VERDER HI-CLEAN VA-H20 User manual

Instructions/Parts List
Verder HI-CLEAN VA-H20
Diaphragm Pumps
819.0416
Rev. L
EN
For use in sanitary applications. For professional use only.
6.9 bar (0.7 MPa, 100 psi) Maximum Fluid Working Pressure
6.9 bar (0.7 MPa, 100 psi) Maximum Air Input Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
ti17529a

2 819.0416
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Available Configurations . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Information . . . . . . . . . . . . . . . . . . . . . . 6
Tighten Clamps Before First Use . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fluid Suction Line . . . . . . . . . . . . . . . . . . . . . . . . 7
Fluid Outlet Line . . . . . . . . . . . . . . . . . . . . . . . . . 8
Changing the Orientation of the Fluid Inlet and
Outlet Ports . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air Exhaust Ventilation . . . . . . . . . . . . . . . . . . . 10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Relief Procedure . . . . . . . . . . . . . . . . 11
Sanitize the Pump Before First Use . . . . . . . . . 11
Starting and Adjusting the Pump . . . . . . . . . . . 11
Pump Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Air Valve Lubrication . . . . . . . . . . . . . . . . . . . . . 12
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tightening Connections . . . . . . . . . . . . . . . . . . . 12
Preventive Maintenance Schedule . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Ball Check Valve . . . . . . . . . . . . . . . . . . . . . . . . 16
Standard Diaphragms . . . . . . . . . . . . . . . . . . . . 16
Overmolded PTFE Diaphragms . . . . . . . . . . . . 18
Air Center Service . . . . . . . . . . . . . . . . . . . . . . . 19
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fluid Section Repair Kits* . . . . . . . . . . . . . . . . . . . 22
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 24
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Customer Services/Guarantee . . . . . . . . . . . . . . . 29

Models
819.0416 3
Models
Sample Configuration Number: VA-H20 SP ST TF TF T2 FD
NOTE: Some combinations are not possible. Please check with your local supplier or on www.verderair.com.
Available Configurations
ATEX T-code rating is dependent on the temperature of the fluid being pumped. Fluid temperature is limited by the
materials of the pump interior wetted parts. See Technical Data for the maximum fluid operating temperature for
your specific pump model.
VA-H 20 SP ST TF TF T2 FD
Pump Model Size Fluid Section
and Air Section
Seats and
O-Rings
Balls Diaphragms Connections Pump
Style
Pump
Model
Fluid Section and Air Section
Material
Seats and O-Rings Check Valve Balls
VA-H20 SP Stainless Steel Pump with
Polypropylene Air Section
SE Stainless Steel Seats
with EPDM O-Rings
SP Santoprene
ST Stainless Steel Seats
with PTFE O-Rings
TF PTFE
Diaphragm Connections Pump Style Certification
SP Santoprene D2 DIN 11851, 25 mm FD FDA 31 EN 10204 type 3.1
TF PTFE/TPE 2-Piece T2 Tri-clamp, 1 in.
TO PTFE Overmolded
Model Configuration Number Approvals
810.0824 VA-H20 SP ST TF TF T2 FD
810.0825 VA-H20 SP ST TF TF D2 FD
810.0826 VA-H20 SP ST TF TO T2 FD
810.0827 VA-H20 SP ST TF TO D2 FD
810.0828 VA-H20 SP SE SP SP T2 FD
810.0829 VA-H20 SP SE SP SP D2 FD
EC 1935/2004 Compliant
II 2 GD
Ex h llC 66°C...135°C Gb
Ex h IIIC T135°C Db
II 2 GD
Ex h llC 66°C...135°C Gb
Ex h IIIC T135°C Db

Warnings
4 819.0416
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are antistatic or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into the air.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause
serious injury.
• Follow the Pressure Relief Procedure when you stop spraying/dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

Warnings
819.0416 5
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is
not limited to:
• Protective eyewear and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNING

Installation
6 819.0416
Installation
General Information
• The typical installation shown in FIG. 2, page 8, is
only a guide for selecting and installing system com-
ponents. Contact your Verder representative for
assistance in planning a system to suit your needs.
• Reference numbers and letters in parentheses refer
to the callouts in the figures.
Tighten Clamps Before First Use
After you unpack the pump, and before you use it for the
first time, check all clamps and tighten as necessary.
Grounding
•Pump: Attach a ground wire (Y) to the grounding
strip (8) with the screw (9a), lockwasher (9b), and
nut (9c), as shown in FIG. 1, and per local code.
Connect the clamp end of the ground wire to a true
earth ground. Order ground wire Part Number
819.0673.
•Fluid hoses: Use only grounded hoses with a maxi-
mum of 150 m (500 ft) combined hose length to
ensure grounding continuity.
•Air compressor: Follow the manufacturer’s recom-
mendations.
•All solvent pails used when flushing: Follow the local
code. Use only metal pails, which are conductive.
Do not place the pail on a non-conductive surface,
such as paper or cardboard, which interrupts the
grounding continuity.
•Fluid supply container: Follow the local code.
The pump is heavy and may cause injury if dropped.
Lift the pump by grasping the outlet manifold securely.
If dropped, the pump may rupture. To avoid serious
injury from splashing fluid, follow the Pressure Relief
Procedure on page 11 before moving the pump.
To reduce the risk of serious injury due to burns, insu-
late the pump before pumping hot fluids.
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
FIG. 1: Ground the pump
Y
ti17654a 9c
9b
9a
8

Installation
819.0416 7
Mounting
• Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as well
as the stress caused during operation.
• For all mountings, be sure the pump is bolted
directly to the mounting surface.
• For ease of operation and service, mount the pump
so the air valve cover, air inlet, and fluid inlet and
outlet ports are easily accessible.
Air Line
1. Install the air line accessories as shown in FIG. 2.
Mount these accessories on the wall or on a
bracket. Be sure the air line supplying the accesso-
ries is grounded.
a. Install an air regulator/filter assembly (C) and
gauge to control the fluid pressure. The fluid
outlet pressure will be the same as the setting of
the air regulator. The air line filter removes
harmful dirt and moisture from the compressed
air supply.
b. Locate one bleed-type master air valve (B)
close to the pump and use it to relieve trapped
air. See the WARNING above. Locate the other
master air valve (E) upstream from all air line
accessories and use it to isolate them during
cleaning and repair.
2. Install a grounded, flexible air hose (A) between the
accessories and the 1/4 npt(f) pump air inlet. Use a
minimum 6.3 mm (1/4 in) ID air hose. Screw an air
line quick disconnect coupler (D) onto the end of the
air hose (A), and screw the mating fitting into the
pump air inlet snugly.
Fluid Suction Line
1. Use flexible, grounded fluid hoses (F). The inlet fits
sanitary tubing of 1 to 1.5-inch OD.
2. For best sealing results, use an appropriate
tri-clamp-style or DIN-style sanitary gasket of a flex-
ible material such as EPDM or Buna-N.
3. If the fluid inlet pressure to the pump is more than
25% of the outlet working pressure, the ball check
valves will not close fast enough, resulting in ineffi-
cient pump operation. Excessive inlet fluid pressure
also will shorten diaphragm life. Approximately
0.21-0.34 bar (0.02 - 0.03 MPa, 3 - 5 psi) should be
adequate for most materials.
4. For maximum suction lift (wet and dry), see Techni-
cal Data, page 26. For best results, always install
the pump as close as possible to the material
source.
NOTICE
Pump exhaust air may contain contaminants that can
contaminate the fluid supply. Ventilate to a remote
area. See Air Exhaust Ventilation on page 10.
Trapped air can cause the pump to cycle unexpect-
edly, which could result in serious injury, including
splashing in the eyes or on the skin, injury from moving
parts, or contamination from hazardous fluids. A
bleed-type master air valve (B) is required in the sys-
tem to relieve air trapped between this valve and the
pump.
See FIG. 2, page 8.
In the step below, do not connect the quick-disconnect
coupler (D) on the air hose to the mating fitting on the
pump until you are ready to operate the pump. Con-
necting the coupler too early can result in unintentional
operation of the pump, leading to serious injury from
moving parts, splashing fluid in the eyes or on the skin,
and contact with hazardous fluids.

Installation
8 819.0416
Fluid Outlet Line 1. Use flexible grounded fluid hoses (J).
2. For best sealing results, use an appropriate stan-
dard tri-clamp-style or DIN-style sanitary gasket of a
flexible material such as EPDM or Buna-N.
3. Install a fluid drain valve (G) near the fluid outlet.
See FIG. 2.
4. Install a shutoff valve (H) in the fluid outlet line.
FIG. 2: Typical Floor-Mount Installation
A fluid drain valve (G) is required to relieve pressure in
the hose if it is plugged. The drain valve reduces the
risk of serious injury, including splashing in the eyes or
on the skin, or contamination from hazardous fluids
when relieving pressure.
ti17652a
Key:
A Air supply line
B Bleed-type master air valve
(required for pump)
C Air regulator/filter assembly
D Air line quick disconnect
E Master air valve (for accessories)
F Flexible fluid suction line
G Fluid drain valve (required)
H Fluid shutoff valve
J Flexible fluid line
Y Ground wire (required; see
page 6 for installation
instructions).
E
C
B
A
H
J
G
F
Y
D

Installation
819.0416 9
Changing the Orientation of the
Fluid Inlet and Outlet Ports
The pump is shipped with the ports facing the same
direction. To reverse the orientation of the ports:
1. Remove the clamps (12) holding the inlet and/or
outlet manifold to the covers.
NOTE: Inspect the o-rings and replace if necessary.
2. Reverse the manifold and reattach. Install and
tighten clamps snugly.
FIG. 3: Reverse the Manifolds
ti17529a
12

Installation
10 819.0416
Air Exhaust Ventilation The air exhaust port is 3/8 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
erratic pump operation.
To provide a remote exhaust:
1. Remove the muffler (P) from the pump air exhaust
port.
2. Install a grounded air exhaust hose (T) and connect
the muffler (P) to the other end of the hose. The
minimum size for the air exhaust hose is 9.5 mm
(3/8 in.) ID. If a hose longer than 4.57 m (15 ft) is
required, use a larger diameter hose. Avoid sharp
bends or kinks in the hose.
3. Place a container (U) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures. See
FIG. 4.
FIG. 4: Venting Exhaust Air
To avoid serious injury from explosion or hazardous
fluids:
• be sure the system is properly ventilated for your
type of installation.
• vent the exhaust away from people, animals, food
handling areas, and all sources of ignition
• place an appropriate container at the end of the air
exhaust line to catch fluid. If a diaphragm ruptures,
the fluid being pumped will exhaust with the air.
See FIG. 4.
Key:
A Air supply line
B Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
P Muffler
T Grounded air exhaust hose
U Container for remote air exhaust
P
U
T
D
A
B
C
E
ti17648a

Operation
819.0416 11
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Shut off the air to the pump.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve fluid pressure.
Have a container ready to catch the drainage.
Sanitize the Pump Before First
Use
It is the user’s responsibility to properly sanitize the
pump before first use. As necessary, follow the steps
under Starting and Adjusting the Pump, at right,
under Flushing on page 12, or under Disassembly in
the Service section, starting on page 16.
Starting and Adjusting the Pump
1. Be sure the pump is properly grounded. Refer to
Grounding on page 6.
2. Check connections to be sure they are tight. Tighten
fluid inlet and outlet connections securely.
3. Connect suction line (F) to material supply.
NOTE: If fluid inlet pressure to the pump is more than
25% of outlet working pressure, the ball check valves
will not close fast enough, resulting in inefficient pump
operation.
4. Place the end of fluid hose (J) into an appropriate
container.
5. Close the fluid drain valve (G).
6. Back out the air regulator (C) knob, and open all
bleed-type master air valves (B, E).
7. If the fluid hose has a dispensing device, hold it
open while continuing with the following step.
8. Slowly increase air pressure with the air regulator
(C) until the pump starts to cycle. Allow the pump to
cycle slowly until all air is pushed out of the lines
and the pump is primed.
Pump Shutdown
At the end of the work shift, follow the Pressure Relief
Procedure.
The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of serious injury
from pressurized fluid or splashing fluid, follow this
procedure whenever you stop pumping and before
cleaning, checking, or servicing equipment.
To avoid serious injury from splashing fluid, never
move or lift a pump under pressure. If dropped, the
fluid section may rupture. Always follow the Pressure
Relief Procedure before lifting the pump.

Maintenance
12 819.0416
Maintenance
Air Valve Lubrication
The air valve is designed to operate unlubricated, how-
ever if lubrication is desired, every 500 hours of opera-
tion (or monthly) remove the hose from the pump air
inlet and add two drops of machine oil to the air inlet.
Flushing
Insert suction tube into cleaning solution. Open air regu-
lator to supply low pressure air to the pump. Run the
pump long enough to thoroughly clean the pump and
hoses. Close the air regulator. Remove the suction tube
from the cleaning solution and drain pump. Place suc-
tion tube in the fluid to be pumped.
Flush the pump often enough to prevent the fluid you
are pumping from drying or freezing in the pump and
damaging it. Flushing schedule will be based on what
the pump is being used for. Use a compatible cleaning
solution and always cycle the pump during the entire
flushing process.
Always flush the pump and follow the Pressure Relief
Procedure, page 11, before storing it for any length of
time.
Tightening Connections
Before each use, check all hoses for wear or damage,
and replace as necessary. Check to be sure all connec-
tions are tight and leak-free.
Preventive Maintenance
Schedule
Establish a preventive maintenance schedule, based on
the pump’s service history. This is especially important
for prevention of spills, leakage, or food contamination
due to diaphragm failure. Inspect all diaphragms for
damage at every cleaning.
NOTICE
Do not over-lubricate the pump. Oil is exhausted
through the muffler and could contaminate your fluid
supply or other equipment. Excessive lubrication also
can cause the pump to malfunction.

Troubleshooting
819.0416 13
Troubleshooting
1. Follow the Pressure Relief Procedure, page 11.
2. Check all possible problems and causes before dis-
assembling the pump.
PROBLEM CAUSE SOLUTION
Pump will not cycle, or cycles once
and stops.
Air valve is stuck or dirty. Disassemble and clean air valve.
See page 14. Use filtered air.
Check valve ball is severely worn and
wedged in seat or manifold.
Replace ball and seat. See page 16.
Pump cycles at stall or fails to hold
pressure at stall.
Worn check valve balls, seats, or
o-rings.
Replace. See page 16.
Check valve ball wedged in seat. Repair or replace. See page 16.
Worn diaphragm shaft seals. Replace. See page 16 (standard dia-
phragms).
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking check valve balls. Clean or replace. See page 16.
Diaphragm ruptured. Replace. See page 16 (standard dia-
phragms) or page 18 (overmolded
diaphragms).
Restricted exhaust. Remove restriction.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace. See page 16 (standard dia-
phragms) or page 18 (overmolded
diaphragms).
Loose inlet manifold, damaged seal
between manifold and seat, or dam-
aged manifold o-rings.
Tighten manifold clamps, or replace
seats or o-rings. See page 16.
Loose diaphragm shaft bolt or fluid
side diaphragm plates.
Tighten or replace. See page 16
(standard diaphragms).
Fluid in exhaust air. Diaphragm ruptured. Replace. See page 16 (standard dia-
phragms) or page 18 (overmolded
diaphragms).
Loose diaphragm shaft bolt or fluid
side diaphragm plates.
Tighten. See page 16 (standard dia-
phragms).
Worn diaphragm shaft seals. Replace. See page 16 (standard dia-
phragms).
Pump exhausts air from clamps. Loose manifolds, damaged seal
between manifold and seat, or dam-
aged manifold o-rings.
Tighten manifold clamps, or replace
seats or o-rings. See page 16.
Air valve o-ring is damaged. Inspect; replace. See page 14.
Pump leaks fluid from check valves. Worn or damaged check valve o-ring. Inspect; replace. See page 16.
No fluid output, and pump cycles
rapidly.
Pump mounted incorrectly. Mount the pump in the upright posi-
tion.
Pump leaks air through the exhaust
port.
Worn air valve u-cups. Inspect; replace. See page 14.

Service
14 819.0416
Service
Air Valve
NOTE: Air Valve Repair Kit 819.0662 is available. Parts
included in the kit are marked †. Use all parts in the kit.
1. Follow the Pressure Relief Procedure, page 11.
2. Remove the air chamber cover (110) and the o-ring
(104).
3. Remove the carriage plungers (107), carriages
(108), carriage pins (109), and valve plate (114)
from the center housing (111).
4. Remove the u-cups (102) from the carriage plung-
ers (107).
5. Clean all parts and inspect them for wear or dam-
age.
NOTE: When instructed to lubricate, apply appropriate
waterproof sanitary lubricant.
6. Lubricate the lapped surface of the valve plate
(114), and install with the lapped surface facing up.
7. Lubricate and install the carriage pins (109).
8. Install the carriages (108). Make sure the carriages
engage the clip ends of the carriage pins (109).
9. Lubricate the bores of the center housing (111),
then install the u-cups (102) on the carriage plung-
ers (107), with the u-cups facing toward smaller
end.
10. Slide the carriage plungers into the bores, with the
smaller ends facing toward the center of the
center housing (111). See FIG. 5.
11. Lubricate and install the o-ring (104) on the cover
(110).
12. Screw the cover (110) into the center housing.
Torque to 9.0 to 13.6 N•m (80 to 100 in-lb.).
FIG. 5. Disassemble/Reassemble the Air Valve
110
104†
114†
108†
107†
102†
109† 108†
Apply appropriate waterproof sanitary lubricant.
2
Lips must face the smaller end of the carriage
plunger.
3
Smaller ends must face toward the center of the
center housing. Lubricate bores of center housing
before installing.
4
Torque to 9.0-13.6 N•m. (80-100 in-lb).
1
1
2
2
2
2
2
3
4
Note: The center housing may
remain assembled to the air and
fluid covers for this service.
2
2
ti17557a
111
101

Service
819.0416 15
FIG. 6: Disassemble/Reassemble the Pump
TI17530a
1
2
3
6
8
9a
9b
9c
12
13
13
13
13
14 15
16
16
20
25
20
21
23
34
31
31
12
105
Apply appropriate waterproof sanitary lubricant to the
threads and inside of clamp.
1
Torque to 7.9 N•m (70 in-lb). Do not use rotary power
tools.
2
2
1
Air side markings on diaphragm must face housing.
3
3
3
Torque to 9-10 N•m (80-90 in-lb) at 100 rpm maximum.
4
4
1
Flat side must face toward shaft.
5
5
1
1

Service
16 819.0416
Ball Check Valve
Disassembly
NOTE:
• PTFE o-rings should be replaced every time mani-
folds are removed.
1. Follow the Pressure Relief Procedure, page 11.
Disconnect all hoses.
2. Remove the pump from its mounting.
3. Remove the clamps (12) holding the outlet manifold
(2) to the fluid covers (1). See FIG. 6.
4. Remove the o-rings (13), seats (31), and balls (16).
5. Remove the clamps (12) and the inlet manifold (3).
Remove the o-rings (13), seats (31), and balls (16).
Reassembly
NOTE: When instructed to lubricate, apply appropriate
waterproof sanitary lubricant.
1. Clean all parts and inspect for wear or damage.
Replace parts as needed.
2. Reassemble in the reverse order, following all notes
in FIG. 6, page 15. Be sure the ball checks and man-
ifolds are assembled exactly as shown. The arrows
(A) on the fluid covers (1) must point toward the
outlet manifold (2).
Standard Diaphragms
NOTE: If your pump uses overmolded PTFE dia-
phragms, see page 18.
Disassembly
1. Follow the Pressure Relief Procedure, page 11.
2. Remove the manifolds and disassemble the ball
check valves as explained at left.
3. Remove the nuts (34) and the grounding strip (8),
then remove the clamps (6) holding the fluid covers
(1) to the air covers (21). Pull the fluid covers (1) off
the pump. See FIG. 6.
4. Loosen but do not remove the diaphragm shaft bolts
(14), using a 10 mm socket wrench on both bolts.
5. Unscrew one bolt from the diaphragm shaft (105)
and remove the o-ring (15), fluid side diaphragm
plate (23), diaphragm (20), backer (24) used only on
PTFE models, and air side diaphragm plate (25).
See FIG. 7.
6. Pull the other diaphragm assembly and the dia-
phragm shaft (105) out of the center housing. Hold
the shaft flats with a 19 mm open end wrench, and
remove the bolt (14) from the shaft. Disassemble
the remaining diaphragm assembly.
7. Clean all parts and replace as needed.

Service
819.0416 17
Reassembly
NOTE: When instructed to grease, apply appropriate
waterproof sanitary lubricant.
1. Install the diaphragm assembly on one end of the
shaft (105) as follows:
a. Install the o-ring (15) on the shaft bolt (14).
b. Install the fluid side diaphragm plate (23) on the
bolt so the rounded side faces the diaphragm
(20).
c. Install the diaphragm (20). Make certain the
side marked AIR SIDE faces the center hous-
ing.
d. On PTFE models only, install the backer on the
bolt. Make certain the side marked AIR SIDE
faces the center housing.
e. Install the air side diaphragm plate (25) so the
rounded side faces the diaphragm (20).
f. Screw the bolt into the shaft (105) hand tight.
2. Grease the length and ends of the diaphragm shaft
(105), and slide it through the housing.
3. Assemble the other diaphragm assembly to the
shaft as explained in step 1.
4. Hold one shaft bolt (14) with a wrench and torque
the other bolt to 9-10 N•m (80-90 in-lb) at 100 rpm
maximum.
NOTE: When you install the clamps in Step 5, orient the
center housing so the air inlet is approximately 45°
above horizontal and the muffler is approximately hori-
zontal.
5. Position the fluid covers (1) and the center housing
so the arrows (A) on the covers face the same direc-
tion. See FIG. 7. Apply appropriate, waterproof sani-
tary lubricant and install the clamps around the fluid
and air covers. Install the grounding strip on the
clamps, and torque the t-handle nuts to 7.9 N•m
(70 in-lb). Do not use rotary power tools.
6. Reassemble the ball check valves and manifolds as
explained on page 16.
FIG. 7: Standard Diaphragm
14
15
23 20
25
105
16
A
ti17650a
4
Torque to 9-10 N•m (80-90 in-lb ) at 100 rpm maximum.
4
Air side markings on diaphragm must face housing.
3
3
Apply appropriate waterproof sanitary lubricant to the
threads and inside of clamp.
1
Torque to 7.9 N•m (70 in-lb). Do not use rotary power tools.
2
1 2
Flat side must face toward shaft.
5
5
1
24 3

Service
18 819.0416
Overmolded PTFE Diaphragms
NOTE: If your pump uses standard diaphragms, see
page 16.
Disassembly
1. Follow the Pressure Relief Procedure, page 11.
2. Remove the manifolds and disassemble the ball
check valves as explained on page 16.
3. Remove the clamps (6) holding the fluid covers (1)
to the air covers (21). Pull the fluid covers (1) off the
pump. See FIG. 8.
4. Once the fluid covers are removed, the diaphragm
on the side of the pump which was last pressurized
with air will be separated from the center section/air
cover. This allows you to grip the diaphragms.
5. Diaphragms are assembled handtight. To loosen,
grip both diaphragms securely around the outer
edge and rotate counterclockwise. One diaphragm
assembly will come free and the other will remain
attached to the shaft. Remove the freed diaphragm
(20) and air side plate (25).
6. Pull the opposite diaphragm assembly and shaft
(105) out of the center housing. Hold the shaft flats
with a 19 mm open end wrench and remove the dia-
phragm and air side plate from the shaft.
7. Clean all parts and replace as needed.
Reassembly
NOTE: When instructed to grease, apply appropriate
waterproof sanitary lubricant.
1. Assemble the air side plate (25) onto the diaphragm
(20). The wide, radiused side of the plate must face
the diaphragm. Screw the assembly (diaphragm
and plate) onto the shaft (105) hand tight.
2. Grease the length and ends of the diaphragm shaft
(105). Insert the shaft/diaphragm assembly into one
side of the pump.
3. Assemble the other diaphragm assembly to the
shaft as explained in Step 1.
4. Push the assembly down on the work surface to
raise the diaphragm up and out so the edges can be
gripped. Hand tighten the second diaphragm onto
the shaft.
FIG. 8: Overmolded PTFE Diaphragm
To reduce the risk of serious injury, including amputa-
tion, do not put your fingers or hand between the air
cover and the diaphragm.
ti17651a
6
20 25
105
6
1
A
1 2
Apply appropriate waterproof sanitary lubricant to the threads
and inside of clamp.
1
Torque to 7.9 N•m (70 in-lb).
2
Flat side must face toward shaft.
3
3
1

Service
819.0416 19
NOTE: When you install the clamps in Step 5, orient the
center housing so the air inlet is approximately 45°
above horizontal and the muffler is approximately hori-
zontal.
5. Position the fluid covers (1) and the center housing
so the arrows (A) on the covers face the same direc-
tion. See FIG. 8. Apply appropriate, waterproof sani-
tary lubricant and install the clamps around the fluid
and air covers. Install the grounding strip on the
clamps, and torque the t-handle nuts to 7.9 N•m
(70 in-lb). Do not use rotary power tools.
6. Reassemble the ball check valves and manifolds as
explained on page 14.
Air Center Service
Remove air covers for easier replacement of u-cups and
to replace the poppet o-ring, if needed. See parts illus-
tration, page 20.
NOTE: When instructed to grease, apply appropriate
waterproof sanitary lubricant.
1. Follow all disassembly directions for diaphragm ser-
vice. See Standard Diaphragms, page 16, or
Overmolded PTFE Diaphragms, page 18.
2. Remove the muffler (103).
3. Use a phillip’s screwdriver to remove 6 screws (22),
and remove one air cover (21) and gasket (112).
4. Remove u-cup (102) and poppet o-ring (101).
5. Lubricate and install new u-cup (102) and poppet
o-ring (101). U-cup lips must face out of center
housing.
6. Reinstall the gasket (112) and air cover (21). Torque
screws (22) to 4-5 N•m (35-45 in-lb).
7. Repeat for other side.
8. Reinstall the muffler (103).
9. Follow all reassembly directions for diaphragm ser-
vice. See page 17 for standard diaphragms or page
18 for overmolded diaphragms.

Parts
20 819.0416
Parts
TI18040a
1
2
3
6
8
9a
9b
9c
12
13
13
13
13
14
15
16
16
20
25
20
21
23
30
34
31
31
12
105
Apply appropriate waterproof sanitary lubricant.
1
Torque to 7.9 N•m (70 in-lb ). Do not use rotary
power tools.
2
2
1
Air side markings on diaphragm must face housing.
3
3
3
Torque to 9-10 N•m (80-90 in-lb ) at 100 rpm maximum.
4
4
101
102
103
104
107
108 109
108
110
111
104
113
114 1
1
1
1
1
81
112
102 1
22
Torque to 4-5 N•m (35-45 in-lb).
5
5
Torque to 9-11 N•m (80-100 in-lb).
8
Lips must face the smaller end of the carriage plunger.
6
Smaller ends must face toward the center of the center
housing.
7
6
7
Lips must face out of center housing.
9
9
Flat side must face toward shaft.
10
10
1
Tri-clamp Model Shown