VERDER VA 50 Operation manual

819.4496
Rev. ZAL
EN
INSTRUCTIONS – PARTS LIST
For fluid transfer applications. For professional use only.
8.3 bar Maximum Fluid Working Pressure
8.3 bar Maximum Air Input Pressure
Patent No.
CN ZL941026434.4
FR 9408894
JA 35107270
US 5,368,452
*Applies only to pumps with
conductive polypropylene fluid
sections.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
*
II 2 GD
Ex h IIC 66°C...135°C Gb
Ex h IIIC T135°C Db
04613B
CONDUCTIVE POLYPROPYLENE*, POLYPROPYLENE AND PVDF
VERDERAIR VA 50
Air-Operated
Diaphragm Pumps

2 819.4496
Table of Contents
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Relief Procedure . . . . . . . . . . . . . . . . 13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Repairing the Air Valve . . . . . . . . . . . . . . . . . . . 16
Ball Check Valve Repair . . . . . . . . . . . . . . . . . . 18
Diaphragm Repair . . . . . . . . . . . . . . . . . . . . . . . 19
Bearing and Air Gasket Removal . . . . . . . . . . .23
Repair Kit Listing . . . . . . . . . . . . . . . . . . . . . . . . . . 25

819.4496 3
Configuration Number Matrix
Check the identification plate (ID) for the 15–digit Configuration Number of your pump. Use the following matrix to define
the components of yourpump.
Sample Configuration Number: VA50PA – SS TF TF FE 00
NOTE: Some combinations are not possible. Please check with your local supplier or www.verderair.com.
VA50 P A SS TF TF FE 00
Pump Model Fluid Section Air Section Seats Checks Diaphragms Connections Options
Pump Model
(1 and 2) Fluid Section Material (3) Air Section Material (4) Seats (5)
VA50 C Conductive
Polypropylene* AAluminum BN Buna–N
KPVDF SStainlessSteel HY TPE
PPolypropylene KY PVDF
PP Polypropylene
SP Santoprene
SS StainlessSteel
VT FKM
Balls
(6) Diaphragm (7) Connections (8) Options (9)
BN Buna–N BN Buna–N FE End Flange 00 Standard
GE Geolast GE Geolast RE Remote
HY TPE HY TPE
SP Santoprene SP Santoprene
TF PTFE TF PTFE/EPDM
2–Piece
VT FKM TO PTFE/EPDM
Overmolded
VT FKM
*Conductive Polypropylene is certified: II 2 GD ATEX T-code rating is dependent on the temperature of the
fluid being pumped. Fluid temperature is limited by the ma-
terials of the pump interior wetted parts. See Technical
Data for the maximum fluid operating temperature for your
specific pump model.
Ex h IIC 66°C...135°C Gb
Ex h IIIC T135°C Db

4 819.4496
Symbols
Warning Symbol Caution Symbol
Warning
This symbol alerts you to the possibility of serious injury
or death if you do not follow the instructions.
Caution
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the
instructions.
Warning
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
•This equipment is for professional use only.
•Read all instruction manuals, tags, and labels before operating theequipment.
•Use the equipment only for its intended purpose. If you are not sure, call VERDER After Sales Service.
•Do not alter or modify thisequipment.
•Check equipment daily. Repair or replace worn or damaged parts immediately.
•Do not exceed the maximum working pressure of the lowest rated component in your system. This
equipment has a 8.3 bar maximum working pressure at 8.3 bar maximum incoming air pressure.
•Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical
Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
•Do not use hoses to pull equipment.
•Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
VERDER hoses to temperatures above 82°C or below -40°C.
•Do not lift pressurized equipment.
•Wear hearing protection when operating this equipment.
•Comply with all applicable local, state, and national fire, electrical, and safety regulations.

819.4496 5
Warning
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or
swallowed.
•Know the specific hazards of the fluid you areusing.
•Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state,
and national guidelines.
•Alwayswearprotective eyewear,gloves,clothing,andrespirator asrecommendedbythe fluidandsolvent
manufacturer.
•Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas. If the
diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 12.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a
fire or explosion and seriousinjury.
•Ground the equipment. Refer to Grounding on page6.
•Never use a non–conductive polypropylene or PVDF pump in an explosive atmosphere or with non-
conductive flammable fluids as specified by your local fire protection code. Refer to Grounding on page6
for additional information. Consult your fluid supplier to determine the conductivity or resistivity of your
fluid.
•If there is any static sparking or you feel an electric shock while using this equipment, stop pumping
immediately. Do not use the equipment until you identify and correct theproblem.
•Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being
sprayed, dispensed, or transferred.
•Pipe and dispose of the exhaust air safely, away from allsources ofignition. If thediaphragm fails,the fluid
is exhausted along with the air. See Air Exhaust Ventilation on page 12.
•Keep the work area free of debris, including solvent, rags, andgasoline.
•Electrically disconnect all equipment in the work area.
•Extinguish all open flames or pilot lights in the workarea.
•Do not smoke in the work area.
•Do not turn on or off any light switch in the work area while operating or if fumes are present.
•Do not operate a gasoline engine in the workarea.

6 819.4496
Installation
General Information
1. The Typical Installation shown in FIG. 2 is only aguide
for selecting and installing systemcomponents. Contact
your VERDER Customer Service for assistance
in planning a system to suit yourneeds.
2. Always use Genuine VERDER Parts andAccessories.
Be sure all accessories are adequately sized and
pressure-rated to meet the system’srequirements.
3. Reference numbers and letters in parentheses refer to
the callouts in the figures and the parts listson pages
28–29.
4. Variations in color between the plastic componentsof
this pump are normal. Color variation does not affect the
performance of the pump.
Tightening Screws Before First Use
Before using the pump for the first time, check and retorque
all external fasteners. See Diaphragm Kits, page 29.After
the first day of operation, retorque the fasteners. Although
pump use varies, a general guideline is to retorque fasteners
every twomonths.
Grounding
The non–conductive polypropylene and PVDF pumps are
not conductive. Attaching the ground wire to the grounding
strip grounds only the airmotor.
When pumping conductive flammable fluids,always ground
the entire fluid system by making sure the fluid has an
electrical path to a true earth ground. See FIG. 1.
Never use a non–conductive polypropylene or PVDF pump
in an explosive atmosphere or with non-conductive
flammable fluids as specified by your localfire protection
code.
U.S. Code (NFPA 77 Static Electricity) recommendsa
conductivity greater than 50 x 10–12 Siemans/meter
(mhos/meter) over your operating temperature range to
reduce the hazard of fire. Consult your fluid supplier to
determine the conductivity or resistivity of yourfluid. The
resistivity must be less than 2 x 1012 ohm-centimeters.
Warning
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes cancause
serious injury or death if splashed in the
eyes or on the skin, inhaled, orswallowed.
1. Read TOXIC FLUID HAZARD on page 5.
2. Use fluids and solvents which are compatible with the
equipment wetted parts. Refer to the Technical Data
section of all equipment manuals. Read the fluid and
solvent manufacturer’s warnings.
Warning
FIRE AND EXPLOSION
HAZARD
This pump must be grounded. Before
operating the pump, ground the system
as explained below. Also, read the
section FIRE AND EXPLOSION
HAZARD, on page 5.

819.4496 7
Installation
Grounding (continued)
To reduce the risk of static sparking, ground the pump and
all other equipment used or located in the pumping area.
Check your local electrical code for detailed grounding
instructions for your area and type of equipment.
Ground all of this equipment:
•Air Motor: Connect a ground wire and clamp as shown
in FIG. 1. Loosen the grounding screw (W). Insert one
end of a 1.5 mm2minimum ground wire (Y) behind the
grounding screw and tighten the screw securely.
Connect the clamp end of the ground wire to a true
earth ground. Order Part No. 819.0157 Ground Wire
and Clamp.
NOTE: When pumping conductive flammable fluids with a
non–conductive polypropylene or a PVDF pump,
always ground the entire fluid system. See the
Warning on page 6.
•Air and Fluid hoses: Use only electrically conductive
hoses.
•Air compressor: Follow the manufacturer’s
recommendations.
•All solvent pails used when flushing, according to 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 local code.
FIG. 1 ________________________
02646B
Y
W

8 819.4496
Installation
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 accessories is electrically
conductive.
a. Install an air regulator (C) and gauge to control
the fluid pressure. The fluid outlet pressure will be
the same as the setting of the air regulator.
b. Locate one bleed-type master air valve (B) close
to the pump and use it to relieve trapped air. See
the Warning at left. Locate the other master air
valve (E) upstream from all air line accessories
and use it to isolate them during cleaning and
repair.
c. The air line filter (F) removes harmful dirt and
moisture from the compressed air supply.
2. Install an electrically conductive, flexible air hose(A)
between the accessories and the 1/2 npt(f) pumpair
inlet (N). See FIG. 2. Use a minimum 13 mm ID air hose.
3. Screw an air line quick disconnect coupler (D) onto the
end of the air hose (A); be sure the coupler porting is
large enough to not restrict the air flow, which will affect
pump performance. Screw the mating fitting intothe
pump air inlet snugly. Do not connect the coupler (D) to
the fitting until you are ready to operate the pump.
FLOOR MOUNT TYPICAL INSTALLATION
FIG. 2 _______________________________________________________________________
Warning
A bleed-type master air valve (B) is required in your system
to relieve air trapped between this valve and the pump.
Trapped air can cause the pump to cycleunexpectedly,
which could result in serious injury, including splashing in
the eyes or on the skin, injury from moving parts, or
contamination from hazardous fluids. See FIG. 2.
YJ
FEB C
A
D
KL
G
H
R
S
N
04614B
KEY
A ElectricallyConductiveAirSupplyHose
B Bleed-Type Master Air Valve
(requiredforpump)
C AirRegulator
D Air Line QuickDisconnect
E Master Air Valve (foraccessories)
F Air Line Filter
G Fluid Suction Hose
HFluidSupply
J FluidDrainValve(required)
K Fluid Shutoff Valve
L FluidHose
N 1/2npt(f)Air Inlet Port
R 2 in. Fluid InletFlange
S 2 in. Fluid OutletFlange
Y GroundWire(required;seepage7 for
installationinstructions)

819.4496 9
Installation
Mountings
1. Be sure the mounting surface can support the weight of
the pump, hoses, and accessories, as well as the stress
caused during operation.
2. For all mountings, be sure the pump is bolted directly to
the mounting surface.
3. For ease of operation and service, mount the pump so
the air valve cover (2), air inlet, and fluid inlet and outlet
ports are easily accessible.
4. Rubber Foot Mounting Kit 819.4333 is available to
reduce noise and pump movement duringoperation.
5. Prolonged exposure to UV radiation will degrade natural
polypropylene components of the pumps. To prevent
potential injury or equipment damage, do not expose
pump or the plastic components to direct sunlight for
prolonged periods.
Fluid Suction Line
1. The pump fluid inlet (R) is a 2 in. raised face flange.
Refer to Flange Connections on page10.
2. Ifthe fluidinlet pressuretothe pumpis morethan 25%of
theoutlet workingpressure, theball checkvalveswill not
close fast enough, resulting in inefficient pump
operation.
3. At inlet fluid pressures greater than 1.05 bar, diaphragm
life will be shortened.
4. See the Technical Data on page 33 for maximum
suction lift (wet and dry).
Fluid Outlet Line
1. The pump fluid outlet (S) is a 2 in. raised face flange.
Refer to Flange Connections on page10.
2. Install a fluid drain valve (J) near the fluid outlet. See the
Warning above.
3. Install a shutoff valve (K) in the fluid outletline.
Caution
The pump exhaust air may contain contaminants. Ventilate
to a remote area if the contaminants could affect your fluid
supply. See Air Exhaust Ventilation on page 12.
Warning
A fluid drain valve (J) 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. Install the valve close to the pump
fluid outlet. See FIG. 2.

10 819.4496
Installation
Flange Connections
The fluid inlet and outlet ports are 2 in. raised face, standard
150 lb class pipe flanges. Connect 2 in. flanged plastic pipe
to the pump as follows. You will need:
•torque wrench
•adjustable wrench
•a 6 in. diameter, 1/8 in. thick PTFE gasket, with four 0.75 in.
diameter holes on a 4.75 in. diameter bolt circle, and a
2.20 in. diametercenter
•four 5/8 in. x 3 in.bolts
•four 5/8 in. spring lockwashers
•eight 5/8 in. flat washers
•four 5/8 in. nuts.
1. Place a flat washer (E) on each bolt (C). Refer to FIG. 3.
2. Align the holes in the gasket (B) and the pipe flange (A)
with the holes in the pump outlet flange(S).
3. Lubricate the threads of the four bolts. Install the bolts
through the holes and secure with the washers (E),
lockwashers (D), and nuts (F).
4. Hold the nuts with a wrench. Refer to the tightening
sequence in FIG. 3 and torque the bolts to 27–41 N•m.
Do not over-torque.
5. Repeat for the pump inlet flange(R).
BOLT TIGHTENING SEQUENCE
FIG. 3 _______________________________________________________________________
1
04405
F
E
S
B
A
E
D
C
R
1
2
3
4
1
04615B
KEY
A FlangedPlasticPipe
B PTFEGasket
C Bolt
D Lockwasher
E Flat Washer
F Nut
R 2 in. Fluid Inlet Flange
S 2 in. Fluid Outlet Flange
Lubricate threads. Torque to 27–41 N•m. Do
not over-torque.
1

819.4496 11
Installation
Changing the Orientation of the Fluid Inlet and Outlet
Ports
The pump is shipped with the fluid inlet (R) and outlet (S)
ports facing the same direction. See FIG. 4. To change the
orientation of the inlet and/or outlet port:
1. Remove the screws and washers (106, 112, 113, and
114) holding the inlet (102) and/or outlet (103) manifold
to the covers (101).
2. Reverse the manifold and reattach. Install the screws
and torque to 17–18 N•m. See Diaphragm Kits, page
29.
Torque to 17–18 N•m. See
Diaphragm Kits, page 29.
FIG. 4 ________________________
Fluid Pressure Relief Valve
KEY
R 2 in. Fluid Inlet Flange
S 2 in. Fluid Outlet Flange
V Pressure ReliefValve
PartNo.819.0159(StainlessSteel)
Install valve between fluid inlet and outlet ports.
Connect fluid inlet line here.
Connect fluid outlet line here.
FIG. 5 ________________________
KEY
N 1/2npt(f)AirInletPort
P Muffler; Air Exhaust
Port is 3/4 npt(f)
R 2 in. Fluid Inlet Flange
S 2 in. Fluid Outlet
Flange
101 Fluid Covers
102 Fluid Inlet Manifold
103 Fluid OutletManifold
106 Fluid Outlet Manifold
Screws (Top)
112 Fluid Inlet Manifold
Screws (Bottom)
113 FluidOutletManifold
Washers
114 Fluid Inlet Manifold
Washers
1
04613B
N
P
R
S
1
103
102
101
1
106
112
113
114
Caution
Some systems may require installation of a pressure relief
valve at the pump outlet to prevent overpressurization and
rupture of the pump or hose. See FIG. 5.
Thermal expansion of fluid in the outlet line can cause
overpressurization. This can occur when using long fluid
lines exposed to sunlight or ambient heat, or when
pumping from a cool to a warm area (for example, from an
underground tank).
Overpressurization can also occur if the VERDERAIR
pump is being used to feed fluid to a piston pump, and the
intake valve of the piston pump does not close, causing
fluid to back up in the outlet line.
1
2
3
R
S
1
2
V
3
04616B

12 819.4496
Installation
Air Exhaust Ventilation
Diaphragm failure will cause the fluid being pumped to
exhaust with the air. Place an appropriate container at the
end of the air exhaust line to catch the fluid. See FIG. 6.
The air exhaust port is 3/4 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
erratic pump operation.
If the muffler (P) is installed directly to the air exhaust port,
apply PTFE thread tape or anti–seize lubricant to the muffler
threads before assembly.
To provide a remote exhaust:
1. Remove the muffler (P) from the pump air exhaust port.
2. Install an electrically conductive 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 19 mm ID.
If a hose longer than 4.57 m is required, use a larger
diameter hose. Avoid sharp bends or kinks in the hose.
See FIG. 6.
3. Place a container (U) at the end of the air exhaust line to
catch fluid in case a diaphragm ruptures.
VENTING EXHAUST AIR
FIG. 6 _______________________________________________________________________
Warning
FIRE AND EXPLOSION
HAZARD
Be sure to read and follow the warnings
and precautions regarding TOXIC FLUID
HAZARD, and FIRE AND EXPLOSION
HAZARD on page 5, before operating
this pump.
Be sure the system is properly ventilated
for your type of installation. You must
vent the exhaust to a safe place, away
from people, animals, food handling
areas, and all sources of ignition when
pumping flammable or hazardous fluids.
04617
FBEC
A
D
P
TU
KEY
A Air SupplyLine
B Bleed-Type Master Air Valve
(required forpump)
C Air Regulator
D Air Line QuickDisconnect
E Master Air Valve (foraccessories)
F Air Line Filter
P Muffler
T ElectricallyConductiveAirExhaustHose
U ContainerforRemoteAirExhaust

819.4496 13
Operation
Pressure Relief Procedure
•Are instructed to relieve pressure,
•Stop pumping,
•Check, clean or service any systemequipment,
•Install or clean fluid nozzles.
1. Shut off the air to the pump.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve all fluid pressure,
having a container ready to catch thedrainage.
Flush the Pump Before First Use
The pump was tested in water. If water could contaminate
the fluid you are pumping, flush it thoroughly with a
compatible solvent. Follow the steps under Starting and
Adjusting the Pump.
Starting and Adjusting the Pump
1. Be sure the pump is properly grounded. Referto
Grounding on page6.
2. Check all fittings to be sure they are tight. Be sure to use
a compatible liquid thread sealant on all malethreads.
Tighten the fluid inlet and outlet fittingssecurely.
3. Place the suction tube (if used) in the fluid to be pumped.
NOTE: 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
inefficient pump operation.
4. Place the end of the fluid hose (L) into an appropriate
container.
5. Close the fluid drain valve (J). See FIG. 2.
6. With the pump air regulator (C) closed, 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 followingstep.
8. Slowly open 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 isprimed.
If you are flushing, run the pump long enough to
thoroughly clean the pump and hoses. Close the air
regulator. Remove the suction tube from the solvent and
place it in the fluid to be pumped.
Pump Shutdown
At the end of the work shift, relieve the pressure.
Warning
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of serious injury from
pressurized fluid, accidental spray from the gun or
splashing fluid, follow this procedure whenever you:
Warning
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause
serious injury or death if splashed in the
eyes or on the skin, inhaled, or swallowed.
Do not lift a pump under pressure. If
dropped, the fluid section may rupture.
Always follow the Pressure Relief
Procedure above before lifting the pump.
Warning
Toreduce the risk of serious injury whenever youare
instructed to relieve pressure, always follow the
Pressure Relief Procedure atleft.

14 819.4496
Maintenance
Lubrication
The air valve is designed to operate unlubricated. However,
if lubrication is desired, every 500 hours of operation (or
monthly) remove the hose from the pump air inlet and add
two drops of machine oil to the air inlet.
Flushing and Storage
Flush the pump often enough to prevent the fluid you are
pumping from drying or freezing in the pump and damaging
it. Flush with a fluid that is compatible with the fluid you are
pumping and with the wetted parts in your system. Check
with your fluid manufacturer or supplier for recommended
flushing fluids and flushing frequency.
Always flush the pump and relieve the pressure before
storing it for any length of time.
Tightening Threaded Connections
Before each use, check all hoses for wear or damage, and
replace as necessary. Check to be sure all threaded
connections are tight and leak-free. Check fasteners.
Tighten or retorque as necessary. Although pump use
varies, ageneral guideline is to retorque fasteners every two
months. See Diaphragm Kits, page 29.
Preventive Maintenance Schedule
Establish a preventive maintenance schedule, based on the
pump’s service history. This is especially important for
prevention of spills or leakage due to diaphragm failure.
Caution
Do not over-lubricate the pump. Oil is exhausted through the
muffler, which could contaminate your fluid supply or other
equipment. Excessive lubrication can also cause the pump
to malfunction.
Warning
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pressure
Relief Procedure on page 13.

819.4496 15
Troubleshooting
1. Relieve the pressure before checking or servicing the
equipment.
2. Check all possible problems and causes before
disassembling the pump.
Warning
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pressure
Relief Procedure on page 13.
PROBLEM CAUSE SOLUTION
Pump cycles at stall or fails to hold
pressure atstall. Worn check valve balls(301), seats (201) or o-rings(202). Replace. See page18.
Pump will not cycle, or cycles onceand
stops. Air valve is stuck ordirty. Disassemble and clean air valve.See pages 16–17. Use filteredair.
Check valve ball (301) severelyworn
and wedged in seat (201) ormanifold
(102 or103).
Replace ball and seat. See page18.
Check valve ball (301) is wedgedinto
seat (201), due tooverpressurization. Install Pressure Relief Valve(see page 11).
Dispensing valve clogged. Relieve pressure and clearvalve.
Pump operates erratically. Clogged suctionline. Inspect; clear.
Sticky or leaking balls(301). Clean or replace. See page18.
Diaphragmruptured. Replace. See pages 19–22.
Restrictedexhaust. Removerestriction.
Air bubbles influid. Diaphragmruptured. Replace. See pages 19–22.
Loose inlet manifold (102),damaged
seal between manifold and seat(201),
damaged o-rings(202).
Tighten manifold bolts (112) orreplace
seats (201) or o-rings (202).See page
18.
Loose fluid side diaphragm plate(105). Tighten or replace. See pages19–22.
Fluid in exhaustair. Diaphragmruptured. Replace. See pages 19–22.
Loose fluid side diaphragm plate(105). Tighten or replace. See pages19–22.
Pump exhausts excessive air atstall. Worn air valve block (7), o-ring (6),plate
(8), pilot block (18), u-cups (10), or pilot
pin o-rings(17).
Inspect; replace. See pages16–17.
Worn shaft seals (402). Replace. See pages 19–22.
Pump leaks air externally. Air valve cover (2) or air valve cover
screws (3) areloose. Tighten screws. See page17.
Air valve gasket (4) or air covergas- ket
(22) isdamaged. Inspect; replace.See pages 16–17, 23– 24.
Air cover screws (25) areloose. Tighten screws. See pages23–24.
Pump leaks fluid externally fromball
check valves. Loose manifolds (102, 103),damaged seal between manifold and seat(201),
damaged o-rings(202).
Tighten manifold bolts (106 and 112)or
replace seats (201) or o-rings (202).See
page 18.

16 819.4496
Service
Repairing the Air Valve
Tools Required
•Torque wrench
•Torx (T20) screwdriver or 7 mm socket wrench
•Needle-nose pliers
•O-ring pick
•Lithium base grease
NOTE: Air Valve Repair Kits 819.4274 (aluminum center
housing models) and 819.0249 (stainless steel
center housing models) are available. Refer to page
28. Parts included in the kit are marked with a
symbol, for example (4†). Use all the parts in the kit
for the best results.
Disassembly
1. Relieve the pressure.
2. With a Torx (T20) screwdriver or 7 mm socket wrench,
remove the six screws (3), air valve cover (2), and
gasket (4). See FIG. 7.
3. Move the valve carriage (5) to the center positionand
pull it out of the cavity. Remove the valve block (7)and
o-ring (6) from the carriage. Using a needle-nose pliers,
pull the pilot block (18) straight up and out of the cavity.
See FIG. 8.
4. Pull the two actuator pistons (11) out of thebearings
(12). Remove the u-cup packings (10) from the pistons.
Pull the pilot pins (16) out of the bearings (15). Remove
the o-rings (17) from the pilot pins. See FIG. 9.
5. Inspect the valve plate (8) in place. If damaged, use a
Torx (T20) screwdriver or 7 mm socket wrench to
remove the three screws (3). Remove the valve plate (8)
and, on aluminum center housing models, remove the
seal (9). See FIG. 10.
6. Inspect the bearings (12, 15) in place. See FIG. 9.The
bearings are tapered and, if damaged, must be removed
from the outside. This requires disassembly of the fluid
section. See page 23.
7. Clean all parts and inspect for wear or damage. Replace
as needed. Reassemble as explained on page 17.
FIG. 7 ________________________
FIG. 8 ________________________
Warning
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pressure
Relief Procedure on page 13.
3
2
4
2
04618B
Torque to 5.6–6.8 N•m.
2
18
5
1
7
6
5
2
3
3
11
16 04900B
See Detail at right.
Grease.
Grease lower face.
1
2
3

819.4496 17
Service
FIG. 9 _______________________
FIG. 10 _______________________
Reassembly
1. Ifyou removed thebearings (12,15), install new ones as
explained on page 23. Reassemble the fluidsection.
2. On aluminum center housing models, install the valve
plate seal (9†) into the groove at the bottom of the valve
cavity. The rounded side of the seal must face down
into the groove. See FIG. 10.
3. Install the valve plate (8) in the cavity. On aluminum
center housing models, the plate is reversible, so either
side can face up. Install the three screws (3), using a
Torx (T20) screwdriver or 7 mm socket wrench. Tighten
until the screws bottom out on the housing. See FIG. 10.
4. Install an o-ring (17†) on each pilot pin (16). Grease the
pins and o-rings. Insert the pins into the bearings (15),
narrow end first. See FIG. 9.
5. Install a u-cup packing (10†) on each actuator piston (11),
so the lips of the packings face the narrow end of the
pistons. See FIG. 9.
6. Lubricate the u-cup packings (10†) and actuator pistons
(11). Insert the actuator pistons in the bearings (12),
wide end first. Leave the narrow end of the pistons
exposed. See FIG. 9.
7. Grease the lower face of the pilot block (18†) and install
so its tabs snap into the grooves on the ends of the pilot
pins (16). See FIG. 8.
8. Grease the o-ring (6†) and install it in the valve block (7†).
Push the block onto the valve carriage (5). Grease the
lower face of the valve block. See FIG. 8.
9. Install the valve carriage (5) so its tabs slip into the
grooves on the narrow end of the actuator pistons (11).
See FIG. 8.
10. Align the valve gasket (4†) and cover (2) with the six
holes in the center housing (1). Secure with six screws
(3), using a Torx (T20) screwdriver or 7 mmsock- et
wrench. Torque to 5.6–6.8 N•m. See FIG. 7.
Insert narrow end first.
Grease.
Install with lips facing
narrow end of piston (11).
Insert wide end first.
1
2
3
4
17 16
11
10
12
15 1
2
3
4
2
04901B
03947
8
9
3
1
2
Rounded side must face
down.
Tighten screws until they
bottom out on the housing.
1
2

18 819.4496
Service
Ball Check Valve Repair
Tools Required
•Torque wrench
•10 mm socket wrench
•O-ring pick
Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to page
25 to order the correct kit for your pump. Parts
included in the kit are marked with an asterisk, for
example (201*).Use allthe partsin thekit forthe best
results.
NOTE: Toensure proper seating of the balls (301), always
replace the seats (201) when replacing the balls.
1. Relieve the pressure. Disconnect all hoses.
2. Remove the pump from its mounting.
3. Using a 10 mm socket wrench, remove theeight bolts
(106) and four washers (113), holding theoutlet manifold
(103) to the fluid covers (101). See FIG. 11.
4. Remove the seats (201), balls (301), and o-rings (202)
from the manifold.
NOTE: Some models do not use o-rings (202).
5. Turn the pump over and remove the bolts (112),
washers (114), and inlet manifold (102). Remove the
seats (201), balls (301), and o-rings (202) from the fluid
covers (101).
Reassembly
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. 11. Be sure the ball checks are assembled exactly
as shown. The arrows (A) on the fluid covers (101)
must point toward the outlet manifold (103).
Torque to 17–18 N•m. See Diaphragm Kits, page 29.
Arrow (A) must point toward outlet manifold (103).
Not used on some models.
FIG. 11 _______________________
Warning
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pressure
Relief Procedure on page 13.
1
2
3
106
103
101
A
201*
301*
112
102
201*
301*
2
1
1
202*
202*
3
3
04619C
113
114

819.4496 19
Service
Diaphragm Repair
Tools Required
•Torque wrench
•13 mm socket wrench
•Adjustable wrench
•19 mm open–end wrench
•O-ring pick
•Lithium-base grease
Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to page
25 to order the correct kit for your pump. Parts
included in the kit are marked with an asterisk, for
example (401*). Use all the parts in the kit for the
best results.
1. Relieve the pressure.
2. Remove the manifolds and disassemble the ball check
valves as explained on page 18.
3. Using 13 mm socket wrenches, removethe screws (107
and 108) holding the fluid covers (101) to the air covers
(23). Pull the fluid covers (101) off the pump. See FIG.
12.
FIG. 12 ___________________________________________________
Warning
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pressure
Relief Procedure on page 13.
23
101
A2
B
1
107
108 1
04620B
You must torque the eight long screws (108) first, then
the short screws (107). Torque to 22–25 N•m. See
Diaphragm Kits, page 29.
Arrow (A) must point toward air valve (B).
1
2

20 819.4496
Service
4. Unscrew one outer plate (105) from thediaphragm shaft
(24). Remove one diaphragm (401), and the inner plate
(104). See FIG. 13.
For overmolded diaphragms: Grip both diaphragms
securely around the outer edge and rotate
counterclockwise. One diaphragm assembly will come
free andthe other will remain attached to the shaft.
Remove the freed diaphragm and air sideplate.
NOTE: Two–piece PTFE models include a PTFEdiaphragm
(403) in addition to the backup diaphragm (401).
5. Pull the other diaphragm assembly and the diaphragm
shaft (24) out of the center housing (1). Hold the shaft
flats with a 19 mm open–end wrench, and remove the
outer plate (105) from the shaft. Disassemble the
remaining diaphragm assembly.
For overmolded diaphragms: Pull the otherdiaphragm
assembly and the diaphragm shaft (24) out of the center
housing (1). Hold the shaft flats with a 19 mm open-end
wrench and remove the diaphragm and air sideplate
from theshaft.
6. Inspectthe diaphragmshaft (24)forwear orscratches. If
it is damaged, inspect the bearings (19) in place. If the
bearings are damaged, refer to page 23.
7. Reach into the center housing (1) with an o-ring pick and
hook the u-cup packings (402), then pull them out of the
housing. This can be done with the bearings (19)in
place.
8. Clean all parts and inspect for wear or damage. Replace
parts as needed.
Reassembly – Standard Diaphragms
1. Grease the shaft u-cup packings (402*) and install them
so the lips face out of the housing (1). See FIG. 13.
2. Grease the length and ends of the diaphragm shaft (24)
and slide it through the housing (1).
3. Assemble the inner diaphragm plates (104),diaphragms
(401*), PTFE diaphragms (403*, if present), and outer
diaphragm plates (105) exactly as shownin FIG. 13.
These parts must be assembledcorrectly.
4. Apply medium-strength (blue) Loctite® or equivalentto
the threads of the fluid-side plates (105). Hold one of the
outer plates (105) with a wrench and torque the other
outer plate to 27 to 34 N•m at 100 rpm maximum. Do not
over-torque.
5. Alignthe fluid covers(101) and the center housing(1) so
the arrows (A) on the covers face the same direction as
the air valve (B). Secure the covers with the screws (107
and 108), handtight. Install the longer screws (108) in
the top and bottom holes of the covers. See FIG. 12.
6. First, torque the longer screws (108) oppositelyand
evenly to 22–25 N•m, using a 13 mm socketwrench.
Then torque the shorter screws (107). See Diaphragm
Kits, page 29.
7. Reassemble the ball check valves and manifolds as
explained on page 18.