All-Flo KE-05 1/2 PVDF - Manual

7. Take one diaphragm and invert (reverse the natural bow of the material) and
with the curved side of the inner diaphragm plate facing the diaphragm
assemble onto outer diaphragm plate stud and then screw assembly into
diaphragm rod. Push diaphragm rod to the opposite side of the intermediate
and add the opposite diaphragm assembly. Tighten the outer diaphragm
plates to 70 in-lbs (7,91 NM) of torque. After tightening, reverse the inverted
diaphragm back to its original state, allowing the outer bead to seat in the
groove of the intermediate.
NOTE: Inverting the first diaphragm aids reassembly.
8. Position outer diaphragm chambers onto intermediate making sure that witness
lines are matching.
NOTE: If air valve has been removed, proper orientation of air system with
fluid chambers must be observed. The bottom of the intermediate has the
smaller hook shaped air passage slot on the air valve mounting face, and
the outer chamber check ball cavity should be pointing downward.
9. Tighten all external fasteners to final torque requirement after pump is
completely assembled.
10. Position the manifolds making sure of the proper orientation in relation to the air
valve for your application. Also make sure that the manifold o-rings do not shift
from their grooves during reassembly. Tighten all external fasteners to final torque
requirement after pump is completely assembled.
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.
AIR VALVE CAP SCREWS 40 in-lbs (4,52 NM)
MANIFOLD BOLTS, 90-100 in-lbs (10,17-11,3 NM)
OUTER CHAMBER CAP SCREWS, 75-85 in-lbs (8,48-9,61 NM)
AIR VALVE MAINTENANCE
11. To evaluate air valve components, remove the four cap screws (11), washers,
(25, 10) and nuts (17) from the air valve body (7). The shuttle plate (5) and
shuttle (6) can be inspected by removing them from their location in the slot in
the back of the air valve. Inspect for scratches or surface irregularities. Replace
if necessary. Remove the plug (1) at the bottom of the air valve. Next push the air
valve spool (2) out of the air valve body. Gently reach in and pull lip seals (43) out
of inside bore of the air valve body. Check for cracks, splitting or scratches. Clean
components if replacement is not necessary. Inspect plug o-ring (44) for any
damage, replace if necessary and reposition o-ring into groove in air valve body.
NOTE: Make sure that the open sides of the two lip seals face each other
when reassembling air valve. Lube all components with suggested main-
tenance grease as an aid in reassembly.
12. Reinsert air valve spool inside of air valve body. Place shuttle on middle rib of air
valve spool through the square slot in back of air valve. Lubricate side of plate
that faces the shuttle and reposition valve plate over shuttle. Press the valve
plug into air valve body, chamfered end first.
13. Check that gasket (4) is not cracked. If damaged replace.
14. After gasket is pressed back into position align air valve onto intermediate and
reinsert the four cap screws with lock washer and flat washers. Apply 40 in-lbs
(4,52 NM) of torque to fasteners.
U.S. Patent Number 5232352
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PERFORMANCE PLUS
PLASTIC 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 nuts (18) from bolts (16) in both the discharge and suctions manifolds.
Suction check valve seats and check balls (26, 27) are located inside of the
bottom of the outer chamber (28). Gently remove and inspect for excessive
wear, pitting or other signs of degradation. Inspect valve seat and manifold
o-rings (38, 19). Replace if necessary. Discharge check valves are located
inside of the bottom of the discharge manifold (32). Repeat procedure for
inspection of discharge check valves and o-rings. (Pumps built with optional
Max-Pass valves, repeat procedure for removing and inspecting Max-Pass
valves(48), back-ups(49) and o-rings (50, 19).
3. When re-assembling, the check ball should fit within the ball cavity of the cham-
ber and discharge manifold. Press fit the valve seats into position with the curved
portion facing the ball. Lightly tighten fasteners. Tighten all external fasteners to
final torque requirement after pump is completely assembled.
NOTE: When using pumps built with PTFE o-rings always replace with new
PTFE o-rings, since the original o-rings may not reseal the pump.
DIAPHRAGM AND PILOT SLEEVE ASSEMBLY MAINTENANCE
4. To inspect diaphragms remove nuts (18) from bolts (16) from the outer pumping
chambers (28). If replacement is necessary due to abrasion or rupture, unscrew
the outer diaphragm plates (29). Models that are built with PTFE elastomers will
have a PTFE overlay (30) that faces the outer pumping chamber and a back-up
diaphragm (31) on the air side of pump. Pumps without PTFE will contain only
the back-up diaphragms.
5. If there has been a diaphragm rupture and corrosive or viscous fluid has
entered the air side of pump the complete air system should be inspected.
After removing diaphragms and inner diaphragm plate (33), the pilot sleeve
assembly (14, 40, 42, 45-47) and diaphragm rod assembly (13, 15) may be
removed by removing the retaining plates (41) and pushing the entire unit out
through the bore in the intermediate (34). Diaphragm rod assembly must be
unscrewed to remove pilot sleeve.
NOTE: To aid in reassembly use a non-synthetic, petroleum based lubricating
grease without EP additives. Carleton-Stuart MagnaLube G is recommended.
6. 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 and lip seals (40) within bore of intermediate. Make
sure that the open side, of the lip seals are facing outward toward the
diaphragms. Also make sure that the end pilot spacers (14) are at the end on
either side of the pilot sleeve assembly and all inner spacers (47) are
separated by o-rings. 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 (24).