VERDER Verderair VA-E80 Use and care manual

Repair/Parts
Verderair Verderair
VerderairVA VA VA- - -E80 E80 E80
Electric Electric
Electric- - -Operated Operated OperatedDiaphragm Diaphragm Diaphragm
Pump Pump
Pump859.0635
Rev.D
EN
3 3
3- - -Inch Inch 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 explosive
atmospheres atmospheres
atmospheresor or orhazardous hazardous hazardouslocations locations locationsunless unless unlessotherwise otherwise otherwisestated. stated. stated.
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:5.5bar
(0.55MPa,80psi)
Seepage7forapprovals.

Contents Contents
Contents
RelatedManuals................................................2
Warnings...........................................................3
Con󰘰gurationNumberMatrix...............................6
Troubleshooting..................................................8
Repair................................................................10
PressureReliefProcedure............................10
CheckValveRepair.....................................10
StandardDiaphragmReplacement................12
CenterSectionRepair..................................14
LeakSensorRepair.....................................18
ReplacetheCompressor..............................19
TorqueInstructions.............................................20
TorqueSequence........................................20
Parts..................................................................22
KitsandAccessories....................................31
TechnicalData...................................................32
CustomerServices/Guarantee.............................35
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
859.0634VA-E80Electric-OperatedDiaphragmPump,Operation
2859.0635

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
DANGER
SEVERE SEVERE
SEVEREELECTRIC ELECTRIC ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentcanbepoweredbymorethan240V.Contactwiththisvoltagewill
causedeathorseriousinjury.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesand
beforeservicingequipment.
•Thisequipmentmustbegrounded.Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocal
codesandregulations.
WARNING
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.
859.06353

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.
4859.0635

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.
859.06355

CongurationNumberMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix 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- - -E80AASSTFTFTNAC5 E80AASSTFTFTNAC5 E80AASSTFTFTNAC5
VA VA
VA- - -E E E80 80
80A A
AA A ASS SS
SSTF TF
TFTF TF TFTN TN TNAC5 AC5
AC5
Pump
Model
Pump
Size
Wetted
Section
Material
Center
Section
Material
SeatsBallsDiaphragmsConnectionsOptions
NOTE: NOTE:
NOTE:Somecombinationsarenotpossible.Please
checkwithyourlocalsupplieroronverderair.com.
Pump Pump
Pump
Model Model
Model
Pump Pump
PumpSize Size SizeWetted Wetted WettedSection Section SectionMaterial Material MaterialCenter Center CenterSection Section SectionMaterial Material Material
VA VA
VA- - -E E E80 80
8080mmA A
AAluminumA A AAluminum
P P
PPolypropylene
S S
SStainlessSteel
Seat Seat
SeatMaterial Material MaterialBall Ball
BallMaterial Material MaterialDiaphragm Diaphragm
DiaphragmMaterial** Material** Material**Connections Connections ConnectionsOptions Options Options
BN BN
BNBuna-N*AC AC
ACAcetalGE GE GEGeolastFC FC
FCCenter
Flanged,80
mm(3in.)
DIN/ANSI
AC5 AC5
AC5Standard
Induction
Motor
GE GE
GEGeolastBN BN
BNBuna-NTF TF TFPTFETN TN TNThreadedNPTA25 A25
A25Standard
Motor/240V
Compressor
HY HY
HYHytrel*GE GE
GEGeolastSP SP SPSantopreneTB TB
TBThreadedBSPWG WG
WGNoMotoror
Compressor
SP SP
SPSantopreneTF TF
TFPTFEHY HY HYHytrelAX5 AX5 AX5ATEX
Induction
Motor
SS SS
SSStainlessSteelSP SP SPSantopreneAF5 AF5
AF5Flameproof
Induction
Motor
PP PP
PPPolypropylene
*ModelswithBuna-NorHytrelseatsdonothavemanifold/seato-rings.
**Alldiaphragmshavea󰘰ber-reinforcedNeoprenebacker.
6859.0635

CongurationNumberMatrix
Approvals Approvals
Approvals
✦Aluminumandstainlesssteelpumpswith
optioncodeAX5arecerti󰘰edto:
II2GExhdIIBT3Gb
✚Aluminumandstainlesssteelpumpswith
optioncodeWGarecerti󰘰edto:
II2GExhIIBT3Gb
★PumpoptionscodedAF5arecerti󰘰edto:
ClassI,Div1,GroupD,T3B
ClassII,Div1,GroupF&G,T3B
AllModels(exceptoptioncodeAF5)are
marked:
859.06357

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
•FollowthePressureReliefProcedure,page10,
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.
8859.0635

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.
859.06359

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.Removepowertothesystem.
2.Openthe󰘱uiddrainvalvetorelieve󰘱uid
pressure.Haveacontainerreadytocatchthe
drainage.
3.Shutoffthemasterairvalve.
4.Turndowncentersectionregulatortozeroto
relieveairpressureincentersection.
Check Check
CheckValve Valve ValveRepair Repair Repair
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,page10.
Removepowertothemotor.Disconnectall
hoses.
2.NOTE NOTE
NOTEfor for forplastic plastic plasticpumps: pumps: pumps:Usehandtoolsuntil
thread-lockingadhesivepatchreleases.
3.Removethemanifoldfasteners(29)andnuts
(33;usedonlyonstainlesssteelandplastic
models),andwashers(28;usedonlyonstainless
steelandplasticmodels),thenremovetheoutlet
manifold(24).
4.Removetheseats(26),balls(27),ando-rings
(25)ifpresent.
NOTE: NOTE:
NOTE:Somemodelsdonotuseo-rings(25).
5.Repeatfortheinletmanifold(23),o-rings(25)if
present,seats(26),andballs(27).
Tocontinuedisassembly,see
DisassembletheStandardDiaphragms,page12.
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(24).
10859.0635

Repair
Check Check
Checkvalve valve valveassembly, assembly, assembly,aluminum aluminum aluminummodel model modelshown shown shown
1
Applymedium-strength(blue)threadlocker.Torquetothevaluespeci󰘰edforyourpump.See
TorqueInstructions,page20.
2
Arrow(A)mustpointtowardoutletmanifold.
3
Notusedonsomemodels.
4
Plasticandstainlesssteelmodelsincludenuts(33)andwashers(28).
859.063511

Repair
Standard Standard
StandardDiaphragm Diaphragm DiaphragmReplacement Replacement Replacement
Disassemble Disassemble
Disassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page10.
Removepowertothemotor.Disconnectall
hoses.
2.Removethemanifoldsanddisassemble
theballcheckvalvesasexplainedin
CheckValveRepair,page10.
3.Removethebolts(29)fromthe󰘱uidcovers,then
pullthe󰘱uidcoversoffofthepump.
4.Toremovethediaphragms,thepistonmust
bemovedfullytooneside.Ifthepumpisnot
attachedtothegearbox,turntheshaftbyhand
tomovethepiston.Ifthepumpisstillattached
tothegearbox,loosenthescrewsandremove
thefancover.Turnthefanbyhandtorotatethe
shafttoshiftthepistontooneside.
5.Holda28mmwrenchonthewrench󰘱atsofthe
exposedpistonshaft.Useanotherwrenchon
theshaftbolt(20)toremoveit.Thenremoveall
partsofthediaphragmassembly.
6.Rotatethedriveshafttomovethepistonfullyto
theotherside.Seeinstructionsinstep4.Repeat
step5.
7.Tocontinuewithdisassembly,see
DisassembletheCenterSection,page14.
12859.0635

Repair
Reassemble Reassemble
Reassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthe
centersection(driveshaft,piston,etc.),see
CenterSectionRepair,page14,beforeyouputthe
diaphragmsbackon.
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.Besurethecenter
sectioniscleananddry.
2.Thoroughlycleanorreplacethediaphragmbolt
(20).Installtheo-ring(54,metalpumponly)and
washer(21,metalpumponly).
3.Assemblethe󰘱uidsideplate(19),thediaphragm
(16),thebackupdiaphragm(17),andtheair
sidediaphragmplate(15)ontheboltexactlyas
shown.
4.Cleanthefemalethreadsofthepistonshaft
withawirebrushdippedinsolventtoremove
anyresidualthreadlocker.Applythread-locking
primerandallowittodry.
5.Applymedium-strength(blue)threadlockerto
thethreadsofthebolt.
6.Holda28mmwrenchonthewrench󰘱atsofthe
pistonshaft.Screwtheboltontotheshaftand
torqueto203N•m(150ft-lb).
7.Rotatethedriveshafttomovethepistonfully
tooneside.Seeinstructionsinstep4of
DisassembletheStandardDiaphragms,page12.
8.Repeattoinstalltheotherdiaphragmassembly.
9.Attachthe󰘱uidcovers.Thearrowoneach󰘱uid
covermustpointtowardtheoutletmanifold.
Applymedium-strength(blue)threadlockertothe
boltthreads.SeeTorqueInstructions,page20,
totighten.
10.Reassemblethecheckvalvesandmanifolds.
SeeReassembletheCheckValve,page10.
11.Restoremotorcoolingfancoverandpin(131)to
theiroriginallocations.
1
Roundedsidefacesdiaphragm.
2
Applymedium-strength(blue)thread
lockertothethreads.
3
AIRSIDEmarkingsondiaphragmmust
facethecenterhousing.
4
Torqueto203N•m(150ft-lb)at100
rpmmaximum.
5
Applyprimertothefemalethreads.
Allowtodry.
859.063513

Repair
Center Center
CenterSection Section SectionRepair Repair Repair
Disassemble Disassemble
Disassemblethe the theCenter Center CenterSection Section Section
SeetheillustrationsinCenterSection,page28.
1.FollowthePressureReliefProcedure,page10.
Removepowertothemotor.Disconnectall
hoses.
2.Removethemanifoldsand
checkvalvepartsasdirectedin
DisassembletheCheckValve,page10.
3.Removethe󰘱uidcoversand
diaphragmsasdirectedin
DisassembletheStandardDiaphragms,page12.
TIP: TIP:
TIP:Clampthegearboxbracket(6or8)tothe
bench.Leavethepumpconnectedtothemotor.
4.Usea10mmhexwrenchtoremove4bolts(3).
Pullthepumpoffthealignmenthousing(110).
TIP: TIP:
TIP:Itmaybenecessarytotapthepumpwitha
rubbermallettodisengagethecoupler.
5.Usea5/16hexwrenchtoremovetheplug(124).
Usea30mmsocketwrenchtoremovethe
bearingbolt(114)andtheo-ring(113)fromthe
top.
6.Turntheshaftsothegrooveontheshaft(B)isat
thetop,inlinewiththealignmentmarkings(C).
7.Usea3/4-16bolttopushoutthedriveshaft
assembly(109).Youcanalsousethebearing
bolt(114),butremovethebearing(112)󰘰rst.Be
surethatthegrooveonthedriveshaftremains
alignedwiththemarkingsinthecentersection.
NOTE: NOTE:
NOTE:Removetheboltafterthedriveshaftis
freed.
NOTICE NOTICE
NOTICE
Properalignmentisessential.Donotapply
morethanabout14N•m(10ft-lbs)oftorque.
Excessivetorquecoulddamagethehousing
thread.Ifyouencounterresistance,check
alignmentorcontactyourdistributor.
8.Theshaftcoupler(115)mightcomeoutwith
thedriveshaftassembly.Ifnot,removefrom
gearbox(118).
9.Removethesealcartridge(106),theo-ring(108)
andtheradialseal(107)fromthedriveshaft
assembly.
10.Slidethepistonassembly(105)outofthecenter.
11.Onlyremovethealignmenthousing(110)if
needed.Usea10mmhexwrenchtoremove4
bolts(111).Pullthealignmenthousingoffthe
gearbox(118).
12.Leavethegearboxcoupler(118a)attachedtothe
gearboxshaft(118)unlessitisdamaged.Ifyou
needtoremoveit,abearingpullermustbeused.
14859.0635

Repair
Reassemble Reassemble
Reassemblethe the theCenter Center CenterSection Section Section
1.Cleananddrythecenterhousing(101),the
centerofthepiston(105)andthedriveshaft
(109).
2.Inspectthepistonandcentersectionbearings
forexcessivewearandreplaceifneeded.Install
thepistoninthecentersectionwiththesloton
thetop,inlinewiththealignmentmarkingsinthe
centersection.
3.Installtheo-ring(113)andapplymedium-strength
(blue)threadlockertothebearingbolt(114)
andscrewintothecentersection.Besurethat
thebearing(112)isintheslotonthepistonas
shown.Besurethatthepistonmovesfreely.
Torquethebolt(114)to20–34N•m(15–25ft-lb).
4.Besurethesealingsurfaceofthedriveshaft
(109)isclean.Installthesealcartridge(106)and
theradialseal(107)onthedriveshaft.Thelips
ontheradialseal(107)mustfaceIN IN
INtowardthe
center.Inspectseallipfordamage.Replace
ifnecessary.
5.Installo-ring(108)tothecenterhousing(101).
6.Applyanti-seizelubricantonthematingedgesof
thedriveshaftasshownintheillustration,page
17.
7.ApplyLoctite®Primer7471andRetaining
Compound641tothebearingboreandouter
race.Assembleimmediately.Allowtocurefora
minimumof12hoursbeforerunningthepump.
8.Centerthepistoninthehousingandinstall
thedriveshaftassembly(109)intothecenter
housing(101)withthegroovefacingup.
9.Inspecttheshaftcoupler(115)forwearand
replaceifneeded.Installonthedriveshaft.
10.Ifremoved,installthealignmenthousingtothe
centersection.Applymedium-strength(blue)
threadlockerandinstallthehousingscrews
(111).Torqueto15–18N•m(130–160in-lb).
11.Ifremoved,installthegearboxcoupler(4)onthe
gearboxshaft.UseanM12x30boltandalarge
washerinsertedintotheholeintheshafttopress
thecouplerintoposition.Thecouplerisinproper
positionwhenitis󰘱ushwiththeendoftheshaft.
12.Besurethegearboxcoupler(4)isaligned
properly.Turnbyhandifneeded.Connectthe
pumptothegearboxassembly,engagingthe
couplers.
13.Applymedium-strength(blue)threadlockerand
installthegearboxscrews(3).Torqueto15–18
N•m(130–160in-lb).
14.Besureo-ring(127)isontheplug(124).Install
theplugandtorqueto20–34N•m(15–25ft-lb).
15.SeeReassembletheStandardDiaphragms,page
13,andReassembletheCheckValve,page10.
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Repair
1
Applymedium-strength(blue)thread
lockertothreads.
2
Torqueto20–34N•m(15–25ft-lb).
3
LipsmustfaceIN IN
INtowardthecenter.
4
ApplyLoctite®Primer7471and
RetainingCompound641tothe
bearingboreandouterrace.
Assembleimmediately.Allowtocure
foraminimumof12hoursbefore
runningthepump.
5
Installthedriveshaftassemblywith
thegroovefacingup.
6
Tightenscrewsinacrisscross
pattern,5turnsatatime,toengage
thecouplerevenly.Torqueto15–18
N•m(130–160in-lb).
7
Applylubricanttoinnermating
surface.
8
Applyanti-seizelubricantliberallyon
thisradialsurfaceofthedriveshaft
assembly.
16859.0635

Repair
Disconnect Disconnect
Disconnectthe the theMotor Motor Motorand and andGearbox Gearbox Gearbox
NOTE: NOTE:
NOTE:Normally,themotorremainsconnectedtothe
gearbox.Disconnectthemotoronlyifyoususpect
thatthemotororgearboxmustbereplaced.
TIP: TIP:
TIP:Clampthegearboxbrackettothebench.
Startatstep1forATEXorFlameproofmotors.
StandardACmotorsareofonepiecewiththe
gearbox,sobeginwithstep3.
NOTE: NOTE:
NOTE:Useahoistandslingtoremovemotorweight
fromthegearboxduringremoval.
1.Usea3/4in.socketwrenchtoremove4screws
(122).
2.Pullthemotor(121)straightoffofthegearbox
(118).
3.Usea3/4in.socketwrenchtoremove4bolts(7)
andnuts(11,ifpresent).Liftthegearboxoffof
thebracket.NOTE: NOTE:
NOTE:IfyouhaveanACmotorwith
gearbox,liftthewholeunitoffofthebracket.
859.063517

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,page10.
RemovepowertothemotorandVFD.
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.Ifthecontinuitytestresultindicatesthat
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.
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Repair
Replace Replace
Replacethe the theCompressor Compressor Compressor
Toavoidinjuryfrom󰘰re,explosion,orelectric
shock,allelectricalwiringmustbedonebya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
1.FollowthePressureReliefProcedure,page10.
2.Removeelectricalpowertothepump.
3.Removethe8boltsholdingthepumptothe
mountingsurface.
4.Tipthepumponitssidetoprovideaccesstothe
compressorbox.
5.Removeriserbracket(8).
6.Removetheairline(A1)fromthecompressor.
Disconnectthecompressorwiresattheterminal
block(L1,L2,andground).Removethefour
boltsandcarefullypullthecompressoroutof
thebox.
7.Usethefourboltstoinstallthenewcompressor.
ConnecttheairlinefromA1toA1asshown.
8.Connectthewiresfromthenewcompressorto
theterminalblockasshown.
9.Replaceriserbracket.
10.Returnthepumptoitsmountinglocation.Secure
itwiththe8bolts.
11.Returnpowertothepump.
L1
L2
A
859.063519

TorqueInstructions
Torque Torque
TorqueInstructions Instructions Instructions
If󰘱uidcoverormanifoldfastenershavebeen
loosened,itisimportanttotorquethemusingthe
followingproceduretoimprovesealing.
NOTE: NOTE:
NOTE:Fluidcoverandmanifoldfastenershavea
thread-lockingadhesivepatchappliedtothethreads.
Ifthispatchisexcessivelyworn,thefastenersmay
loosenduringoperation.Replacescrewswithnew
onesorapplymedium-strength(blue)threadlocker
tothethreads.
NOTE: NOTE:
NOTE:Alwayscompletelytorque󰘱uidcoversbefore
torquingmanifolds.
1.Startall󰘱uidcoverscrewsafewturns.Then,turn
downeachscrewjustuntilheadcontactscover.
2.Turneachscrewby1/2turnorlessworkingina
crisscrosspatterntospeci󰘰edtorque.
3.Repeatformanifolds.
Torque Torque
TorqueSequence Sequence Sequence
Aluminum Aluminum
AluminumPumps Pumps Pumps
Torqueboltsto74.6–81.3N•m(55-60ft-lb)
1.Left/RightFluidCovers 2.InletManifold 3.OutletManifold
SIDEVIEW
BOTTOMVIEWTOPVIEW
20859.0635