®
Graymills Corporation 3705 N. Lincoln Avenue Chicago, Illinois 60613
773-248-6825 FAX 773-477-8673 www.graymills.com
Air Operated
Double Diaphragm Pumps
Operations and
Maintenance
Instructions
795–08691
GM 12–07
www.graymills.com
WARNING/CAUTIONS
Read all these SAFETY INSTRUCTIONS
BEFORE installing or using this equipment.
Keep this manual handy for reference/training.
DACT50 Acetal NPT Pumps*
PLHG50 Polypropylene Pumps
PQHG50
PLTG50
PQTG50
* These models are certified.
2
Table of Contents
Symbols
Safety Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Charts 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graymills Warranty 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graymills Phone Number 21. . . . . . . . . . . . . . . . . . . . . . . .
EC–Declaration of Conformity 22. . . . . . . . . . . . . . . . . . . .
WARNING
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious injury or
death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the instructions.
Safety Alert Symbol
SAFETY ALERT
The safety Alert Symbol means ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
HAZARDOUS FLUIDS
Improper handling of hazardous fluids or inhaling toxic vapors can cause extremely serious injury or death
from splashing in the eyes, ingestion, or bodily contamination. Observe all the following precautions when
you handle hazardous or potentially hazardous fluids.
Know what fluid you are pumping and its specific hazards. Take precautions to avoid a toxic fluid spill.
Always wear appropriate clothing and equipment, such as eye protection and breathing apparatus, to
protect yourself.
Store hazardous fluid in an appropriate, approved container. Dispose of it according to all Local, State,
and Federal guidelines for hazardous fluids.
Secure the fluid outlet hose tightly into the receiving container to prevent it from coming loose and
improperly draining the fluid.
Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas. If the
diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 7.
Use static wire hoses when pumping flammables.
Keep containers closed when not in use.
3
WARNING
EQUIPMENT MISUSE HAZARD
Any misuse of the equipment or accessories, such as overpressurizing, modifying parts, using incompatible
chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in splashing in
the eyes or on the skin, other serious injury, or fire, explosion or property damage.
This equipment is for professional use only. Observe all warnings. Read and understand all instruction
manuals, warning labels, and tags before you operate this equipment. If you are not sure, or if you have
questions about installation or operation, call Graymills Corporation.
Never alter or modify any part of this equipment; doing so could cause it to malfunction.
Check all equipment regularly and repair or replace worn or damaged parts immediately.
Never exceed the recommended working pressure or the maximum air inlet pressure stated on your pump
or in the Technical Data on page 4.
Do not exceed the maximum working pressure of the lowest rated component in your system. This
equipment has a 100 psi (0.7 MPa, 7 bar) maximum working pressure at 100 psi (0.7 MPa, 7 bar, )
maximum incoming air pressure.
Be sure that all fluids and solvents used are chemically compatible with the wetted parts shown in the
Technical Data on page 4. Always read the manufacturer’s literature before you use fluid or solvent in
the pump.
Never move or lift a pump under pressure. If dropped, the fluid section may rupture. Always follow the
Pressure Relief Procedure on page 10 before you move or lift the pump.
FIRE AND EXPLOSION HAZARD
Static electricity is created by the flow of fluid through the pump and hose. If the equipment is not properly
grounded, sparking may occur. Sparks can ignite fumes from solvents and the fluid being pumped, dust
particles, and other flammable substances, whether you are pumping indoors or outdoors, and can cause a
fire or explosion and serious injury and property damage.
To reduce the risk of static sparking, ground the pump and all other equipment used or located in the
work area. Check your local electrical code for detailed grounding instructions for your area and type of
equipment. See Grounding on page 6.
If you experience any static sparking or even a slight shock while using this equipment, stop pumping
immediately. Check the entire system for proper grounding. Do not use the system again until you have
identified and corrected the problem.
Pipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm fails, the
fluid is exhausted along with the air. See Air Exhaust Ventilation on page 7.
Do not smoke in the work area. Do not operate the equipment near a source of ignition or an open flame,
such as a pilot light.
4
SAFETY PRECAUTIONS
CAUTION
Verify the chemical compatibility of the pump wetted parts and the substance being pumped, flushed or
recirculated. Chemical compatibility may change with temperature and concentration of the chemical(s)
within the substance being pumped, flushed or recirculated.
The pump should not be used for the structural support of the piping system. Be certain system components are properly supported to prevent stress on the pump parts.
Do not allow pump to operate dry for long periods of time; this may cause unnecessary wear or damage
to the pump.
Maximum temperature limits are based upon mechanical stress only. Certain chemicals will significantly
reduce maximum safe operating temperatures. Consult Graymills for chemical compatibility and temperature limits.
United States Government safety standards have been adopted under the Occupational Safety and Health Act. You should
consult these standards—particularly the General Standards, Part 1910, and the Construction Standards, Part 1926.
Technical Data
Maximum fluid working pressure 100 psi (0.7 MPa, 7 bar). . . . . .
Air pressure operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 to 100 psi (0.18 to 0.7 MPa, 1.8 to 7 bar )
Maximum air consumption 28 scfm (0.672 cubic meters/min.). .
Maximum free flow delivery (1/2 in. ports) 15 gpm (57 l/min). . .
Maximum pump speed 400 cpm. . . . . . . . . . . . . . . . . . . . . . . . . .
Gallons (Liters) per cycle 0.04 (0.15). . . . . . . . . . . . . . . . . . . . . .
Maximum suction lift (water w/buna balls) . . . . . . . . . . . . . . . . . .
15 ft (4.5 m) dry, 25 ft (7.6 m) wet
Maximum size pumpable solids 3/32 in. (2.5 mm). . . . . . . . . . . .
Sound power level (measured per ISO standard 9614–2)
At 70 psig (0.48 MPa, 4.8 bar) at 50 cycles per minute 77 dBa. . .
At 100 psig (0.7 MPa, 7 bar) at maximum cycles per minute 95 dBa
Sound pressure level (measured 1 meter from pump)
At 70 psig (0.48 MPa, 4.8 bar) at 50 cycles per minute 67 dBa. . .
At 100 psig (0.7 MPa, 7 bar) at maximum cycles per minute 85 dBa
Air inlet size 1/4 npt(f). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air exhaust port size 3/8 npt(f). . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid inlet size. 1/2 and 3/4 in. npt(f) or bspt(f). . . . . . . . . . . . . . .
Fluid outlet size. 1/2 and 3/4 in. npt(f) or bspt(f). . . . . . . . . . . . . .
Wetted parts (in addition to ball, seat, duckbill, and diaphragm
materials, which vary by pump)
Polypropylene pumps polypropylene, PTFE. . . . . . . . . . . . . . . . .
Non-wetted external parts polypropylene, stainless steel, polyester
and aluminum (labels), nickel-plated brass
Weight (approximate) 6.5 lb (2.9 kg). . . . . . . . . . . . . . . . . . . . . . .
Hytrel
is a registered trademark of the DuPont Company.
Loctite is a registered trademark of the Loctite Corporation.
5
Installation
The typical Installations in Figure 1 are only guides for selecting and installing system components. Contact Graymills or
your distributor for assistance in planning a system to suit your needs.
Figure 1
ABOVE-GROUND TRANSFER INSTALLATION
A
D
H
N
L
KEY
A Pump
C Electrically conductive air supply line
D Air line quick disconnect
H Fluid drain valve (required)
K Electrically conductive fluid supply hose
L Fluid suction line
Y Ground wire (required; see page 6
P
KEY
A Pump
C Electrically conductive air line to pump
T
E Gun air line shutoff valve
F Air line filter
K
H
U
G Gun air regulator
H Fluid drain valve (required)
K Electrically conductive fluid supply hose
P Circulating valve
R Electrically conductive air line to gun
S Air spray gun
T Electrically conductive fluid return line
U 5-gallon pail
V Agitator
Y Ground wire (required; see page 6
for installation instructions)
E
F
B
G
Y
AIR SPRAY INSTALLATION
E
F
D
G
C
V
Y
A
C
S
R
J
K
9074A
M
55-GALLON BUNG PUMP INSTALLATION
for installation instructions)
KEY
APump
B Bleed-type master air valve
(required for pump)
C Electrically conductive
air supply line
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
G Pump air regulator
H Fluid drain valve (required)
J Fluid regulator (optional)
K Electrically conductive
fluid supply hose
L Fluid suction line
M Underground storage tank
N Wall mounting bracket
Y Ground wire (required; see page 6
for installation instructions)
A
C
D
Y
K
H
L
9075A
KEY
W Muffler
X Electrically Conductive Air Exhaust Hose
Z Container for Remote Air Exhaust
All wetted and non-wetted pump parts must be
compatible with the fluid being pumped.
VENTING EXHAUST AIR
Z
W
X
6
Installation
Tightening Threaded Fasteners Before
First Use
After unpacking the pump, and before using it for the first
time, check and retorque all external fasteners. See the
Service section for torque specifications. After the first day
of operation, retorque the fasteners again. Although pump
use varies, a general guideline is to retorque fasteners every
two months.
Use a compatible thread sealant on all male threads.
Tighten all connections firmly to avoid air or fluid leaks.
CAUTION
To avoid pump damage, do not overtighten the fittings
to the pump.
Grounding
Figure 2
KEY
APump
H Fluid drain valve (required)
S Dispense valve
T Fluid drain line
Y Fluid section grounding via grounding strip or grounding
screw (required for metal and acetal pumps)
Z Container ground wire (required)
Hose must be conductive.
Dispense valve nozzle must be in contact with container.
Y
Z
GROUNDING A PUMP
Y
A
H
T
S
WARNING
FIRE AND EXPLOSION HAZARD
This pump must be grounded when using
flammables. Before operating the pump,
ground the system as explained below. Also
read the section Fire and Explosion
Hazard on page 3.
When pumping conductive flammable fluids, always
ground the entire fluid system by making sure the fluid
system has an electrical path to a true earth ground (see
Fig. 2). Never use a polypropylene pump with non-conductive flammable fluids as specified by your local fire
protection code.
US Code (NFPA 77 Static Electricity) recommends a
conductivity greater than 50 x 10
(mhos/meter) over your operating temperature range to
reduce the hazard of fire. Consult your fluid supplier to
determine the conductivity or resistivity of your fluid.
The resistivity must be less than 2 x 1012 ohm-centimeters.
To reduce the risk of static sparking, ground the pump and
all other equipment used or located in the pumping area.
Check your local electrical code for detailed grounding
instructions for your area and type of equipment.
–12
Siemans/meter
Attaching the ground wire to the grounding screw (106)
grounds the wetted parts. See grounding screw on page 16.
Fig. 2 shows a recommended method of grounding flammable fluid containers during filling. Ground all of this
equipment:
Pump: Connect the non–clamp end of the ground wire
to the grounding strip or grounding screw, and connect
the clamp end of the ground wire to a true earth ground.
To order a ground wire and clamp, order Part No.
790–100835.
Air and fluid hoses: Use only electrically conductive
hoses.
Air compressor: Follow manufacturer’s recommendations.
Solvent pails used when flushing: Follow the local
code. Use only grounded metal pails, which are conductive. Do not place the pail on a non–conductive surface,
such as paper or cardboard, which interrupts the
grounding continuity.
Fluid supply container: Follow the local code. Dispense valve nozzle must be in contact with container.
7
Installation
Mountings
CAUTION
The pump exhaust air may contain contaminants. If
needed, ventilate to a remote area to reduce possible
fluid contamination. See Air Exhaust Ventilation on
this page.
Be sure the mounting can support the weight of the
pump, hoses, and accessories, as well as the stress
caused during operation.
For all mountings, be sure the pump is secured with
screws and nuts.
WARNING
To reduce the risk of serious injury, splashing in the
eyes or on the skin, and toxic fluid spills, never
move or lift a pump under pressure. If dropped, the
fluid section may rupture. Always follow the Pres-
sure Relief Procedure on page 10 before you move
or lift the pump.
Air Exhaust Ventilation
WARNING
TOXIC FLUID HAZARD
Read the USING HAZARDOUS FLUIDS
and FIRE AND EXPLOSION HAZARD
sections on page 2 before you operate this
pump with flammable liquids.
Be sure the system is properly ventilated for
your type of installation. You must vent the
exhaust to a safe place, away from people,
sources of ignition, animals or food
handling areas when pumping flammable
or hazardous fluids.
If the diaphragm ruptures, the fluid being pumped is
exhausted with the air. Place a container at the end of
the air exhaust line to catch fluid in case the diaphragm
ruptures, and disconnect the pump.
The air exhaust port is 3/8 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause erratic
pump operation.
See Venting Exhaust Air in Fig. a. Exhaust to a remote
location as follows:
1. Remove the muffler (W) from the pump air exhaust
port.
2. Install an electrically conductive air exhaust hose (X)
and connect the muffler to the other end of the hose.
The minimum size for the air exhaust hose is 3/8”
(10mm) ID. If a hose longer than 15 ft (4.57) is required, use a larger diameter hose. Avoid sharp bends
or kinks in the hose.
3. Place a container (Z) at the end of the air exhaust line
to catch fluid in case a diaphragm ruptures. See Fig. 1.
Air Lines
WARNING
Bleed-Type Master Air Valve and Fluid Drain
Valve
A bleed-type master air valve and a fluid drain valve
are required on your system.
The bleed-type master air valve relieves air trapped
between itself and the pump. Trapped air can cause
the pump to cycle unexpectedly, which could result in
serious bodily injury, including splashing in the eyes,
injury from moving parts, or contamination from
hazardous fluids.
The fluid drain valve reduces the risk of serious
bodily injury, including splashing in the eyes or on the
skin, or contamination from hazardous fluids. Install
the fluid drain valve close to the pump’s fluid outlet to
relieve pressure in the hose if the hose becomes
plugged.
1. Mount the air line accessories on the wall or on a
bracket. Be sure the air line supplying the accessories
is grounded.
a. The pump speed can be controlled in one of two
ways: To control it on the air side, install an air
regulator (Order Graymills Part No. FRL–2). To
control it on the fluid side, install a fluid valve
near the outlet.
Install a bleed-type master air valve downstream
from the air regulator, and use it to relieve trapped
air. See the Bleed-Type Master Air Valve and
Fluid Drain Valve warning on page 5. Locate
another bleed-type master air valve upstream from
all air line accessories, and use it to isolate the
accessories during cleaning and repair.
The air line filter removes harmful dirt and moisture from the compressed air supply.
2. Install a flexible air hose between the accessories and
the pump air inlet. Screw the air line fitting into the
air inlet.
3. Do not restrict the exhaust port. Excessive exhaust
restriction can cause erratic pump operation.
8
Installation of Remote Pilot Air Lines
1. Refer to Parts Drawings. Connect air line to pump as in
preceding steps.
Fluid Pressure Relief Valve
CAUTION
2. Connect 1/4” O.D. tubing to push type connectors (16)
on underside of pump.
3. NOTE: by replacing the push type connectors, other
sizes or types of fittings may be used. The new fittings
will require 1/8” npt threads.
4. Connect remaining ends of tubes to external air signal.
5. NOTE: the air pressure at the connectors must be at
least 30% of the air pressure to the air motor for the
pump to operate.
Fluid Suction Line
Ground the fluid system. Read Grounding on page 6. The
fluid inlet port is 1/2” or 3/4”. At inlet fluid pressure
greater than 15 psi (0.1 MPa, 1 bar), diaphragm life will be
shortened.
a. The fluid pressure can be controlled in either of
two ways. To control it on the air side, install an
air regulator (G). To control it on the fluid side,
install a fluid regulator (J) near the pump fluid
outlet (see Fig. 1).
Some systems may require installation of a pressure relief
valve at the pump outlet to prevent overpressurization
and rupture of the pump or hose. See Fig. 3.
Thermal expansion of fluid in the outlet line can cause
overpressurization. This can occur when using long fluid
lines exposed to sunlight or ambient heat, or when
pumping from a cool to a warm area (for example, from
an underground tank).
Overpressurization can also occur if the pump is being
used to feed fluid to a piston pump, and the intake valve
of the piston pump does not close, causing fluid to back
up in the outlet line.
igure 3
Install valve between fluid inlet and outlet ports.
Connect fluid inlet line here.
Connect fluid outlet line here.
b. Locate one bleed-type master air valve (B) close
to the pump and use it to relieve trapped air. Read
the WARNING on page 7. Locate the other master
air valve (E) upstream from all air line accessories
and use it to isolate them during cleaning and
repair.
c. The air line filter (F) removes harmful dirt and
moisture from the compressed air supply.
6. Install an electrically conductive, flexible air hose (C)
between the accessories and the 1/4 npt(f) pump air
inlet. Use a minimum 1/4” (6.3 mm) ID air hose.
Screw an air line quick disconnect coupler (D) onto the
end of the air hose (C), and screw the mating fitting
into the pump air inlet snugly. Do not connect the
coupler (D) to the fitting yet.
CAUTION
For solenoid operation, the pump must exhaust through
the solenoid. Failure to exhaust through solenoid could
cause the diaphragms to fail..
9
Changing the Orientation of the Fluid Inlet
and Outlet Ports
You can change the orientation of the fluid inlet and outlet
ports by repositioning the manifolds.
Figure 4
Torque to 80 to 90 in-lb (9 to 10 N-m).
1.
Remove the four manifold nuts (109), Figure 4. For
2.
Relieve the pressure. See Pressure
Relief Procedure on page 10.
double diaphragm pumps with 2 inlets/2 outlets,
remove two bolts (105), Figure 5.
3. Turn the manifold to the desired position, reinstall the
nuts or bolts, and torque to 80 to 90 in-lb (9 to 10
N-m).
NOTE: Make sure all manifold o-rings are positioned
correctly before you fasten the manifold.
To convert an existing pump with 1 inlet/1 outlet to
4.
2 inlets/2 outlets, consult factory.
*NOTE: Pump inlet is on the bottom for all duckbill
pumps.
109
*outlet
*inlet
109
9065A
Figure 5
Torque to 80 to 90 in-lb (9 to 10 N-m).
*outlet
*inlet
105
*outlet
*inlet
9071A
10
Operation
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is manually relieved. To reduce the risk of serious injury from
pressurized fluid, accidental spray, or splashing fluid,
follow this procedure whenever you
Are instructed to relieve pressure
Stop pumping
Check, clean, or service any system equipment
Install or clean fluid nozzles
1. Shut off the air to the pump.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve all fluid pressure,
and have a container ready to catch the drainage.
Flush Pump Before First Use
NOTE: If the inlet fluid pressure to the pump is more than
25% of the outlet working pressure, the ball check valves
will not close fast enough, resulting in inefficient pump
operation.
6. Place the end of the fluid hose (K) into an appropriate
container. Refer to Figure 1 on page 5.
7. Close the fluid drain valve (H). See Fig. 1.
8. With the pump air regulator (G) closed, open all
bleed-type master air valves (B, E). See Fig. 1.
9. If the fluid hose has a dispensing device, hold it open
while continuing with the following step. Slowly open
the air regulator (G) until the pump starts to cycle.
Allow the pump to cycle slowly until all air is pushed
out of the lines and the pump is primed. See Fig.1.
If you are flushing, run the pump long enough to
thoroughly clean the pump and hoses. Close the air
regulator. Remove the suction tube from the solvent
and place it in the fluid to be pumped.
Operation of Remote Piloted Pumps
The pump was tested in water. Prior to use, flush the
pump thoroughly with a compatible liquid. Follow the steps
under Starting and Adjusting Pump.
Starting and Adjusting Pump
1.
2.
3.
4. Check all fittings to be sure they are tight. Use a
compatible liquid thread sealant on all male threads.
Tighten the fluid inlet and outlet fittings snugly. Do not
overtighten the fittings into the pump.
5. Place the suction tube (if used) in the fluid to be
pumped.
If lifting the pump, follow the Pressure
Relief Procedure above.
Read HAZARD FLUIDS on
page 2.
Be sure the pump is
properly grounded.
Read Fire and
Explosion Hazard
on page 3.
1. Fig. 1 and Parts Drawings. Follow preceding steps 1
through 8 of Starting and Adjusting Pump.
2. Open air regulator (G). See Fig. 1.
WARNING
The pump may cycle once before the external signal is
applied. Injury is possible. If pump cycles, wait until
end before proceeding.
3. Pump will operate when air pressure is alternately
applied to push type connectors (16).
NOTE: Leaving air pressure applied to the air motor for
extended periods when the pump is not running may
shorten the diaphragm life. Using a 3–way solenoid valve
to automatically relieve the pressure on the air motor when
the metering cycle is complete prevents this from occurring.
Pump Shutdown
At the end of the work shift, relieve the
pressure as described in Pressure
Relief Procedure at left.
11
Maintenance
Lubrication
The air valve is lubricated at the factory to operate without
additional lubrication. If you want to provide additional
lubrication, remove the hose from the pump air inlet and
add two drops of machine oil to the air inlet every 500
hours of operation or every month.
CAUTION
Do not over-lubricate the pump. Oil is exhausted through
the muffler, which could contaminate your fluid supply or
other equipment. Excessive lubrication can also cause the
pump to malfunction
Flushing and Storage
Flush the pump to prevent the fluid you are pumping from
drying or freezing in the pump and damaging it. Use a
compatible solvent.
Always flush the pump and relieve the pressure before
you store it for any length of time.
Read Pressure Relief Procedure on
page 10.
Tightening Threaded Connections
Before each use, check all hoses for wear or damage and
replace as necessary. Check to be sure all threaded connections are tight and leak-free.
Check and retorque all threaded connections, including
manifold screws, clamps, and air valve screws, at least
every two months. Although the recommended frequency
for retorquing of fasteners varies with pump usage, a
general guideline is to retorque every two months.
Preventive Maintenance Schedule
Establish a preventive maintenance schedule, based on the
pump’s service history. This is especially important for
prevention of spills or leakage due to diaphragm failure.
12
Troubleshooting
Read Pressure Relief Procedure on page 10, and relieve the pressure before you check or service the equip-
ment. Check all possible problems and causes before disassembling the pump.
PROBLEM
Pump will not cycle, or cycles once
and stops.
Pump cycles at stall or fails to hold
pressure at stall.
Pump operates erratically. Clogged suction line. Inspect; clear.
Air bubbles in fluid. Suction line is loose. Tighten.
Fluid in exhaust air. Diaphragm ruptured. Replace.
Pump exhausts air from clamps (metal
pumps).
Pump leaks fluid from check valves. Worn or damaged check valve o-rings. Inspect; replace.
CAUSE SOLUTION
Air valve is stuck or dirty. Use filtered air.
Leaky check valves or o-rings. Replace.
Worn check balls or duckbill valves or
guides.
Check ball wedged in guide. Repair or replace.
Worn diaphragm shaft seals. Replace.
Sticky or leaking check valve balls. Clean or replace.
Diaphragm ruptured. Replace.
Diaphragm ruptured. Replace.
Loose manifolds or damaged manifold
o-rings.
Loose fluid side diaphragm plates. Tighten.
Loose fluid side diaphragm plates. Tighten.
Worn diaphragm shaft seals. Replace.
Loose clamps. Tighten clamp nuts.
Air valve o-ring is damaged. Inspect; replace.
Replace.
Tighten manifold bolts or nuts; replace
o-rings.
13
Service
Air Valve
NOTE: Air Valve Repair Kit 784–90611 is available. Parts included in the kit are marked with a dagger ( ) in Fig. 6 and in
the Parts Drawings and Lists. A tube of general purpose grease is supplied in the kit. Service the air valve as follows. See
Fig. 6.
1. Relieve the pressure. See Pres-
sure Relief Procedure on page 10.
2. Remove the cover (10) and the o-ring (4).
3. Remove the carriage plungers (7), carriages (8),
carriage pins (9), and valve plate (14) from the center
housing (11).
4. Clean all the parts, and inspect them for wear or
damage.
NOTE: If you are installing the new Air Valve Repair
Kit 784–90611, use all the parts in the kit.
5. Grease the lapped surface of the valve plate (14), and
install the valve plate with the lapped surface facing
up.
6. Grease the bores of the center housing (11), install the
u-cup packings (2) on the carriage plungers (7), and
slide the carriage plungers into the carriage plunger
bores. See the following important installation notes:
NOTES:
When you install each u-cup packing (2) on each
carriage plunger (7), make sure the lips of the u-cup
packing face toward the clip end (the smaller end) of
the carriage plunger.
When you slide the carriage plungers (7) into the
bores, slide them in with the clip ends (the smaller
ends) facing toward the center of the center housing (11).
7. Grease the carriage pins (9), and slide the carriage pins
into the carriage pin bores.
8. Install the carriages (8). Make sure the carriages
engage the clip ends of the carriage plungers (7) and
carriage pins (9).
9. Grease the o-ring (4), and seat it in the groove around
the cover opening of the center housing (11).
10. Screw the cover (10) into the center housing, and
torque the cover to 80 to 100 in-lb (9.0 to 13.6 N-m).
Figure 6
NOTE: Center housing (11) is
shown separated from the air covers,
but it is not necessary to remove the
air covers for this service. Leave the
center housing and air covers
assembled for this service.
Included in Air Valve Repair Kit 784–90611
Torque to 80 to 100 in-lb (9.0 to 13.6 N-m).
Apply grease.
Apply grease to lapped face.
Apply grease to bores of center housing (11) before installing.
Seal lips face clip end (the smaller end) of carriage plunger (7).
Install with the clip ends (the smaller ends) facing toward center
of center housing (11).
8
10
2
2
7
7
14
11
4
9
8
9
9069A
14
Service
Ball or Duckbill Check Valves
NOTE: Use Fluid Section Repair Kit 784–90612 for
Hytrel Diaphragm pumps and 784–90613 for PTFE Diaphragm pumps. General purpose grease and adhesive are
supplied in the kits.
1. Relieve the pressure. See Pres-
sure Relief Procedure on page 10.
2. Remove the top and bottom manifolds (102, 103).
Figure 7
Split Manifold Pump
109
103
139
201
139
202
301
201
3. Remove all parts shown with a dagger ( ).
4. Clean all parts, and replace worn or damaged parts.
5. Reassemble the pump.
NOTE: Torque the manifold nuts (109) or bolts (105)
to 80 to 90 in-lb (9 to 10 N-m).
Inlet and Outlet for Pumps with Duckbill
Check Valves
Pumps with duckbill check valves are shipped with the
inlet manifold on bottom and the outlet manifold on the
top. To make the inlet manifold on the top and the outlet
manifold on the bottom, rotate each of the four duckbill
assemblies vertically 180 as shown below. This may be
necessary in applications where pump priming is problematic.
202
139
201
202
139
139
202
301
201
139
102
202
201
139
109
Torque to 80 to 90 in-lb (9 to 10 N-m).
15
Service
Diaphragms
NOTE: Fluid Section Repair Kit 784–90612 for Hytrel and 784–90613 for PTFE Diaphragms are available. Parts included
in the kit are marked with a double dagger ( ) in Fig. 8 and in the Parts Drawings and Lists. General purpose grease and
adhesive are supplied in the kit. Service the diaphragms as follows. See Fig. 8.
Disassembly
1. Relieve the pressure. See Pres-
sure Relief Procedure on page 10.
2. Remove manifolds (102 and 103) and fluid covers (101).
NOTE: Make sure all the check valve parts stay in
place.
3. Remove one of the fluid-side diaphragm plates (105)
(whichever one comes loose first when you use a
wrench on the hex of each), and pull the diaphragm
shaft out of the center housing (11).
4. Use a wrench on the flats of the diaphragm shaft (15)
to remove the other fluid-side diaphragm plate (105)
from the diaphragm shaft.
Reassembly
1. Insert a diaphragm shaft u-cup (16) and a pilot pin
o-ring (1) into the bores of the center housing (11).
NOTE: Make sure the lips of the u-cup face out of the
center housing.
2. Line up the holes in the gasket (12) with the holes in
the end of the center housing (11), and use six screws
(106) to fasten an air cover (113 or 114) to the end of
the center housing (11). Torque the screws to 35 to 45
in-lb (4.0 to 5.1 N-m).
3. Position the exhaust cover (13) and o-ring (4) on the
center housing (11).
4. Repeat steps 1 and 2 for the other end of the center
housing and the remaining air cover.
5. Apply medium-strength (blue) Loctite or equivalent to
the threads of the fluid-side diaphragm plates (105).
Install on one end of the diaphragm shaft (15) the
following parts (see proper order in Fig. 8): air-side
diaphragm plate (6) diaphragm (401), and fluid-side
diaphragm plate (105).
NOTE: The words “AIR SIDE” on the diaphragm
(401) and the flat side of the air-side diaphragm plate
(6) must face toward the diaphragm shaft (15)
5. Remove the screws (106), remove the left (114) and
right (113) air covers, and remove all old gasket (12)
material from the ends of the center housing (11) and
the surfaces of the air covers.
6. Remove the diaphragm shaft u-cups (16) and pilot pin
o-rings (1).
7. Inspect all parts for wear or damage, and replace as
necessary.
6. Put grease on the diaphragm shaft (15), and carefully
(do not damage the shaft u-cups) run the diaphragm
shaft (15) through the center housing (11) bore.
7. Repeat step 5 for the other end of the diaphragm shaft
(15), and torque the fluid-side diaphragm plates (105)
to 80 to 90 in-lb (9 to 10 N-m) at 100 rpm maximum.
8. Install the muffler (3).
9. Make sure all the check valve parts are in place.
10. Reinstall the fluid covers (101) and manifolds (102 and
103), and torque the fluid cover and manifold nuts
(109) to 80 to 90 in-lb (9 to 10 N-m).
16
Service
Figure 8
11
101
109
103
109
6
105
114
106
102
401
12
1
15
16
Included in Fluid Section Repair Kit 784–90612 or
784–90613
Install with lips facing out of center housing (11).
4
13
3
109
Torque to 35 to 45 in-lb (4.0 to 5.1 N-m).
Apply grease.
The words “AIR SIDE” on diaphragm must face toward
diaphragm shaft (15).
Flat side of air-side diaphragm plate must face toward
diaphragm shaft (15).
Apply medium-strength (blue) Loctite or equivalent
to threads, and torque to 80 to 90 in-lb (9 to 10 N-m) at
100 rpm maximum.
Torque to 80 to 90 in-lb (9 to 10 N-m).
9066A
17
Parts Drawing
103
139
201
202
101
115
109
111
139
202
301
201
139
6
105
106
grounding screw
(acetal pump only)
114
106
401
12
Included in Air Valve Repair Kit 784–90611
Included in Fluid Section Repair Kit
784–90612 and 784–90613
* These parts are unique to the remote oper–
ated air motor.
10
139
201
202
104
102
109
139
202
301
201
139
117
109
16
16
8
2
14
4
7
101
9
116
11
1
17
15
113
4
13
3
9064A
18
Dimensions
1/4 npt(f)
Air Inlet
(196.9 mm)
SIDE VIEW
(79.5 mm)
7.75 in.
3.13 in.
4.70 in.
(119 mm)
1/2 npt(f) or
bspt(f)
Fluid Inlet *
FRONT VIEW
5.01 in.
(127 mm)
6.12 in.
(155.4 mm)
3/4 npt(f) or
bspt(f)
Fluid Inlet *
1/2 npt(f) or bspt(f) Fluid Outlet *
10.63 in.
(270.0 mm)
9.94 in.
(252.5
mm)
8.56 in.
(217.4
mm)
1.38 in.
(35.1 mm)
3/4 npt(f) or
bspt(f)
Fluid Outlet *
3/4 npt (f)
or bspt(f)
Fluid Inlet *
4.30 in.
(109.2 mm)
6.25 in.
(158.8 mm)
(109.2 mm)
PUMP MOUNTING HOLE PATTERN
Four 0.30 in.
(7.6 mm)
Diameter Slots
4.30 in.
6.12 in.
(155.4 mm)
9077A
19
Performance Charts
Test Conditions: Pump tested in water with inlet submerged.
)
rab ,aPM( isp – erusserP teltuO diulF
(0.55, 5.5)
(0.41, 4.1)
(0.28, 2.8)
(0.14, 1.4)
(0.7, 7)
A at 100 psi (0.7 MPa, 7 bar) air pressure
B at 70 psi (0.48 MPa, 4.8 bar) air pressure
C at 40 psi (0.28 MPa, 2.8 bar) air pressure
C
(7.6)
Fluid Pressure Curves
B
(15.2)
(22.7)
(30.3) (37.9)
FLUID FLOW––gpm (lpm)
A
(45.4)
(53.0) (60.6)
To find Fluid Outlet Pressure (psi/MPa/bar) at a
specific fluid flow (gpm/lpm) and operating air pressure
(psi/MPa/bar):
1. Locate fluid flow rate along bottom of chart.
2. Follow vertical line up to intersection with selected fluid
outlet pressure curve.
3. Follow left to scale to read fluid outlet pressure.
Fluid Outlet Pressure
Air Consumption
Air Consumption Curves
A at 100 psi (0.7 MPa, 7 bar) air pressure
B at 70 psi (0.48 MPa, 4.8 bar) air pressure
C at 40 psi (0.28 MPa, 2.8 bar) air pressure
B
C
(22.7)
(30.3) (37.9)
FLUID FLOW––gpm (lpm)
(45.4) (53.0)
A
)nim/sretem cibuc( mfcs – noitpmusnoC riA
Test Conditions: Pump tested in water with inlet submerged.
(0.84)
(0.70)
(0.56)
(0.42)
(0.28)
(0.14)
(7.6) (15.2)
To find Pump Air Consumption (scfm or m#/min)
at a specific fluid flow (gpm/lpm) and air pressure
(psi/MPa/bar):
1. Locate fluid flow rate along bottom of chart.
2. Read vertical line up to intersection with selected
air consumption curve.
3. Follow left to scale to read air consumption.
(60.6)
WARRANTY
Graymills Corporation warrants that the equipment manufactured and
delivered, when properly installed and maintained , shall be free from
defects in workmanship and will function as quoted in the published specification. Graymills does not warrant process performance, nor assume any
liability for equipment selection, adaptation, or installation.
Warranty does not apply to damages or defects caused by shipping, operator carelessness, mis–use, improper application or installation, abnormal
use, use of add–on parts or equipment which damages or impairs the proper function of the unit and modifications made to the unit. Warranty does
not apply to expendable parts needing replacement periodically due to
normal wear and tear.
A new Warranty period shall not be established for repaired or replaced
materials or products. Such items shall remain under Warranty for only the
remainder of the Warranty period of the original materials or product.
THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER
WARRANTIES, WHETHER ORAL, WRITTEN, EXPRESSED, IMPLIED
OR STATUTORY. GRAYMILLS CORPORATION MAKES NO OTH-
ER WARRANTY OF ANY KIND EXPRESS OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND
Graymills Corporation 3705 N. Lincoln Avenue Chicago, Illinois 60613 773/248–6825 FAX 773/477–8673 www.graymills.com
FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE A
FORESTATED OBLIGATION ARE HEREBY DISCLAIMED BY GRAY-
MILLS CORPORATION AND EXCLUDED FROM THIS SALE.
Graymills warranty obligations and Buyer remedies (except to title) are
solely and exclusively stated herein. In no case will Graymills be liable
for consequential damages, loss of production, or any other loss incurred
due to interruption of service.
Graymills’ obligation under this Warranty shall be limited to:
a) Repairing or replacing (at Graymills sole discretion) any non–conforming or defective component within one year from the date of
shipment from Graymills.
b) Repairing or replacing (at Graymills sole discretion), components
supplied by, but not manufactured by Graymills, to the extent of the
warranty given by the original manufacturer.
Buyer must give Graymills prompt notice of any defect or failure.
If you believe that you have a Warranty claim, contact Graymills at
(773)248–6825. Any return material must have an RMA number on the
outside of the package and must be shipped prepaid or shipment will be
refused. Graymills will promptly examine the material and determine if it
is defective and within the Warranty period.
20
1/2” Model
DACT50
98/37/EC Machinery Directive
94/9/EC ATEX Directive (Ex II 2 G T6)
EN 292 EN 1127–1 EN 13463–1
Graymills Corporation
3705 N. Lincoln Avenue
Chicago, Illinois 60613
ISO 9614–1
0359
9–9–2005
Jerry Shields
9–9–2005
PRESIDENT (Print)
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