User Manual

NOTE: For models with PTFE overlays (30), position the overlay between the outer dia-
phragm plate (52) and the diaphragm (31) before attaching the inner diaphragm plate (51).
9. Invert one diaphragm assembly. Place bumper (3) onto diaphragm rod. Place washer
(47) onto stud (35). Attach inverted diaphragm assembly to rod and hand tighten the
outer plate. Repeat this process with the second diaphragm assembly. Note! It is not
necessary to invert the second diaphragm assembly. Torque the outer plates to a
minimum of 10 ft-lbs (13,56 NM). Position outer chamber (28, dish side up) and
secure to workbench. Place the intermediate assembly (center section) onto the
chamber with the inverted diaphragm to the top. Note the orientation of the intermediate
to the chamber and to the top and bottom of pump. Install all fasteners (16, 17, 18, 33) to
inner and outer chambers. Tighten fasteners to 20 ft-lbs (27,12 NM). Insert a pry bar
into the suction opening of the secured chamber until it contacts the hex boss of the outer
diaphragm plate (52). Pry upward until the top diaphragm is as high as it will go. While
supporting the pry bar in this up position, slip a second pry bar under the top diaphragm
plate and pry upward until it stops. Flip (invert) the top diaphragm down so it is resting on
the groove of the inner chamber. Note! When using the pry bar, exercise care not to
damage the diaphragms or machined surfaces. Properly orient the second chamber (28)
to the intermediate (center section) and repeat installation and torque procedures.
10. Place the check balls (27) and check valve seats (26) in the discharge manifold (22),
position on the outer chamber and reassemble using fasteners (16, 17, 18). Place the
check balls (27) and check valve seats (26) in the outer chambers (28), position the
suction manifold (23) and reassemble using fasteners (16, 17, 18). Torque all manifold
fasteners to 37 ft-lbs (50,17NM)
Note! For models using check valve seats (25), and o-rings (24), make sure that
the o-rings (24) are facing the machined flanges of the suction manifold (23) and/
or discharge manifold (22). Also make sure that the o-rings do not shift from their
grooves during reassembly.
AIR VALVE MAINTENANCE
11. To evaluate the air valve components, remove the eight cap screws (11), washers (8,
10) from the air body (7). Inspect the gasket (4), valve plate (5) and shuttle (6) for
scratches, surface irregularities, and excessive wear. Replace if necessary.
Using needle nose pliers, pull out both of the end plugs. Push the air valve spool (2) out
of the valve. Carefully reach in and pull the lip seals (43) and o-rings (44) out of the air
valve body. Check the air valve spool, lip seals and o-rings for cracks, splitting, scratches,
and wear. Replace and/or clean items as necessary.
12. Lubricate lip seals (43) and o-rings (44). Reinstall the o-rings and lip seals making sure
that the lips of the seals are facing each other. Lubricate and insert the air valve spool
(2) with the chamfered end entering the air valve body (7) through the end that has the
spool image pictured. Press the end plugs into position. Lubricate and reinsert the
shuttle valve (6) and valve plate (5). Place the gasket (4) with the words “THIS SIDE
UP” facing the valve plate. Reassemble to the intermediate using cap screws (11) and
washers (8, 10). Flat washers (8) should be touching the plastic air valve body. Tighten
cap screws to 40 in-lbs (4,52 NM).
EXTERNAL FASTENER TORQUE REQUIREMENTS
NOTE: When reassembling loosely tighten all external fasteners, adjusting and
aligning and gradually, in an alternating fashion, tighten to torque requirements
listed below.
Diaphragm Plates 12.5 ft-lbs (17,0 NM)
Diaphragm/Rod 10.0 ft-lbs (13,56 NM)
Chambers 20.0 ft-lbs (27,12 NM)
Manifolds/Chamber 37.0 ft-lbs (50,17 NM)
Air Valve Body 40.0 in-lbs (4,52 NM)
U.S. Patent Number 5232352
3˝CLASSIC PERFORMANCE
MAINTENANCE MANUAL
CHECK VALVE AND O-RING MAINTENANCE
1. Flush and neutralize the pump to be certain all corrosives or hazardous materials are
removed prior to any maintenance. This procedure should always be followed when
returning pumps for factory service also.
2. Remove the suction and discharge manifolds fasteners (16, 17, 18). The check valve
seats (26) and check balls (27) are located inside the bottom of the Outer Chamber
(28) or inside the Discharge Manifold (22). Remove the seat and balls and inspect for
excessive wear, pitting, or other signs of degradation. On models using check valve
seats (25) and o-rings (24), check the seats, balls, for excessive wear, pitting, or other
signs of degradation.
NOTE: When using pumps built with PTFE o-rings, always replace with new PTFE
o-rings since the original o-rings will not reseal the pump.
DIAPHRAGM AND PILOT SLEEVE ASSEMBLY MAINTENANCE
3. To inspect the diaphragms, remove the eight fasteners (16, 17, 18, 33) from the outer
chamber. If replacement is necessary due to abrasion or rupture, remove the outer
diaphragm plates (52) by turning counter-clockwise. Models built with PTFE elastomers
will have PTFE overlays (30) that face the outer chamber (28) and back-up diaphragms
(31) on the air side of the pump. Pumps without PTFE will contain only the back-up
diaphragms (31).
4. If diaphragm replacement is required, remove the inner diaphragm plate by removing
fasteners (55, 56).
5. If a diaphragm has been ruptured and corrosive or viscous fluid has entered the air side
of the pump, the complete air system should be cleaned and inspected.
6. After removing the diaphragm-plate assemblies, bumpers (3), & flat washers (47) the
pilot sleeve assembly (13, 14, 15, 42, 45, & 48) and diaphragm rod assembly (34, 49)
may be removed after removing the retaining plate (46) fasteners (38) and pushing the
entire unit out through the bore in the intermediate (41). The diaphragm rod assembly
must be unscrewed to remove the pilot sleeve (13).
NOTE: To aid in reassembly apply a non-synthetic, petroleum based lubricating
grease without EP additives. Carleton-Stuart MagnaLube G is recommended.
7. Clean or replace any components that have excessive wear, dirt build-up, or chemical
attack. Lube all components prior to reassembling. Reassemble pilot sleeve spacers,
o-rings (42) and lip seals (14) within bore of intermediate. Make sure that the open side
of the lip seals is facing outward toward the diaphragms. Also make sure that the end
pilot spacers (45) are at the end on either side of the pilot sleeve assembly and all inner
spacers (48) are separated by o-rings (15). Next carefully insert the diaphragm rod
assembly with pilot sleeve inside the assembly in the bore. Reattach retaining plates.
Do not over tighten self-tapping screws (38).
NOTE: To aid in reassembly of the diaphragms apply a non-synthetic, petroleum
based lubricating grease without EP additives to the diaphragm’s outside
diameter sealing bead. Carleton-Stuart MagnaLube G is recommended.
8. Inspect stud (35) for damage to threads. Replace if necessary by threading into outer
plate (52) leaving 7/8” sticking out. Note! Use red (permanent) “Locktite #262” on the
threads. Reassemble the diaphragms (31) by placing the “liquid side” on the outer
diaphragm plate (52), place the inner diaphragm plate (51) on the opposite side of the
diaphragm, insert fasteners (56) with washers (55) and tighten fasteners to 12.5 ft-
lbs (17,0 NM) of torque.