VERDER VERDERAIR VA 40 Operation manual

819.4334
Rev. ZAC
EN
Aluminum Model Shown 3263B
INSTRUCTIONS–PARTS LIST
ALUMINIUM AND STAINLESS STEEL
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
Important Safety Instructions
Read all warnings and instructions in the
manual. Save these instructions.
* NOTE: Refer to the Pump Listing on page 22 to
determine the Model No. of your pump.
Patent No.
CN ZL94102643.4
FR 9408894
JA 3517270
US 5,368,452

2 819.4334
Table of Contents
Safety Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service
Repairing the Air Valve 14. . . . . . . . . . . . . . . . . . . . . . . . . .
Ball Check Valve Repair 16. . . . . . . . . . . . . . . . . . . . . . . . .
Diaphragm Repair 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing and Air Gasket Removal 20. . . . . . . . . . . . . . . . .
Pump Listing 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Kit Listing 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Sequence 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data and Performance Chart 30. . . . . . . . . . . . . . . .
Customer Services/Guarantee 32. . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
Warning
Warning
This symbol alerts you to the possibility of serious injury or
death if you do not follow the instructions.
Caution Symbol
Caution
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the instructions.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call VERDER After Sales Service.
DDo not alter or modify this equipment.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated component in your system. This equip-
ment has an 8.4 bar maximum working pressure at 8.4 bar maximum incoming air pressure.
DUse 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.
DDo not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use could result in a chemical reaction,
with the possibility of explosion.
DDo not use hoses to pull equipment.
DRoute 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.
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
Warning
INSTRUCTIONS

819.4334 3
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.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state, and
national guidelines.
DAlways wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid and solvent
manufacturer.
DPipe 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 8.
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.
DGround the equipment. Refer to Grounding on page 4.
DIf 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.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.
DPipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm fails, the fluid is
exhausted along with the air. See Air Exhaust Ventilation on page 8.
DKeep the work area free of debris, including solvent, rags, and gasoline.
DElectrically disconnect all equipment in the work area.
DExtinguish all open flames or pilot lights in the work area.
DDo not smoke in the work area.
DDo not turn on or off any light switch in the work area while operating or if fumes are present.
DDo not operate a gasoline engine in the work area.
Warning

4 819.4334
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 plan-
ning a system to suit your needs.
2. Always use Genuine VERDER Parts and Accessories.
Refer to Product Data Sheet 819.4335.
3. Reference numbers and letters in parentheses refer to
the callouts in the figures and the parts lists on
pages 24–25.
4. Lift the pump by grasping the outlet manifold (1)
securely. See Fig. 3 on page 7.
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 3.
2. Use fluids and solvents which are compatible
with the equipment wetted parts. Refer to the
Technical Data section of all equipment manu-
als. Read the fluid and solvent manufacturer’s
warnings.
Warning
Tightening Screws Before First Use
Before using the pump for the first time, check and retorque
all external fasteners. See Torque Sequence, page 28.
After the first day of operation, retorque the fasteners.
Although pump use varies, a general guideline is to retorque
fasteners every two months.
Grounding
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 3.
Warning
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:
DPump: Connect a ground wire and clamp as shown in
Fig. 1. Loosen the grounding screw (W). Insert one end of
a 1.5 mm@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.
02646B
Fig. 1
Y
W
DAir and fluid hoses: Use only grounded hoses with a
maximum of 150 m combined hose length to ensure
grounding continuity.
DAir compressor: Follow the manufacturer’s recommenda-
tions.
DAll 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.
DFluid supply container: Follow the local code.

819.4334 5
Installation
Mountings
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 8.
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 vibration during operation.
Air Line
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.
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 grounded.
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 above. 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 mois-
ture from the compressed air supply.
2. Install a grounded, flexible air hose (A) between the
accessories and the 1/2 npt(f) pump air inlet (N). See
Fig. 3. Use a minimum 13 mm ID air hose. Screw an air
line quick disconnect coupler (D) onto the end of the air
hose (A), and screw the mating fitting into the pump air
inlet snugly. Do not connect the coupler (D) to the fitting
until you are ready to operate the pump.
Fluid Suction Line
1. Use grounded fluid hoses (G). The pump fluid inlet (R)
is 1–1/2 in. bspt. On pumps 810.0195, 810.0196,
810.0197, and 810.0198, the pump fluid inlet is 1–1/2 in.
npt. Screw the fluid fitting into the pump inlet securely.
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 30 for maximum suc-
tion lift (wet and dry).
Fluid Outlet Line
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 seri-
ous injury, including splashing in the eyes or on the skin, or
contamination from hazardous fluids when relieving pres-
sure. Install the valve close to the pump fluid outlet. See
Fig. 2.
1. Use grounded fluid hoses (L). The pump fluid out-
let (S) is 1–1/2 in. bspt. On pumps 810.0195, 810.0196,
810.0197, and 810.0198, the pump fluid outlet is 1–1/2
in. npt. Screw the fluid fitting into the pump outlet secure-
ly.
2. Install a fluid drain valve (J) near the fluid outlet. See the
Warning above.
3. Install a shutoff valve (K) in the fluid outlet line.

6 819.4334
Installation
KEY
A 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
R* 1–1/2 in. bspt Fluid Inlet Port
S* 1–1/2 in. bspt Fluid Outlet Port
Y Ground Wire (required; see page 4
for installation instructions)
Fig. 2
FLOOR MOUNT TYPICAL
INSTALLATION
Y
J
F
BE
C
A
DKL
G
H
R
S
03265B
* On pumps 810.0195, 810.0196, 810.0197, and 810.0198, inlet and outlet ports are 1–1/2 in. npt threads.

819.4334 7
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. 3. To change the
orientation of the inlet and/or outlet port:
1. Remove the screws (106) 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 14–17 NSm. See Torque Sequence, page
28.
03263B
Fig. 3
1Torque to 14–17 NSm. See Torque Sequence,
page 28.
KEY
N 1/2 npt(f) Air Inlet Port
P Muffler; Air Exhaust Port
is 3/4 npt(f)
R* 1–1/2 in. bspt Fluid
Inlet Port
S* 1–1/2 in. bspt Fluid
Outlet Port
101 Covers
102 Fluid Inlet Manifold
103 Fluid Outlet Manifold
106 Manifold and Cover
Screws
112 Bottom Cover Screws
N
P
R
S
Aluminum Model Shown
1
106
106
102
103
101
112
2Torque to 22–25 NSm. See Torque Sequence,
page 28.
2
2
Fluid Pressure Relief Valve
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. 4.
Thermal expansion of fluid in the outlet line can cause over-
pressurization. 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 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.
Caution
03461B
Fig. 4
1
2Connect fluid inlet line here.
KEY
R* 1–1/2 in. bspt Fluid Inlet Port
S* 1–1/2 in. bspt Fluid Outlet Port
V Pressure Relief Valve (Order Part No. 819.0159)
R
S
Connect fluid outlet line here.
1
2
3
Install valve between fluid inlet and outlet ports.
V
3
* On pumps 810.0195, 810.0196, 810.0197, and 810.0198, inlet and outlet ports are 1–1/2 in. npt threads.

8 819.4334
Installation
Air Exhaust Ventilation
FIRE AND EXPLOSION HAZARD
Be sure to read and follow the warnings and
precautions regarding TOXIC FLUID
HAZARD, and FIRE OR EXPLOSION
HAZARD on page 3, 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.
Diaphragm failure will cause the fluid being pumped to ex-
haust with the air. Place an appropriate container at the end
of the air exhaust line to catch the fluid. See Fig. 5.
Warning
The air exhaust port is 3/4 npt(f). Do not restrict the air ex-
haust 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 a grounded air exhaust hose (T) and connect the
muffler (P) to the other end of the hose. The minimum
size for the air exhaust hose is 19 mm ID. If a hose long-
er than 4.57 m is required, use a larger diameter hose.
Avoid sharp bends or kinks in the hose. See Fig. 5.
3. Place a container (U) at the end of the air exhaust line to
catch fluid in case a diaphragm ruptures.
03267A
Fig. 5
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 Grounded Air Exhaust Hose
U Container for Remote Air Exhaust
FBEC
A
D
VENTING EXHAUST AIR
P
T
U

819.4334 9
Operation
Pressure Relief Procedure
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is manually
relieved. To reduce the risk of serious injury from pressur-
ized fluid, accidental spray from the gun or splashing fluid,
follow this procedure whenever you:
DAre instructed to relieve pressure,
DStop pumping,
DCheck, clean or service any system equipment,
DInstall or clean fluid nozzles.
Warning
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 with lightweight oil, which is left in the
fluid passages to protect parts. To avoid contaminating your
fluid with oil, flush the pump with a compatible solvent before
using the equipment. Follow the steps under Starting and
Adjusting the Pump.
Starting and Adjusting the Pump
TOXIC FLUID HAZARD
To reduce the risk of serious injury, splashing
in the eyes or on the skin, and toxic fluid
spills, never move or lift a pump under
pressure. If dropped, the fluid section may
rupture. Always follow the Pressure Relief Procedure
above before lifting the pump.
Warning
1. Be sure the pump is properly grounded. Refer to
Grounding on page 4.
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 ineffi-
cient 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. Close the pump air regulator (C). 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
Warning
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pressure
Relief Procedure at left.
At the end of the work shift, relieve the pressure.

10 819.4334
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.
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.
Flushing and Storage
Warning
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pressure
Relief Procedure on page 9.
Flush the pump often enough to prevent the fluid you are
pumping from drying or freezing in the pump and damaging it.
Use a compatible solvent.
Always flush the pump and relieve the pressure before stor-
ing 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 connec-
tions 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 28.
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.

819.4334 11
Notes

12 819.4334
Troubleshooting
Warning
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pressure
Relief Procedure on page 9.
1. Relieve the pressure before checking or servicing the
equipment.
2. Check all possible problems and causes before
disassembling the pump.
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 16.
Pump will not cycle, or cycles once and
stops. Air valve is stuck or dirty. Disassemble and clean air valve. See pages 14–15. 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 16.
Check valve ball (301) is wedged into
seat (201), due to overpressurization. Install Pressure Relief Valve (see page 7).
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 16.
Diaphragm ruptured. Replace. See pages 17–19.
Restricted exhaust. Remove restriction.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace. See pages 17–19.
Loose inlet manifold (102), damaged
seal between manifold and seat (201),
damaged o-rings (202).
Tighten manifold bolts (106) or replace
seats (201) or o-rings (202). See
page 16.
Loose diaphragm shaft bolt (107). Tighten or replace. See pages 17–19.
Damaged o-ring (108). Replace. See pages 17–19.

819.4334 13
Troubleshooting
PROBLEM CAUSE SOLUTION
Fluid in exhaust air. Diaphragm ruptured. Replace. See pages 17–19.
Loose diaphragm shaft bolt (107). Tighten or replace. See pages 17–19.
Damaged o-ring (108). Replace. See pages 17–19.
Pump exhausts excessive air at stall. Worn air valve block (7{H), o-ring (6{H),
plate (8H), pilot block (18), u-cups
(10{H), or pilot pin o-rings (17{H).
Repair or replace. See pages 14–15.
Worn shaft seals (402). Replace. See pages 17–19.
Pump leaks air externally. Air valve cover (2) or air valve cover
screws (3) are loose. Tighten screws. See page 15.
Air valve gasket (4{H) or air cover
gasket (22) is damaged. Inspect; replace. See pages 14–15, 20–21.
Air cover screws (25) are loose. Tighten screws. See pages 20–21.
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) or replace
seats (201) or o-rings (202). See
page 16.

14 819.4334
Service
Repairing the Air Valve
Tools Required
DTorque wrench
DTorx (T20) screwdriver or 7 mm socket wrench
DNeedle-nose pliers
DO-ring pick
DLithium base grease
NOTE: Air Valve Repair Kits 819.4274 (aluminum center
housing models) and 819.0249 (sst center housing
models) are available. Refer to page 23. Parts in-
cluded in the kit are marked with a symbol, for exam-
ple (4{H). Use all the parts in the kit for the best re-
sults.
Disassembly
Warning
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pressure
Relief Procedure on page 9.
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 gas-
ket (4). See Fig. 6.
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) from the carriage. Using a needle-nose pliers,
pull the pilot block (18) straight up and out of the cavity.
See Fig. 7.
4. Pull the two actuator pistons (11) out of the bear-
ings (12). Remove the u-cup packings (10{H) from the
pistons. Pull the pilot pins (16) out of the bearings (15).
Remove the o-rings (17{H) from the pilot pins. See Fig.
8.
5. Inspect the valve plate (8H) in place. If damaged, use a
Torx (T20) screwdriver or 7 mm socket wrench to re-
move the three screws (3). Remove the valve plate (8H)
and, on aluminum center housing models, remove the
seal (9{). See Fig. 9.
6. Inspect the bearings (12, 15) in place. See Fig. 8. The
bearings are tapered and, if damaged, must be removed
from the outside. This requires disassembly of the fluid
section. See page 20.
7. Clean all parts and inspect for wear or damage. Replace
as needed. Reassemble as explained on page 15.
Torque to 50–60 in–lb (5.6–6.8 NSm)
Fig. 6
3
2
4†H
2
2
03268B
03269B
18{H 5
Fig. 7
1
2
See Detail at right.
Grease.
3Grease lower face.
1
{H7
{H6
5
2
3
3
11

819.4334 15
Service
Fig. 8 17{H 16
11
10{H
12
15
1
2
Insert narrow end first.
Grease.
3Install with lips facing
narrow end of piston (11).
4Insert wide end first.
1
2
3
4
2
03270B
03271
1
2
8H
9†
3
Rounded side must face down (alu-
minum center housing models only).
Tighten screws until they bottom
out on the housing.
Fig. 9
1
2
Reassembly
1. If you removed the bearings (12, 15), install new ones as
explained on page 20. 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. 9.
3. Install the valve plate (8H) 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. 9.
4. Install an o-ring (17{H) on each pilot pin (16). Grease the
pins and o-rings. Insert the pins into the bearings (15),
narrow end first. See Fig. 8.
5. Install a u-cup packing (10{H) on each actuator pis-
ton (11), so the lips of the packings face the narrow end
of the pistons. See Fig. 8.
6. Lubricate the u-cup packings (10{H) and actuator pis-
tons (11). Insert the actuator pistons in the bearings (12),
wide end first. Leave the narrow end of the pistons
exposed. See Fig. 8.
7. Grease the lower face of the pilot block (18{H) and install
so its tabs snap into the grooves on the ends of the pilot
pins (16). See Fig. 7.
8. Grease the o-ring (6{H) and install it in the valve block
(7{H). Push the block onto the valve carriage (5). Grease
the lower face of the valve block. See Fig. 7.
9. Install the valve carriage (5) so its tabs slip into the
grooves on the narrow end of the actuator pistons (11).
See Fig. 7.
10. Align the valve gasket (4{H) 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 sock-
et wrench. Torque to 50–60 in–lb (5.6–6.8 NSm). See
Fig. 6.

16 819.4334
Service
Ball Check Valve Repair
Tools Required
DTorque wrench
D13 mm socket wrench
DO-ring pick
Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to
page 23 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.
Also, on some models, replace the o-rings (202).
Warning
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pressure
Relief Procedure on page 9.
1. Relieve the pressure. Disconnect all hoses.
2. Remove the pump from its mounting.
3. Using a 13 mm socket wrench, remove the four
bolts (106) holding the outlet manifold (103) to the fluid
covers (101). See Fig. 10.
4. Remove the o-rings (202, not used on some models),
seats (201), and balls (301) from the manifold.
5. Turn the pump over and remove the inlet manifold (102).
Remove the o-rings (202, not used on some models),
seats (201), and balls (301) 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. 10. 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). Fig. 10
1
2
Torque to 14–17 NSm. See Torque Sequence, page 28.
Arrow (A) must point toward outlet manifold (103).
106
103
101
A
201*
301*
106
102
201*
301*
2
1
1
202*
202*
3Not used on some models.
3
3
4Beveled seating surface must face ball (301).
4
4
03272B

819.4334 17
Service
Diaphragm Repair
Tools Required
DTorque wrench
D13 mm open–end wrench
D15 mm socket wrench (aluminum models) or 1 in. socket
wrench (stainless steel models)
D19 mm socket wrench
DO-ring pick
DLithium-base grease
Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to
page 23 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.
Warning
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pressure
Relief Procedure on page 9.
1. Relieve the pressure.
2. Remove the manifolds and disassemble the ball check
valves as explained on page 16.
3. Using a 13 mm socket wrench, remove the screws
(106 and 112) holding the fluid covers (101) to the air
covers (23). Pull the fluid covers (101) off the pump. See
Fig. 11.
Fig. 11
1
2
23
101
A2
B
Arrow (A) must point toward air valve (B).
Torque to 22–25 NSm. See Torque Sequence, page 28.
1
106
112 1
03273B

18 819.4334
Service
4. Loosen but do not remove the diaphragm shaft
bolts (107), using a 15 mm socket wrench (1 in. on stain-
less steel models) on both bolts.
5. Unscrew one bolt from the diaphragm shaft (24) and
remove the o-ring (108), fluid side diaphragm plate (105),
PTFE diaphragm (403, used on PTFE models only), dia-
phragm (401), and air side diaphragm plate (104). See
Fig. 12.
6. 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
bolt (107) from the shaft. Disassemble the remaining
diaphragm assembly.
7. Inspect the diaphragm shaft (24) for wear or scratches. If
it is damaged, inspect the bearings (19) in place. If the
bearings are damaged, refer to page 20.
8. 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.
9. Clean all parts and inspect for wear or damage. Replace
parts as needed.
Reassembly
1. Install the shaft u-cup packings (402*) so the lips face
out of the housing (1). Lubricate the packings. See
Fig. 12.
2. Install the diaphragm assembly on one end of the
shaft (24) as follows:
a. Install the o-ring (108*) on the shaft bolt (107).
b. Install the fluid side diaphragm plate (105) on the
bolt so the rounded side faces in, toward the dia-
phragm (401).
c. On PTFE models only, install the PTFE dia-
phragm (403*). Make certain the side marked AIR
SIDE faces the center housing (1).
d. Install the diaphragm (401*) on the bolt. Make
certain the side marked AIR SIDE faces the center
housing (1).
e. Install the air side diaphragm plate (104) so the
recessed side faces the diaphragm (401).
f. Apply medium-strength LoctiteRor equivalent to the
bolt (107) threads. Screw the bolt (107) into the
shaft (24) handtight.
3. Grease the length and ends of the diaphragm shaft (24),
and slide it through the housing (1).
4. Assemble the other diaphragm assembly to the shaft as
explained in step 2.
5. Hold one shaft bolt (107) with a wrench and torque the
other bolt to 27–34 NSm at 100 rpm maximum.
6. Align the 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 (106
and 112), handtight. Install the longer screws (112) in the
bottom holes of the covers. See Fig. 11. Using a 13 mm
socket wrench, torque the screws oppositely and evenly
to 22–25 NSm. See Torque Sequence, page 28.
7. Reassemble the ball check valves and manifolds as
explained on page 16.

819.4334 19
Service
0327503274
Fig. 12
1
3
4
2
24 104
403*
401*
108*
107
24
24 104 401*
403*
107
105
19 402*
Cutaway View, with Diaphragms in Place Cutaway View, with Diaphragms Removed
1
Lips face out of housing (1).
Rounded side faces diaphragm (401).
Air Side must face center housing (1).
1
Grease.
Apply medium-strength LoctiteRor equivalent.
Torque to 27–34 NSm at 100 rpm maximum.
Used on pumps with PTFE diaphragms only.
5
6
1
2
3
3
3
3
1
4
4
4
5
5
6
6
105
2
7Recessed side faces diaphragm (401).
7
7
03276B

20 819.4334
Service
Bearing and Air Gasket Removal
Tools Required
DTorque wrench
D10 mm socket wrench
DBearing puller
DO-ring pick
DPress, or block and mallet
Disassembly
NOTE: Do not remove undamaged bearings.
Warning
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pressure
Relief Procedure on page 9.
1. Relieve the pressure.
2. Remove the manifolds and disassemble the ball check
valves as explained on page 16.
3. Remove the fluid covers and diaphragm assemblies as
explained on page 17.
NOTE: If you are removing only the diaphragm shaft bear-
ing (19), skip step 4.
4. Disassemble the air valve as explained on page 14.
5. Using a 10 mm socket wrench, remove the screws (25)
holding the air covers (23) to the center housing (1). See
Fig. 13.
6. Remove the air cover gaskets (22). Always replace the
gaskets with new ones.
7. Use a bearing puller to remove the diaphragm shaft
bearings (19), air valve bearings (12) or pilot pin bear-
ings (15). Do not remove undamaged bearings.
8. If you removed the diaphragm shaft bearings (19), reach
into the center housing (1) with an o-ring pick and hook
the u-cup packings (402), then pull them out of the hous-
ing. Inspect the packings. See Fig. 12.
Reassembly
1. If removed, install the shaft u-cup packings (402*) so the
lips face out of the housing (1).
2. The bearings (12, 15, and 19) are tapered and can only
be installed one way. Insert the bearings into the center
housing (1), tapered end first. Using a press or a block
and rubber mallet, press-fit the bearing so it is flush with
the surface of the center housing.
3. Reassemble the air valve as explained on page 15.
4. Align the new air cover gasket (22) so the pilot pin (16)
protruding from the center housing (1) fits through the
proper hole (H) in the gasket.
5. Align the air cover (23) so the pilot pin (16) fits in the
middle hole (M) of the three small holes near the center
of the cover. Install the screws (25), handtight. See
Fig. 13. Using a 10 mm socket wrench, torque the
screws oppositely and evenly to 15–17 NSm.
6. Install the diaphragm assemblies and fluid covers as
explained on page 17.
7. Reassemble the ball check valves and manifolds as ex-
plained on page 16.