VERDER VERDERAIR VA 40 Datasheet

819.4486
Rev. ZAL
EN
INSTRUCTIONS–PARTS LIST
CONDUCTIVE POLYPROPYLENE*, POLYPROPYLENE, AND PVDF
VERDERAIR VA 40
Air-Operated
Diaphragm Pumps
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 ZL94102643.4
FR 9408894
JA 3517270
US 5,368,452
* Applies only to pumps with
conductive polypropylene fluid
sections.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE.
II 2 GD
Ex h IIC 66°C...135°C G
b
Ex h IIIC T135°C Db
*
04700B

2 819.4486
Table of Contents
Configuration Number Matrix . . . . . . . . . . . . . . . . . . . 3
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air Exhaust Ventilation . . . . . . . . . . . . . . . . . . . 12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Relief Procedure . . . . . . . . . . . . . . . . 13
Flush the Pump Before First Use . . . . . . . . . . . 13
Starting and Adjusting the Pump . . . . . . . . . . . 13
Pump Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Flushing and Storage . . . . . . . . . . . . . . . . . . . . 15
Tightening Threaded Connections . . . . . . . . . . 15
Preventive Maintenance Schedule . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Repairing the Air Valve . . . . . . . . . . . . . . . . . . . 17
Ball Check Valve Repair . . . . . . . . . . . . . . . . . . 19
Diaphragm Repair . . . . . . . . . . . . . . . . . . . . . . . 20
Bearing and Air Gasket Removal . . . . . . . . . . . 23
Repair Kit Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Performance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 34

819.4486 3
Configuration Number Matrix
Check the identification plate (ID) for the 16-digit Configuration Number of your pump. Use the following matrix to
define the components of your pump.
Sample Configuration Number: VA40PA - PP TF TF FE OO
NOTE: Some combinations are not possible. Please check with your local supplier or on www.verderair.com.
*Certified
VA40 P A PP TF TF FE OO
Pump Model Fluid Section Air Section Seats Balls Diaphragms Connections Options
Pump Model
(1 and 2) Fluid Section Material (3) Air Section Material (4) Seats (5)
VA40 CConductive Polypropylene* AAluminum BN Buna-N
KPVDF SStainless Steel HY TPE
PPolypropylene KY PVDF
PP Polypropylene
SP Santoprene
SS Stainless Steel
VT FKM
Balls
(6) Diaphragm (7) Connections (8) Options (9)
BN Buna-N BN Buna-N FE Flange End OO Standard
GE Geolast GE Geolast RE Remote
HS 440C SST HY TPE
HY TPE SP Santoprene
SP Santoprene TF PTFE/Neoprene
2-Piece
TF PTFE TO PTFE Overmolded
VT FKM VT FKM
II 2 GD
Ex h IIC 66°C...135°C Gb
Ex h IIIC T135°C Db
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.

4 819.4486
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 the equipment.
•Use the equipment only for its intended purpose. If you are not sure, call VERDER After Sales
Service.
•Do not alter or modify this equipment.
•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 an 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.

819.4486 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 are using.
•Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state, and national guidelines.
•Always wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid
and solvent 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 serious injury
•Ground the equipment. Refer to Grounding on page 6.
•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 page 6 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 the problem.
•Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed, dispensed, or transferred.
•Pipeanddisposeoftheexhaustairsafely,awayfromallsourcesofignition.Ifthediaphragmfails,
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, and gasoline.
•Electrically disconnect all equipment in the work area.
•Extinguish all open flames or pilot lights in the work area.
•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 work area.

6 819.4486
Installation
General Information
1. The Typical Installation shown in FIG. 2 is only a
guide for selecting and installing system
components.
Contact your VERDER Customer Service for
assistance in planning a system to suit your needs.
2. Always use Genuine VERDER Parts and
Accessories. Be sure all accessories are adequately
sized and pressure-rated to meet the system's
requirements.
3. Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 27-28.
4. Variations in color between the plastic components
of 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 Torque Sequence,
page 30. After the first day of operation, retorque the
fasteners. Although pump use varies, a general
guideline is to retorque fasteners every two months.
Grounding
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.
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.
Non-Conductive Polypropylene and PVDF
are not conductive.
Attaching the ground wire to the grounding lug will
ground only the air motor. When pumping conductive
flammable fluids, always make sure the fluid has an
electrical path to a true earth ground. Possible
methods of grounding the fluid are through the fluid
containers or piping. Contact your VERDER
Customer Service for assistance in grounding your
system. Never use a non-conductive polypropylene
or a PVDF pump in an explosive atmosphere with
non-conductive flammable fluids as specified by your
local fire protection code. US Code (NFPA 77 Static
Electricity) recommends a conductivity greater than
50 x 10-12 Siemans/meter (ohms/meter) over your
operating temperature range to reduce the hazard of
fire. Consult your fluid supplier to determine the
conductivity or resistivity of your fluid. The resistivity
must be less than 2 x 1012 ohm-centimeters.

819.4486 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.
•Pump: Connect a ground wire and clamp as shown
in FIG. 1 Loosen the grounding screw (W). Insert
one end of a 1.5 mm² minimum 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 the local code.
Fig. 1 ______________________________________
Y
W
02646B

8 819.4486
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) pump air
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 into the pump air inlet snugly. Do not
connect the coupler (D) to the fitting until you are
ready to operate the pump.
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 cycle
unexpectedly, 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.
04701B
YJ
F
BE
C
A
DKL
G
H
R
S
N
FLOOR MOUNT TYPICAL INSTALLATION
KEY
A Electrically Conductive Air Supply Hose
B Bleed-Type Master Air Valve
(required for pump)
C Air Regulator
D Air Line Quick Disconnect
E Master Air Valve (for accessories)
F Air Line Filter
G Fluid Suction Hose
H Fluid Supply
J Fluid Drain Valve (required)
K Fluid Shutoff Valve
L Fluid Hose
N 1/2 npt(f) Air Inlet Port
R 1-1/2 in. Fluid Inlet Flange
S 1-1/2 in. Fluid Outlet Flange
Y Ground Wire (required; see page 7
for installation instructions)

819.4486 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 during
operation.
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 1-1/2 in. raised face
flange. Refer to Flange Connections on page 10.
2. 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.
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 1-1/2 in. raised face
flange. Refer to Flange Connections on page 10.
2. Install a fluid drain valve (J) near the fluid outlet. See
the Warning above.
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.

10 819.4486
Installation
Flange Connections
The fluid inlet and outlet ports are 1-1/2 in. raised face,
standard 150 lb class pipe flanges. Connect 1-1/2 in.
flanged plastic pipe to the pump as follows. You will need:
•Torque wrench
•Adjustable wrench
•a 5 in. diameter, 1/8 in. thick PTFE gasket, with four
0.63 in. diameter holes on a 3.88 in. diameter bolt
circle, and a 1.75 in. diameter center
•four 1/2 in. x 3 in. bolts
•four 1/2 in. spring lockwashers
•eight 1/ in. flat washers
•four 1/2 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 14-20 N•m.
Do not over-torque.
5. Repeat for the pump inlet flange (R).
Fig. 3 ______________________________________________________________________________________
04405
F
E
S
B
A
E
D
C
R
1
2
3
4
1
04703B
KEY
A Flanged Plastic Pipe
B PTFE Gasket
C Bolt
D Lockwasher
E Flat Washer
F Nut
R 1-1/2 in. Fluid Inlet DIN 40 Flange
S 1-1/2 in. Fluid Outlet DIN 40 Flange
Lubricate threads. Torque to 14-20 N•m. Do not over-torque.
1
BOLT TIGHTENING SEQUENCE 1

819.4486 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 (106 and 112) 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 9-10 N•m. See Torque
Sequence, page 30.
KEY
Fig. 4 ______________________________________
Fluid Pressure Relief Valve
KEY
R 1-1/2 in. Fluid Inlet DIN 40 Flange
S 1-1/2 in. Fluid Outlet DIN 40 Flange
V Pressure Relief Valve
Part No. 819.0159 (Stainless Steel)
Fig. 5 ______________________________________
N 1/2 npt(f) Air Inlet Port 101 Fluid Covers
P Muffler; Air Exhaust Port is
3/4 npt(f) 102 Fluid Inlet Manifold
R 1-1/2 in. Fluid Inlet DIN 40
Flange 103 Fluid Outlet Manifold
S 1-1/2 in. Fluid Outlet DIN
40 Flange 106 Fluid Outlet Manifold Screws (Top)
112 Fluid Inlet Manifold
Screws (Bottom)
04700B
N
P
R
S
1
103
102
101
1
106
112
Torque to 9-10 N•m. See Torque
Sequence, page 30.
1
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
VA 40 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.
04702B
R
S
1
2
V
3
Install valve between fluid inlet and outlet ports
Connect fluid inlet line here.
Connect fluid outlet line here.
1
2
3

12 819.4486
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 thread
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.
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.
04704
FBEC
A
D
P
TU
VENTING EXHAUST AIR
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)
F Air Line Filter
P Muffler
T Electrically Conductive Air Exhaust Hose
U Container for Remote Air Exhaust

819.4486 13
Operation
Pressure Relief Procedure
•Are instructed to relieve pressure,
•Stop pumping,
•Check, clean or service any system equipment,
•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 the
drainage.
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. Refer to
Grounding on page 6.
2. Check all fittings to be sure they are tight. Be sure to
use a compatible liquid thread sealant on all male
threads. Tighten the fluid inlet and outlet fittings
securely.
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 following step.
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 is
primed.
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
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.

14 819.4486
Notes

819.4486 15
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, a general guideline is to retorque fasteners every
two months. See Torque Sequence, page 30.
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.

16 819.4486
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 at stall. Worn check valve balls (301), seats (201) or o-rings (202). Replace. See page 19.
Pump will not cycle, or cycles once and
stops. Air valve is stuck or dirty. Disassemble and clean air valve. See pages 17-18. Use filtered air.
Check valve ball (301) severely worn and
wedged in seat (201) or manifold (102 or
103).
Replace ball and seat. See page 19.
Check valve ball (301) is wedged into
seat (201), due to overpressurization. Install Pressure Relief Valve (see page 11).
Dispensing valve clogged. Relieve pressure and clear valve.
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking balls (301). Clean or replace. See page 19.
Diaphragm ruptured. Replace. See pages 20-22.
Restricted exhaust. Remove restriction.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace. See pages 20-22.
Loose inlet manifold (102), damaged
seal between manifold and seat (201),
damaged o-rings (202).
Tighten manifold bolts (112) or replace
seats (201) or o-rings (202). See
page 19.
Loose fluid side diaphragm plate (105). Tighten or replace. See pages 20-22.
Fluid in exhaust air. Diaphragm ruptured. Replace. See pages 20-22.
Loose fluid side diaphragm plate (105). Tighten or replace. See pages 20-22.
Pump exhausts excessive air at stall. Worn air valve block (7†Q), o-ring (6†Q),
plate (8Q), pilot block (18), u-cups
(10†Q), or pilot pin o-rings (17†Q).
Inspect; replace. See pages 17-18.
Worn shaft seals (402). Replace. See pages 20-22.
Pump leaks air externally. Air valve cover (2) or air valve cover
screws (3) are loose. Tighten screws. See page 18.
Air valve gasket (4†Q) or air cover
gasket (22) is damaged. Inspect; replace. See
pages 17-18, 23-24.
Air cover screws (25) are loose. Tighten screws. See pages 23-24.
Pump leaks fluid externally from ball
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 19.

819.4486 17
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 27. Parts included in the kit are
marked with a symbol, for example (4†Q). 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†Q). See FIG. 7.
3. Move the valve carriage (5) to the center position
and pull it out of the cavity. Remove the valve block
(7) and o-ring (6†Q) 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 the bearings
(12). Remove the u-cup packings (10†Q) from the
pistons. Pull the pilot pins (16) out of the bearings
(15). Remove the o-rings (17†Q) from the pilot pins.
See FIG. 9.
5. Inspect the valve plate (8Q) in place. If damaged,
use a Torx (T20) screwdriver or 7 mm socket
wrench to remove the three screws (3). Remove the
valve plate (8Q) 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 18.
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.
32
4
2
4705B
Torque to 5.6-6.8 N•m.
1
18 51
7
6
5
2
3
3
11
16
04898B
See Detail at right.
Grease.
Grease lower face.
1
2
3

18 819.4486
Service
Fig. 9 ______________________________________
Fig. 10 _____________________________________
Reassembly
1. If you removed the bearings (12, 15), install new
ones as explained on page 23. Reassemble the fluid
section.
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 (8Q) 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†Q) 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†Q)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†Q) 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†Q) 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†Q) and install it in the valve
block (7†Q). 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†Q) and cover (2) with the
six holes in the center housing (1). Secure with six
screws (3), using a Torx (T20) screwdriver or 7 mm
socket 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
03271
8
9
3
1
2
Rounded side must face down
(aluminum center housing models only).
Tighten screws until they bottom
out on the housing.
1
2

819.4486 19
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 all the parts in
the kit for the best results.
NOTE: To ensure 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 the eight
bolts (106) holding the outlet 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) 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 9-10 N•m. See Torque Sequence, page 30.
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
04706B
106
103
101
A
201*
301*
112
102
201*
301*
2
1
1
202*
202*
3
3

20 819.4486
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 19.
3. Using 13 mm socket wrenches, remove the 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.
4. Unscrew one outer plate (105) from the diaphragm
shaft (24). Remove one diaphragm (401), and the
inner plate (104). See FIG. 13.
NOTE: PTFE models include a PTFE diaphragm (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.
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.
04707B
23
101
A2
B
1
107
108 1
You must torque the eight long screws (108) first, then the
short screws (107). Torque to 22-25 N•m. See Torque
Sequence, page 30.
Arrow (A) must point toward air valve (B).
1
2