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Repair
Center Center
CenterSection Section SectionRepair Repair Repair
Tools Tools
ToolsRequired: Required: Required:
•Torquewrench
•10mmsocketwrench
•9/16in.socketwrench
•Bearingpuller
•O-ringpick
•Press,orblockandmallet
Disassemble Disassemble
Disassemblethe the theCenter Center CenterSection Section Section
NOTE: NOTE:
NOTE:Donotremoveundamagedbearings.
1.FollowthePressureReliefProcedure,page9.
Disconnectall󰘱uidandairlines.
2.Removethemanifoldsand
checkvalvepartsasdirectedin
DisassembleBallCheckValves,page12.
3.Removethe󰘱uidcoversanddiaphragms
asdirectedinDisassembletheStandard
Diaphragms,page14orDisassemblethe
OvermoldedDiaphragms,page16.
NOTE: NOTE:
NOTE:Ifyouareremovingonlythediaphragm
shaftbearing(111),skipstep4.
4.Disassembletheairvalveasexplainedin
AirValveRepair,page9.
5.Usea9/16in.socketwrenchtoremovethe
screws(3)andnuts(105)holdingtheaircovers
totheframe.
6.Usea10mmsocketwrenchtoremovethe
screws(104)holdingtheaircovers(103)tothe
centerhousing(101).
7.Removetheaircovergaskets(102).Always
replacethegasketswithnewones.
NOTE: NOTE:
NOTE:Ifremovingthediaphragmshaftbearings
(111),useano-ringpicktoremovetheu-cups
(106)󰘰rst.
8.Useabearingpullertoremovethediaphragm
shaftbearings(111),airvalvebearings(115)
orpilotpinbearings(113).Donotremove
undamagedbearings.
9.Inspecttheu-cups.Replaceasneeded.
812.006419

Repair
Reassemble Reassemble
Reassemblethe the theCenter Center CenterSection Section Section
1.Installtheshaftu-cups(106)sothelipsface
out out
out
ofthehousing.
2.Insertnewbearings(111,113,and115)intothe
centerhousing(101),
tapered tapered
taperedend end end󰘰rst 󰘰rst 󰘰rst
.Using
apressorablockandrubbermallet,press-󰘰t
thebearingsoitis󰘱ushwiththesurfaceofthe
centerhousing.
3.Reassembletheairvalveasexplainedin
ReassembleAirValve,page11
4.Alignthenewaircovergasket(102)sothepilot
pin(112)protrudingfromthecenterhousing
(101)󰘰tsthroughtheproperholeinthegasket.
5.Aligntheaircover(103)sothepilotpin(112)󰘰ts
inthemiddlehole(M)ofthethreesmallholes
nearthecenterofthecover.
6.Applyamedium-strengththreadlockertothe
threadsofthescrews(106).Installthescrews
(106),handtight.Usinga10mmsocketwrench,
torquethescrewsoppositelyandevenlyto
15-17N•m(130-150in-lb).Installthediaphragm
assembliesand󰘱uidcoversasexplainedin
Diaphragms,page26.
7.SeeReassembletheCheckValves,page13.
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