Graco 308368ZAD User's Manual
Contents
1. Loose inlet manifold 102 damaged Tighten manifold bolts 106 or replace seal between manifold and seat 201 seats 201 or o rings 202 See page or damaged o rings 202 16 Loose diaphragm shaft bolt 107 Tighten or replace See pages 17 to 19 Damaged o ring 108 Replace See pages 17 to 19 Fluid in exhaust air Diaphragm ruptured Replace See pages 17 to 19 Loose diaphragm shaft bolt 107 Tighten or replace See pages 17 to 19 Damaged o ring 108 Replace See pages 17 to 19 Pump exhausts excessive air at stall Worn air valve block 7 o ring 6 Repair or replace See pages 13 to 14 plate 8 pilot block 18 u cups 10 or pilot pin o rings 17 Worn shaft seals 402 Replace See pages 17 to 19 Pump leaks air externally Air valve cover 2 or air valve cover Tighten screws See page 14 screws 3 are loose Air valve gasket 4 or air cover gasket Inspect replace See pages 13 to 14 22 is damaged 20 to 21 Air cover screws 3 are loose Tighten screws See pages 20 to 21 Pump leaks fluid externally from ball Loose manifolds 102 103 damaged Tighten manifold bolts 106 or replace check valves seal between manifold and seat 201 seats 201 or o rings 202 See page or damaged o rings 202 16 12 308368 Service Repairing the Air Valve Tools Required e Torque wrench e Torx T20 screwdriver or 7 mm 9 32 socket wrench Needle nose pliers O2. 60 152 6 5 165 60 152 6 0 152 65 165 6 0 152 E 17 5 443 17 4 442 18 1 459 18 5 469 17 5 443 18 1 459 18 5 469 F 19 9 506 22 9 581 22 3 565 19 3 491 19 9 506 22 3 565 19 3 491 G 21 9 557 24 9 632 24 9 631 21 3 542 21 9 557 24 8 629 21 3 542 H 23 6 598 26 5 673 26 3 668 22 8 578 23 6 598 26 3 668 22 8 578 J 2 0 51 2 0 51 2 5 64 2 0 51 2 0 51 2 5 64 2 0 51 K 0 4 10 0 4 10 0 9 24 0 6 14 0 4 10 0 9 24 0 6 14 L 6 0 152 60 152 6 0 152 60 152 6 0 152 60 152 6 0 152 M 6 0 152 60 152 58 146 7 0 178 6 0 152 58 146 7 0 178 Aluminum extended pump matches the inlet to outlet dimensions of Wilden and Aro aluminum pumps This will help for ease of installation during upgrades 308368 31 Technical Data Maximum fluid working pressure 1 nett nett anana 120 psi 0 8 MPa 8 bar Air pressure operating range 0 cee nent ttt e nent e nee 20 to 120 psi 0 14 to 0 8 MPa 1 4 to 8 bar Maximum air consumption 00 R E EEA INAO nent n nent eee 175 scfm Air consumption at 70 psi 0 48 MPa 4 8 bar 60 gpm 1 eee eee 60 scfm see chart Maximum free flow delivery 0 cece tenet ented 150 gpm 568 l min Maximum pump Sped oa see aee td ieee en ae bnew rie eed eet dake Wesabe ie eee ee eh 145 cpm Gallons Liters per cyclers cccsecce poet Seek eed Barns Be G
3. AIR CONSUMPTION 308368 33 Graco Warranties Graco Standard Husky Pump Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of five years from the date of sale repair or replace any part of the equipment determined by Graco to be defec tive This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recom mendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or sub stitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified
4. Graco distributor or call to identify the distributor closest to you Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflect the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 308368 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O Box 1441 MINNEAPOLIS MN 55440 1441 Copyright 1994 All Graco manufacturing locations are registered to ISO 8001 www graco com Revision ZAD December 2013 34 308368
5. Kit is available Refer to Tools Required page 23 to order the correct kit for your pump Parts e Torque wrench included in the kit are marked with an asterisk for example 401 Use all the parts in the kit for the best e 10mm socket wrench results e 13 mm socket wrench 1 Follow the Pressure Relief Procedure Warning on page 10 e 15 mm socket wrench aluminum models or 1 socket wrench stainless steel models 2 Remove the manifolds and disassemble the ball check valves as explained on page 16 e 19 mm open end wrench 3 Using 10 and 13 mm socket wrenches remove the e O ring pick screws 106 and 112 holding the fluid covers 101 to the air covers 23 Pull the fluid covers e Lithium base grease 101 off the pump See Fig 11 Fig 11 Apply medium strength blue Loctite or equivalent to the threads You must torque the eight long screws 112 first then the short screws 106 Torque to 190 to 220 in lb 22 to 25 Nem See Torque Sequence page 29 Arrow A must point toward air valve B 03949B 308368 17 Service Loosen but do not remove the diaphragm shaft bolts 107 using a 15 mm socket wrench 1 on stainless steel models on both bolts NOTE This step does not apply to pumps with overmolded diaphragms Unscrew one bolt from the diaphragm shaft 24 and remove the o ring 108 fluid side diaphragm plate 105 PTFE diaphragm 403 used on PTFE Models only diaphragm 401 and a
6. Nem SIDE VIEW 2 Inlet Manifold Torque bolts to 190 220 in lb 22 25 Nem 16 14 BOTTOM VIEW 3 Outlet Manifold Torque bolts to 190 220 in lb 22 25 Nem TOP VIEW 308368 29 Dimensions FRONT VIEW PUMP MOUNTING HOLE PATTERN four 0 625 in 16 mm diameter holes 1 2 npt f L air inlet 3 4 npt f E O air exhaust muffler l p included w TA y e fas im E TEE gt Jl Wi j Ril I LJ Iu ji SIDE VIEW Dimensions B C F G H and M can 6 25 in vary by up to 1 4 in 6 3 mm depending ee on the seat and diaphragm material 2 in 50 8 mm port diameter fitted in the pump 6 0 in 152 5 mm 12 5 in 317 5 mm 7440B 30 308368 Dimensions Aluminum Center Aluminum Aluminum Aluminum Center Cover Aluminum Center SST Center SST Center Aluminum Extended Center Cast Iron Aluminum SST Center Cast tron Cover Pump SST Cover Cover Cover SST Cover Cover Dimension B 9 0 229 9 1 231 9 4 238 9 7 245 9 0 229 9 4 238 9 7 245 Cc 12 9 328 12 9 328 15 2 385 12 9 327 12 9 328 15 2 385 12 9 327 D 6 0 152
7. area Check your local electrical code for detailed grounding instructions for your area and type of equipment Refer to Grounding on page 5 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 the problem has been identified and corrected 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 9 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 HALOGENATED HYDROCARBON HAZARD Never use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in Aluminum Pumps Such use could result in a serious chemical reaction with the possibility of explosion which could cause death serious injury and or substantial property damage Consult your fluid suppliers to ensure that the fluids used are compatible with aluminum parts 4 308368 Installation General Information e The Typical Installation shown in Fig 2 is only a guide for selecting and installing system compo nents Contact your Graco distributor or Graco Technical Assistance see back page for assis tance in planning a system to suit your needs e Always use Genuine Graco Pa
8. avoid contam inating your fluid with oil flush the pump with a com patible solvent before using the equipment Follow the steps under Starting and Adjusting the Pump Starting and Adjusting the Pump A WARNING HAZARDOUS FLUIDS 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 Pressure Relief Procedure Warning at right before moving or lifting the pump 1 Be sure the pump is properly grounded Refer to Grounding on page 5 2 Check all fittings to be sure they are tight Be sure to use a compatible liquid thread sealant on all male threads Tighten the fluid inlet and outlet fittings securely 3 Place the suction tube if used in the fluid to be pumped NOTE If the fluid inlet 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 4 Place the end of the fluid hose L into an appropri ate container 5 Close the fluid drain valve J See Fig 2 6 With the pump air regulator C closed open all bleed type master air valves B E 7 If the fluid hose has a dispensing device hold it open while continuing with the following step 8 Slowly open the air regulator C until the pump starts to cycle Allow the pump to cycle slowly until all air is pushed
9. exhaust port is 3 4 npt f Do not restrict the air exhaust port Excessive exhaust restriction can cause erratic pump operation If the muffler P is installed directly to the air exhaust port apply PTFE thread tape or anti seize thread lubricant to the muffler threads before assembly To provide a remote exhaust 1 i ARI A WII OU Remove the muffler P from the pump air exhaust port Install a grounded air exhaust hose T and con nect the muffler P to the other end of the hose The minimum size for the air exhaust hose is 3 4 in 19 mm ID If a hose longer than 15 ft 4 57 m is required use a larger diameter hose Avoid sharp bends or kinks in the hose See Fig 5 Place a container U at the end of the air exhaust line to catch fluid in case a diaphragm ruptures VENTING EXHAUST AIR LIAL KEY Air supply line Bleed type master air valve required for pump Air regulator Air line quick disconnect Master air valve for accessories Air line filter Muffler Grounded air exhaust hose Container for remote air exhaust D gt caAavu7 7mMoo we Fig 5 03942 308368 9 Operation Flush the Pump Before First Use The pump was tested with lightweight oil which is left in the fluid passages to protect parts To
10. out of the lines and the pump is primed 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 10 308368 Operation of Remote Piloted Pumps 1 Fig 2 and Parts Drawings Follow preceding steps 1 through 7 of Starting and Adjusting Pump 2 Open air regulator C A WARNING The pump may cycle once before the external sig nal is applied Injury is possible If pump cycles wait until end before proceeding 3 Pump will operate when air pressure is alternately applied and relieved to push type connectors 14 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 and before checking adjusting cleaning or repairing the system follow the Pressure Relief Procedure below Pressure Relief Procedure A WARNING To reduce the risk of serious injury including splashing fluid in the eyes or on the skin follow this procedure when this manual instructs you to relieve pressure when you shut off the pump and before checking adjusting cleaning moving or repairing any system equipment 1 Shut off the
11. pin 16 protruding from the center housing 1 fits through the proper hole H in the gasket Align the air cover 23 so the pilot pin 16 fits in the middle hole M of the three small holes near the center of the cover Install the screws 25 handtight See Fig 13 Using a 10 mm socket wrench torque the screws oppositely and evenly to 120 to 150 in Ib 14 to 17 Nem Install the diaphragm assemblies and fluid covers as explained on page 17 Reassemble the ball check valves and manifolds as explained on page 16 Service Insert bearings tapered end first Press fit bearings flush with surface of center housing 1 gt gt gt Apply medium strength blue Loctite or equivalent to the threads Torque to 120 to 150 in lb 14 to 17 Nem cel M1 0 Van 15 AA Detail of Air Valve Bearings 03951 03952B Fig 13 308368 21 Pump Matrix Husky 2150 Aluminum Stainless Steel and Ductile Iron Pumps Series A Your Model No is marked on the pump s serial plate To determine the Model No of your pump from the following matrix select the six digits which describe your pump working from left to right The first digit is always D designating Husky diaphragm pumps The remaining five digits define the materials of construction For example a pump with an aluminum air motor and fluid section polypropylene seats PTFE balls and PTFE diaphragms is Model No D F 3 9 1 1 To order replacement
12. 4319 188621 102656 112543 114862 COVER fluid 316 stainless steel MANIFOLD inlet 316 stainless steel MANIFOLD outlet 316 stainless steel PLATE air side aluminum PLATE fluid side 316 stainless steel SCREW M10 x 1 38 35 mm BOLT M12 x 1 75 55 mm 2 17 in 316 stainless steel O RING PTFE LABEL warning MUFFLER SCREW M10 x 1 50 110 mm 4 33 in stainless steel NUT M10 Fluid Section Parts List Matrix Column 3 191541 191542 191543 189298 189820 112416 189410 104319 188621 102656 112543 15A612 192086 15A614 189298 189820 115644 189410 104319 188970 102656 115645 COVER fluid ductile iron MANIFOLD inlet ductile iron MANIFOLD outlet ductile iron PLATE air side aluminum PLATE fluid side carbon steel SCREW M10 x 1 38 35 mm BOLT M12 x 1 75 55 mm 2 17 in 316 stainless steel O RING PTFE LABEL warning MUFFLER SCREW M10 x 1 50 110 mm 4 33 in stainless steel COVER fluid aluminum MANIFOLD inlet aluminum BSPT MANIFOLD outlet aluminum BSPT PLATE air side aluminum PLATE fluid side carbon steel SCREW M10 x 1 18 30 mm BOLT M12 x 1 75 55 mm 2 17 in 316 stainless steel O RING PTFE LABEL warning MUFFLER SCREW M10 x 1 50 90 mm 3 54 in carbon steel 194279 195576 195577 189298 189299 112416 189410 104319 188621 102
13. 656 112543 114862 191541 192088 192089 189298 189820 112416 COVER fluid 316 stainless steel MANIFOLD inlet 316 stainless steel BSPT MANIFOLD outlet 316 stainless steel BSPT PLATE air side aluminum PLATE fluid side 316 stainless steel SCREW M10 x 1 38 35 mm BOLT M12 x 1 75 55 mm 2 17 in 316 stainless steel O RING PTFE LABEL warning MUFFLER SCREW M10 x 1 50 110 mm 4 33 in stainless steel NUT M10 COVER fluid ductile iron MANIFOLD inlet ductile iron BSPT MANIFOLD outlet ductile iron BSPT PLATE air side aluminum PLATE fluid side carbon steel SCREW M10 x 1 38 35 mm 308368 27 Parts Seat Parts List Matrix Column 4 SEAT 316 stainless steel O RING PTFE SEAT 174 stainless steel O RING PTFE SEAT TPE Not Used SEAT Santoprene O RING PTFE SEAT Buna N 112359 112363 112360 112745 301 112361 301 15B492 301 15B491 301 114753 189288 112358 189289 112358 189292 301 301 301 301 None 189290 112358 15B267 None Not used 15B265 SEAT Fluoroelastomer i JA O not sold separately 112181 15K313 189295 189296 15B313 15B502 194216 None Not used 189291 112358 194215 112358 SEAT polypropylene O RING PTFE SEAT Geolast O RING PTFE ae ae ee Diaphragm Parts List Matrix Column 6 Parno Description Ball Parts List Matrix Colum
14. 7 is 168518 O ring Fluoroelastomer Use 243492 as the Air Valve Repair Kit Ref 106 is 112416 SCREW SST M10 x 1 5 30 mm Ref 112 is 112417 SCREW SST M10 x 1 5 90 mm 24B782 Aluminum Pump This pump is the same as Model DF3311 except for the serial plate and parts listed in the chart at right 24J360 Aluminum Pump This pump is the same as Model DF3321 except for the serial plate and parts listed in the chart at right 22 308368 24B783 Stainless Steel Plus Pump This pump is the same as Model DV4311 except for the serial plate and parts listed in the chart below 24B801 Stainless Steel Pump This pump is the same as Model DF4311 except for the serial plate and parts listed in the chart below 24G413 Aluminum pump This pump is the same as Model DFC311 except for the serial plate and parts listed in the chart below PLATE air side alum not used not used not used 15G746 DIAPHRAGM HD overmolded PTFE EPDM Repair Kit Matrix For Husky 2150 Aluminum and Stainless Steel Pumps Series A Repair Kits may be ordered separately To repair the air valve order Part No 236273 for aluminum center housing models or Part No 255061 for stainless steel housing models see page 24 Parts included in the Air Valve Repair Kit are marked with a symbol in the parts list for example 4T To repair the seats balls and diaphragms select the six digits which describe your pump from the following matrix working from
15. AL anes tha he dee het eae ele 1 03 3 90 Maximum suction lift 0 00 0 eee tenet tenes 18 ft 5 48 m wet or dry Maximum size pumpable solids 0 cee eee ene teens 1 4 in 6 3 mm Maximum noise level at 100 psi 0 7 MPa 7 bar 50 com 6 eee ees 90 dBa SOUNG p w r level 22 5 vert ey aah eA aati ee dare Lae ae Pa ee OE eB ede da 103 dBa Noise level at 70 psi 0 48 MPa 4 8 bar and 50 com 0 cece eee eens 85 dBa Maximum operating temperature 0 eee ene nees 150 F 65 5 200 F 93 3 C for models with PTFE diaphragms AFET SZE vaca ete cs ete pote ee as Dit gy ee ede tee Weer eae age Bere 1 2 npt f FIUIGINIGE SIZE aapear s pee Radon ed Glee eek Das Siw heals Le ei eee dg dye alan ee ands 2 npt f Fluid Oulletsize gt oa3 over Pep taakti eee s ated eho fed wow aE etka aol Ea wee te beet ee eee 2 npt f Wetted pants 2c erra E E ia eens he ae ee eh one aes Vary by Model See pages 22 to 25 Non wetted external parts 0000 eee ences aluminum 302 and 316 stainless steel polyester labels Weight ALUMINUM PUMPS irera eee genie a een E AREE ie Sate Jove wie KERIA LI ete ave ARRERA 58 Ib 26 3 kg Stainless steel pumps with aluminum center section 006 cece eet eee eee 111 Ib 50 3 kg Ductile Iron pumps with stainless steel center section cece eee eee ees 130 Ib 59 0 kg Stainless Steel pumps with stainless steel center section 0 cece e
16. Air regulator Air line quick disconnect Master air valve for accessories Air line filter Fluid suction hose Fluid supply Fluid drain valve required Fluid shutoff valve DL Use grounded fluid hoses L The pump fluid outlet S is 2 npt f Screw the fluid fitting into the pump outlet securely Install a fluid drain valve J near the fluid outlet See the WARNING above Install a shutoff valve K in the fluid outlet line Fluid hose 1 2 npt f air inlet port 2 npi f fluid inlet port 2 npt f fluid outlet port lt NDZ ACTOTMMVUO Ground wire required see page 5 for installation instructions Fig 2 03943B 308368 7 Installation Changing the Orientation of the Fluid Inlet and Outlet Ports The pump is shipped with the fluid inlet R and outlet S ports facing the same direction See Fig 3 To change the orientation of the inlet and or outlet port 1 Remove the screws 106 holding the inlet 102 and or outlet 103 manifold to the co
17. Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnais sent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concern es Extended Product Warranty Graco warrants all Husky 205 307 515 716 1040 1590 2150 and 3275 air valve center sections to be free from defects in material and workmanship for a period of fifteen years from date installed in service by the original purchaser Normal wear of items such as packings or seals are not considered to be defects in material and workmanship Five years Graco will provide parts and labor Six to Fifteen years Graco will replace defective parts only Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your
18. Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within six years of the date of sale Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will
19. Instructions Parts List GRACO ALUMINUM STAINLESS AND DUCTILE IRON Husky 2150 Air Operated Diaphragm Pumps S 2 inch AODD pump for fluid transfer applications For professional use only See Models on page 2 for a list of pump models and descriptions 120 psi 0 8 MPa 8 bar Maximum Fluid Working Pressure 120 psi 0 8 MPa 8 bar Maximum Air Input Pressure Patent No CN ZL94102643 4 FR 9408894 JA 3517270 US 5 368 452 Important Safety Instructions Read all warnings and instructions in the manual SJ Save these instructions 03940B Aluminum Model Shown C 2 ESE PROVEN QUALITY LEADING TECHNOLOGY Table of Contents Modeli orner cult Dah Pale E ee ee wallace 2 Safety WarningS 0 cece eee eee eee 3 Wistallation a sio eaiesesedcea we wiv area dee dcea ee eke 5 Operation vere eget tate page He ew eae cana deine 10 Maintenance 0 0 cece eee eee 11 Troubleshooting 0 0 c ee eee eee eee eee 12 Service Repairing the Air Valve 0 000000 13 Ball Check Valve Repair 5 16 Diaphragm Repair 0 eee eee eee 17 Bearing and Air Gasket Removal 20 NOTE Plus Models include stainless steel center sections 2 Model No Pump Matrix 0 2 0 0 cece 22 Repair Kit Matrix 0 0 0 0 0 cece eee eee 23 Pans einean a pace aae ioe Aw eal Paste ota 24 Torque Sequence 60e cece eee eee 29 DIMENSIONS
20. air to the pump 2 Open the dispensing valve if used 3 Open the fluid drain valve to relieve all fluid pres sure having a container ready to catch the drain age Maintenance Lubrication The air valve is designed to operate unlubricated however if lubrication is desired every 500 hours of operation or monthly remove the hose from the pump air inlet and add two drops of machine oil to the air inlet CAUTION Do not over lubricate the pump Oil is exhausted through the muffler which could contaminate your fluid supply or other equipment Excessive lubrica tion can also cause the pump to malfunction Flushing and Storage Flush the pump often enough to prevent the fluid you are pumping from drying or freezing in the pump and damaging it Always flush the pump and follow the Pressure Relief Procedure Warning on page 10 before storing it for any length of time Use a compat ible solvent 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 fasteners Tighten or retorque as necessary Although pump use varies a general guideline is to retorque fasteners every two months See Torque Sequence page 29 Preventive Maintenance Schedule Establish a preventive maintenance schedule based on the pump s service history This is especially impor tant for prevention of spills or lea
21. all the o ring 108 on the shaft bolt 107 b Install the fluid side diaphragm plate 105 on the bolt so the rounded side faces in toward the diaphragm 401 308368 c On PTFE Models only install the PTFE dia phragm 403 Make certain the side marked AIR SIDE faces the center housing 1 d Install the diaphragm 401 on the bolt Make certain the side marked AIR SIDE faces the center housing 1 e Install the air side diaphragm plate 104 so the recessed side faces the diaphragm 401 f Apply medium strength blue Loctite or equivalent to the bolt 107 threads Screw the bolt into the shaft 24 hand tight g For overmolded diaphragms Assemble the air side plate 104 onto the diaphragm 403 The wide radiused side of the plate must face the diaphragm Apply medium strength blue Loctite or equivalent to the threads of the diaphragm assembly Screw the assembly into the shaft 24 hand tight Grease the length and ends of the diaphragm shaft 24 and slide it through the housing 1 Assemble the other diaphragm assembly to the shaft as explained in step 2 Hold one shaft bolt 107 with a wrench and torque the other bolt to 20 to 25 ft lb 27 to 34 Nem at 100 rpm maximum NOTE This step does not apply to pumps with overmolded diaphragms Align the fluid covers 101 and the center housing 1 so the arrows A on the covers face the same direction as the air valve B Secure the covers wit
22. d to a piston pump and the intake valve of the piston pump does not close causing fluid to back up in the outlet line KEY R 2 npt f fluid inlet port S 2 npt f fluid outlet port V Pressure relief valve Part No 112119 stainless steel AN Install valve between fluid inlet and outlet ports A Connect fluid inlet line here A Connect fluid outlet line here S A A z ont lt DA al f ENA T A Ba av A T R Fig 4 Installation Air Exhaust Ventilation A WARNING FIRE AND EXPLOSION HAZARD HAZARDOUS FLUIDS Be sure to read and follow the warnings k y and precautions regarding HAZ ARDOUS FLUIDS and FIRE OR EXPLOSION HAZARD on page 4 before operating this pump a Be sure the system is properly ventilated IA for your type of installation You must vent the exhaust to a safe place away from people animals food handling areas and all sources of ignition when pumping flammable or hazardous fluids Diaphragm failure will cause the fluid being pumped to exhaust with the air Place an appropri ate container at the end of the air exhaust line to catch the fluid See Fig 5 The air
23. dous fluids or inhaling toxic vapors can cause extremely serious injury even death due to splashing in the eyes ingestion or bodily contamination Observe all the follow ing precautions when handling known 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 appara tus 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 9 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 out doors and can cause a fire or explosion and serious injury and property damage e To reduce the risk of static sparking ground the pump and all other equipment used or located in the work
24. e Pilot Air Lines 1 Refer to Parts Drawings Connect air line to pump as in preceding steps 2 Connect 1 4 in O D tubing to push type connec tors 14 on air motor of pump NOTE by replacing the push type connectors other sizes or types of fittings may be used The new fittings will require 1 8 in npt threads 3 Connect remaining ends of tubes to external air signal such as Graco s Cycleflo P N 195264 or Cycleflo II P N 195265 controllers Fluid Suction Line 1 Use grounded fluid hoses G The pump fluid inlet R is 2 npt f Screw the fluid fitting into the pump inlet securely 2 Ifthe fluid inlet 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 3 At inlet fluid pressures greater than 15 psi 0 1 MPa 1 bar diaphragm life will be shortened 4 See the Technical Data on page 32 for maximum suction lift wet and dry Installation Fluid Outlet Line A WARNING A fluid drain valve J is required to relieve pres sure in the hose if it is plugged The drain valve reduces the risk of serious injury including splash ing in the eyes or on the skin or contamination from hazardous fluids when relieving pressure Install the valve close to the pump fluid outlet See Fig 2 FLOOR MOUNT TYPICAL INSTALLATION KEY Air supply hose Bleed type master air valve required for pump
25. e eee eee 134 Ib 61 0 kg Geolast and Santoprene are registered trademarks of the Monsanto Co Loctite is a registered trademark of the Loctite Corporation Noise levels measured with the pump mounted on the floor using Rubber Foot Kit 236452 Sound power measured per ISO Standard 9216 32 308368 Performance Chart Example of Finding Pump Air Consumption and Air Pressure at a Specific Fluid Delivery and Discharge Head To supply 60 gpm 227 liters fluid flow horizontal scale at 40 psi 0 28 MPa 2 8 bar discharge head pressure vertical scale requires approximately 50 scfm 1 68 m min air consumption at 70 psi 0 49 MPa 4 9 bar inlet air pressure PUMP DISCHARGE HEAD Inlet Air Pressures 120 psi air 0 8 MPa 8 bar 100 psi air 0 7 MPa 7 bar 70 psi air 0 48 MPa 4 8 bar 40 psi air 0 28 MPa 2 8 bar F X G H Air Consumption E 25 scfm 0 70 m min 50 scfm 1 40 m3 min 75 scfm 2 10 m3 min 100 scfm 2 80 m min 90 341 FLUID FLOW GPM Ipm feet psi meters MPa bar 280 120 85 3 0 8 8 Aw i 240 73 2 100g R 0 7 7 F Cc 200 p 61 0 3 0 56 5 6 160 S 48 8 60 120 0 42 4 2 36 6 40 80 0 28 2 8 D 24 4 40 et 12 2 0 14 1 4 0 30 60 114 227 TEST CONDITIONS Pump tested in water with PTFE diaphragm and inlet submerged KEY 120 454 150 568 FLUID PRESSURE AND FLOW SCFM
26. h the screws 106 and 112 handtight Install the longer screws 112 in the top and bottom holes of the covers See Fig 11 First torque the longer screws 112 oppositely and evenly to 190 to 220 in Ib 22 to 25 Nem using a 13 mm socket wrench Then torque the shorter screws 106 using a 10 mm socket wrench See Torque Sequence page 29 Reassemble the ball check valves and manifolds as explained on page 16 Service 03981A 03982A Cutaway View with Diaphragms in Place Cutaway View with Diaphragms Removed Lips face out of housing 1 Rounded side faces diaphragm 401 Air Side must face center housing 1 Grease Apply medium strength blue Loctite or equivalent Torque to 20 to 25 ft lb 27 to 34 Nem at 100 rpm maximum Used on Models with PTFE diaphragms only Pe PPP PP Recessed side faces diaphragm 401 03950B Fig 12 308368 19 Service Bearing and Air Gasket Removal Tools Required Torque wrench 10 mm socket wrench Bearing puller O ring pick Press or block and mallet Disassembly NOTE Do no
27. ine A WARNING A bleed type master air valve B is required in your system to relieve air trapped between this valve and the pump Trapped air can cause the pump to cycle unexpectedly which could result in serious injury including splashing in the eyes or on the skin injury from moving parts or contamination from hazardous fluids See Fig 2 1 Install the air line accessories as shown in Fig 2 Mount these accessories on the wall or ona bracket Be sure the air line supplying the acces sories is grounded a Install an air regulator C and gauge to control the fluid pressure The fluid outlet pressure will be the same as the setting of the air regulator 6 308368 b Locate one bleed type master air valve B close to the pump and use it to relieve trapped air See the WARNING above 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 2 Install a grounded flexible air hose A between the accessories and the 1 2 npt f pump air inlet N See Fig 2 Use a minimum 1 2 13 mm ID air hose Screw an air line quick disconnect cou pler D onto the end of the air hose A and screw the mating fitting into the pump air inlet snugly Do not connect the coupler D to the fitting until you are ready to operate the pump Installation of Remot
28. ir side dia phragm plate 104 See Fig 12 For overmolded diaphragms Grip both dia phragms securely around the outer edge and rotate counterclockwise One diaphragm assembly will come free and the other will remain attached to the shaft Remove the freed diaphragm and air side plate Pull the other diaphragm assembly and the dia phragm shaft 24 out of the center housing 1 Hold the shaft flats with a 19 mm open end wrench and remove the bolt 107 from the shaft Disassemble the remaining diaphragm assembly For overmolded diaphragms Pull the other dia phragm assembly and the diaphragm shaft 24 out of the center housing 1 Hold the shaft flats with a 19 mm open end wrench and remove the diaphragm and air side plate from the shaft Inspect the diaphragm shaft 24 for wear or scratches If it is damaged inspect the bearings 19 in place If the bearings are damaged refer to page 20 Reach into the center housing 1 with an o ring pick and hook the u cup packings 402 then pull them out of the housing This can be done with the bearings 19 in place Clean all parts and inspect for wear or damage Replace parts as needed Reassembly 1 18 Install the shaft u cup packings 402 so the lips face out of the housing 1 Lubricate the pack ings See Fig 12 Install the diaphragm assembly on one end of the shaft 24 as follows For pumps with overmolded diaphragms go directly to step g a Inst
29. kage due to dia phragm failure 308368 11 Troubleshooting A WARNING To reduce the risk of serious injury including splashing fluid in the eyes or on the skin follow the Pressure Relief Procedure on page 10 when this manual instructs you to relieve pressure when you shut off the pump and before checking adjusting cleaning moving or repairing any system equipment NOTE Check all possible problems and causes before disassembling the pump PROBLEM CAUSE SOLUTION Pump cycles at stall or fails to hold pres Worn check valve balls 301 seats Replace See page 16 sure at stall 201 or o rings 202 Pump will not cycle or cycles once and Air valve is stuck or dirty Disassemble and clean air valve See stops pages 13 to 14 Use filtered air Check valve ball 301 severely worn Replace ball and seat See page 16 and wedged in seat 201 or manifold 102 or 108 Check valve ball 301 is wedged into Install Pressure Relief Valve seat 201 due to overpressurization see page 8 Dispensing valve clogged Relieve pressure and clear valve Pump operates erratically Clogged suction line Inspect clear Sticky or leaking check valve balls Clean or replace See page 16 301 Diaphragm ruptured Replace See pages 17 to 19 Restricted exhaust Remove restriction Air bubbles in fluid Suction line is loose Tighten Diaphragm ruptured Replace See pages 17 to 19 Pay essere ol
30. left to right The first digit is always D and the second digit is always 0 zero The remaining four digits define the materials of construction Parts included in the kit are marked with an asterisk in the parts list for example 201 For example if your pump has polypropylene seats PTFE balls and PTFE diaphragms you need to order Repair KitD 0 F 91 1 The digits in the matrix do not correspond to the ref nos in the parts drawing and lists on pages 24 and 25 8 Fiuoroelastomer 8 Fluoroelastomer 8 Fluoroelastomer 9 Polypropylene G Geolast G Geolast G Geolast Diaphragm Pump Null Shaft O Ring Seats Balls Diaphragms D for all pumps O for all pumps F PTFE 0 null O null 0 null eee te 1 not used 1 PTFE 1 PTFE 2 2 not used 2 acetal 2 not used 3 3 316 sst 3 not used 3 not used 4 4 17 4 PH sst 4 440C sst 4 not used 5 TPE 5 TPE 5 TPE 6 Santoprene 6 Santoprene 6 Santoprene 7 Buna N 7 Buna N 7 Buna N E E Part No 253628 Husky 2150 HD Overmolded PTFE EPDM Diaphragm Repair Kit Part No 289226 Husky 2150 HD Overmolded PTFE EPDM Diaphragm Repair Kit with new air side diaphragm plates Part No 24F400 Husky 2150 PTFE Santoprene Backer Diaphragm Repair Kit for Metal Pumps Extension Conversion Kit To convert an existing 2150 Al
31. m stainless steel 108730 O RING nitrile 15A735 COVER air valve stainless steel 188616 BLOCK air valve acetal 15H178 PLATE air valve 7 188615 PLATE air valve sst stainless steel 188617 SEAL valve plate buna 9 E N 23 15A742 COVER air stainless 2 112181 PACKING u cup nitrile steel 188612 PISTON actuator acetal 188613 BEARING piston acetal 104765 PLUG pipe headless 115671 FITTING connector male 188611 BEARING pin acetal 188610 PIN pilot stainless steel 157628 O RING buna N 188614 BLOCK pilot acetal 188609 BEARING shaft acetal 116343 SCREW grounding 188603 GASKET air cover foam 189300 COVER air aluminum 189304 SHAFT diaphragm sst 115643 SCREW M8x 25 25 mm 308368 25 Parts Fluid Section Parts List Matrix Column 3 26 15A612 189302 15A613 189298 189820 115644 189410 104319 188970 102656 115645 15B131 106260 112417 308368 COVER fluid aluminum MANIFOLD inlet aluminum MANIFOLD outlet aluminum PLATE air side aluminum PLATE fluid side carbon steel SCREW M10 x 1 18 30 mm BOLT M12 x 1 75 55 mm 2 17 in 316 stainless steel O RING PTFE LABEL warning MUFFLER SCREW M10 x 1 50 90 mm 3 54 in carbon steel EXTENSION 2150 PACKING o ring PTFE M10x1 5 90mm SCREW mach hex 194279 194280 194281 189298 189299 112416 189410 10
32. n 5 Description BALL PTFE BALL acetal BALL 440C SS BALL TPE BALL Santoprene BALL Buna N BALL Fluoroelastomer BALL Geolast DIAPHRAGM backup polychloroprene CR PACKING u cup nitrile DIAPHRAGM PTFE DIAPHRAGM TPE PACKING u cup nitrile DIAPHRAGM Santo prene PACKING u cup nitrile DIAPHRAGM Buna N PACKING u cup nitrile DIAPHRAGM Fluoroe lastomer PACKING u cup nitrile DIAPHRAGM Geolast PACKING u cup nitrile These parts are included in the pump repair kit purchased separately See Repair Kit Matrix on page 23 to determine the correct kit for your pump 28 308368 Torque Sequence Aluminum Pumps Model Numbers DF3 DG3 DFH DGH DFC__ DGC__ DFG DGG___ and 232503 DGC__ DFG__ Always follow torque sequence when instructed to torque fasteners 1 Left Right Fluid Covers Torque bolts to 190 220 in Ib 22 25 Nem 1 3 SIDE VIEW 2 Inlet Manifold Torque bolts to 120 150 in lb 14 17 Nem 16 14 BOTTOM VIEW 3 Outlet Manifold Torque bolts to 120 150 in Ib 14 17 Nem TOP VIEW Ductile Iron and Stainless Steel Pumps Model Numbers DF4 DG4 DF6 DG6 DFD___ DGD__ DFF___ DGF___ DV4_ DVD___ Always follow torque sequence when instructed to torque fasteners 1 Left Right Fluid Covers Torque bolts to 190 220 in lb 22 25
33. o rupture and result in splashing in the eyes or on the skin other serious injury or fire explosion or property dam age e This equipment is for professional use only Observe all warnings Read and understand all instruction manuals warning labels and tags before operating the equipment Never alter or modify any part of this equipment doing so could cause it to malfunction Use only genuine Graco parts and accessories 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 32 Do not exceed the maximum working pressure of the lowest rated component in your system This equipment has a 120 psi 0 8 MPa 8 bar maximum working pressure at 120 psi 0 8 MPa 8 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 32 Always read the manufacturer s literature before using 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 moving or lifting the pump The pump is very heavy If it must be moved have two people lift the pump by grasping the outlet manifold securely 308368 3 A WARNING HAZARDOUS FLUIDS Improper handling of hazar
34. parts refer to the part lists on pages 24 and 25 The digits in the matrix do not correspond to the ref nos in the parts drawing and lists on pages 24 and 25 C aluminum BSPT D sst BSPT 8 Fluoroelastomer 8 Fluoroelastomer 8 Fluoroelastomer fe ductile iron 9 Polypropylene G Geolast BSPT G aluminum G Geolast G Geolast BSPT extended H aluminum extended Diaphragm Pump Air Motor Fluid Section Seats Balls Diaphragms 232503 aluminum aluminum TPE acetal TPE D for all pumps F aluminum 1 not used 1 not used 1 PTFE 1 PTFE standard i 24B782 G aluminum 2 not used 2 not used E 2 acetal K 2 not used remote 24B783 V SST standard 3 aluminum 3 316 sst 3 not used 3 not used 2468801 4 ssi 4 oe PHsst 4 as sst 4 used 24G413 5 not used 5 TPE 5 TPE 5 TPE fo 6 ductile iron 6 2 6 anise 6 oe i 7 Buna N 7 Buna N 7 Buna N 81 246452 Stainless Steel Air Motor Conversion Kit Use kit 246452 and refer to manual 309643 included in kit to convert from aluminum air motor to stainless steel air motor 232503 Aluminum 2150 Pump Series D Model No 232503 is a private label aluminum 2150 pump This pump is the same as Model No DF3525 except for the label and Ref Nos 10 and 402 are 115666 Packing U cup Fluoroelastomer Ref No 1
35. pect for wear or damage Replace as needed Reassemble as explained on page 14 A Torque to 50 to 60 in lb 5 6 to 6 8 Nem Fig 6 A See Detail at right A Grease AN Grease lower face A a Fig 7 Pi 20 308368 03944 03945 13 Service Reassembly A Insert narrow end first Grease A Install with lips facing narrow end of piston 11 A Insert wide end first PO A17 1516A RETA Fig 8 A Rounded side must face down aluminum center housing models only A Tighten screws until they bottom out on the housing Fig 9 14 308368 1 10 If you removed the bearings 12 15 install new ones as explained on page 20 Reassemble the fluid section On aluminum center housing models install the valve plate seal 9T into the groove at the bottom of the valve cavity The rounded side of the seal must face down into the groove See Fig 9 Install the valve plate 8m in the cavity On alumi num center housing models the plate is reversible so either side can face up Install the three screws 3 using a Torx T20 screwdriver or 7 mm 9 32 socket wrench Tighten until the screws bottom out on the housing See Fig 9 Install an o ring 17tm on each pilot pin 16 Grease the pins and o rings Insert the pins into the bearings 15 narrow end first See Fig 8 Install a u cup packing 10tm on each actuator piston 11 so the lips of the packings face the na
36. ring pick Lithium base grease NOTE Air Valve Repair Kits 236273 aluminum center housings and 255061 stainless steel center hous ings are available Refer to page 24 Parts included in the kit are marked with a symbol for example 4tm Use all the parts in the kit for the best results Disassembly 1 Follow the Pressure Relief Procedure Warning on page 10 2 With a Torx T20 screwdriver or 7 mm 9 32 socket wrench remove the six screws 3 air valve cover 2 and gasket 4 See Fig 6 3 Move the valve carriage 5 to the center position and pull it out of the cavity Remove the valve block 7 and o ring 6 from the carriage Using a needle nose pliers pull the pilot block 18 straight up and out of the cavity See Fig 7 4 Pull the two actuator pistons 11 out of the bear ings 12 Remove the u cup packings 10 from the pistons Pull the pilot pins 16 out of the bearings 15 Remove the o rings 17 from the pilot pins See Fig 8 5 Inspect the valve plate 8 in place If damaged use a Torx T20 screwdriver or 7 mm 9 32 socket wrench to remove the three screws 3 Remove the valve plate 8 and on aluminum center housing models only remove the seal 9 See Fig 9 6 Inspect the bearings 12 15 in place See Fig 8 The bearings are tapered and if damaged must be removed from the outside This requires disas sembly of the fluid section See page 20 7 Clean all parts and ins
37. rrow end of the pistons See Fig 8 Lubricate the u cup packings 10T and actuator pistons 11 Insert the actuator pistons in the bearings 12 wide end first Leave the narrow end of the pistons exposed See Fig 8 Grease the lower face of the pilot block 18T and install so its tabs snap into the grooves on the ends of the pilot pins 16 See Fig 7 Grease the o ring 6T and install it in the valve block 7tm Push the block onto the valve carriage 5 Grease the lower face of the valve block See Fig 7 Install the valve carriage 5 so its tabs slip into the grooves on the narrow end of the actuator pistons 11 See Fig 7 Align the valve gasket 4 and cover 2 with the six holes in the center housing 1 Secure with six screws 3 using a Torx T20 screwdriver or 7 mm 9 32 socket wrench Torque to 50 to 60 in Ib 5 6 to 6 8 Nem See Fig 6 Notes 308368 15 Service Ball Check Valve Repair Tools Required e Torque wrench 10mm socket wrench e O ring pick Disassembly NOTE A Fluid Section Repair Kit is available Refer to page 23 to order the correct kit for your pump Parts included in the kit are marked with an asterisk for example 201 Use all the parts in the kit for the best results NOTE To ensure proper seating of the balls 301 always replace the seats 201 when replacing the balls NOTE Extension Version To ensure proper sealing of extension 115 al
38. rts and Accessories e Reference numbers and letters in parentheses refer to the callouts in the figures and the parts lists on pages 24 to 25 A WARNING 2 HAZARDOUS FLUIDS a To reduce the risk of serious injury IA 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 Pressure Relief Procedure Warning on page 10 before moving or lifting the pump e The pump is very heavy If it must be moved have two people lift the pump by grasping the outlet manifold 103 securely See Fig 3 on page 8 Tightening Screws Before First Use Before using the pump for the first time check and retorque all external fasteners See Torque Se quence page 29 After the first day of operation retorque the fasteners Although pump use varies a general guideline is to retorque fasteners every two months Grounding A WARNING FIRE AND EXPLOSION HAZARD This pump must be grounded Before operating the pump ground the system as explained below Also read the section FIRE AND EXPLOSION HAZARD on page 4 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 equip ment Ground all of this equipment e Pump Connect a ground wire and clamp as shown in Fig 1 Loo
39. sen the grounding screw W Insert one end of a 12 ga 1 5 mm2 minimum ground wire Y behind the grounding screw and tighten the screw securely Connect the clamp end of the ground wire to a true earth ground Order Part No 222011 Ground Wire and Clamp Fig 1 02646E e Air and fluid hoses Use only grounded hoses with a maximum of 500 ft 150 m combined hose length to ensure grounding continuity e Air compressor Follow the manufacturer s recom mendations e All solvent pails used when flushing Follow the local code Use only metal pails which are conduc tive Do not place the pail on a non conductive surface such as paper or cardboard which inter rupts the grounding continuity e Fluid supply container Follow the local code 308368 5 Installation Mountings CAUTION The pump exhaust air may contain contaminants Ventilate to a remote area if the contaminants could affect your fluid supply See Air Exhaust Ventilation on page 9 e Be sure the mounting surface can support the weight of the pump hoses and accessories as well as the stress caused during operation e For all mountings be sure the pump is bolted directly to the mounting surface e For ease of operation and service mount the pump so the air valve cover 2 air inlet and fluid inlet and outlet ports are easily accessible e Rubber Foot Mounting Kit 236452 is available to reduce noise and vibration during operation Air L
40. sy eria S ake hah haan eres RG 30 Techni al Datari eii eien teln ede esha eE 32 Performance Chart 0 000 cee eee neues 33 Graco Warranties 0 0 cee eee 34 Graco Information 00 0 0 c eee eee 34 DG3 DGH Aluminum Pumps Remote Aluminum Extended Pump Aluminum Extended Pump Remote Stainless Steel Pumps DG4 DG6 Stainless Steel Pumps Remote Ductile Iron Pumps Remote Aluminum BSPT Pumps DGC Aluminum BSPT Pumps Remote Stainless Steel BSPT Pumps DGD Stainless Steel BSPT Pumps Remote Ductile Iron BSPT Pumps DGF Ductile Iron BSPT Pumps Remote Aluminum BSPT Extended Pump DGG Aluminum BSPT Extended Pump Remote Stainless Steel Plus Pumps Stainless Steel BSPT Plus Pumps 232503 Private Label Aluminum 2150 Pump See page 22 24B782 Aluminum Pump with overmolded diaphragms NOTE Refer to the Pump Matrix on page 22 to determine the Model No of your pump 308368 Symbols Warning Symbol Caution Symbol This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions or destruction of equipment if you do not follow the instructions A 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 t
41. t remove undamaged bearings 1 Follow the Pressure Relief Procedure Warning on page 10 Remove the manifolds and disassemble the ball check valves as explained on page 16 Remove the fluid covers and diaphragm assem blies as explained on page 17 NOTE If you are removing only the diaphragm shaft bearing 19 skip step 4 4 20 Disassemble the air valve as explained on page 13 Using a 10 mm socket wrench remove the screws 25 holding the air covers 23 to the center housing 1 See Fig 13 Remove the air cover gaskets 22 Always replace the gaskets with new ones 308368 Use a bearing puller to remove the diaphragm shaft bearings 19 air valve bearings 12 or pilot pin bearings 15 Do not remove undamaged bearings If you removed the diaphragm shaft bearings 19 reach into the center housing 1 with an o ring pick and hook the u cup packings 402 then pull them out of the housing Inspect the packings See Fig 12 Reassembly 1 If removed install the shaft u cup packings 402 so the lips face out of the housing 1 The bearings 19 12 and 15 are tapered and can only be installed one way Insert the bearings into the center housing 1 tapered end first Using a press or a block and rubber mallet press fit the bearing so it is flush with the surface of the center housing Reassemble the air valve as explained on page 14 Align the new air cover gasket 22 so the pilot
42. uminum pump to an extended version use conversion kit 234019 This kit is for 2 in 50 8 mm npt or bspt ported aluminum pumps only It extends the outlet manifold to match the inlet to outlet dis tance of a Wilden or ARO aluminum pump 308368 23 Parts lt gt te Aluminum Model Shown 108 107 A Not used on some models TI0353B A Used on stainless steel model only Extension These parts are included in the Pump Repair Kit which may be purchased separately Refer to the Repair Kit Matrix on page 23 to determine the cor rect kit for your pump t These parts are included in Air Valve Repair Kit 236273 aluminum center housing models which may be purchased separately E These parts are included in Air Valve Repair Kit 255061 stainless steel center housing models which may be purchased separately A Replacement Danger and Warning labels tags and cards are available at no cost These parts are unique to remote piloted air motor DG These parts are used on extension version only Ref No 106 is qty 20 on extension version T12233A 24 308368 Parts Air Motor Parts List Matrix Column 2 188838 HOUSING center Same as F with the following exceptions 188854 COVER air valve alum 195921 HOUSING center remote aluminum 116344 SCREW mach hex flange hd M5x0 8 12 mm COVER air remote 0 47 in 188618 GASKET cover foam 15K009 HOUSING center 188855 CARRIAGE aluminu
43. vers 101 2 Reverse the manifold and reattach Install the screws and torque to 120 to 150 in Ib 14 to 17 Nem on aluminum pumps Torque to 190 220 in Ib 22 25 Nem on ductile iron and stainless steel pumps See Torque Sequence page 29 KEY N 1 2 npt f air inlet port 101 Covers P Muffler Air exhaust 102 Fluid inlet manifold port is 3 4 npt f 103 Fluid outlet manifold R 2 npt f fluid 106 Manifold and cover inlet port screws S 2npt f fluid 112 Cover screws outlet port top and bottom Apply medium strength blue Loctite or equivalent to the threads Torque to 120 to 150 in lb 14 to 17 Nem on Aluminum pumps Torque to 190 220 in lb 22 25 Nem on ductile iron and stain less steel pumps See Torque Sequence page 29 AN Apply medium strength blue Loctite or equivalent to the threads Torque to 190 to 220 in lIb 22t em 22 to 25 Nem Aluminum Model Shown Fig 3 03940B 8 308368 Fluid Pressure Relief Valve 4 CAUTION Some systems may require installation of a pres sure relief valve at the pump outlet to prevent overpressurization and rupture of the pump or hose See Fig 4 Thermal expansion of fluid in the outlet line can cause overpressurization This can occur when using long fluid lines exposed to sunlight or ambi ent heat or when pumping from a cool to a warm area for example from an underground tank Overpressurization can also occur if the Husky pump is being used to feed flui
44. ways replace o rings 116 when replacing the balls 1 Follow the Pressure Relief Procedure Warning on page 10 Disconnect all hoses 2 Remove the pump from its mounting 3 Using a 10 mm socket wrench remove the four bolts 106 holding the outlet manifold 103 to the fluid covers 101 See Fig 10 4 Remove the seats 201 balls 301 and o rings 202 from the manifold NOTE Some models do not use o rings 202 5 Turn the pump over and remove the inlet manifold 102 Remove the seats 201 balls 301 and o rings 202 from the fluid covers 101 Reassembly 1 Clean all parts and inspect for wear or damage Replace parts as needed 2 Reassemble in the reverse order following all notes in Fig 10 Be sure the ball checks are assembled exactly as shown The arrows A on the fluid covers 101 must point toward the outlet manifold 103 16 308368 Apply medium strength blue Loctite or equivalent to the threads Torque to 120 to 150 in lb 14 to 17 Nem on aluminum pumps Torque to 190 220 in lb 22 25 Nem on ductile iron and stain less steel pumps See Torque Sequence page 29 gt Arrow A must point toward outlet manifold 103 Not used on some models Beveled seating surface must face ball 301 Daag Used on stainless steel model only O17 Extension Models Only T12233A 106 AN T10352B Fig 10 Service Diaphragm Repair Disassembly NOTE A Fluid Section Repair
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