SERVICE & OPERATING MANUAL

C ® US
LISTED
1TA3

Models 85634 & 85635

1" Aluminum UL Listed
Air-Operated Double Diaphragm Pump II 2GD T5

Table of Contents
Engineering Data and Temperature Limitations..................................................... 1 Composite Repair Parts List................................................................................. 11
Explanation of Pump Nomenclature....................................................................... 2 Air Distribution Valve Assembly Drawing and Parts List....................................... 12
Performance Curve................................................................................................ 3 Air Distribution Valve Servicing............................................................................. 13
Dimensions . .......................................................................................................... 4 Diaphragm Service Drawing, with Overlay........................................................... 14
Metric Dimensions ................................................................................................. 5 Diaphragm Service Drawing, Non-Overlay.......................................................... 14
Principle of Pump Operation.................................................................................. 6 Diaphragm Servicing............................................................................................ 15
Installation and Start-Up......................................................................................... 6 Overlay Diaphragm Servicing . ............................................................................ 15
Air Supply............................................................................................................... 6 Pilot Valve Servicing, Assembly Drawing & Parts List.......................................... 16
Air Valve Lubrication............................................................................................... 6 Actuator Plunger Servicing................................................................................... 17
Air Line Moisture.................................................................................................... 6 Check Valve Servicing.......................................................................................... 18
Air Inlet and Priming............................................................................................... 6 Check Valve Drawing........................................................................................... 18
Between Uses........................................................................................................ 6 Pumping Hazardous Liquids................................................................................ 19
Installation Guide.................................................................................................... 7 Converting Pump for Piping Exhaust Air.............................................................. 19
Troubleshooting...................................................................................................... 8 Converted Exhaust Illustration............................................................................. 19
Warranty................................................................................................................. 8 Grounding The Pump........................................................................................... 20
Recycling................................................................................................................ 9 CE Declaration of Conformity............................................................................... 21
Important Safety Information.................................................................................. 9 ATEX Declaration of Conformity........................................................................... 22
Composite Repair Parts Drawing......................................................................... 10
Available Service and Conversion Kits................................................................. 10

Section - B5
Page - 42A

LINCOLN • One Lincoln Way, St. Louis, MO 63120-1578 • Customer Service (314) 679-4200
LINCOLN Model 85634, 85635 sm-rev0510 Form #404104
 Models
85634 & 85635
C ® US
LISTED 1" Aluminum
1TA3
UL Listed

Air-Operated
Double Diaphragm Pump
II 2GD T5
ENGINEERING, PERFORMANCE
& CONSTRUCTION DATA

INTAKE/DISCHARGE PIPE SIZE CAPACITY AIR VALVE SOLIDS-HANDLING HEADS UP TO DISPLACEMENT/STROKE

1" NPT(internal) 0 to 45 gallons per minute No-lube, no-stall Up to .25 in. (6mm) 100 psi or 230.7 ft. of water .11 Gallon / .42 liter
1" BSPT Tapered (internal) (0 to 170 liters per minute) design (7 Kg/cm2 or 70 meters)

CAUTION! Operating temperature limitations are as follows:

Operating Temperatures
Materials Maximum Minimum
Nitrile 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
hydrocarbons and nitro hyrdrocarbons. 88°C -23°C
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
esters, nitro hydrocarbons and chlorinated aromatic hydrocarbons. 77°C -23°C
Virgin PTFE Chemically inert, virtually impervious. Very few chemicals are known to react chemically with
PTFE: molten alkali metals, turbulent liquid or gaseous fluorine and a few fluoro-chemicals such as 212°F -35°F
chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures. 100°C -37°C

Polypropylene 150°F -40°F

65°C -40°C
Polyethylene 180°F -40°F
82°C -40°C
For specific applications, always consult a “Chemical Resistance Chart”

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 1

 Explanation of Pump Nomenclature

Diaphragm/ Check Non-Wetted Shipping

Model Wetted Check Valve Valve Material Porting Weight
Material Materials Seat Options Options lbs. (kg)
85634 Unpainted Nitrile/Nitrile PTFE Unpainted 1" NPT 53 (24)
Aluminum Aluminum
85635 Unpainted PTFE-Neoprene/PTFE PTFE Unpainted 1" NPT 53 (24)
Aluminum Aluminum

Model 85634 is UL79 listed for pumping: Gasoline, Diesel Fuel, No. 4 Fuel Oils (or lighter), Motor Oil,
Kerosene, Aviation Fuel and Water

Model 85635 is UL79 listed for pumping: Gasoline (Including Alcohol Blends), Diesel Fuel, Motor Oil, No. 4 Oil
(or lighter), Kerosene, Aviation Fuel, Automatic Transmission Fluid, Alcohol, Water, Waste Oil, Ethyl Alcohol,
Methyl Alcohol and Ethylene Glycol.

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 2

Performance Curve, Models 85634 & 85635

MODEL U1F Metallic Performance Curve

Performance based on the following: elastomer fitted pump, flooded suction, water at ambient conditions.
BAR

The use of other materials and varying hydraulic conditions may result in deviations in excess of 5%.
PSI

5(00)
7 100 10(17)
100
PSI
(6.8 15(00)
Bar 20(34)
)
6

NPSHR
25(00)
80
80 P
SI (5 30(51)
5 .44 B
ar)
35(00)

60
4
HEAD

60 PS 40(68)
I (4.0

METERS
8 Bar
)

FEET
3
40 40 PS
I (2.72
Bar)
30 9.1
2 25 7.6
20 20 6
20 PSI (1.3
1 6 Bar) Air In 15 4.5
let Pressure
10 3
5 1.5
0 0
0 5 10 15 20 25 30 35 40 45 50
U.S. Gallons per minute
0 20 40 60 80 100 120 140 160 180
Liters per minute
CAPACITY

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 3

Dimensions: Models 85634 & 85635
Dimensions in Inches
Dimensional Tolerance:±1/8"

WITH 273020
MUFFLER

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 4

Metric Dimensions: 85634 & 85635
Dimensions in Millimeters
Dimensional Tolerance:± 3mm

WITH 273020 MUFFLER

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 5

PRINCIPLE OF PUMP OPERATION body, the pressure to the chambers is the pump and the piping to reduce AIR INLET AND PRIMING
This ball type check valve pump reversed. The air distribution valve spool strain to the piping. The weight of the To start the pump, open the air valve
is powered by compressed air and is is moved by a internal pilot valve which air supply line, regulators and filters approximately 1/2" to 3/4" turn. After
a 1:1 ratio design. The inner side of alternately pressurizes one end of the air must be supported by some means the pump primes, the air valve can be
one diaphragm chamber is alternately distribution valve spool while exhausting other than the air inlet cap. Failure to opened to increase air flow as desired.
pressurized while simultaneously the other end. The pilot valve is shifted provide support for the piping may result If opening the valve increases cycling
exhausting the other inner chamber. at each end of the diaphragm stroke in damage to the pump. A pressure rate, but does not increase the rate of
This causes the diaphragms, which when a actuator plunger is contacted regulating valve should be installed flow, cavitation has occurred. The valve
are connected by a common rod by the diaphragm plate. This actuator to insure air supply pressure does not should be closed slightly to obtain the
secured by plates to the centers of the plunger then pushes the end of the pilot exceed recommended limits. most efficient air flow to pump flow ratio.
diaphragms, to move in a reciprocating valve spool into position to activate the
action. (As one diaphragm performs the air distribution valve. AIR VALVE LUBRICATION BETWEEN USES
discharge stroke the other diaphragm is The chambers are connected with The air distribution valve and the When the pump is used for materials
pulled to perform the suction stroke in manifolds with a suction and discharge pilot valve are designed to operate that tend to settle out or solidify when
the opposite chamber.) Air pressure is check valve for each chamber, WITHOUT lubrication. This is the not in motion, the pump should be
applied over the entire inner surface of maintaining flow in one direction through preferred mode of operation. There may flushed after each use to prevent
the diaphragm while liquid is discharged the pump. be instances of personal preference or damage. (Product remaining in the
from the opposite side of the diaphragm. poor quality air supplies when lubrication pump between uses could dry out or
The diaphragm operates in a balanced INSTALLATION AND START-UP of the compressed air supply is required. settle out. This could cause problems
condition during the discharge stroke Locate the pump as close to the The pump air system will operate with with the diaphragms and check valves
which allows the pump to be operated product being pumped as possible. Keep properly lubricated compressed air at restart.) In freezing temperatures
at discharge heads over 200 feet (61 the suction line length and number of supply. Proper lubrication requires the pump must be completely drained
meters) of water. fittings to a minimum. Do not reduce the the use of an air line lubricator set between uses in all cases.
For maximum diaphragm life, keep suction line diameter. to deliver one drop of SAE 10 non-
the pump as close to the liquid being For installations of rigid piping, short detergent oil for every 20 SCFM (9.4
pumped as possible. Positive suction sections of flexible conductive hose liters/sec.) of air the pump consumes
head in excess of 10 feet of liquid should be installed between the pump at the point of operation. Consult the
(3.048 meters) may require a back and the piping. The flexible conductive pump’s published Performance Curve
pressure regulating device to maximize hose reduces vibration and strain to the to determine this.
diaphragm life. pumping system. A surge suppressor
is recommended to further reduce AIR LINE MOISTURE
Alternate pressurizing and Water in the compressed air supply
exhausting of the diaphragm chamber pulsation in flow.
can create problems such as icing or
is performed by an externally mounted, AIR SUPPLY freezing of the exhaust air, causing
pilot operated, four way spool type Air supply pressure cannot exceed the pump to cycle erratically or stop
air distribution valve. When the spool 125 psi (8.6 bar). Connect the pump air operating. Water in the air supply can
shifts to one end of the valve body, inlet inlet to an air supply of sufficient capacity be reduced by using a point-of-use
pressure is applied to one diaphragm and pressure required for desired air dryer to supplement the user’s air
chamber and the other diaphragm performance. When the air supply line drying equipment. This device removes
chamber exhausts. When the spool is solid piping, use a short length of water from the compressed air supply
shifts to the opposite end of the valve flexible conductive hose not less than and alleviates the icing or freezing
1/2" (13mm) in diameter between problems.

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 6

 INSTALLATION GUIDE
Top Discharge Ball Valve Pump

1 Surge Suppressor 1
2 Filter/Regulator
3 Air Dryer

CAUTION
Use a gasoline-resistant pipe
compound to make pipe joints tight.

Pump shall be installed in accordance to Flammable

and Combustible Liquids Code, NFPA 30 or the Automotive
and Marine Service Station Code, NFPA 30A, as appropriate
to the intended use of the pump.

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

WARNING
To maintain conductivity,
do not paint the pump, or if 3
painted, use a conductive
paint or coating.
2

The pump must be rigidly mounted

with fasteners to a conductive base
or natural ground.

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 7

TROUBLESHOOTING What to Check: Undersized suction What to Check: Pumped fluid in air What to Check: Blocked discharge
Possible Symptoms: line. exhaust muffler. line.
• Pump will not cycle. Corrective Action: Meet or exceed Corrective Action: Disassemble Corrective Action: Check for
• Pump cycles, but produces no flow. pump connection recommendations pump chambers. Inspect for diaphragm obstruction or closed discharge line
shown on the DIMENSIONAL rupture or loose diaphragm plate valves.
• Pump cycles, but flow rate is DRAWING. assembly. Refer to the Diaphragm What to Check: Blocked pumping
unsatisfactory. Replacement section of your pump chamber.
• Pump cycle seems unbalanced. What to Check: Restricted or SERVICE MANUAL. Corrective Action: Disassemble
• Pump cycle seems to produce undersized air line. and inspect the wetted chambers
excessive vibration. Corrective Action: Install a larger What to Check: Suction side air of the pump. Remove or flush any
air line and connection. Refer to air leakage or air in product. obstructions. Refer to the pump
What to Check: Excessive suction lift inlet recommendations shown in your Corrective Action: Visually inspect SERVICE MANUAL for disassembly
in system. pump’s SERVICE MANUAL. all suction side gaskets and pipe instructions.
Corrective Action: For lifts exceeding connections.
20 feet (6 meters), filling the pumping What to Check: Check ESADS, the What to Check: Entrained air or vapor
chambers with liquid will prime the Externally Serviceable Air Distribution What to Check: Obstructed check lock in one or both pumping chambers.
pump in most cases. System of the pump. valve. Corrective Action: Purge chambers
Corrective Action: Disassemble and Corrective Action: Disassemble the through tapped chamber vent plugs.
What to Check: Excessive flooded inspect the main air distribution valve, wet end of the pump and manually PURGING THE CHAMBERS OF AIR
suction in system. pilot valve and pilot valve actuators. dislodge obstruction in the check valve CAN BE DANGEROUS! Contact the
Corrective Action: For flooded Refer to the parts drawing and air valve pocket. Refer to the Check Valve Technical Services Department before
conditions exceeding 10 feet (3 meters) section of the SERVICE MANUAL. section of the pump SERVICE MANUAL performing this procedure. Any model
of liquid, install a back pressure device. Check for clogged discharge or closed for disassembly instructions. with top-ported discharge will reduce or
valve before reassembly. eliminate problems with entrained air.
What to Check: System head exceeds What to Check: Worn or misaligned If your pump continues to perform
air supply pressure. What to Check: Rigid pipe connections check valve or check valve seat. below your expectations, contact your
Corrective Action: Increase the to pump. Corrective Action: Inspect check local Distributor or factory Technical
inlet air pressure to the pump. Most Corrective Action: Install flexible valves and seats for wear and proper Services Group for a service evaluation.
diaphragm pumps are designed for 1:1 connectors and a surge suppressor. seating. Replace if necessary. Refer
pressure ratio at zero flow. to Check Valve section of the pump WARRANTY
What to Check: Blocked air exhaust SERVICE MANUAL for disassembly Refer to the enclosed Warranty
What to Check: Air supply pressure or muffler. instructions. Certificate.
volume exceeds system head. Corrective Action: Remove muffler
Corrective Action: Decrease inlet screen, clean or de-ice and reinstall. What to Check: Blocked suction line.
air pressure and volume to the Refer to the Air Exhaust section of your Corrective Action: Remove or flush
pump as calculated on the published pump SERVICE MANUAL. obstruction. Check and clear all suction
PERFORMANCE CURVE. Pump is screens and strainers.
cavitating the fluid by fast cycling.

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 8

RECYCLING WARNING IMPORTANT SAFETY WARNING
Many components of LINCOLN ®
Systems which will be dispensing fluids under
INFORMATION Take action to prevent static
Metallic AODD pumps are made of pressure may need to be protected by using sparking. Fire or explosion
recyclable materials (see chart on a thermal relief kit which will safely limit the can result, especially
pressures caused by thermal expansion. Please when handling flammable
page 10 for material specifications). contact your local Lincoln distributor and liquids. The pump, piping,
We encourage pump users to recycle refer to Service Page Section K5 Page 31 for IMPORTANT valves, containers or
more details. Failure to include thermal relief other miscellaneous equipment must be
worn out parts and pumps whenever protection may cause damage not covered Read these safety warnings grounded. (See page 21)
possible, after any hazardous pumped under Lincoln’s warranty policy. and instructions in this
manual completely, before
fluids are thoroughly flushed. installation and start-up WARNING
of the pump. It is the
WARNING responsibility of the purchaser to retain this
manual for reference. Failure to comply with
This pump is pressurized
internally with air pressure
Do not smoke near the the recommendations stated in this manual will during operation. Always
pump or use the pump damage the pump, and void factory warranty. make certain that all bolting
near an open flame. Fire or is in good condition and
explosion could result. that all of the correct
bolting is reinstalled during assembly.

CAUTION
WARNING Before pump operation, WARNING
Do not use this pump with portable water inspect all gasketed
When used for toxic or
or fluids for human consumption. fasteners for looseness
aggressive fluids, the pump
caused by gasket creep. Re-
should always be flushed
torque loose fasteners to
clean prior to disassembly.
prevent leakage. Follow recommended torques
stated in this manual.

WARNING
Pump complies with EN809 Pumping WARNING Before doing any main-
Directive and Directive 2006/42/EC tenance on the pump,
II 2GD T5 Machinery, and Directive 94/9/EC, EN
Before maintenance or
repair, shut off the com-
be certain all pressure is
completely vented from the
13463-1 Equipment for use in potentially pressed air line, bleed the pump, suction, discharge,
pressure, and disconnect piping, and all other
Explosive Environments. The Technical the air line from the pump. openings and connections. Be certain the air
File AX1 is stored at KEMA, Notified Body The discharge line may be pressurized and must supply is locked out or made non‑operational,
so that it cannot be started while work is being
be bled of its pressure.
0344, under Document #203040000. done on the pump. Be certain that approved
eye protection and protective clothing are worn
all times in the vicinity of the pump. Failure to
follow these recommendations may result in
serious injury or death.
Underwriters Laboratories,
WARNING
Inc., an Internationally In the event of diaphragm
C US rupture, pumped material
recognized independent WARNING
®

LISTED may enter the air end of the

1TA3 organization for testing pump, and be discharged
into the atmosphere. If Airborne particles and loud
products to ensure public pumping a product which is hazardous or toxic, noise hazards.
safety. the air exhaust must be piped to an appropriate Wear ear and eye protection.
area for safe disposition.

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 9

Composite Repair Parts Drawing
AVAILABLE SERVICE AND CONVERSION KITS
8

274577 Air End Kit 18

Seals, O-Rings, Gaskets, Retaining Rings, Air Valve Assembly 4
11
32
and Pilot Valve Assembly
274578 Wetted End Kit 17 ATTACH EYELET TO ONE
Nitrile Diaphagms, Nitrile Check Balls and OF THE FOUR
CAPSCREWS ITEM #11
PTFE Check Valve Seats 31
274579 Wetted End Kit
Neoprene Backup Diaphragms, PTFE Overlay
Diaphragms, PTFE Check Balls and
25
PTFE Check Valve Seat 20
12 22 7
9
26
30

2
3
28 29
16
27
5
1 13
21 6

10
23
14

15 14 24

2
23

29

OPTIONAL OVERLAY 19 30

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 10

Composite Repair Parts List
ITEM PART NUMBER DESCRIPTION QTY ITEM PART NUMBER DESCRIPTION QTY
1 273013 Air Valve Assembly 1 16 271795 Gasket, Air Valve 1
2 274566 Ball, Nitrile Check 4 17 271796 Gasket, Pilot Valve 1
271815 Ball, PTFE Check 4 18 273018 Gasket, Air Inlet 1
3 240720 Bushing 2 19 271823 Manifold, Suction 1
4 274583 Pilot Valve Assembly 1 20 274571 Manifold, Discharge 1
5 274568 Intermediate 1 21 273020 Metal Muffler 1
6 240727 Bumper 2 22 274572 O-Ring 2
7 252901 Bushing 2 23 240729 Plate, Inner Diaphragm 2
8 271818 Cap, Air Inlet Assembly 1 24 240728 Plate, Outer Diaphragm Assembly 2
9 245754 Capscrew, Hex Hd 5/16-18 X 1.00 16 25 271825 Pin, Actuator 2
10 273015 Capscrew, Hex Hd 3/8-16 X 1.00 4 26 240717 Ring, Retaining 2
27 271826 Rod, Diaphragm 1
11 240731 Capscrew, Hex Hd 5/16-18 X 1.25 16
28 240721 Seal, U-Cup 2
12 271820 Capscrew, Hex Hd 5/16-18 X 1.75 4 29 274573 Seat, Check Ball 4
13 271822 Chamber, Outer 2 30 240693 Lock Washer 16
14 274570 Diaphragm, Nitrile 2 31 271809 Flat Washer 4
240873 Diaphragm, Neoprene 2 32 274574 Ground Strap 1
15 240749 Diaphragm, PTFE Overlay 2

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 11

Air Valve Assembly Drawing, Parts List

1-F

1-E

1-D
1-D

1-C

1-B

1-B

AIR VALVE ASSEMBLY PARTS LIST

1-E ITEM PART NUMBER DESCRIPTION QTY
1 273013 Air Valve Assembly 1
1-A 273041 Valve Body 1
1-B 271774 Sleeve and Spool Set 1
1-A 1-C 273042 Bumper 2
1-D 271780 O-Ring 10
1-C 1-E 273043 Cap, End 2
1-D 1-F 240934 Capscrew 8

1-F

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 12

AIR DISTRIBUTION VALVE Inspect the inner diameter of the
SERVICING sleeve (part of item 1-A) for dirt, IMPORTANT
To service the air valve first shut scratches, or other contaminants. Remove Read these instructions
off the compressed air, bleed pressure the sleeve if needed and replace with completely, before in-
from the pump, and disconnect the air a new sleeve and spool set (item 1-A). stallation and start-up.
supply line from the pump. It is the responsibility of
the purchaser to retain
STEP #3: Reassembly of the this manual for reference. Failure to
STEP #1: See COMPOSITE air valve. comply with the recommendations stated
REPAIR PARTS DRAWING. Install one bumper (item 1-C) and in this manual will damage the pump, and
Using a 9/16" wrench or socket, one end cap (item 1-E) with two o-rings void factory warranty.
remove the four hex head capscrews (item 1-D) and fasten with four hex
(item 10). Remove the air valve capscrews (items (1-F) to the valve
assembly from the pump. body (items 1-A).
Remove and inspect gasket (item Remove the new sleeve an spool
16) for cracks or damage. Replace set (item 1-A) from the plastic bag.
gasket if needed. Carefully remove the spool from the
sleeve. Install the six o-rings (item 1-G)
STEP #2: Disassembly of the into the six grooves on the sleeve. Apply
air valve. a light coating of grease to the o-rings
Using a 7/16" wrench or socket, before installing the sleeve into the
remove the eight hex caprscrews (item valve body (item 1-B), align the slots
1-F) that fasten the end caps to the in the sleeve with the slots in the valve
valve body. body. Insert the spool into the sleeve.
Next remove the two end caps Be careful not to scratch or damage
(items 1-E). Inspect two o-rings (items the spool during installation. Push the
1-D) on each end cap for damage or spool in until it touches the bumper on
wear. Replace the o-rings as needed. the opposite end.
Remove the bumpers (items 1-C). Install the remaining bumper, end
Inspect the bumpers for damage or cap (with o-rings), and fasten with the
wear. remaining hex capscrews.
Remove the spool (part of item Fasten the air valve assembly (item
1-A) from the sleeve. Be careful not to 1) and gasket (item 16) to the pump.
scratch or damage the outer diameter Connect the compressed air line to
of the spool. Wipe spool with a soft cloth the pump. The pump is now ready for
and inspect for scratches or wear. operation.

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 13

Diaphragm Service Drawing, Diaphragm Service Drawing,
with Overlay Non-Overlay

6
23 14

24
5 28

6
23 14
11

15
5 28
13

24

11

13

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 14

DIAPHRAGM SERVICING Step #4: Assembling the Align one diaphragm with the
To service the diaphragms first shut diaphragm and diaphragm plates to the intermediate and install the outer IMPORTANT
off the suction, then shut off the dis- diaphragm rod. chamber to the pump using the 8 Read these instructions
charge lines to the pump. Shut off the Push the threaded stud of one outer capscrews. Tighten the opposite completely, before in-
compressed air supply, bleed the diaphragm plate assembly through the diaphragm plate until the holes in the stallation and start-up.
pressure from the pump and disconnect center of one diaphragm and through diaphragm align with the holes in the It is the responsibility of
the purchaser to retain
the air supply line from the pump. Drain one inner diaphragm plate. Install the intermediate.Then, install the other this manual for reference. Failure to
any remaining liquid from the pump. diaphragm with the natural bulge facing outer chamber using the 8 capscrews. comply with the recommendations stated
away from the diaphragm rod and make in this manual will damage the pump, and
Step #1: See the pump assembly sure the radius on the inner diaphragm Step #6: Reinstall the manifolds void factory warranty.
drawing and the diaphragm servicing plate is towards the diaphragm, as to the pump using the 16 capscrews.
illustration. indicated on the diaphragm servicing The pump is now ready to be
Using a 1/2” wrench or socket, illustration. Thread the assembly onto reinstalled, connected and returned to
remove the 16 capscrews (item 9) that the diaphragm rod, leaving loose. operation.
fasten the manifolds (items 19 & 20) to
the outer chambers (item 13). Step #5: Installing the diaphragm OVERLAY DIAPHRAGM SERVICING
and rod assembly to the pump. The overlay diaphragm (item 15)
Step #2: Removing outer Make sure the bumper (item 6) is is designed to fit over the exterior of the
chambers. installed over the diaphragm rod. Insert standard diaphragm (item 14).
Using a 1/2” wrench or socket, rod into pump. Follow the same procedures
remove the 16 capscrews (item 11), that On the opposite side of the pump, described for the standard diaphragm
fasten the outer chambers (item 13), pull the diaphragm rod out as far as for removal and installation, except
diaphragms (item 14) and intermediate possible. Make sure the second bum- tighten the outer diaphragm plate
(item 5) together. per is installed over the diaphragm rod. assembly, diaphragms and inner
Push the threaded stud of the other diaphragm plate to the diaphragm rod
Step #3: Removing the dia- outer diaphragm plate assembly through to 350 in. lbs. (39.5 Newton meters).
phragms and diaphragm plates. the center of the other diaphragm and
Use a 7/8” wrench or six point through the other inner diaphragm
socket to remove the outer diaphragm plate. Make sure the radius on the inner
plate assemblies (item 24), diaphragms diaphragm plate is towards the
(item 14) and inner diaphragm plates diaphragm. Thread the assembly onto
(item 23) from the diaphragm rod (item the diaphragm rod. Use a 7/8” wrench
28) by turning counterclockwise. In- or socket to hold one outer diaphragm
spect the diaphragm for cuts, punctures, plate. Then, use a torque wrench to
abrasive wear or chemical attack. tighten the other outer diaphragm plate
Replace the diaphragms if necessary. to the diaphragm rod to 350 in. lbs.
DO NOT USE A WRENCH ON THE (39.5 Newton meters).
DIAPHRAGM ROD. FLAWS ON THE
SURFACE MAY DAMAGE BEARINGS
AND SEALS.

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 15

Pilot Valve Servicing, Assembly Drawing & Parts List

pilot valve assembly parts list

Item Part Number Description Qty

4 274583 Pilot Valve Assembly 1
4-A 274584 Valve Body 1
4-B 275805 Sleeve (With O-rings) 1
4-C 274586 O-ring (Sleeve) 6
4-D 274587 Spool (With O-rings) 1
4-E 274588 O-ring (Spool) 3
4-F 274589 Retaining Ring 1

Pilot Valve Servicing STEP #2: Disassembly of the STEP #3: Re-assembly of the STEP #4: Re-install the pilot valve
To service the pilot valve first shut pilot valve. pilot valve. assembly into the intermediate.
off the compressed air supply, bleed Remove the pilot valve spool (item Generously lubricate outside Be careful to align the ends of the
the pressure from the pump, and 4-D). Wipe clean and inspect spool and diameter of the sleeve and o-rings. pilot valve stem between the plunger
disconnect the air supply line from the o-rings for dirt, cuts or wear. Replace Then carefully insert sleeve into valve pins when inserting the pilot valve into
pump. the o-rings and spool if necessary. body. Take CAUTION when inserting the cavity of the intermediate.
Remove the retaining ring (item sleeve, not to shear any o-rings. Install Re-install the gasket, air inlet cap
STEP #1: See pump assembly 4-F) from the end of the sleeve (item retaining ring to sleeve. Generously and capscrews. Connect the air supply
drawing. 4-B) and remove the sleeve from the lubricate outside diameter of spool and to the pump. The pump is now ready
Using a 1/2" wrench or socket, valve body (item 4-A). Wipe clean and o-rings. Then carefully insert spool into for operation.
remove the four capscrews (item 11). inspect sleeve and o-rings for dirt, cuts sleeve. Take CAUTION when inserting
Remove the air inlet cap (item 8) and or wear. Replace the o-rings and sleeve spool, not to shear any o-rings. Use
air inlet gasket (item 18). The pilot valve if necessary. BP-LS-EP-2 multipurpose grease, or
assembly (item 4) can now be removed equivalent.
for inspection and service.

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 16

ACTUATOR PLUNGER SERVICING NOTE: It is recommended that new
To service the actuator plunger first retaining rings be installed. IMPORTANT
shut off the compressed air supply, Step #3: Re-install the pilot valve
Read these instructions
bleed the pressure from the pump, and assembly into the intermediate assembly. completely, before in-
disconnect the air supply line from Be careful to align the ends of stallation and start-up.
the pump. the stem between the plungers when It is the responsibility of
inserting the stem of the pilot valve into the purchaser to retain
this manual for reference. Failure to
Step #1: See pump assembly the cavity of the intermediate. comply with the recommendations stated
drawing. Re-install the gasket (item 18), air in this manual will damage the pump, and
Using a 1/2" wrench or socket, inlet cap (item 8) and capscrews (item void factory warranty.
remove the four capscrews (items 11). 11).
Remove the air inlet cap (item 8) and Connect the air supply to the pump.
air inlet gasket (item 18). The pilot The pump is now ready for operation.
valve assembly (item 4) can now be
removed.
ACTUATOR PLUNGER SERVICING
Step #2: Inspect the actuator
plungers. 25

See ILLUSTRATION AT RIGHT.

The actuator plungers (items 25)
can be reached through the pilot valve
cavity in the intermediate assembly
(item 5).
Remove the plungers (item 25) from
the bushings (item 7) in each end of 7
22
the cavity. Inspect the installed o-ring
26
(items 22) for cuts and/or wear. Replace
the o-rings if necessary. Apply a light
coating of grease to each o-ring and
re-install the plungers in to the bushings.
Push the plungers in as far as they
will go.
To remove the bushings (item 5

7), first remove the retaining rings

(item 26) by using a flat screwdriver.

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 17

CHECK VALVE SERVICING
Before servicing the check valve
Check Valve Drawing
components, first shut off the suction
line and then the discharge line to the
pump. Next, shut off the compressed
20
air supply, bleed air pressure from the
pump, and disconnect the air supply
line from the pump. Drain any remaining
fluid from the pump. The pump can now 9
be removed for service.
To a c c e s s t h e c h e c k v a l v e
components, remove the manifold
(item 20 or item 19 not shown). Use a
1/2" wrench or socket to remove
the fasteners. Once the manifold is
removed, the check valve components
30
can be seen.
Inspect the check balls (items 2) for
wear, abrasion, or cuts on the spherical
surface. The check valve seats (item
30) should be inspected for cuts,
abrasive wear, or embedded material 2
on the surfaces of both the external
and internal chambers. The spherical
surface of the check balls must seat
flush to the surface of the check valve
seats for the pump to operate to
peak efficiency. Replace any worn or
29
damaged parts as necessary.
Re-assemble the check valve
components. The seat should fit into
the counter bore of the outer chamber.
The pump can now be reassembled,
reconnected and returned to operation.

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 18

PUMPING HAZARDOUS LIQUIDS IMPORTANT INSTALLATION CONVERTED EXHAUST ILLUSTRATION
When a diaphragm fails, the pumped NOTE: The manufacturer recommends PUMP INSTALLATION AREA
liquid or fumes enter the air end of the installing a flexible conductive hose SAFE AIR
EXHAUST
pump. Fumes are exhausted into or connection between the pump DISPOSAL
the surrounding environment. When and any rigid plumbing. This reduces AREA
pumping hazardous or toxic materials, stresses on the molded threads of the 1" DIAMETER AIR
the exhaust air must be piped to an air exhaust port. Failure to do so may EXHAUST PIPING
appropriate area for safe disposal. See result in damage to the air distribution MUFFLER
illustration #1 at right. valve body.
This pump can be submerged if Any piping or hose connected to
the pump materials of construction the pump’s air exhaust port must be
are compatible with the liquid being conductive and physically supported. Illustration #1
pumped. The air exhaust must be Failure to support these connections
piped above the liquid level. See could also result in damage to the air
illustration #2 at right. Piping used for distribution valve body.
the air exhaust must not be smaller MUFFLER
than 1" (2.54 cm) diameter. Reducing Air Valve Assembly
the pipe size will restrict air flow and 1
reduce pump performance. When the 1" DIAMETER AIR
LIQUID
pumped product source is at a higher LEVEL
EXHAUST PIPING

level than the pump (flooded suction

condition), pipe the exhaust higher than
SUCTION
the product source to prevent siphoning LINE
spills. See illustration #3 at right. 21
Converting the pump for Illustration #2
piping the exhaust air
The following steps are necessary
to convert the pump to pipe the exhaust
air away from the pump. MUFFLER
Remove the muffler (item 21). The
air distribution valve (item 1) has 1" NPT
threads for piped exhaust. The pump comes equipped 1" DIAMETER AIR
with a standard metal muffler LIQUID EXHAUST PIPING
LEVEL

SUCTION
LINE

Illustration #3

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 19

Grounding The Pump
One eyelet is fastened to the pump hardware.

One eyelet is installed to a true earth ground. (Requires a 5/16 or 8mm maximum diameter bolt)

This 8 foot long (244 centimeters) Ground Strap

(Item 32) is shipped with the eyelet end fastened to
the pump hardware.

To reduce the risk of static electrical sparking, this

pump must be grounded. Check the local electrical
code for detailed grounding instruction and the type
of equipment required, or in the absence of local
codes, an industry or nationally recognized code
having juristiction over specific installations and
installation codes.

WARNING
Take action to prevent static
sparking. Fire or explosion
can result, especially when
handling flammable liquids.
The pump, piping, valves, con-
tainers or other miscellaneous
equipment must be grounded.

LINCOLN Model 85634, 85635 sm-rev0510 Form #404104 Page 20