1' aluminum air-powered diaphragm pump - sec b5 - page 28€¦ · converting pump for piping...

LINCOLN® • One Lincoln Way, St. Louis, MO 63120-1578 • Customer Service (314) 679-4300

520-357-000 12/01 Revision A Form # 403161

Engineering Data and Temperature Limitations .................................................. 1

Performance Curve ............................................................................................... 2

Dimensions ........................................................................................................... 3

Metric Dimensions ................................................................................................ 4

Principle of Pump Operation ................................................................................ 5

Installation and Start-Up ....................................................................................... 5

Air Supply ............................................................................................................. 5

Air Valve Lubrication ............................................................................................. 5

Air Line Moisture .................................................................................................. 5

Air Inlet and Priming ............................................................................................. 5

Between Uses ...................................................................................................... 5

Installation Guide .................................................................................................. 6

Troubleshooting .................................................................................................... 7

Warranty ............................................................................................................... 7

Recycling .............................................................................................................. 8

Important Safety Information ................................................................................ 8

Composite Repair Parts Drawing ......................................................................10

Available Service and Conversion Kits ..............................................................10

Composite Repair Parts List ..............................................................................11

Air Distribution Valve Assembly Drawing and Parts List ....................................12

Air Distribution Valve Servicing ..........................................................................13

Pilot Valve Assembly Drawing and Parts List .....................................................14

Pilot Valve Servicing ...........................................................................................15

Actuator Plunger Servicing .................................................................................15

Diaphragm Service Drawing, with Overlay ........................................................16

Diaphragm Service Drawing, Non-Overlay .......................................................16

Diaphragm Servicing ..........................................................................................17

Overlay Diaphragm Servicing ............................................................................17

Check Valve Servicing ........................................................................................18

Check Valve Drawing .........................................................................................18

Pumping Hazardous Liquids ..............................................................................19

Converting Pump for Piping Exhaust Air ............................................................19

Converted Exhaust Illustration ...........................................................................19

SERVICE & OPERATING MANUAL

Models 85627, 85628, 856291" Aluminum Air-Powered Diaphragm Pump

Table of ContentsCE

U.S. Patent #5,996,6276,241,487Other U.S. PatentsApplied for

Section - B5Section - B5Section - B5Section - B5Section - B5Page - 28Page - 28Page - 28Page - 28Page - 28

To order call 1-800-548-1191 or visit www.partdeal.com - [email protected]

520-357-000 12/01 Revision A Page 1

Models 85627,85628, 856291" Aluminum Air-PoweredDiaphragm Pump

ENGINEERING, PERFORMANCE& CONSTRUCTION DATA

CE

U.S. Patent #5,996,6276,241,487Other U.S. PatentsApplied for

BunaBunaBunaBunaBuna General purpose, oil-resistant. Shows good solvent, oil, water and hydraulic fluid resistance.Should not be used with highly polar solvents like acetone and MEK, ozone, chlorinated 190°F -10°F 50° to 140°Fhydrocarbons and nitro hyrdrocarbons. 88°C -23°C 10°C to 60°C

Neoprene Neoprene Neoprene Neoprene Neoprene All purpose. Resistant to vegetable oil. Generally not affected by moderate chemicals,fats, greases and many oils and solvents. Generally attacked by strong oxidizing acids, ketones, 170°F -10°F 50° to 130°Festers, nitro hydrocarbons and chlorinated aromatic hydrocarbons. 77°C -23°C 10°C to 54°C

SantopreneSantopreneSantopreneSantopreneSantoprene® Injection molded thermoplastic elastomer with no fabric layer. Long mechanical flex 212°F -10°F 50° to 212°Flife. Excellent abrasion resistance. 100°C -23°C 10°C to 100°C

VVVVVirgin PTFE irgin PTFE irgin PTFE irgin PTFE irgin PTFE Chemically inert, virtually impervious. Very few chemicals are known to react chemically withPTFE: molten alkali metals, turbulent liquid or gaseous fluorine and a few fluoro-chemicals such as 212°F -35°F 50°F to 212°Fchlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures. 100°C -37°C 10°C to 100°C

PolypropylenePolypropylenePolypropylenePolypropylenePolypropylene 150°F -40°F65°C -40°C

PolyethylenePolyethylenePolyethylenePolyethylenePolyethylene 180°F -40°F 50°F to 140°F82°C -40°C 10°C to 60°C

HytrelHytrelHytrelHytrelHytrel®®®®® 190°F -10°F 50°F to 140°F

88°C -23°C 10°C to 60°C

MaterialsMaterialsMaterialsMaterialsMaterials Maximum*Maximum*Maximum*Maximum*Maximum* Minimum*Minimum*Minimum*Minimum*Minimum* Optimum**Optimum**Optimum**Optimum**Optimum**Operating TOperating TOperating TOperating TOperating Temperaturesemperaturesemperaturesemperaturesemperatures

INTAKE/DISCHARGE PIPE SIZE1" NPT(internal)

CAPACITY0 to 45 gallons per minute(0 to 170 liters per minute)

AIR VALVENo-lube, no-stall

design

SOLIDS-HANDLINGUp to .25 in. (6mm)

HEADS UP TO125 psi or 289 ft. of water(8.6 Kg/cm2 or 86 meters)

DISPLACEMENT/STROKE.11 Gallon / .42 liter

CAUTION! Operating temperature limitations are as follows:

Air Inlet Side View Air Exhaust Side View


520-357-000 12/01 Revision A Page 2

Performance Curve

Capacity

Liters per minute

Hea

d

5(00)

15(00)20(34)

U.S. Gallons per minute

25(00)

0 5 10 15 20 25 30 35 40 45

160140120100806040200

BA

R

PS

I100

80

60

40

20

00

1

2

3

4

5

6

7

30

2025

1015

5

9.1

67.6

34.5

1.5

NP

SH

R

ME

TE

RS

FE

ET

100 PSI (6.8 Bar)

60 PSI (4.08 Bar)

20 PSI (1.36 Bar) Air Inlet Pressure

40 PSI (2.72 Bar)

80 PSI (5.44 Bar)

10(17)

30(51)

35(00)

40(68)


520-357-000 12/01 Revision A Page 3

DISCHARGE PORT1" NPT

SUCTION PORT1" NPT

STANDARD PUMP SHOWNWITH ENCAPSULATED MUFFLER

STANDARD ENCAPSULATED MUFFLER1" NPT EXHAUST PORTFOR OPTIONAL MUFFLERSTYLES OR PIPING EXHAUSTAIR IN SUBMERGEDAPPLICATIONS.

AIR INLET1/2" NPT

Dimensions:

Dimensions in InchesDimensional Tolerance:±1/8"

DIMENSION A

Standard Pump 10 3/8"

Mesh Muffler 12 7/8"


520-357-000 12/01 Revision A Page 4

Metric Dimensions:

DISCHARGE PORT1" NPT

SUCTION PORT1" NPT

STANDARD PUMP SHOWNWITH ENCAPSULATED MUFFLER

STANDARD ENCAPSULATED MUFFLER1" NPT EXHAUST PORTFOR OPTIONAL MUFFLERSTYLES OR PIPING EXHAUSTAIR IN SUBMERGEDAPPLICATIONS.

Dimensions in MillimetersDimensional Tolerance:± 3mm

DIMENSION A

Standard Pump 264mm

Mesh Muffler 327mm


520-357-000 12/01 Revision A Page 5

PRINCIPLE OF PUMP OPERATIONThis ball type check valve pump is

powered by compressed air and is a 1:1ratio design. The inner side of onediaphragm chamber is alternatelypressurized while simultaneouslyexhausting the other inner chamber. Thiscauses the diaphragms, which areconnected by a common rod securedby plates to the centers of thediaphragms, to move in a reciprocatingaction. (As one diaphragm performs thedischarge stroke the other diaphragmis pulled to perform the suction strokein the opposite chamber.) Air pressureis applied over the entire inner surfaceof the diaphragm while liquid isdischarged from the opposite side of thediaphragm. The diaphragm operates ina balanced condition during thedischarge stroke which allows the pumpto be operated at discharge heads over200 feet (61 meters) of water.

For maximum diaphragm life, keepthe pump as close to the liquid beingpumped as possible. Positive suctionhead in excess of 10 feet of liquid (3.048meters) may require a back pressureregulating device to maximizediaphragm life.

Alternate pressurizing andexhausting of the diaphragm chamberis performed by an externally mounted,pilot operated, four way spool type airdistribution valve. When the spool shiftsto one end of the valve body, inletpressure is applied to one diaphragmchamber and the other diaphragmchamber exhausts. When the spool

shifts to the opposite end of the valvebody, the pressure to the chambers isreversed. The air distribution valve spoolis moved by a internal pilot valve whichalternately pressurizes one end of theair distribution valve spool whileexhausting the other end. The pilot valveis shifted at each end of the diaphragmstroke when a actuator plunger iscontacted by the diaphragm plate. Thisactuator plunger then pushes the end ofthe pilot valve spool into position toactivate the air distribution valve.

The chambers are connected withmanifolds with a suction and dischargecheck valve for each chamber,maintaining flow in one direction throughthe pump.

INSTALLATION AND START-UPLocate the pump as close to the

product being pumped as possible. Keepthe suction line length and number offittings to a minimum. Do not reduce thesuction line diameter.

For installations of rigid piping, shortsections of flexible hose should beinstalled between the pump and thepiping. The flexible hose reducesvibration and strain to the pumpingsystem. A surge suppressor isrecommended to further reduce pulsationin flow.

AIR SUPPLYAir supply pressure cannot exceed

125 psi (8.6 bar). Connect the pump airinlet to an air supply of sufficient capacityand pressure required for desiredperformance. When the air supply line

is solid piping, use a short length offlexible hose not less than ½" (13mm)in diameter between the pump and thepiping to reduce strain to the piping. Theweight of the air supply line, regulatorsand filters must be supported by somemeans other than the air inlet cap. Failureto provide support for the piping mayresult in damage to the pump. A pressureregulating valve should be installed toinsure air supply pressure does notexceed recommended limits.

AIR VALVE LUBRICATIONThe air distribution valve and the pilot

valve are designed to operate WITHOUTlubrication. This is the preferred mode ofoperation. There may be instances ofpersonal preference or poor quality airsupplies when lubrication of thecompressed air supply is required. Thepump air system will operate withproperly lubricated compressed airsupply. Proper lubrication requires theuse of an air line lubricator set to deliverone drop of SAE 10 non-detergent oil forevery 20 SCFM (9.4 liters/sec.) of air thepump consumes at the point of operation.Consult the pump’s publishedPerformance Curve to determine this.

AIR LINE MOISTUREWater in the compressed air supply

can create problems such as icing orfreezing of the exhaust air, causing thepump to cycle erratically or stopoperating. Water in the air supply canbe reduced by using a point-of-use airdryer to supplement the user’s air dryingequipment. This device removes water

from the compressed air supply andalleviates the icing or freezing problems.

AIR INLET AND PRIMINGTo start the pump, open the air valve

approximately ½ to ¾ turn. After thepump primes, the air valve can be openedto increase air flow as desired. If openingthe valve increases cycling rate, but doesnot increase the rate of flow, cavitationhas occurred. The valve should be closedslightly to obtain the most efficient airflow to pump flow ratio.

BETWEEN USESWhen the pump is used for materials

that tend to settle out or solidify whennot in motion, the pump should be flushedafter each use to prevent damage.(Product remaining in the pump betweenuses could dry out or settle out. Thiscould cause problems with thediaphragms and check valves at restart.)In freezing temperatures the pump mustbe completely drained between uses inall cases.


520-357-000 12/01 Revision A Page 6

1

2 3

1

2

3

Surge Suppressor

Filter/Regulator

Lubricator

CAUTIONThe air exhaust should be piped to an area for safe disposition of the product being pumped, in the event of a diaphragm failure.

INSTALLATION GUIDETop Discharge Ball Valve Unit


520-357-000 12/01 Revision A Page 7

TROUBLESHOOTINGPossible Symptoms:• Pump will not cycle.• Pump cycles, but produces no flow.• Pump cycles, but flow rate is

unsatisfactory.• Pump cycle seems unbalanced.• Pump cycle seems to produce

excessive vibration.

What to Check: Excessive suction liftin system.Corrective Action: For lifts exceeding20 feet (6 meters), filling the pumpingchambers with liquid will prime the pumpin most cases.

What to Check: Excessive floodedsuction in system.Corrective Action: For floodedconditions exceeding 10 feet (3 meters)of liquid, install a back pressure device.

What to Check: System head exceedsair supply pressure.Corrective Action: Increase the inlet airpressure to the pump. Most diaphragmpumps are designed for 1:1 pressureratio at zero flow.

What to Check: Air supply pressure orvolume exceeds system head.Corrective Action: Decrease inlet airpressure and volume to the pump ascalculated on the publishedPERFORMANCE CURVE. Pump iscavitating the fluid by fast cycling.

What to Check: Undersized suctionline.

Corrective Action: Meet or exceedpump connection recommendationsshown on the DIMENSIONALDRAWING.

What to Check: Restricted orundersized air line.Corrective Action: Install a larger airline and connection. Refer to air inletrecommendations shown in your pump’sSERVICE MANUAL.

What to Check: Check ESADS, theExternally Serviceable Air DistributionSystem of the pump.Corrective Action: Disassemble andinspect the main air distribution valve,pilot valve and pilot valve actuators. Referto the parts drawing and air valve sectionof the SERVICE MANUAL. Check forclogged discharge or closed valve beforereassembly.

What to Check: Rigid pipe connectionsto pump.Corrective Action: Install flexibleconnectors and a surge suppressor.

What to Check: Blocked air exhaustmuffler.Corrective Action: Remove mufflerscreen, clean or de-ice and reinstall.Refer to the Air Exhaust section of yourpump SERVICE MANUAL.

What to Check: Pumped fluid in airexhaust muffler.Corrective Action: Disassemble pumpchambers. Inspect for diaphragm ruptureor loose diaphragm plate assembly. Referto the Diaphragm Replacement section

of your pump SERVICE MANUAL.

What to Check: Suction side airleakage or air in product.Corrective Action: Visually inspect allsuction side gaskets and pipeconnections.

What to Check: Obstructed checkvalve.Corrective Action: Disassemble the wetend of the pump and manually dislodgeobstruction in the check valve pocket.Refer to the Check Valve section of thepump SERVICE MANUAL fordisassembly instructions.

What to Check: Worn or misalignedcheck valve or check valve seat.Corrective Action: Inspect check valvesand seats for wear and proper seating.Replace if necessary. Refer to CheckValve section of the pump SERVICEMANUAL for disassembly instructions.

What to Check: Blocked suction line.Corrective Action: Remove or flushobstruction. Check and clear all suctionscreens and strainers.

What to Check: Blocked discharge line.Corrective Action: Check forobstruction or closed discharge linevalves.

What to Check: Blocked pumpingchamber.Corrective Action: Disassemble andinspect the wetted chambers of thepump. Remove or flush any obstructions.Refer to the pump SERVICE MANUAL

for disassembly instructions.

What to Check: Entrained air or vaporlock in one or both pumping chambers.Corrective Action: Purge chambersthrough tapped chamber vent plugs.PURGING THE CHAMBERS OF AIRCAN BE DANGEROUS! Contact theCustomer Service Department beforeperforming this procedure. Any modelwith top-ported discharge will reduce oreliminate problems with entrained air.

If your pump continues to performbelow your expectations, contact yourlocal Distributor or factory CustomerService Department for a serviceevaluation.

WarrantyThis pump is warranted for a period

of five years against defective materialand workmanship.


520-357-000 12/01 Revision A Page 8

RECYCLINGMany components of LINCOLN

AODD pumps are made of recyclablematerials (see chart on page 10 formaterial specifications). We encouragepump users to recycle worn out partsand pumps whenever possible, after anyhazardous pumped fluids are thoroughlyflushed.

This pump is pressurizedinternally with air pressureduring operation. Alwaysmake certain that all boltingis in good condition and that

all of the correct bolting is reinstalled duringassembly.

WARNING

Before pump operation,inspect all gasketedfasteners for loosenesscaused by gasket creep.Re-torque loose fasteners

to prevent leakage. Follow recommendedtorques stated in this manual.

CAUTION

When used for toxic oraggressive fluids, the pumpshould always be flushedclean prior to disassembly.

WARNING

Before maintenance orrepair, shut off the com-pressed air line, bleed thepressure, and disconnectthe air line from the pump.

The discharge line may be pressurized andmust be bled of its pressure.

WARNING

Take action to preventstatic sparking. Fire orexplosion can result,especially when handlingflammable liquids. The

pump, piping, valves, containers or othermiscellaneous equipment must be grounded.

WARNING

IMPORTANTRead these safety warningsand instructions in thismanual completely, beforeinstallation and start-upof the pump. It is the

responsibility of the purchaser to retain thismanual for reference. Failure to comply withthe recommendations stated in this manual willdamage the pump, and void factory warranty.

WARNINGAirborne particles and loudnoise hazards.

Wear ear and eye protection.

Before doing any main-tenance on the pump, becertain all pressure iscompletely vented from thepump, suction, discharge,

piping, and all other openings and connections.Be certain the air supply is locked out or madenon-operational, so that it cannot be started whilework is being done on the pump. Be certain thatapproved eye protection and protective clothingare worn all times in the vicinity of the pump.Failure to follow these recommendations mayresult in serious injury or death.

WARNING

WARNINGIn the event of diaphragmrupture, pumped materialmay enter the air end of thepump, and be dischargedinto the atmosphere. If

pumping a product which is hazardous or toxic,the air exhaust must be piped to an appropriatearea for safe disposition.

IMPORTANT SAFETYINFORMATION


520-357-000 12/01 Revision A Page 9


520-357-000 12/01 Revision A Page 10

Composite Repair Parts DrawingAVAILABLE SERVICE AND CONVERSION KITS

271811 WET END KITBuna Diaphragms, Buna Balls, andUHMW Polyethylene Seats.

271813 WET END KITHytrel Diaphragms, Hytrel Balls andUHMW Polyethylene Seats.

271812 WET END KITNeoprene Diaphragms, PTFEOverlay Diaphragms, PTFE Balls andPTFE Seats.


520-357-000 12/01 Revision A Page 11

Composite Repair Parts ListITEM DESCRIPTION QTY MODEL 85627 MODEL 85628 MODEL 856291 Air Valve Assembly 1 271773 271773 2717732 Ball, Check 4 271814 271815 2718163 Bearing, Sleeve 2 240720 240720 2407204 Pilot Valve Assembly 1 271782 271782 2717825 Bracket, Intermediate 1 271817 271817 2718176 Bumper 2 240727 240727 2407277 Bushing, Plunger 2 252901 252901 2529018 Cap, Air Inlet 1 271818 271818 2718189 Capscrew, Hex Head 5/16-18UNC x .88 16 271819 271819 27181910 Capscrew, Hex Head 5/16-18 x 1.25 16 240731 240731 24073111 Capscrew, Hex Head 5/16-18UNC x 1.75 4 271820 271820 27182012 Capscrew, Socket Head 3/8-16UNC x 2.50 4 271821 271821 27182113 Chamber, Outer 2 271822 271822 27182214 Diaphragm 2 240983 240873 24073015 Diaphragm, Overlay 2 24074916 Gasket, Air Valve 1 271795 271795 27179517 Gasket, Pilot Valve 1 271796 271796 27179618 Gasket, Air Inlet 1 271797 271797 27179719 Manifold, Suction 1 271823 271823 27182320 Manifold, Discharge 1 271824 271824 27182421 O-Ring 2 240655 240655 24065523 Plate, Inner Diaphragm 2 240729 240729 24072924 Plate, Outer Diaphragm 2 240728 240728 24072825 Plunger, Actuator 2 271825 271825 27182526 Ring, Retaining 2 240717 240717 24071727 Rod, Diaphragm 1 271826 271826 27182628 Seal, U-Cup 2 240721 240721 24072129 Seat, Check Valve 4 271827 271827 27182730 Washer, Flat 4 271810 271810 271810


520-357-000 12/01 Revision A Page 12

Air Valve Assembly Drawing, Parts List

AIR VALVE ASSEMBLY PARTS LISTITEM PART NUMBER DESCRIPTION QTY1 271773 Air Valve Assembly 11-A 271774 Sleeve and Spool Set 11-B 271775 Body, Air Valve 11-C 271776 Bumper 21-D 271777 Cap, Muffler 11-E 271778 Cap, End 21-F 271779 Muffler 11-G 271780 O-Ring 81-H 271781 Ring, Retaining 21-J 240932 Screw, Self-tapping 4

1-J

1-D

1-F

1-G

1-H

1-G

1-E

1-C

1-A

1-A

1-B

1-C

1-E

1-G

1-H


520-357-000 12/01 Revision A Page 13

AIR DISTRIBUTION VALVESERVICING

To service the air valve first shut offthe compressed air, bleed pressure fromthe pump, and disconnect the air supplyline from the pump.

STEP #1: See COMPOSITE REPAIRPARTS DRAWING.

Using a 5/16" Allen wrench, removethe four hex socket capscrews (item 12)and four flat washers (item 30). Removethe air valve assembly from the pump.

Remove and inspect gasket (item 16)for cracks or damage. Replace gasket ifneeded.

STEP #2: Disassembly of the airvalve.

To access the internal air valvecomponents first remove the two retainingrings (item 1-H) from each end of the airvalve assembly using clip ring pliers.

Next remove the two end caps (item1-E). Inspect the o-ring (item 1-G) for cutsor wear. Replace the o-rings if necessary.

Remove the spool (part of item 1-A)from the sleeve. Be careful not to scratchor damage the outer diameter of thespool. Wipe spool with a soft cloth andinspect for scratches or wear.

Inspect the inner diameter of thesleeve (part of item 1-A) for dirt,scratches, or other contaminants. Removethe sleeve if needed and replace with anew sleeve and spool set (item 1-A).

STEP #3: Reassembly of the air valve.Install one end cap (item 1-E) with

an o-ring (item 1-G) into one end of theair valve body (item 1-B). Install oneretaining ring (item 1-H) into the grooveon the same end.

Remove the new sleeve an spool set(item 1-A) from the plastic bag. Carefullyremove the spool from the sleeve. Installthe six o-rings (item 1-G) into the sixgrooves on the sleeve. Apply a lightcoating of grease to the o-rings beforeinstalling the sleeve into the valve body(item 1-B), align the slots in the sleevewith the slots in the valve body. Insertthe spool into the sleeve. Be careful notto scratch or damage the spool duringinstallation. Push the spool in until ittouches the bumper on the opposite end.

Install the remaining end cap with o-ring and retaining ring.

Fasten the air valve assembly (item1) and gasket (item 16) to the pump.

Connect the compressed air line tothe pump. The pump is now ready foroperation.

Read these instructionscompletely, before in-stallation and start-up. Itis the responsibility ofthe purchaser to retain

this manual for reference. Failure tocomply with the recommendations statedin this manual will damage the pump, andvoid factory warranty.

IMPORTANT


520-357-000 12/01 Revision A Page 14

PILOT VALVE ASSEMBLY PARTS LIST

ITEM PART NUMBER DESCRIPTION QTY4 271782 Pilot Valve Assembly 14-A 271783 Body, Pilot Valve 14-B 271784 Bushing 24-C 252935 Ring, Retaining 24-D 252936 Spacer 54-E 252937 Spool, Pilot 14-F 252938 Wiper 6

Pilot Valve Assembly Drawing, Parts List


520-357-000 12/01 Revision A Page 15

PILOT VALVE SERVICINGTo service the pilot valve first shut off

the compressed air supply, bleed thepressure from the pump, and disconnectthe air supply line from the pump.

Step #1: See PUMP ASSEMBLYDRAWING.

Using a ½" wrench or socket,remove the four capscrews (items 11).Remove the air inlet cap (item 8) andair inlet gasket (item 18). The pilot valveassembly (item 4) can now be removedfor inspection or service.

Step #2: Disassembly of the pilotvalve.

Remove the pilot valve spool (item4-E). Wipe clean, and inspect for dirt,scratches or wear. Replace the spool ifnecessary.

Remove the two retaining rings(items 4-C) from each end of the pilotvalve body.

Remove the two pilot valve bushings(items 4-B), five spacers (items 4-D),and six spool wipers (items 4-F) bypushing gently from other end of thepilot valve body. Inspect the wipers forcuts and/or wear. Replace any wipersas necessary.

Step #3: Re-assembly of the pilotvalve.

First install a retaining ring to oneend of the pilot valve. Install one bushingmaking sure the step side faces towardthe wiper. Apply a light coating of greaseto the outside diameter of each wiper.

Next, gently push in the wipers andspacers until they are against theinstalled retaining ring and bushing inthe opposite end of the pilot valve body.Install the remaining bushing makingsure the step side faces the wiper. Installthe remaining retaining ring.

Apply a light coating of grease to theinner diameter of each wiper. Also applya light coating of grease to the outerdiameter of the pilot valve spool andgently push the spool through each wiper.

Step #4: Inspect the actuatorplungers.

See ILLUSTRATION AT RIGHT.The actuator plungers (items 25) can

be reached through the pilot valve cavityin the intermediate assembly (item 5).

Remove the plungers (item 25) fromthe bushings (item 7) in each end of thecavity. Inspect the installed o-ring (items21) for cuts and/or wear. Replace the o-rings if necessary. Apply a light coatingof grease to each o-ring and re-installthe plungers in to the bushings. Pushthe plungers in as far as they will go.

To remove the bushings (item 7), firstremove the retaining rings (item 26) byusing a flat screwdriver. NOTE: It isrecommended that new retaining ringsbe installed.

Step #5: Re-install the pilot valveassembly into the intermediate assembly.

Be careful to align the ends of thestem between the plungers wheninserting the stem of the pilot valve intothe cavity of the intermediate.

Re-install the gasket (item 18), airinlet cap (item 8) and capscrews(item 11).

Connect the air supply to the pump.The pump is now ready for operation.

ACTUATOR PLUNGERSERVICING

5

26

721

25



IMPORTANT


520-357-000 12/01 Revision A Page 16

Diaphragm Service Drawing,Non-Overlay

Diaphragm Service Drawing,with Overlay


520-357-000 12/01 Revision A Page 17

DIAPHRAGM SERVICINGTo service the diaphragms first shut offthe suction, then shut off the dischargelines to the pump. Shut off the com-pressed air supply, bleed the pressurefrom the pump and disconnect the airsupply line from the pump. Drain anyremaining liquid from the pump.

Step #1: See the pump assemblydrawing and the diaphragm servicing il-lustration.

Using a 1/2” wrench or socket, re-move the 16 capscrews (item 9) that fas-ten the manifolds (items 19 & 20) to theouter chambers (item 13).

Step #2: Removing outer cham-bers.

Using a 1/2” wrench or socket,remove the 16 capscrews (item 10), thatfasten the outer chambers (item 13),diaphragms (item 14) and intermediate(item 5) together.

Step #3: Removing the diaphragmsand diaphragm plates.

Use a 7/8” wrench or six pointsocket to remove the outer diaphragmplate assemblies (item 24), diaphragms(item 14) and inner diaphragm plates(item 23) from the diaphragm rod (item27) by turning counterclockwise. Inspectthe diaphragm for cuts, punctures, abra-sive wear or chemical attack. Replacethe diaphragms if necessary. DO NOTUSE A WRENCH ON THE DIAPHRAGMROD. FLAWS ON THE SURFACE MAYDAMAGE BEARINGS AND SEALS.

Step #4: Assembling the

diaphragm and diaphragm plates to thediaphragm rod.

Push the threaded stud of one outerdiaphragm plate assembly through thecenter of one diaphragm and through oneinner diaphragm plate. Install the dia-phragm with the natural bulge facingaway from the diaphragm rod and makesure the radius on the inner diaphragmplate is towards the diaphragm, as indi-cated on the diaphragm servicing illus-tration. Thread the assembly onto thediaphragm rod, leaving loose.

Step #5: Installing the diaphragmand rod assembly to the pump.

Make sure the bumper (item 6) isinstalled over the diaphragm rod. Insertrod into pump.

On the opposite side of the pump,pull the diaphragm rod out as far as pos-sible. Make sure the second bumper isinstalled over the diaphragm rod.

Push the threaded stud of the otherouter diaphragm plate assembly throughthe center of the other diaphragm andthrough the other inner diaphragm plate.Make sure the radius on the inner dia-phragm plate is towards the diaphragm.Thread the assembly onto the diaphragmrod. Use a 7/8” wrench or socket to holdone outer diaphragm plate. Then, use atorque wrench to tighten the other outerdiaphragm plate to the diaphragm rod to500 in. lbs. (56.5 Newton meters).

Align one diaphragm with the inter-mediate and install the outer chamberto the pump using the 8 capscrews.Tighten the opposite diaphragm plateuntil the holes in the diaphragm align with

the holes in the intermediate. Then, in-stall the other outer chamber using the8 capscrews.

Step #6: Reinstall the manifoldsto the pump using the 16 capscrews.

The pump is now ready to be rein-stalled, connected and returned tooperation.

OVERLAY DIAPHRAGM SERVICINGThe overlay diaphragm (item 15)

is designed to fit over the exterior of thestandard diaphragm (item 14).

Follow the same proceduresdescribed for the standard diaphragmfor removal and installation, excepttighten the outer diaphragm plateassembly, diaphragms and inner dia-phragm plate to the diaphragm rod to 500in. lbs. (56.5 Newton meters).



IMPORTANT


520-357-000 12/01 Revision A Page 18

Check Valve DrawingCHECK VALVE SERVICINGBefore servicing the check valve

components, first shut off the suction lineand then the discharge line to the pump.Next, shut off the compressed air supply,bleed air pressure from the pump, anddisconnect the air supply line from thepump. Drain any remaining fluid from thepump. The pump can now be removedfor service.

To access the check valvecomponents, remove the manifold(item 20 or item 19 not shown). Use a1/

2" wrench or socket to remove the

fasteners. Once the manifold is removed,the check valve components can beseen.

Inspect the check balls (items 2) forwear, abrasion, or cuts on the sphericalsurface. The check valve seats (item 29)should be inspected for cuts, abrasivewear, or embedded material on thesurfaces of both the external and internalchambers. The spherical surface of thecheck balls must seat flush to thesurface of the check valve seats for thepump to operate to peak efficiency.Replace any worn or damaged parts asnecessary.

Re-assemble the check valvecomponents. The seat should fit into thecounter bore of the outer chamber.

The pump can now be reassembled,reconnected and returned to operation.

20

9

2

29


520-357-000 12/01 Revision A Page 19

SAFE AIREXHAUSTDISPOSALAREA

PUMP INSTALLATION AREA

1" DIAMETER AIREXHAUST PIPING



MUFFLER

LIQUIDLEVEL

SUCTIONLINE

LIQUIDLEVEL

SUCTIONLINE

MUFFLER

MUFFLER

PUMPING HAZARDOUS LIQUIDSWhen a diaphragm fails, the pumped

liquid or fumes enter the air end of thepump. Fumes are exhausted into thesurrounding environment. When pumpinghazardous or toxic materials, theexhaust air must be piped to anappropriate area for safe disposal. Seeillustration #1 at right.

This pump can be submerged if thepump materials of construction arecompatible with the liquid being pumped.The air exhaust must be piped above theliquid level. See illustration #2 at right.Piping used for the air exhaust must notbe smaller than 1" (2.54 cm) diameter.Reducing the pipe size will restrict airflow and reduce pump performance.When the pumped product source is ata higher level than the pump (floodedsuction condition), pipe the exhausthigher than the product source to preventsiphoning spills. See illustration #3 atright.

CONVERTING THE PUMP FORPIPING THE EXHAUST AIR

The following steps are necessary toconvert the pump to pipe the exhaust airaway from the pump.

Use a #8 Torx or flat screwdriverto remove the four self-tapping screws(item 1-J).

Remove the muffler cap and muffler(items 1-D and 1-F). The air distributionvalve body (item 1-B) has 1" NPT threadsfor installation of alternate mesh or sounddampening mufflers or piped exhaust.

IMPORTANT INSTALLATIONNOTE: The manufacturer recommendsinstalling a flexible hose or connectionbetween the pump and any rigidplumbing. This reduces stresses on themolded plastic threads of the air exhaustport. Failure to do so may result indamage to the air distribution valve body.

Any piping or hose connected to thepump’s air exhaust port must bephysically supported. Failure to supportthese connections could also result indamage to the air distribution valve body.

CONVERTED EXHAUST ILLUSTRATION

Illustration #1

Illustration #2

Illustration #3


1' aluminum air-powered diaphragm pump - sec b5 - page 28€¦ · converting pump for piping...

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