PD02PĆX
Page 6 of 8
PUMP DISASSEMBLY AND REASSEMBLY
GENERAL PUMP REPAIR NOTES:
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Tools needed to complete disassembly and repair:
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5/16" wrench or socket, 7/16" socket, 5/8" wrench or socket, 3/8"
Allen wrench, spanner wrench, torque wrench (measuring inch
pounds), O" ring pick.
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Once the pump is disassembled, you have the opportunity to clean
and inspect all parts for wear. Look for deep scratches on metallic
surfaces and nicks or cuts in O" rings. Replace old parts with new
ones as necessary.
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Take precautions to prevent cutting O" rings upon installation.
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Lubricate ``O" rings and U" cups with Lubriplate. A packet of this luĆ
bricant is included in each Service Kit.
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Do not overĆtighten fasteners. Refer to torque specification block on
page 5.
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ReĆtorque fasteners following restart.
Service Kits available.
From your local distributor.
(Kits also include Lubriplate grease packet.)
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SERVICE KIT: 637314ĆXX contains parts for a complete pump rebuild.
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SERVICE KIT: 637276 contains parts to rebuild the air valve.
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SERVICE KIT: 637313ĆXX contains parts to rebuild the diaphragms
and checks.
FLUID SECTION DISASSEMBLY
1. Place the pump on a flat workbench.
2. Using 7/16" sockets, remove six (62) nuts and (131) bolts.
3. Set the pump on end, with the air inlet" end up.
4. Using a flat blade screwdriver, remove (17) air inlet manifold and
(A") fluid cap.
5. Remove (13) backĆup ring and (33) O" ring from (A") fluid cap.
6. Remove two (147) O" rings from (A") fluid cap.
7. Remove (18) manifold and (B") fluid cap.
8. Remove (13) backĆup ring and (33) O" ring from (B") fluid cap.
9. Using 5/8" wrenches on (6) diaphragm screws, unthread and reĆ
move diaphragm assemblies.
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NOTE: Air valve section can be repaired at this time, refer to Air
Valve Disassembly".
10. Using a 5/16" wrench or flat blade screwdriver, remove two (43)
screws from (17) air inlet manifold.
11. Separate (17) air inlet manifold and (A") fluid cap. NOTE: (41)
spring stops and (22) discs may fall out. If not, remove at this time.
12. Remove (19) seals and (161) O" rings.
13. Disassembly of the opposite end of the pump is the same as the air
inlet" end, except for the following: a.) the opposite end does not
contain (161) O" rings and b.) the top tube has the outside shoulder,
the bottom tube has the inside shoulder.
14. Wrap (1) rod in a shop rag and secure in a softĆfaced vise.
15. Using a 5/8" wrench, unthread (6) diaphragm screw from (1) rod.
16. Using a 5/8" wrench on (6) diaphragm screw and a spanner wrench
on (5) washer, unthread and remove (6) diaphragm screw.
FLUID SECTION REASSEMBLY
NOTE: Lubricate all O" rings, U" cups seals and their mating parts with
94276 Lubriplate upon assembly.
1. Place the new (7) diaphragms on the (6) diaphragm screw, with the
bowed side of the diaphragm oriented against (6) diaphragm screw.
2. Assemble (5) washer to (6) diaphragm screw and torque to 75 Ć 85
in. lbs (8.5 Ć 9.6 Nm), using a spanner wrench and a 5/8" wrench.
NOTE: Be sure not to strip the plastic nut.
3. Assemble (1) rod to one of the diaphragm assemblies and tighten
finger tight.
4. Models PD02PĆXXSĆXTT only: Assemble (64) O" rings into
grooves in (68 and 69) air caps.
5. Assemble diaphragm assemblies into air caps and torque to 75 Ć 85
in. lbs (8.5 Ć 9.6 Nm), using 5/8" wrenches.
6. Assemble two (147) O" rings to the raised air passages, opposite
each other, inside (68) air cap.
7. Set (A") fluid cap on the workbench, with the tube side" down.
8. Assemble two (161) O" rings to counterbores in (A") fluid cap.
9. Assemble (22) disc and (41) spring stop to the check seat nearest the
top tube of (A") fluid cap (top tube has the shoulder on the outside).
10. Assemble (41) spring stop and (22) disc (disc on top) to check seat
nearest the bottom tube (shoulder on outside).
11. Lubricate seal grooves in (17) air inlet manifold and assemble (19)
seals to grooves.
12. Assemble (17) air inlet manifold to (A") fluid cap, aligning fluid inlet
with lower tube (shoulder on outside).
13. Secure with two (43) screws. Torque to 20 Ć 25 in. lbs (2.3 Ć 2.8 Nm),
using a 5/16" wrench.
14. Repeat steps 9 thru 13 for opposite end of pump. NOTE: The tubes
are reversed on (B") fluid cap (top tube has outside shoulder).
15. Assemble (33) O" rings and (13) backĆup rings to the outside shoulĆ
der of tubes of (A" and B") fluid caps.
16. Assemble (17) air inlet manifold and components into (68) air cap,
being sure to align groove in manifold with rib in air cap.
17. Assemble (18) manifold and components into (69) air cap, being
sure to align groove in manifold with rib in air cap.
18. Assemble six (131) bolts and (62) nuts to pump and torque to 70 in.
lbs max (7.9 Nm max), using 7/16" sockets, hold the nut, torque the
bolt only. NOTE: Allow the pump to sit for at least 15 minutes, then
reĆtorque bolts to 70 in. lbs max (7.9 Nm max).
AIR VALVE SECTION DISASSEMBLY
1. Refer to Fluid Section Disassembly", steps 1 thru 9.
2. Separate (68 and 69) air caps, releasing (103) bushing and logo
plates.
3. Remove air valve assembly, (102, 137 and 146) O" rings and (144)
U" cups from air caps.
4. Remove (111) spool assembly, (178) trip rods and (179) sleeve asĆ
sembly from (145) valve block.
5. Remove O" rings and U" cup from (111) spool assembly.
6. Inspect (119) O" rings on (178) trip rods and (179) sleeve assembly.
7. Remove three (134) screws, releasing (145) minor valve block and
(132) gasket.
AIR VALVE SECTION REASSEMBLY
1. Assemble (132) gasket and (145) minor valve block to (135) valve
block, securing with three (134) screws. NOTE: Torque to 3.5 Ć 4.5
in. lbs (0.40 Ć 0.51 Nm).
2. Assemble (119) O" rings to (178) trip rods and (179) sleeve assembly.
3. Assemble (178) trip rods and (179) sleeve assembly into (145) valve
block.
4. Assemble (138 and 180) O" rings and (110) U" cup to (111) spool
assembly.
5. Assemble (111) spool assembly into (135) valve block, with small
end of spool going into valve block first.
6. Assemble (102, 137 and 146) O" rings to valve block.
7. Assemble (144) U" cups to (68 and 69) air caps.
8. Place one (68 or 69) air cap on end, with legs down and seat valve
block into air cap.
9. Assemble logo plates and (103) bushing into air cap.
10. Assemble other air cap to air cap, aligning logo plates, (178) trip rod
and (103) bushing.
11. Refer to Fluid Section Reassembly", steps 5 thru 18 to complete
reassembly.
