VERDER HI-CLEAN VA-2H52 Use and care manual

Repair/Parts
Verder Verder
VerderHI HI HI- - -CLEAN CLEAN CLEANDiaphragm Diaphragm Diaphragm
Pumps Pumps
Pumps812.0065
Rev.A
EN
Models Models
ModelsVA VA VA- - -2H52, 2H52, 2H52,VA VA VA- - -2H53, 2H53, 2H53,and and andVA VA VA- - -2H54 2H54 2H54
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 For
professional professional
professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandinyour
Operationmanualbeforeusingtheequipment.Save Save
Savethese these these
instructions. instructions.
instructions.
8bar(0.8MPa,120psi)MaximumFluid
WorkingPressure
8bar(0.8MPa,120psi)MaximumAir
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.................................................29
TechnicalData...................................................33
CustomerServices/Guarantee.............................35
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualNumber Number NumberTitle Title Title
812.0061VerderHI-CLEANDiaphragmPumps,Operation
812.0254LeakDetectionSystem,Instructions/Parts
2812.0065

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.
812.00653

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.
4812.0065

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- - -2H52XS 2H52XS 2H52XS- - -STTFTSD5SB21 STTFTSD5SB21 STTFTSD5SB21
VA VA
VA- - -2H 2H 2H52 52 52X X
XS S
SST ST STTF TF
TFTS TS
TSD5 D5
D5SB 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 2H52 52 5250mm(2
inchport)X X
XHighSanitation,
3-A0.8μmE E
EPolishedStainless
SteelSB SB
SBStainlessSteel,
Buna-Ngasket
53 53
5350mm(3
inchport)Y Y
YPharmaceutical,
0.5μmS S
SStainlessSteelSE SE SEStainlessSteel,
EPDMgasket
54 54
5450mm(4
inchport)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-N— —
—Poultry3A 3A
3A3-A21 21 21EN10204
type2.1
EP EP
EPEPDMEO EO
EOEPDM
OvermoldedD5 D5
D5DIN11851
(DN50)FH FH
FHFlapper
horizon-
tal
31 31
31EN10204
type3.1
FL FL
FLStainlessSteel
󰘱apperSO SO
SOSantoprene
OvermoldedD8 D8
D8DIN11851
(DN80)FP FP
FPFlapper
poultry
NW NW
NWPolychloroprene
weightedSP SP
SPSantopreneD1 D1 D1DIN11851
(DN100)SB SB
SBSanitary
ball
SP SP
SPSantopreneTO TO
TOPTFE
OvermoldedT5 T5
T5TRI-CLAMP
2”SF SF
SFSanitary
󰘱apper
TF TF
TFPTFETS TS
TSPTFE/San-
toprene,
2-piece
T8 T8
T8TRI-CLAMP
3”
VT VT
VTFKMVT VT VTFKMT1 T1
T1TRI-CLAMP
4”
812.00655

CongurationNumberMatrix
Approvals Approvals
Approvals
Exceptfor3-Apumps,allpumpsare
approvedto:
II2GD
ExhIIAT6...T3Gb
ExhIIIBT160°CDb
DiaphragmmaterialscodedEO,TO,orTS
combinedwith󰘱apperorTFballchecks
complywith:
EC1935/2004
DiaphragmmaterialscodedEOorTS
combinedwith󰘱apperorTFballchecks
complywith:
ClassVI
Allmodelsareapprovedto:
All󰘱uidcontactmaterialsareFDAcompliant
andmeettheUnitedStatesCodeofFederal
Regulations(CFR)
ATEXT-coderatingisdependentonthetemperatureofthe󰘱uidbeingpumped.Fluidtemperatureislimited
bythematerialsofthepumpinteriorwettedparts.SeeTechnicalData,page33,forthemaximum󰘱uid
operatingtemperatureforyourspeci󰘰cpumpmodel.
6812.0065

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
•FollowthePressureReliefProcedure,page9,
beforecheckingorservicingtheequipment.
•Checkallpossibleproblemsandcausesbefore
disassembly.
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Pumpcyclesatstallorfails
toholdpressureatstall.
Wornchecksorseats.Replace.
Airvalveisstuckordirty.Disassembleandcleanairvalve.Use
󰘰lteredair.
Checkballisseverelywornandwedged
inseatormanifold.
Replaceballandseatcomponent.
Checkvalveballisseverelywedgedinto
seatduetooverpressurization.
Follow
PressureReliefProcedure,page9.
Disassembleballcheckassemblyand
inspectfordamage.
Cloggeddispensingvalve.Follow
PressureReliefProcedure,page9.
Clearvalve.
Pumpwillnotcycle,or
cyclesonceandstops.
Leakdetectorhasactivatedashut-
downsolenoid.
Investigatefailureandresetleak
detector.
Cloggedsuctionline.Inspect;clear.
Stickyorleakingcheckballsor󰘱ap
valves.
Cleanorreplace.
Flapvalvesinstalledupside-down.Installthe󰘱appervalvewiththetextside
facingtheseat.
Ruptureddiaphragm.Replace.Seestandardorovermolded
diaphragmrepairprocedure.
ReducedPump
Performance
Restrictedexhaust.Removerestriction.
Loosesuctionline.Tighten.
Ruptureddiaphragm.Replace.Seestandardorovermolded
diaphragmrepairprocedure.
Airbubblesin󰘱uid.
Looseinletmanifold,damagedseal
betweenmanifoldand󰘱uidcover,
damagedgaskets.
Tightenmanifoldclampsorreplace
gasketsorseatingcomponents.
Loosesanitaryclamp.Tightenclamp.
Damagedorworngasket.Replacegasket.
Leakininletoroutletsanitary
󰘰tting.
Misalignmentofinlet/outlet󰘱uidlinesor
pipe.
Use󰘱exible󰘱uidlinesatpumpinletand
outlet.
Manifoldsdonot󰘰tfor
installationonto󰘱uidcovers.
Useofincorrectaircovergasketsresults
inmisalignment.
Installcorrectaircovergasketsforthe
typeofdiaphragmsinuse.SeePartslist
forcorrectgasket.
812.00657

Troubleshooting
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Diaphragmruptured.Replace.Seestandardorovermolded
diaphragmrepairprocedure.
Fluidinexhaustair.
Loosediaphragmplate.Tightenorreplace.Seestandard
orovermoldeddiaphragmrepair
procedure.
Wornairvalveblock,plate,pilotblock,
u-cups,orpilotpino-rings.
Repairorreplace. Pumpexhaustsexcessive
airatstall.
Wornshaftseals.Replace.Seestandardorovermolded
diaphragmrepairprocedure.
Airvalvecoverisloose.Tightenscrews.
Airvalvegasketoraircovergasketis
damaged.
Inspect;replace.
Pumpleaksairexternally.
AircoverclampsarelooseTightenclamps.
Pumpleaks󰘱uidexternally
fromballcheckvalves.
Loosemanifolds,damagedseal
betweenmanifoldand󰘱uidcover,or
damagedgaskets.
Tightenmanifoldclampsorreplace
seatsorclamps.
Chattering.Checkvalveballsnotseating
properly/cleanlyduetoimbalance
between󰘱uidinletandoutletlinesizing.
Noiseisaccentuatedwithlightviscosity
󰘱uids.
Reducesize/diameterofinletline
relativetooutletline.Outletlinesize
shouldnotexceedpumpsize.
8812.0065

Repair
Repair Repair
Repair
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressureis
manuallyrelieved.Tohelppreventseriousinjury
frompressurized󰘱uid,suchassplashing󰘱uid,
followthePressureReliefProcedurewhenyou
stopdispensingandbeforecleaning,checking,or
servicingtheequipment.
1.Closethemasterairvalve(A)toshutofftheair
tothepump.
2.Openoutbound󰘱uidvalvetorelieve󰘱uid
pressurefromthepump.
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.
812.00659

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.
10812.0065

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.Greasethelowerfaceofthepilotblock(116)and
installsoitstabssnapintothegroovesonthe
endsofthepilotpins(112).
6.Lubricatetheu-cups(106)andactuatorpistons
(114).Inserttheactuatorpistonsinthebearings
(115),
wide wide
wide
end󰘰rst.Leavethenarrowendof
thepistonsexposed.
7.Greasethelowerfaceofthevalvecarriage(119).
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).
812.006511

Repair
Check Check
CheckValve Valve ValveRepair Repair Repair
NOTE: NOTE:
NOTE:Kitsareavailablefornewcheckvalve
󰘱appers,orcheckvalveballsinarangeofmaterials.
Gasketkitsalsoareavailable.
Disassemble Disassemble
Disassemblethe the theCheck Check CheckValve Valve Valve
1.FollowthePressureReliefProcedure,page9.
Disconnectall󰘱uidandairlines.
2.Drainthepump
a.Onrotatablestand,pulltheframe
quick-releasepins(207)androtatethe
pump.
NOTE: NOTE:
NOTE:Afterdraining,rotatethepumpto
positionswhichwillaiddisassembly.
b.Onnon-rotatablestand,partiallydisassemble
the󰘱uidsectionasinstructedinthefollowing
steps.
NOTE: NOTE:
NOTE:Theverticalpumpscanbedrained
byremovingtheinletmanifoldandmanually
raisingtheinlet󰘱appers.Horizontalpumps
willrequireremovalofthe󰘱uidcovers.
3.Removetheclamps(23)ontheoutletmanifold
(17)andremovethemanifold.
NOTE: NOTE:
NOTE:Usecarewhileremovingmanifoldto
avoiddamagetocheckvalvecomponents.
4.Removeremainingclamps,manifolds,gaskets
andcheckvalves.
NOTE NOTE
NOTE:Inspectallcomponentsforanydamage
andreplaceasnecessary.
5.Cleanandinspectgaskets,checkvalve
components,andseatingsurfacesforany
damageandreplaceasnecessary.
6.Tocontinuewithdiaphragmdisassembly,see
DisassembletheStandardDiaphragms,page14.
Ball Ball
Ballpump pump pumpshown shown shown
12812.0065

Repair
Vertical Vertical
Vertical󰘱apper 󰘱apper 󰘱apperpump pump pumpshown shown shown
Horizontal Horizontal
Horizontal󰘱apper 󰘱apper 󰘱apperpump pump pumpshown shown shown
Reassemble Reassemble
Reassemblethe the theCheck Check CheckValves Valves Valves
NOTE: NOTE:
NOTE:Lubricateclampsandclampingsurfaceswith
waterproof,sanitarylubricant.
1.Reassembleballor󰘱appercheckassemblyin
reverseorder.
2.Attachthemanifoldstothe󰘱uidcovers.Tighten
clampshandtight.
NOTE: NOTE:
NOTE:Installthe󰘱appervalve(8)withthetext
sidefacingtheseat.
NOTE: NOTE:
NOTE:Flapper󰘱uidcoversarenot
interchangeableandtheirorientationis
criticalonhorizontalpumps.Horizontalpump
󰘱uidcoversmustbepositionedsothatthe
󰘱appershangdownfromthehingepinwhen
placedinthe󰘱uidcover.Installthe󰘱appervalves
(8)withthetextsidefacingtheseat.
812.006513

Repair
Standard Standard
StandardDiaphragm Diaphragm DiaphragmRepair Repair Repair
NOTE: NOTE:
NOTE:Overmoldeddiaphragmsarecoveredin
OvermoldedDiaphragmRepair,page16.
Tools Tools
ToolsRequired: Required: Required:
•Torquewrench
•5/8in.wrench
•19mmopenendwrench
•O-ringpick
•Lithiumbasegrease
NOTE: NOTE:
NOTE:Centersectiongasketisdependenton
diaphragmmaterial.Ifchangingdiaphragmmaterial,
itmaybenecessarytoalsoreplacethecenter
sectionaircovergaskets.SeeDiaphragms,page29,
foraffectedaircovergaskets.
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(4,
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.
14812.0065

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.Assembleplate(9)ontodiaphragm(10),with
screw(14).Roundedsideofplate(9)should
facediaphragm.MakesurethesidemarkedAIR
SIDEfacesthecenterhousing.
NOTE: NOTE:
NOTE:Threadlockermustbeappliedtoscrew
(14)asshownforalldiaphragmassemblies.
Applyahigh-strengththreadlockertoattach
thescrewtothediaphragmplate,ifneeded.
Applyamedium-strengththreadlockertothe
shaftsideofthescrew.
3.Screwassembleddiaphragmassemblyintoshaft
(24)andhandtighten.
4.Greasethelengthofthediaphragmshaft(24),
andslideitthroughthehousing(101).
5.Assembletheotherdiaphragmassemblytothe
shaftasexplainedinstep2.
6.Usinga5/8in.wrenchholdthewrench󰘱atsof
onediaphragmassemblyandtorquetheother
diaphragmto81-94N•m(60-70ft-lb).
NOTE: NOTE:
NOTE:Applywaterproof,sanitarylubricanttothe
clamp(21)andclampingsurfaceofthecover(4,
15)toeaseassembly.
7.Alignthe󰘱uidcovers(4,15)andthecenter
housing.Securethecoverswiththeclamps(21)
andhandtighten.
NOTE: NOTE:
NOTE:Applyafoodgradeanti-seizelubricanton
theclampthreadstoaidassembly.
NOTE: NOTE:
NOTE:Ballpump󰘱uidcoversare
interchangeable.
NOTE: NOTE:
NOTE:Flapper󰘱uidcoversarenot
interchangeableandtheirorientationis
criticalonhorizontalpumps.Horizontalpump
󰘱uidcoversmustbepositionedsothatthe
󰘱appershangdownfromthehingepinwhen
placedinthe󰘱uidcover.Installthe󰘱appervalves
(8)withthetextsidefacingtheseat.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12.
812.006515

Repair
Overmolded Overmolded
OvermoldedDiaphragm Diaphragm DiaphragmRepair Repair Repair
Tools Tools
ToolsRequired Required Required
•Torquewrench
•19mmopenendwrench
•O-ringpick
•Lithiumbasegrease
NOTE: NOTE:
NOTE:Centersectiongasketisdependenton
diaphragmmaterial.Ifchangingdiaphragmmaterial,
itmaybenecessarytoalsoreplacethecenter
sectionaircovergaskets.SeeDiaphragms,page29,
foraffectedaircovergaskets.
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(4,
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.
16812.0065

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,seeCenterSectionRepair,page19,before
youputthediaphragmsbackon.
1.Lubricateandinstalltheshaftu-cups(110)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)asshownforalldiaphragmassemblies.
Applyahigh-strengththreadlockertoattach
thescrewtothediaphragmplate.
Applyamedium-strengththreadlockertothe
shaftsideofthescrew.
3.Screwassembleddiaphragmassemblyintoshaft
(24)andhandtighten.
4.Greasethelengthofthediaphragmshaft(24),
andslideitthroughthehousing(101).
5.Assembletheotherdiaphragmassemblytothe
shaftasexplainedinstep2.
6.Gripbothdiaphragmssecurelyaroundtheirouter
edgesandrotateclockwiseuntilbottomedonthe
shaft.
NOTE: NOTE:
NOTE:Applywaterproof,sanitarylubricanttothe
clamp(21)andclampingsurfaceofthecover(4,
15)toeaseassembly.
NOTE: NOTE:
NOTE:Useafoodgradeanti-seizelubricanton
theclampthreadstoaidassembly.
812.006517

Repair
7.Alignthe󰘱uidcovers(4,15)andthecenter
housing.Securethecoverswiththeclamps(21)
andhandtighten.If,afterinstallingthe󰘰rst󰘱uid
cover,theopposingdiaphragmprotrudesaway
fromthecenterhousing,leavingagapbetween
thecenterhousingandthesecond󰘱uidcover,
donottrytoforcethediaphragmintoposition.
Instead,completethefollowingproceduresin
steps7a–7itoattachthesecond󰘱uidcover.
NOTE: NOTE:
NOTE:Ballpump󰘱uidcoversare
interchangeable.
NOTE: NOTE:
NOTE:Flapper󰘱uidcoversarenot
interchangeableandtheirorientationis
criticalonhorizontalpumps.Horizontalpump
󰘱uidcoversmustbepositionedsothatthe
󰘱appershangdownfromthehingepinwhen
placedinthe󰘱uidcover.Installthe󰘱appervalves
(8)withthetextsidefacingtheseat.
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.Supplythepumpwith10–20psi(0.07–0.14
MPa,0.7–1.4bar)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).
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
DisassembletheCheckValve,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.
812.006519

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,page29.
7.SeeReassembletheCheckValves,page13.
20812.0065