VERDER VERDERAIR VA-E50 User manual

Repair/Parts
VERDERAIR VERDERAIR
VERDERAIRVA VA VA- - -E50 E50 E50
Electric Electric
Electric- - -Operated Operated OperatedDiaphragm Diaphragm Diaphragm
Pump Pump
Pump859.0765
Rev.D
EN
2–Inch 2–Inch
2–Inchpumps pumps pumpswith with withelectric electric electricdrive drive drivefor for for󰘱uid 󰘱uid 󰘱uidtransfer transfer transferapplications. applications. applications.
Not Not
Notapproved approved approvedfor for foruse use usein in inexplosive explosive explosiveatmospheres atmospheres atmospheresor or orhazardous hazardous hazardouslocations locations locationsunless unless unlessotherwise otherwise otherwisestated. stated. stated.See See See
Approvals Approvals
Approvalspage page pagefor for formore more moreinformation. information. information.For For Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandinyour
Operationmanual.Save Save
Savethese these theseinstructions. instructions. instructions.
MaximumWorkingPressure:7bar(0.7
MPa,100psi).
Seepage8forapprovals.

Contents Contents
Contents
RelatedManuals................................................2
Warnings...........................................................3
PumpMatrix.......................................................6
Troubleshooting..................................................9
Repair................................................................11
PressureReliefProcedure............................11
CheckValveRepair.....................................11
DiaphragmRepair........................................13
CenterSectionRepair..................................15
LeakSensorRepair.....................................19
ReplacetheCompressor..............................20
TorqueInstructions.............................................21
Torquesequence.........................................21
Parts..................................................................23
KitsandAccessories....................................33
TechnicalData...................................................34
CustomerServices/Guarantee.............................39
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
859.0761VA–E50Electric-OperatedDiaphragmPump,Operation
2859.0765

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock.
•Turnoffandremovepowerbeforedisconnectinganycablesandbeforeservicingorinstalling
equipment.Forcart-mountedmodels,unplugthepowercord.Forallotherunits,disconnect
poweratthemainswitch.
•Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
•Wait󰘰veminutesforcapacitordischargebeforeopeningequipment.
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reand
explosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
•Donotoperateelectrostaticgunsinequipmentworkarea.
859.07653

Warnings
WARNING
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestSafetyDataSheet(SDS)fromdistributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
PRESSURIZED PRESSURIZED
PRESSURIZEDALUMINUM ALUMINUM ALUMINUMPARTS PARTS PARTSHAZARD HAZARD HAZARD
Useof󰘱uidsthatareincompatiblewithaluminuminpressurizedequipmentcancauseserious
chemicalreactionandequipmentrupture.Failuretofollowthiswarningcanresultindeath,
seriousinjury,orpropertydamage.
•Donotuse1,1,1-trichloroethane,methylenechloride,otherhalogenatedhydrocarbon
solventsor󰘱uidscontainingsuchsolvents.
•Donotusechlorinebleach.
•Manyother󰘱uidsmaycontainchemicalsthatcanreactwithaluminum.Contactyourmaterial
supplierforcompatibility.
4859.0765

Warnings
WARNING
THERMAL THERMAL
THERMALEXPANSION EXPANSION EXPANSIONHAZARD HAZARD HAZARD
Fluidssubjectedtoheatincon󰘰nedspaces,includinghoses,cancreatearapidriseinpressure
duetothethermalexpansion.Over-pressurizationcanresultinequipmentruptureandserious
injury.
•Openavalvetorelievethe󰘱uidexpansionduringheating.
•Replacehosesproactivelyatregularintervalsbasedonyouroperatingconditions.
PLASTIC PLASTIC
PLASTICPARTS PARTS PARTSCLEANING CLEANING CLEANINGSOLVENT SOLVENT SOLVENTHAZARD HAZARD HAZARD
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.
•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.
•SeeTechnical Technical
TechnicalData Data Datainthisandallotherequipmentinstructionmanuals.Read󰘱uidand
solventmanufacturer’sSafetyDataSheet(SDS)andrecommendations.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
859.07655

PumpMatrix
Pump Pump
PumpMatrix Matrix Matrix
Checktheidenti󰘰cationplate(ID)forthe
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:VA VA
VA- - -E50 E50 E50AA AA AAHY HY HYAC AC ACHY HY HYTB TB TBAC5K5 AC5K5 AC5K5
VA VA
VA- - -E50 E50 E50A A
AA A AHY HY HYAC AC
ACHY HY
HYTB TB TBAC5K5 AC5K5
AC5K5
PumpModelFluidSection
Material
DriveSection
Material
Check
ValveSeats
CheckValve
Balls
DiaphragmConnectionsOptions
NOTE: NOTE:
NOTE:Somecombinationsarenotpossible.Pleasecheckwithyourlocalsupplierorthepumpcon󰘰gurator
onwww.verderair.com.
Pump Pump
PumpFluid Fluid
FluidSection Section SectionMaterial Material MaterialDrive Drive DriveSection Section SectionMaterial Material MaterialCheck Check CheckValve Valve ValveSeats Seats Seats
VA VA
VA- - -E50 E50 E50A A
AAluminumA A
AAluminumGE GE
GEGeolast
C C
CConductive
PolypropyleneS S
SStainlessSteelHY HY
HYTPE
I I
ICastIronKY KY KYPVDF
K K
KPVDFPP PP PPPolypropylene
P P
PPolypropyleneSP SP
SPSantoprene
S S
SStainlessSteelSS SS SSStainlessSteel
6859.0765

PumpMatrix
Balls Balls
BallsDiaphragm Diaphragm DiaphragmConnections Connections
ConnectionsOptions Options Options
AC AC
ACAcetalGE GE GEGeolastFC FC FC- - -H H HCenterFlange,
Horizontal
Outlet
A15K5 A15K5
A15K5StandardACInductionMotor
(HighSpeedGearRatio)with
120VAirCompressor
GE GE
GEGeolastHY HY
HYTPEFC FC
FC- - -V V VCenterFlange,
VerticalOutletA25K5 A25K5
A25K5StandardACInductionMotor
(HighSpeedGearRatio)with
220VAirCompressor
HD HD
HD440CStainless
SteelSP SP
SPSantopreneFE FE
FEEndFlange
DIN/ANSIAC5K5 AC5K5
AC5K5StandardACInductionMotor
(HighSpeedGearRatio)
HY HY
HYTPETF TF TFPTFE/
Polychloroprene
2–Piece
TB TB
TBThreadedBSPAF5K5 AF5K5 AF5K5FlameproofACInductionMotor
(HighSpeedGearRatio)
NW NW
NWPolychloro-
prene
Weighted
TN TN
TNThreadedNPTAX5K5 AX5K5 AX5K5ATEXACInductionMotor(High
SpeedGearRatio)
SP SP
SPSantopreneB14K0 B14K0 B14K0StandardACInductionMotor
(MediumSpeedGearRatio)with
120VCompressor
SS SS
SS316Stainless
SteelB24K0 B24K0
B24K0StandardACInductionMotor
(MediumSpeedGearRatio)with
220VCompressor
TF TF
TFPTFEBC4K0 BC4K0
BC4K0StandardACInductionMotor
(MediumSpeedGearRatio)
BF4K0 BF4K0
BF4K0FlameproofACInductionMotor
(MediumSpeedGearRatio)
BX4K0 BX4K0
BX4K0ATEXACInductionMotor
(MediumSpeedGearRatio)
C12K2 C12K2
C12K2StandardACInductionMotor(Low
SpeedGearRatio)with120V
Compressor
C22K2 C22K2
C22K2StandardACInductionMotor(Low
SpeedGearRatio)with220V
Compressor
CC2K2 CC2K2
CC2K2StandardACInductionMotor(Low
SpeedGearRatio)
CF2K2 CF2K2
CF2K2FlameproofACInductionMotor
(LowSpeedGearRatio)
CX2K2 CX2K2
CX2K2ATEXACInductionMotor(Low
SpeedGearRatio)
WG WG
WGNoMotor,NoGearbox
859.07657

PumpMatrix
Approvals Approvals
Approvals
✦Aluminum,castiron,conductive
polypropylene,andstainlesssteelpumpswith
motorcodeXarecerti󰘰edto:
II2GExhdIIBT3Gb
✚Aluminum,castiron,conductive
polypropylene,andstainlesssteelpumpswith
motorcodeWGarecerti󰘰edto:
II2GExhIIBT3Gb
★MotorscodedFarecerti󰘰edto:
ClassI,Div1,GroupD,T3B
ClassII,Div1,GroupF&G,T3B
AllModels(exceptgearboxandcompressor
code1,ormotorcodeF)arecerti󰘰edto:
8859.0765

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
•FollowthePressureReliefProcedure,page11,
beforecheckingorservicingtheequipment.
•Checkallpossibleproblemsandcausesbefore
disassembly.
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Pumpisrunningtoofast,causing
cavitationbeforeprime.
Slowdownthecontroller(VFD)
Centersectionhasnoairpressure,
orairpressureistoolow.
Applyairpressuretocentersection
peryourapplicationrequirements.
Checkvalveballisseverelywornor
wedgedinseatormanifold.
Replacetheballandseat.
Thepumphasinsuf󰘰cientsuction
pressure.
Increasethesuctionpressure.See
theOperationmanual.
Seatisseverelyworn.Replacetheballandseat.
Outletorinletisrestricted.Removetherestriction.
Inlet󰘰ttingsormanifoldsareloose.Tighten.
Pumpcyclesbutwillnotprime
and/orpump.
Manifoldo-ringsaredamaged.Replaceo-rings.
Thecentersectionisexcessively
hot.
Thedriveshaftisbroken.Replace.
Checkvalveballs,seats,oro-rings
areworn.
Replace.
Manifoldscrewsor󰘱uidcover
screwsareloose.
Tighten.
Pumpfailstohold󰘱uidpressureat
stall.
DiaphragmshaftboltislooseTighten.
Motororcontrolleriswired
improperly.
Wirepermanual. Pumpwillnotcycle.
Theleakdetector(ifinstalled)has
tripped.
Checkdiaphragmforruptureor
incorrectinstallation.Repairor
replace.
Themotorisoperating,butthe
pumpwillnotcycle.
Thejawcouplingbetweenthe
motorandgearboxisnotconnected
properly.
Checktheconnection.
Suctionlineisclogged.Inspect;clear.
Checkballsarestickyorleaking.Cleanorreplace.
Pump󰘱owrateiserratic.
Diaphragm(orbackup)ruptured.Replace.
Pumpmakesunusualnoises.Pumpisoperatingnearoratstall
pressure.
Adjustairpressureorslowthepump
speed.
859.07659

Troubleshooting
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
A󰘰ttingisloose.Tighten.Inspectthreadsealant.
Looseordamagedo-ringsorshaft
seal.
Replace.
Airconsumptionishigherthan
expected.
Diaphragm(orbackup)ruptured.Replace.
Suctionlineisloose.Tighten.
Diaphragm(orbackup)ruptured.Replace.
Loosemanifolds,damagedseatsor
o-rings.
Tightenmanifoldboltsorreplace
seatsoro-rings.
Airbubblesin󰘱uid.
Loosediaphragmshaftbolt.Tighten.
Loosemanifoldscrewsor󰘱uidcover
screws.
Tighten.
Pumpleaks󰘱uidexternallyfrom
joints.
Manifoldo-ringswornout.Replaceo-rings.
AGFCIhastripped.Removethecontrollerfromthe
GFCIcircuit.
Supplypowerispoor.Determineand󰘰xthesourceofthe
powerproblem.
Thecontrollerfaultsorshutsdown.
Operationalparametersare
exceeded.
Seeperformancechart;ensure
pumpisoperatingwithinthe
continuousdutyrange.
Inletcheckclogged/improperly
installed
Removedebris/installproperly
Excessivemotorregenerationfault
fromVFD
BrokendiaphragmboltReplacebolt
NOTE: NOTE:
NOTE:ForproblemswithaVariableFrequencyDevice(VFD),seeyourVFDmanual.
10859.0765

Repair
Repair Repair
Repair
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressure
isrelievedmanually.Tohelppreventserious
injuryfrompressurized󰘱uid,suchassplashing
intheeyesoronskin,followthePressureRelief
Procedurewhenyoustoppumpingandbeforeyou
clean,check,orservicetheequipment.
1.Removepowerfromthesystem.
2.Openthedispensingvalve,ifused.
3.Openthe󰘱uiddrainvalvetorelieve󰘱uid
pressure.Haveacontainerreadytocatchthe
drainage.
4.Backoutregulatorknobtobleedanyinternal
airpressure.
Check Check
CheckValve Valve ValveRepair Repair Repair
Tools Tools
ToolsRequired Required Required
•Torquewrench
•10mmsocketwrench(plasticpumps)
•13mmsocketwrench(metalpumps)
•O-ringpick
NOTE: NOTE:
NOTE:Kitsareavailablefornewcheckvalveballs
andseatsinarangeofmaterials.O-ringandfastener
kitsalsoareavailable.
NOTE: NOTE:
NOTE:Toensureproperseatingofthecheckballs,
alwaysreplacetheseatswhenreplacingtheballs.
Also,replacetheo-ringseverytimethemanifoldis
removed.
Disassemble Disassemble
Disassemblethe the theCheck Check CheckValve Valve Valve
1.FollowthePressureReliefProcedure,page11.
Removepowerfromthemotor.Disconnectall
hoses.
2.NOTE NOTE
NOTEfor for forplastic plastic plasticpumps: pumps: pumps:Usehandtoolsuntil
thread-lockingadhesivepatchreleases.
3.Usea10mm(plasticpump)or13mm(metal
pump)socketwrenchtoremovethemanifold
fasteners(5)andnuts(42;usedonlyonstainless
steelmodels),thenremovetheoutletmanifold
(3).
4.Removetheseats(6),balls(7),ando-rings(8)if
present.
NOTE: NOTE:
NOTE:Somemodelsdonotuseo-rings(8).
5.Repeatfortheinletmanifold(4),o-rings(8)if
present,seats(6),andballs(7).
Tocontinuedisassembly,see
DisassembletheDiaphragms,page13.
Reassemble Reassemble
Reassemblethe the theCheck Check CheckValve Valve Valve
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
2.Reassembleinthereverseorder,followingall
notesintheillustration.Puttheinletmanifoldon
󰘰rst.Besuretheballchecksandmanifoldsare
assembledexactly exactly
exactlyasshown.Thearrows(A)on
the󰘱uidcovers(2)must must
mustpointtowardtheoutlet
manifold(3).
859.076511

Repair
Checkvalveassembly,aluminummodelshown
1
Applymedium-strength(blue)threadlocker.Torquetothevaluespeci󰘰edforyourpump.See
TorqueInstructions,page21.
2
Arrow(A)mustpointtowardoutletmanifold
3
Notusedonsomemodels.
4
Stainlesssteelmodelsincludenuts(42).
12859.0765

Repair
Diaphragm Diaphragm
DiaphragmRepair Repair Repair
Disassemble Disassemble
Disassemblethe the theDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page11.
Removepowerfromthemotor.Disconnectall
hoses.
2.Removethemanifoldsanddisassemble
theballcheckvalvesasexplainedin
CheckValveRepair,page11.
3.Usea13mmsocketwrenchtoremovethebolts
(5)fromthe󰘱uidcovers,thenpullthe󰘱uidcovers
offofthepump.
4.Toremovethediaphragms,thepistonmust
bemovedfullytooneside.Ifthepumpisnot
attachedtothegearbox,turntheshaftbyhand
tomovethepiston.Ifthepumpisstillattached
tothegearbox,loosenthescrewsandremove
thefancover.Turnthefanbyhandtorotatethe
shafttoshiftthepistontooneside.
TIP: TIP:
TIP:Theaircoverhas2holes(H),oneatthe
9o’clockpositionandanotheratthe3o’clock
position(shownbelow).Usepin(131),placedin
eitherhole(H)asabraceforthewrenchwhile
removingorinstallingdiaphragmbolts.
5.All All
AllDiaphragms Diaphragms Diaphragms
a.Metal Metal
MetalPumps: Pumps: Pumps:Holda28mmwrenchonthe
wrench󰘱atsoftheexposedpistonshaft.Use
anotherwrench(10mmhexkey)ontheshaft
bolt(13)toremoveit.Thenremoveallparts
ofthediaphragmassembly.
Plastic Plastic
PlasticPumps: Pumps: Pumps:Holda28mmwrenchon
thewrench󰘱atsoftheexposedpistonshaft.
Usea24mmsocketorboxendwrenchon
thehexofthe󰘱uidsidediaphragmplateto
removethecover.Thenusea10mmhex
keytoremovethebolt.
b.Rotatethedriveshafttomovethepiston
fullytooneside.Seeinstructionsinstep4.
Repeatstep6a.
6.Tocontinuewithdisassembly,see
DisassembletheCenterSection,page15.
859.076513

Repair
Reassemble Reassemble
Reassemblethe the theDiaphragms Diaphragms Diaphragms
Followallnotesintheillustrationsonpage15.These
notescontainimportant important
importantinformation.
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthe
centersection(driveshaft,piston,etc.),see
CenterSectionRepair,page15,beforeyouputthe
diaphragmsbackon.
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.Besurethecenter
sectioniscleananddry.
2.All All
AllDiaphragms-Metal Diaphragms-Metal Diaphragms-MetalPumps Pumps Pumps
a.Thoroughlycleanorreplacethediaphragm
bolt(13).Installtheo-ring(34).
b.Assemblethe󰘱uidsideplate(9),the
diaphragm(11),thebackupdiaphragm(12,
ifpresent),andtheairsidediaphragmplate
(10)ontheboltexactlyasshown.
c.Cleanthefemalethreadsofthepiston
shaftwithawirebrushdippedinsolventto
removeanyresidualthreadlocker.Apply
thread-lockingprimerandallowittodry.
d.Applymedium-strength(blue)threadlocker
tothethreadsofthebolt.
e.Holda28mmwrenchonthewrench󰘱ats
ofthepistonshaft.Screwtheboltontothe
shaftandtorqueto135N•m(100ft-lb).
f.Rotatethedriveshafttomovethepistonfully
tooneside.Seeinstructionsinstep4of
DisassembletheDiaphragms,page13.
g.Repeattoinstalltheotherdiaphragm
assembly.
3.All All
AllDiaphragms-Plastic Diaphragms-Plastic Diaphragms-PlasticPumps Pumps Pumps
a.Thoroughlycleanorreplacethediaphragm
bolt(13).Installtheo-ring(34).
b.Assemblethe󰘱uidsideplate(9),the
diaphragm(11),thebackupdiaphragm(12,
ifpresent),andtheairsidediaphragmplate
(10)ontheboltexactlyasshown.
c.Cleanthefemalethreadsofthepiston
shaftwithawirebrushdippedinsolventto
removeanyresidualthreadlocker.Apply
thread-lockingprimerandallowittodry.
d.Applymedium-strength(blue)threadlocker
tothethreadsofthebolt.
e.Holda28mmwrenchonthewrench󰘱ats
ofthepistonshaft.Screwtheboltontothe
shaftandtorqueto135N•m(100ft-lb).
f.Installano-ring(13b)andplug(13a)onthe
󰘱uidplate.
g.Rotatethedriveshafttomovethepistonfully
tooneside.Seeinstructionsinstep4of
DisassembletheDiaphragms,page13.
h.Repeattoinstalltheotherdiaphragm
assembly.
4.Attachthe󰘱uidcovers.Thearrowoneach󰘱uid
covermustpointtowardtheoutletmanifold.
Applymedium-strength(blue)threadlockertothe
boltthreads.SeeTorqueInstructions,page21,
totighten.
5.Reassemblethecheckvalvesandmanifolds.
SeeReassembletheCheckValve,page11.
6.Restoremotorcoolingfancoverandpin(131)to
theiroriginallocations.
1
Roundedsidefacesdiaphragm.2–Piece 2–Piece
2–Piece( ( (TF, TF, TF,HY, HY, HY,SP, SP, SP,and and andGE GE GE) ) )Models Models Models
2
Applymedium-strength(blue)thread
lockertothethreads.
3
AIRSIDEmarkingsondiaphragmmust
facethecenterhousing.
4
Ifthescrewcomeslooseorisreplaced,
applypermanent(red)threadlocker
todiaphragmsidethreads.Apply
medium-strength(blue)threadlockerto
shaftsidethreads.
5
Torqueto135N•m(100ft-lb)at100
rpmmaximum.
6
Applyprimertothefemalethreads.
Allowtodry.
14859.0765

Repair
Center Center
CenterSection Section SectionRepair Repair Repair
Disassemble Disassemble
Disassemblethe the theCenter Center CenterSection Section Section
Seetheillustrationsonpage18.
1.FollowthePressureReliefProcedure,page11.
Removepowerfromthemotor.Disconnectall
hoses.
2.Removethemanifoldsand
checkvalvepartsasdirectedin
DisassembletheCheckValve,page11.
3.Removethe󰘱uidcoversand
diaphragmsasdirectedin
DisassembletheDiaphragms,page13.
TIP: TIP:
TIP:Clampthegearboxbracket(15)tothe
bench.Leavethepumpconnectedtothemotor.
4.Usea10mmhexwrenchtoremove4bolts(117).
Pullthepumpoffthealignmenthousing(116).
TIP: TIP:
TIP:Itmaybenecessarytotapthepumpwitha
rubbermallettodisengagethecoupler.
5.Usea5/16hexwrenchtoremovetheplug(124).
Usea30mmsocketwrenchtoremovethe
bearingbolt(106)andtheo-ring(108)fromthe
top.
6.Turntheshaftsothegrooveontheshaftisatthe
top,inlinewiththealignmentmarkings.
7.Usea3/4–16bolttopushoutthedriveshaft
assembly(112).Youcanalsousethebearing
bolt(106),butremovethebearing(107)󰘰rst.Be
surethatthegrooveonthedriveshaftremains
alignedwiththemarkingsinthecentersection.
NOTE: NOTE:
NOTE:Removetheboltafterthedriveshaftis
freed.
NOTICE NOTICE
NOTICE
Properalignmentisessential.Donotapply
morethanabout1.1N•m(10in-lb)oftorque.
Excessivetorquecouldstripthehousing
thread.Ifyouencounterresistance,check
alignmentorcontactyourdistributor.
8.Theshaftcoupler(113)mightcomeoutwith
thedriveshaftassembly.Ifnot,removefrom
gearbox(118).
9.Removethesealcartridge(110),theo-ring(109)
andtheradialseal(111)fromthedriveshaft
assembly.
10.Slidethepistonassembly(102)outofthecenter.
11.Onlyremovethealignmenthousing(116)if
needed.Usea10mmhexwrenchtoremove4
bolts(120).Pullthealignmenthousingoffthe
gearbox(118).
12.Leavethegearboxcoupler(114)attachedtothe
gearboxshaft(118)unlessitisdamaged.Ifyou
needtoremoveit,abearingpullermustbeused.
859.076515

Repair
Reassemble Reassemble
Reassemblethe the theCenter Center CenterSection Section Section
1.Cleananddrythecenterhousing(101),the
centerofthepiston(102)andthedriveshaft
(112).
2.Inspectthepistonandcentersectionbearingsfor
excessivewearandreplaceifneeded.Grease
thepistonasshownandinstallitinthecenter
sectionwiththeslotonthetop,inlinewiththe
alignmentmarkingsinthecentersection.
3.Installtheo-ring(108)andapplymedium-strength
(blue)threadlockertothebearingbolt(106)
andscrewintothecentersection.Besurethat
thebearing(107)isintheslotonthepiston,as
shown.Besurethatthepistonmovesfreely.
Torquethebolt(106)to20–34N•m(15–25ft-lb).
4.Besurethesealingsurfaceofthedriveshaft
(112)isclean.Installthesealcartridge(110)and
theradialseal(111)onthedriveshaft.Thelips
ontheradialseal(111)mustfaceIN IN
INtowardthe
center.Inspectseallipfordamage.Replace
ifnecessary.
5.Installo-ring(109)tothecenterhousing(101).
6.Applyanti-seizelubricantonthematingedgesof
thedriveshaft,asshownintheillustration,page
18.
7.Centerthepistoninthehousingandinstall
thedriveshaftassembly(112)intothecenter
housing(101)withthegroovefacingup.
8.Inspecttheshaftcoupler(113)forwearand
replaceifneeded.Installonthedriveshaft.
9.Ifremoved,installthealignmenthousingtothe
centersection.Applymedium-strength(blue)
threadlockerandinstallthehousingscrews
(117).Torqueto15–18N•m(130–160in-lb).
10.Ifremoved,installthegearboxcoupler(114)
onthegearbox(118)shaft.UseanM12x30
boltandalargewasherinsertedintotheholein
theshafttopressthecouplerintoposition.The
couplerisinproperpositionwhenitis󰘱ushwith
theendoftheshaft.
11.Besurethegearboxcoupler(114)isaligned
properly.Turnbyhandifneeded.Connectthe
pumptothegearboxassembly,engagingthe
couplers.
12.Applymedium-strength(blue)threadlockerand
installthegearboxscrews(120).Torqueto
15–18N•m(130–160in-lb).
13.Besureo-ring(127)isontheplug(124).Install
theplugandtorqueto20–34N•m(15–25ft-lb).
14.SeeReassembletheDiaphragms,page14,and
ReassembletheCheckValve,page11.
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Repair
1
Applymedium-strength(blue)thread
lockertothreads.
2
Torqueto20–34N•m(15–25ft-lb).
3
LipsmustfaceIN IN
INtowardthecenter.
4
Applyanti-seizelubricantliberallyon
theradialsurfacesofthedriveshaft
assembly.
5
Installthedriveshaftassemblywith
thegroovefacingup.
6
Tightenscrewsinacrisscross
pattern,5turnsatatime,toengage
thecouplerevenly.Torqueto15–18
N•m(130–160in-lb).
7
Applylubricanttoinnermating
surface.
859.076517

Repair
Disconnect Disconnect
Disconnectthe the theMotor Motor Motorand and andGearbox Gearbox Gearbox
NOTE: NOTE:
NOTE:Normally,themotorremainsconnectedtothe
gearbox.Disconnectthemotoronlyifyoususpect
thatthemotororgearboxmustbereplaced.
TIP: TIP:
TIP:Clampthegearboxbracket(15)tothebench.
Startatstep1forATEXorFlameproofmotors.
StandardACmotors(ACxxx,A1xxx,orA2xxx)areof
onepiecewiththegearbox,sobeginwithstep3.
NOTE: NOTE:
NOTE:Useahoistandslingtoremovemotorweight
fromthegearboxduringremoval.
1.Usea3/4in.socketwrenchtoremove4screws
(122).
2.Pullthemotor(121)straightoffofthegearbox
(118).
3.Usea3/4in.socketwrenchtoremove4bolts
(17)andnuts(18,ifpresent).Liftthegearboxoff
ofthebracket.NOTE: NOTE:
NOTE:IfyouhaveanACmotor
withgearbox,liftthewholeunitoffofthebracket.
18859.0765

Repair
Leak Leak
LeakSensor Sensor SensorRepair Repair Repair
Theleaksensorcanbereplacedorre-positioned.
Whenproperlypositioned,thetwoarrowsimprinted
ontwoofthe󰘱atsurfacesoftheleaksensorhex
headareverticalandpointingdown.
Leak Leak
LeakSensor Sensor SensorTesting Testing Testing
Testingthecontinuityoftheleaksensorispossible
toensureproperoperation.Ifcontinuitytesting
indicatesthattheleaksensorisnotfunctional,
areplacementkit,819.1273,canbeordered
separately.
1.FollowthePressureReliefProcedure,page11.
Removepowerfromthemotor.
2.Totesttheleaksensorwithoutremovingfrom
thepump:
a.Notetheconnectionlocationsoftheleak
sensorwireswithintheVFDorother
monitoringdevice,thendisconnecttheleak
sensorwires.
b.Useanohmmeterattachedtotheleak
sensorleadstotesttheconductivityofthe
leaksensor.Continuityisaf󰘰rmedbya
readingof0-5ohms.
c.Loosentheleaksensorbushing1/2turn
(leaksensorarrowspointup).
d.Useanohmmeterattachedtotheleaksensor
leadstotesttheconductivityoftheleak
sensor.Anopencircuitshouldbeindicated.
Normaloperationpositionshownbydark
󰘱oat.Lighter󰘱oatlineindicatestheopen
circuitposition.
e.Ifthecontinuitytestsresultindicatethat
theleaksensorisnotfunctioningproperly,
proceedtostep3.Otherwise,tightenthe
bushingtoitsoriginalpositionsothatthe
arrowsontheleaksensorpointdown.Attach
theremovedleaksensorwirestothepoint
wheretheyweredisconnectedfromtheVFD
orothermonitoringdevice.
f.Applyairpressuretothepumpandusea
soapysolutionaroundthebushingtoensure
anairtightseal.Ifairbubblesappear,itwill
benecessarytoreturntothestepsabovefor
airpressurereliefandremovingthebushing
fromthepump.Applynewthreadsealer
onthebushingandinstallinthepumpso
thattheleaksensorisproperlypositioned.
Repeatthissteptotestforairleakagearound
thebushing.
3.Removeandreplacetheleaksensoratthe
pump:
a.Notetheconnectionlocationsoftheleak
sensorwireswithintheVFDorother
monitoringdevice,thendisconnecttheleak
sensorwires.
b.Removetheleaksensorandbushingfrom
thepumpcentersection.
c.Applythreadtapeorpastetothebushing
threadsandscrew󰘰ngertightintothepump.
d.Toensureawatertightseal,applyLoctite®
425Assure™threadlockersuppliedwiththe
leaksensorkittotheleaksensorthreads
andscrewtheleaksensorintothebushing.
e.Verifythattheleaksensorwasproperly
orientedinthepumpsothatthearrows
imprintedontheleaksensorhexheadare
verticalpositionedwiththearrowspointing
down.Itmaybenecessarytofurthertighten
boththebushingandleaksensortoachieve
properpositioning.
f.Useanohmmeterattachedtotheleak
sensorleadstotesttheconductivityofthe
leaksensor.Continuityisaf󰘰rmedbya
readingof0-5ohms.Attachtheleaksensor
wirestotheVFDorothermonitoringdevice.
g.Applyairpressuretothepumpandusea
soapysolutionaroundthebushingtoensure
anairtightseal.Ifairbubblesappear,itwill
benecessarytoreturntothestepsabovefor
airpressurereliefandremovingthebushing
fromthepump.Applynewthreadsealer
onthebushingandinstallinthepumpso
thattheleaksensorisproperlypositioned.
Repeatthissteptotestforairleakagearound
thebushing.
859.076519

Repair
Replace Replace
Replacethe the theCompressor Compressor Compressor
Toavoidinjuryfrom󰘰re,explosion,orelectric
shock,allelectricalwiringmustbedonebya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
1.FollowthePressureReliefProcedure,page11.
2.Removeelectricalpowerfromthepump.
3.Removethe8boltsholdingthepumptothe
mountingsurface.
4.Tipthepumponitssidetoprovideaccesstothe
compressorbox.
5.Removeriserbracket(35).
6.Removetheairline(A1)fromthecompressor.
Disconnectthecompressorwiresattheterminal
block(L1,L2,andground).Removethefour
bolts,andcarefullypullthecompressoroutof
thebox.
7.Usethefourboltstoinstallthenewcompressor.
ConnecttheairlinefromA1toA1,asshown.
8.Connectthewiresfromthenewcompressorto
theterminalblock,asshown.
9.Replaceriserbracket.
10.Returnthepumptoitsmountinglocation.Secure
itwiththe8bolts.
11.Returnpowertothepump.
L1
L2
A
20859.0765