VERDER VERDERAIR VA 25 User manual

Repair/Parts
VERDERAIR VA 25
Air-Operated
Diaphragm Pump
859.0089
Rev. M
EN
1-inch pump with modular air valve for fluid transfer applications.
For professional use only.
See page 3 for model information, including approvals.
125 psi (0.86 MPa, 8.6 bar) Maximum Fluid Working Pressure
125 psi (0.86 MPa, 8.6 bar) Maximum Air Input Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Stainless Steel
ti14342a
Aluminum
ti13946a
ti13844a
ti13843a
End
Flange
Center
Flange
Polypropylene
Conductive
Polypropylene
PVDF

2 859.0089
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ATEX Certifications . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 9
Repair or Replace Air Valve . . . . . . . . . . . . . . . . 9
Check Valve Repair . . . . . . . . . . . . . . . . . . . . . 12
Diaphragms and Center Section . . . . . . . . . . . 13
Torque Instructions . . . . . . . . . . . . . . . . . . . . . . 16
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parts/Kits Quick Reference . . . . . . . . . . . . . . . . 18
Fluid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Air Valve and Data Monitoring . . . . . . . . . . . . . 24
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check Balls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Diaphragms . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Seat, Check Ball, and Diaphragm Kits . . . . . . . 29
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Customer Services/Guarantee . . . . . . . . . . . . . . . 35
Related Manuals
Manual Description
859.0088 VERDERAIR VA 25 Air-Operated Diaphragm Pump, Operation
859.0101 Torque Instructions (Manifolds and Fluid Covers)

859.0089 3
Pump Matrix
Check the identification plate (ID) for the 17-digit Configuration Number of
your pump. Use the following matrix to define the components of your
pump.
Sample Configuration Number: VA25AA-SSBNBNTNSS
NOTE: Some combinations are not possible. Please check with your local supplier
or the pump configurator on www.verderair.com.
VA25 A A SS BN BN TN SS
Pump
Model
Fluid
Section
Air
Section
Seats Balls Diaphragms Connections Options
CONFIGURATION NO.PART NO. SERIAL NO.
SERIESDATE CODE MAX WPR PSI-bar MADEIN
Pump ID
Pump
Model
Fluid Section
Material Air Section Material
Check Valve Material
Check Valve Balls
VA25 AAluminum★AAluminum AC Acetal AC Acetal
CConductive
Polypropylene★CConductive Polypropylene
AL Aluminum BN Buna-N
KPVDF PPolypropylene BN Buna-N GE Geolast
PPolypropylene GE Geolast®HY TPE
SStainless Steel★HY TPE NE Polychloroprene
Standard
KY PVDF NW Polychloroprene
Weighted
PP Polypropylene SP Santoprene
SP Santoprene®SS 316 Stainless Steel
SS 316 Stainless Steel TF PTFE
VT FKM Fluoroelastomer VT FKM Fluoroelastomer
★See ATEX Certifications, page 4.
Diaphragm Connections Options
BN Buna-N FC Center Flange, DIN/ANSI 00 Standard
GE Geolast FE End Flange, DIN/ANSI RE Remote
HY TPE TB Threaded BSP SS Stroke Sensor ✖
NO Polychloroprene Overmolded TN Threaded NPT UL UL-Listed
SP Santoprene ✖See ATEX Certifications, page 4.
TF PTFE/EPDM Two-Piece
TO PTFE/EPDM Overmolded
VT FKM Fluoroelastomer
ti14103a

4 859.0089
ATEX Certifications
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 symbol refers to procedure-specific risk. When
these symbols appear in the body of this manual, refer back to these Warnings. Additional, product-specific warnings
may be found throughout the body of this manual where applicable.
★All VA25AA, VA25CC, VA25SA, and VA25SC
pumps are certified:
II 2 GD c IIC T4
II 1 G
EEx ia IIA T3
Nemko06ATEX1124
✖Stroke Sensor is certified:
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.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable
materials and gases. To help prevent fire and explosion:
• Clean plastic parts in a well ventilated area.
• Do not clean with a dry cloth.
• Do not operate electrostatic guns in equipment work area.

859.0089 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 in this manual when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• 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.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop spraying 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.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to
the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or prop-
erty damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Use only compatible water-based solvents to clean plastic structural or pressure-containing parts. Many
solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property
damage. See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent
manufacturer’s warnings.
WARNING

6 859.0089
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 with air.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear impervious gloves when spraying or cleaning equipment.
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.
• Wait until equipment/fluid has cooled completely.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Protective eyewear, gloves, and hearing protection.
WARNING

859.0089 7
Troubleshooting
Problem Cause Solution
Pump cycles but will not prime. Pump is running too fast, causing
cavitation before prime.
Lower air inlet pressure.
Check valve ball severely worn or
wedged in seat or manifold.
Replace ball and seat. See page 12.
Seat severely worn. Replace ball and seat. See page 12.
Outlet or inlet clogged. Unclog.
Inlet or outlet valve closed. Open.
Inlet fittings or manifolds loose. Tighten.
Manifold o-rings damaged. Replace o-rings. See page 12.
Pump cycles at stall or fails to hold
pressure at stall.
Worn check valve balls, seats, or
o-rings.
Replace. See page 26.
Pump will not cycle, or cycles once
and stops.
Air valve is stuck or dirty. Disassemble and clean air valve.
See page 10. Use filtered air.
Check valve ball severely worn and
wedged in seat or manifold.
Replace ball and seat. See page 12.
Pilot valve worn, damaged, or
plugged.
Replace pilot valve. See page 13.
Air valve gasket damaged. Replace gasket. See page 9.
Check valve ball is wedged into seat
due to overpressurization.
Install pressure relief kit. See Acces-
sories, page 31.
Dispensing valve clogged. Relieve pressure and clear valve.
Air tubing is plugged
(remote air control models).
Clear tube.
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking check valve balls. Clean or replace. See page 12.
Diaphragm (and backup) ruptured. Replace. See page 13.
Restricted exhaust. Remove restriction.
Pilot valves damaged or worn. Replace pilot valves. See page 13.
Air valve damaged. Replace air valve. See page 9.
Air valve gasket damaged. Replace air valve gasket. See
page 9.
Air supply erratic. Repair air supply.
Exhaust muffler icing. Use drier air supply.

8 859.0089
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm (and backup) ruptured. Replace. See page 13.
Loose manifolds, damaged seats or
manifold o-rings.
Tighten manifold bolts or replace
seats or o-rings. See page 12.
Diaphragm shaft bolt o-ring dam-
aged.
Replace o-ring.
Pump cavitation. Reduce pump speed or suction lift.
Loose diaphragm shaft bolt. Tighten.
Exhaust air contains fluid being
pumped.
Diaphragm (and backup) ruptured. Replace. See page 13.
Loose diaphragm shaft bolt. Tighten or replace. See page 13.
Diaphragm shaft bolt o-ring dam-
aged.
Replace o-ring. See page 13.
Moisture in exhaust air. High inlet air humidity. Use drier air supply.
Pump exhausts excessive air at stall. Worn air valve cup or plate. Replace cup and plate. See page 10.
Damaged air valve gasket. Replace gasket. See page 9.
Damaged pilot valve. Replace pilot valves. See page 13.
Worn shaft seals or bearings. Replace shaft seals or bearings. See
page 13.
Air tubing is damaged or loose
(remote air control models).
Replace tubing or secure connection.
Remote air pressure is higher than
pump air pressure (remote air control
models).
Regulate remote pilot air pressure to
be equal to or less than main air.
Pump leaks air externally. Air valve or fluid cover screws loose. Tighten.
Diaphragm damaged. Replace diaphragm. See page 13.
Air valve gasket damaged. Replace gasket. See page 9.
Remote air pressure is higher than
pump air pressure (remote air control
models).
Regulate remote pilot air pressure to
be equal to or less than main air.
Pump leaks fluid externally from
joints.
Loose manifold screws or fluid cover
screws.
Tighten manifold screws or fluid
cover screws. See page 16.
Manifold o-rings worn out. Replace o-rings. See page 12.
Pump leaks fluid externally through
manifold or fluid cover.
Excessive pump speed or inlet
starvation.
Replace manifold and reduce pump
speed or improve pump feed.
Problem Cause Solution

859.0089 9
Repair
Pressure Relief Procedure
1. Shut off the air supply 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.
Repair or Replace Air Valve
Replace Complete Air Valve
1. Stop the pump. Relieve the pressure. See Pressure
Relief Procedure in previous section.
2. Disconnect the air line to the motor.
3. For motors with reed switch: Remove screw to dis-
connect the reed switch assembly from the air valve.
4. Remove screws (109, metal pumps) or nuts (112,
plastic pumps). Remove the air valve and gasket
(108).
5. To repair the air valve, go to Disassemble the Air
Valve, step 1, in next section. To install a replace-
ment air valve, continue with Step 6.
6. Align the new air valve gasket (108) on the center
housing, then attach the air valve. See Torque
Instructions, page 16.
7. For motors with reed switch: Use screw to attach
the reed switch assembly to the new air valve.
Reconnect cable.
8. Reconnect the air line to the motor.
Trapped air can cause the pump to cycle unexpect-
edly, which could result in serious injury from splash-
ing.
FIG. 1. Reed switch assembly and air line removal
ti14094a

10 859.0089
Replace Seals or Rebuild Air Valve
NOTE: Repair kits are available. See page 25 to order
the correct kit(s) for your pump. Air Valve Seal Kit parts
are marked with a †. Air Valve Repair Kit parts are
marked with a ◆. Air Valve End Cap Kit parts are
marked with a ✠.
Disassemble the Air Valve
1. Perform steps 1-5 under Replace Complete Air
Valve, page 9.
2. See FIG. 3. Use a Torx screwdriver (T8 for alumi-
num centers, T9 for plastic centers) to remove two
screws (209). Remove the valve plate (205),
cup assembly (212-214), spring (211), and detent
assembly (203).
3. Pull the cup (213) off of the base (212). Remove the
o-ring (214) from the cup.
4. See FIG. 3. Remove the retaining ring (210) from
each end of the air valve. Use the piston (202) to
push the end caps (207, 217) out of the ends.
Remove end cap o-rings (206).
5. Remove the u-cup seals (208) from each end of the
piston (202), then remove the piston. Remove the
detent cam (204) from the air valve housing (201).
Reassemble the Air Valve
NOTE: Apply lithium-based grease whenever instructed
to grease.
1. Use all parts in the repair kits. Clean other parts and
inspect for damage. Replace as needed.
2. Grease the detent cam (204) and install into hous-
ing (201).
3. Grease the u-cups (208) and install on the piston
with lips facing toward the center of the piston.
4. Grease both ends of the piston (202) and install it in
the housing (201), with the flat side toward the cup
(212). Be careful not to tear u-cups (208) when slid-
ing piston into housing.
5. Grease new o-rings (206) and install on the end
caps (207). Install the end caps into the housing.
6. Install a retaining ring (210) on each end to hold end
caps in place.
FIG. 2. Air valve u-cup installation
Lips face down
Lips face up
208◆†
208◆†
202◆
ti12754a

859.0089 11
7. Grease and install the detent assembly (203) into the
piston. Install the o-ring (214) on the cup (213). Apply
a light film of grease to the outside surface of the
o-ring and the inside mating surface of the base
(212).
Orient the end of the base that has a magnet toward
the end of the cup that has the larger cutout. Engage
the opposite end of the parts. Leave the end with the
magnet free. Tilt the base toward the cup and fully
engage the parts, using care so that the o-ring
remains in place. Install the spring (211) onto the pro-
trusion on the cup. Align the magnet in the base with
the air inlet and install the cup assembly.
8. Grease the cup side and install the valve plate (205).
Align the small hole in the plate with the air inlet.
Tighten the screws (209) to hold it in place.
FIG. 3. Air valve assembly
210✠
210✠
207✠
206◆†✠
206◆†✠
208◆†
202◆
208◆†
209◆†
205◆
212◆
211◆
203◆
204◆
ti18205b
201
Apply lithium-based grease.
1
1
1
1
1
1
1
U-cup lips must face piston.
2
2
2
207✠1
air
inlet
214◆
213◆
3
3
Apply lithium-based grease to
contact surface.
3
1
FIG. 4. Cup assembly
211
213
212
214
ti19675a
FIG. 5. Air valve cup and plate installation
magnet
ti14097a
205 212
small
hole

12 859.0089
Check Valve Repair
NOTE: Kits are available for new check valve balls and
seats in a range of materials. See page 26 to order kits
in the material(s) desired. An o-ring kit and fastener kits
also are available.
NOTE: To ensure proper seating of the check balls,
always replace the seats when replacing the balls. Also,
on models with manifold o-rings, replace the o-rings.
Disassembly
1. Follow the Pressure Relief Procedure on page 9.
Disconnect all hoses.
2. Remove the pump from its mounting.
3. Use a 10 mm socket wrench to remove the outlet
manifold fasteners (6). See FIG. 6.
NOTE: For plastic pumps (VA25CC, VA25PP, and
VA25KP), use hand tools only until thread-locking
adhesive patch releases.
4. Remove the o-rings (12, not used on some models),
seats (10), and balls (11).
5. Turn the pump over and remove the inlet manifold.
Remove the o-rings (12, not used on some models),
seats (10), and balls (11).
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. 6. Be sure the ball checks (10-12) and mani-
folds (4, 5) are assembled exactly as shown. The
arrows (A) on the fluid covers must point toward the
outlet manifold (4).
FIG. 6. Ball check valve assembly
Torque to 100 in-lb (11.3 N•m). See Torque Instructions,
page 16.
1
Not used on some models.
3
ti14098a
6
4
11
12
10
12
3
6
5
Arrow (A) must point toward outlet manifold.
2
1
1
2
A
10
12
12
3
3
3
3
11
Aluminum pump
shown
7

859.0089 13
Diaphragms and Center Section
Disassembly
NOTE: Diaphragm kits are available in a range of materi-
als and styles. See page 27 to order the correct dia-
phragms for your pump. A Center Rebuild Kit also is
available. See page 23. Parts included in the Center
Rebuild Kit are marked with an *. For best results, use all
kit parts.
1. Follow the Pressure Relief Procedure on page 9.
2. Remove the manifolds and disassemble the ball
check valves as explained on page 12.
3. Overmolded Diaphragms
a. Orient the pump so one of the fluid covers faces
up. Use a 10 mm socket wrench to remove the
fluid cover screws (7), then pull the fluid cover (3)
up off the pump.
b. The exposed diaphragm (15) will screw off by
hand from the diaphragm shaft (104). The dia-
phragm shaft bolt will remain attached to the dia-
phragm. Remove the air side diaphragm plate
(14).
c. Turn the pump over and remove the other fluid
cover. Pull the diaphragm and shaft up through
the center housing.
d. Grasp the diaphragm firmly and use a wrench on
the flats of the shaft to remove. Also remove the
air side diaphragm plate (14). Continue with Step
5.
4. All Other Diaphragms
a. Orient the pump so one of the fluid covers faces
up. Use a 10 mm socket wrench to remove the
fluid cover screws (7), then pull the fluid cover up
off the pump. Turn the pump over and remove
the other fluid cover.
b. Plastic Pumps: Use a 1-1/4 socket or box end
wrench on the hex of a fluid side diaphragm plate
to remove. Then remove all parts of the dia-
phragm assembly. See FIG. 7.
Metal Pumps: Remove the bolt (304) from one
side of the diaphragm shaft, then remove all
parts of that diaphragm assembly. See FIG. 7.
c. Follow the same procedure to disassemble the
other diaphragm assembly.
5. Inspect the diaphragm shaft (104) for wear or
scratches. If it is damaged, inspect the bearings
(105) in place. If they are damaged, use a bearing
puller to remove them.
NOTE: Do not remove undamaged bearings.
6. Use an o-ring pick to remove the u-cup packings
(106) from the center housing. Bearings (105) can
remain in place.
7. Use a socket wrench to remove the pilot valves
(101).
8. Remove the pilot valve cartridges only if necessary
due to a known or suspected problem. After remov-
ing pilot valves, use a hex to remove the cartridges
(102), then remove o-rings (103). If stripped, use two
screwdrivers to screw out the cartridge.
NOTE: Do not remove undamaged pilot valve
cartridges.

14 859.0089
FIG. 7. Assemble diaphragms and center section
ti14022a
304
301
15
13
14
104* 15
104*
ti14037a
NO and TO
models
304
301
15 13
14
104*
305
14 303
ti14021a
TF models
13 (Plastic pumps)
13 (Metal pumps)
(Plastic pumps)
(Metal pumps)
1
Rounded side faces diaphragm.
1
1
1
1
1
Apply lithium-based grease.
2
2
2
2
Torque to 20-25 ft-lb (27-34 N•m)
at 100 rpm maximum.
3
3
3
AIR SIDE markings on diaphragm
must face center housing.
4
44
4
4
If screw comes loose or is
replaced, apply permanent (red)
Loctite®or equivalent to
diaphragm side threads. Apply
primer and medium-strength (blue)
Loctite®or equivalent to shaft side
threads.
5
101*
102*
102*
103*
103*
104*
105*
105*
106*
106*
110
2
2
2
2
2
2
Lips must face out of housing.
6
6
6
HY, SP, BN,
VT, and GE
models
5
3
3
ti14025b
2
Torque to 20-25 in.-lb (2.3-2.8 N•m).
8
7
Cartridges (102) must be installed in
housing before pilot valves (101) or
inserts (113, for remote air
controls)..
7
2
8
2
7
7 2
113
(remote air control)
78
2

859.0089 15
Reassembly
Follow all notes in FIG. 7. These notes contain
important information.
NOTE: Apply lithium-based grease whenever instructed
to grease.
1. Clean all parts and inspect for wear or damage.
Replace parts as needed.
2. If removed, grease and install the new pilot valve car-
tridges (102) and o-rings (103). Screw in until seated.
NOTE: Cartridges (102) must be installed before pilot
valves (101).
3. Grease and install the pilot valves (101). Torque to
20-25 in.-lb (2.3-2.8 N•m). Do not over-torque.
4. Grease and install the diaphragm shaft u-cup pack-
ings (106) so the lips face out of the housing.
5. If removed, insert the new bearings (105) into the
center housing. Use a press or a block and rubber
mallet to press-fit the bearing so it is flush with the
surface of the center housing.
6. Overmolded Diaphragms:
a. Clamp the shaft flats in a vise.
b. If diaphragm setscrew comes loose or is
replaced, apply permanent (red) Loctite®or
equivalent to diaphragm side threads. Screw into
diaphragm until tight.
c. Assemble the air side plate (14) onto the dia-
phragm. The rounded side of the plate must face
the diaphragm.
d. Apply medium-strength (blue) Loctite or equiva-
lent to the threads of the diaphragm assembly.
Screw the assembly into the shaft as tight as
possible by hand.
e. Grease the shaft u-cups (106) and the length and
ends of the diaphragm shaft (104). Slide the
shaft into the housing.
f. Reattach the first fluid cover (3). See Torque
Instructions, page 16.
g. Repeat Steps b and c for the other diaphragm
assembly. Go to Step 7.
All Other Diaphragms - Metal Pumps:
a. Install the o-ring (301) on the shaft bolt (304).
b. Assemble the fluid side plate (13), the diaphragm
(15), the backup diaphragm (305, if present), and
the air side diaphragm plate (14) on the bolt
exactly as shown in FIG. 7.
c. Apply medium-strength (blue) Loctite or equiva-
lent to the bolt (304) threads. Screw the bolt into
the shaft hand tight.
d. Grease the shaft u-cups (106) and the length and
ends of the diaphragm shaft (104). Slide the
shaft into the housing.
e. Repeat Steps a-c for the other diaphragm
assembly.
f. Hold one shaft bolt with a wrench and torque the
other bolt to 20-25 ft-lb (27-34 N•m) at 100 rpm
maximum. Do not over-torque.
g. Reattach the first fluid cover (3). See Torque
Instructions, page 16. Go to Step 7.
All Other Diaphragms - Plastic Pumps:
a. Assemble the diaphragm (15), the backup dia-
phragm (305, if present), and the air side dia-
phragm plate (14) on the fluid side plate (13)
exactly as shown in FIG. 7.
b. Apply medium-strength (blue) Loctite or equiva-
lent to the threads of the screw on the fluid side
plate. Screw the assembly into the shaft
hand-tight.
c. Grease the shaft u-cups (106) and the length and
ends of the diaphragm shaft (104). Slide the
shaft into the housing.
d. Repeat for the other diaphragm assembly
e. Hold one of the plates with a wrench, and torque
the other plate to 20-25 ft-lb (27-34 N•m) at 100
rpm maximum. Do not over-torque.
f. Reattach the first fluid cover (3). See Torque
Instructions, page 16.

16 859.0089
7. To ensure proper seating and extend diaphragm
life, attach the second fluid cover with air pressure
on the pump.
a. See FIG. 8. Place the supplied tool (302) where
the air valve gasket (108) normally goes.
Arrows (A) must face toward the fluid cover that
is already attached.
b. Reattach the air valve.
c. Supply a minimum of 20 psi (0.14 MPa, 1.4 bar)
air pressure to the air valve. Shop air may be
used. The diaphragm will shift so the second
fluid cover will seat properly. Keep air pressure
on until the second fluid cover is attached.
d. Attach the second fluid cover (3). See Torque
Instructions, page 16.
e. Remove the air valve and the tool (302), replace
the gasket (108), and reattach the air valve. See
Torque Instructions, page 16.
NOTE: If you are replacing the diaphragms but not the
air valve, you must remove the air valve and gasket, put
the tool in place of the gasket, and put the air valve back
on to get the air pressure needed for proper installation
of the second fluid cover. Remember to remove the tool
and replace the gasket when finished.
8. Reassemble the ball check valves and manifolds as
explained on page 12.
Torque Instructions
NOTE: Fluid cover and manifold fasteners have a
thread-locking adhesive patch applied to the threads. If
this patch is excessively worn, the screws may loosen
during operation. Replace screws with new ones, or
apply medium-strength (blue) Loctite or equivalent to
the threads.
If fluid cover or manifold fasteners have been loosened,
it is important to torque them using the following proce-
dure to improve sealing.
NOTE: Always completely torque fluid covers before
torquing manifolds.
Start all fluid cover screws a few turns. Then turn down
each screw just until head contacts cover. Then turn
each screw by 1/2 turn or less working in a crisscross
pattern to specified torque. Repeat for manifolds.
Fluid cover and manifold fasteners:
100 in-lb (11.3 N•m)
Retorque the air valve fasteners (V) in a crisscross pat-
tern to specified torque.
Plastic center sections: 55 in-lb (6.2 N•m)
Metal center sections: 80 in-lb (9.0 N•m)
FIG. 8. Fluid cover tool
302 A
ti14120a
FIG. 9. Torque sequence








 





 9
ti18448a
ti18449a

859.0089 17
Parts
ti14023a
8
1
1
Not used on some models.
1
see page 22
2
see page 24
3
see page 19
4
see page 20
5
see page 21
6
see page 19
7
see page 19
12
see page 26
13
see page 28
10
see page 26
11
see page 26
18
1
9
see page 31
15
see page 27

18 859.0089
Parts/Kits Quick Reference
Use this table as a quick reference for parts/kits. See pages indicated in table for full description of kit contents.
▲Replacement Warning labels, signs, tags, and cards
are available at no cost.
Ref. Part/Kit Description Qty.
1 Varies Center Section; not sold separately, see
page 22
Aluminum
Conductive Polypropylene
Polypropylene
1
2 Varies Air Valve; see page 24 1
3
859.0032
859.0071
859.0070
859.0072
859.0081
Fluid Cover Kits; see page 19
Aluminum
Conductive Polypropylene
Polypropylene
PVDF
Stainless Steel
2
4
859.0028
859.0029
859.0059
859.0062
859.0058
859.0061
859.0060
859.0063
859.0077
859.0078
Outlet Manifold Kits; see page 20
Aluminum, npt
Aluminum, bspt
Conductive Poly, center flange
Conductive Poly, end flange
Polypropylene, center flange
Polypropylene, end flange
PVDF, center flange
PVDF, end flange
Stainless Steel, npt
Stainless Steel, bspt
1
5
859.0030
859.0031
859.0065
859.0068
859.0064
859.0067
859.0066
859.0069
859.0079
859.0080
Inlet Manifold Kits; see page 21
Aluminum, npt
Aluminum, bspt
Conductive Poly, center flange
Conductive Poly, end flange
Polypropylene, center flange
Polypropylene, end flange
PVDF, center flange
PVDF, end flange
Stainless Steel, npt
Stainless Steel, bspt
1
6
859.0033
859.0076
859.0084
Manifold Fasteners; 8-pack, see page
19
Aluminum
Conductive Polypropylene, Polypro-
pylene, and PVDF
Stainless Steel
16
7
859.0033
859.0075
859.0083
859.0076
Fluid Cover Fasteners; 8-pack,
see page 19
Aluminum
Conductive Polypropylene, Polypro-
pylene, and PVDF
Stainless Steel, aluminum
center
Stainless Steel, plastic center
16
8
859.0105
859.0106
Plug, 1 in.; 6-pack, aluminum pumps
only
npt
bspt
6
9 859.0102 Pressure Relief Valve; fuel dispense
model only, see page 19
1
10
859.0009
859.0010
859.0011
859.0017
859.0012
859.0014
859.0087
859.0015
859.0016
859.0013
Seats; 4-pack, includes 8 o-rings where
needed, see page 26
Acetal
Aluminum
Buna-N
FKM Fluoroelastomer
Geolast
Polypropylene
PVDF
Santoprene
Stainless Steel
TPE
4
11
859.0018
859.0019
859.0022
859.0023
859.0027
859.0020
859.0024
859.0025
859.0026
859.0021
Check Balls; 4-pack, includes 8 o-rings,
see page 26
Acetal
Buna-N
Polychloroprene
Polychloroprene with SST core
FKM Fluoroelastomer
Geolast
PTFE
Santoprene
Stainless Steel
TPE
4
12 859.0034 Manifold O-Ring (not used on some
models); ptfe, 8-pack, see page 26
8
13
859.0055
859.0056
859.0056
859.0057
859.0082
Fluid Side Diaphragm Plate; included in
Air and Fluid Plate Kits, see page 28
Aluminum
Conductive Polypropylene
Polypropylene
PVDF
Stainless Steel
2
14 ----- Air Side Diaphragm Plate (not visible);
included in Air and Fluid Plate Kits, see
Part 13 or page 28
2
15
859.0001
859.0008
859.0002
859.0007
859.0003
859.0004
859.0005
859.0006
Diaphragm Kits; see page 27
Buna-N Standard
FKM Fluoroelastomer Standard
Geolast Standard
Santoprene Standard
TPE Standard
Polychloroprene Overmolded
PTFE Overmolded
PTFE/EPDM Two-Piece
2
18 859.0238 Muffler; 3/4 npt, polypropylene 1
19
819.0220
819.0221
Screw, ground, M5 x 0.8; not shown
Aluminum pumps, carbon steel
Conductive Poly Pumps, stainless
steel
1
20▲819.4313 Label, warning (not shown) 1
Ref. Part/Kit Description Qty.

859.0089 19
Fluid Section
Manifold Fasteners (6)
Fluid Cover Fasteners (7)
Fluid Covers
Kits include:
• 1 fluid cover (3)
• 4 o-rings, ptfe (12)
Kit 859.0102, Fluid Pressure Relief Valve
Fuel Dispense Model only
Kit includes:
• 1 valve, 3/8 nptf (9)
NOTE: See page 26 for manifold o-rings (12).
Sample Configuration Number
Pump Size Fluid Section Air Section Seats Balls Diaphragms Connections Options
VA25 AASS BN BN TB 00
Fluid Cover and
Manifold Material Kit Description Qty.
AAluminum 859.0033 BOLT, hex
head, steel,
M8 x 25,
8
C
P
K
Cond. Poly
Polypropylene
PVDF
859.0076 BOLT, flange
head, M8 x
32, stainless
steel, includes
nuts
8
SStainless steel 859.0084 BOLT, hex
head, M8 x
20, stainless
steel, includes
nuts
8
Fluid Cover and
Manifold Material Kit Description Qty.
AAluminum 859.0033 BOLT, hex
head, steel,
M8 x 25
8
CCond. Poly 859.0075 BOLT, flange
head, M8 x
45, stainless
steel,
includes nuts
8
PPolypropylene
KPVDF
S
aluminum
air section
Stainless steel 859.0083 BOLT, flange
head, M8 x
25, stainless
steel
8
S
plastic
air section
Stainless steel 859.0076 BOLT, flange
head, M8 x
32, stainless
steel,
includes nuts
8
Fluid Cover and Manifold
Material
Fluid Cover
Kit
AAluminum 859.0032
CConductive
Polypropylene
859.0071
KPVDF 859.0072
PPolypropylene 859.0070
SStainless Steel 859.0081

20 859.0089
Outlet Manifolds
Aluminum
Kits include:
• 1 outlet manifold (4)
• 3 pipe plugs (8)
• 4 o-rings, ptfe (12)
• 1 warning label (20▲)
Plastic
Kits include:
• 1 outlet manifold (4)
• 4 o-rings, ptfe (12)
• 1 warning label (20▲)
Stainless Steel
Kits include:
• 1 outlet manifold (4)
• 4 o-rings, ptfe (12)
• 1 warning label (20▲)
▲Replacement Danger and Warning tags, labels, and
cards are available at no cost.
Sample Configuration Number
Pump Size Fluid Section Air Section Seats Balls Diaphragms Connections Options
VA25 AASS BN BN TB 00
Fluid Cover and
Manifold Material Connections
Outlet
Manifold Kit
AAluminum TN, npt 859.0028
AAluminum TB, bspt 859.0029
Fluid Cover and
Manifold Material Porting
Outlet
Manifold Kit
CConductive
Polypropylene
FC, Center flange 859.0059
CConductive
Polypropylene
FE, End flange 859.0062
PPolypropylene FC, Center flange 859.0058
PPolypropylene FE, End flange 859.0061
KPVDF FC, Center flange 859.0060
KPVDF FE, End flange 859.0063
ti14307a
4
12
8
20
ti14309a ti14311a
4
12
4
12
Fluid Cover and
Manifold Material Connections
Outlet
Manifold Kit
SStainless Steel TN, npt 859.0077
SStainless Steel TB, bspt 859.0078
ti14313a
4
12