Graco Husky 2150 Datasheet

PROVEN QUALITY. LEADING TECHNOLOGY
2-inch AODD pump for fluid transfer applications. For professional use only.
See Models on page 3 for a list of pump models, descriptions, and approvals.
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
308550ZAJ
EN
Instructions–Parts List
POLYPROPYLENE, CONDUCTIVE POLYPROPYLENE, AND PVDF
Husky™ 2150 Air-Operated
Diaphragm Pumps
Important Safety Instructions
Read all warnings and instructions in the manual.
Save these instructions.
See page 2 for table of contents.
04613B
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2 308550
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 4
Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Information . . . . . . . . . . . . . . . . . . . . . . 6
Tighten Screws Before First Use . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation of Remote Pilot Air Lines . . . . . . . . . 9
Mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fluid Suction Line . . . . . . . . . . . . . . . . . . . . . . . . 9
Fluid Outlet Line . . . . . . . . . . . . . . . . . . . . . . . . . 9
Flange Connections . . . . . . . . . . . . . . . . . . . . . 10
Changing the Orientation of the Fluid Inlet and
Outlet Ports . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fluid Pressure Relief Valve . . . . . . . . . . . . . . . . 11
Air Exhaust Ventilation . . . . . . . . . . . . . . . . . . . 12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Relief Procedure . . . . . . . . . . . . . . . . 13
Flush the Pump Before First Use . . . . . . . . . . . 13
Starting and Adjusting the Pump . . . . . . . . . . . 13
Operation of Remote Piloted Pumps . . . . . . . . 14
Pump Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Flushing and Storage . . . . . . . . . . . . . . . . . . . . 14
Tightening Threaded Connections . . . . . . . . . . 14
Preventive Maintenance Schedule . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Repairing the Air Valve . . . . . . . . . . . . . . . . . . . 18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ball Check Valve Repair . . . . . . . . . . . . . . . . . . 20
Diaphragm Repair . . . . . . . . . . . . . . . . . . . . . . . 21
Bearing and Air Gasket Removal . . . . . . . . . . . 25
Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Repair Kit Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Air Motor Parts List (Matrix Column 2) . . . . . . . 29
Fluid Section Parts List (Matrix Column 3) . . . . 30
Seat Parts List (Matrix Column 4) . . . . . . . . . . . 31
Ball Parts List (Matrix Column 5) . . . . . . . . . . . . 31
Diaphragm Parts List (Matrix Column 6) . . . . . . 31
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Performance Chart . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Website: www.springerpumps.com
Int'l: +001 267 404 2910

308550 3
Models
NOTE: Plus models include stainless steel center sections
*Refer to the Pump Matrix on page 27 to determine the Model No. of your pump.
†Pumps with conductive polypropylene fluid sections have the following approvals:
Model No. Description
*D
F 2 ________ Polypropylene Pumps
*D
G2 _________ Polypropylene Pumps, Remote
*D
F 5 _________ PVDF Pumps
*D
G5 _________ PVDF Pumps, Remote
*D
V 2 _________ Polypropylene Plus Pumps
*D
V 5 _________ PVDF Plus Pumps
*D
FA _________ Conductive Polypropylene P umps†
*D GA _________ Conductive Polypropylene Pumps, Remote†
* DVA _________ Conductive Polypropylene Plus P umps†
24B762 PVDF Plus Pump with overmolded diaphragms
24B763 Polypropylene Plus Pump with overmolded diaphragms
24B764 Polypropylene Pump with overmolded diaphragms
24B765 Polypropylene Pump with overmolded diaphragms and sst seats
24B833 PVDF Pump with overmolded diaphragms
II 2 GD
Ex h IIC 66°...135°C Gb
Ex h IIIC T135°C Db
ATEX T-code rating is dependent on the temperature of the fluid being pumped. Fluid temperature is limited by
the materials of the pump interior wetted parts. See Technical Data for the maximum fluid operating temperature
for your specific pump model.
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4 308550
Symbols
WARNING
Warning Symbol
This symbol alerts you to the possibility of serious injury
or death if you do not follow the instructions.
CAUTION
Caution Symbol
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the
instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
• This equipment is for professional use only.
• Read all instruction manuals, tags, and labels before operating the equipment.
• Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor
• Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• 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.
• Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
• Do not use hoses to pull equipment.
• Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex- pose
Graco hoses to temperatures above 82°C (180°F) or below - 40°C (- 40°F).
• Do not lift pressurized equipment.
• Wear hearing protection when operating this equipment.
• Comply with all applicable local, state, and national fire, electrical, and safety regulations.
INSTRUCTIONS
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308550 5
WARNING
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
• Know the specific hazards of the fluid you are using.
• Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
• Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
• 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 12.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result
in a fire or explosion and serious injury.
• Ground the equipment. Refer to Grounding on page 7.
•Never use a polypropylene or PVDF pump with non-conductive flammable fluids as specified by your
local fire protection code. Refer to Grounding on page 7 for additional information. Consult your fluid
supplier to determine the conductivity or resistivity of your fluid.
• If there is any static sparking or you feel an electric shock while using this equipment, stop pumping
immediately. Do not use the equipment until you identify and correct the problem.
• Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being
sprayed, dispensed, or transferred.
• 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 12.
• Keep the work area free of debris, including solvent, rags, and gasoline.
• Electrically disconnect all equipment in the work area.
• Extinguish all open flames or pilot lights in the work area.
• Do not smoke in the work area.
• Do not turn on or off any light switch in the work area while operating or if fumes are present.
• Do not operate a gasoline engine in the work area.
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Int'l: +001 267 404 2910

6 308550
Installation
General Information
• The Typical Installation shown in Fig. 2 is only a
guide for selecting and installing system
components. Contact your Graco distributor or
Graco Technical Assistance (see back page) for
assistance in planning a system to suit your needs.
• Always use Genuine Graco Parts and Accessories.
Be sure all accessories are adequately sized and
pressure-rated to meet the system’s requirements.
• Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 29- 32.
• Variations in color between the plastic components
of this pump are normal. Color variation does not
affect the performance of the pump.
Tighten Screws Before First Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque Sequence,
page 33. After the first day of operation, retorque the
fasteners.Althoughpumpusevaries,ageneralguideline
is to retorque fasteners every two months.
WARNING
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause
serious injury or death if splashed in the
eyes or on the skin, inhaled, or
swallowed.
1. Read TOXIC FLUID HAZARD on page 5.
2. Use fluids and solvents which are compatible with
the equipment wetted parts. Refer to the
Technical Data section of all equipment
manuals. Read the fluid and solvent
manufacturer’s warnings.
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Int'l: +001 267 404 2910

308550 7
Installation
Grounding
To reduce the risk of static sparking, ground the pump
and all other equipment used or located in the pumping
area. Check your local electrical code for detailed
grounding instructions for your area and type of
equipment.
Ground all of this equipment:
•Air Motor: Connect a ground wire and clamp as
shown in Fig. 1. Loosen 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. 237569 Ground Wire and Clamp.
NOTE: When pumping conductive flammable fluids
with a polypropylene or a PVDF pump, always ground
the entire fluid system. See the WARNING on page 7.
•Air and fluid hoses: Use only electrically conductive
hoses.
•Air compressor: Follow the manufacturer’s recom-
mendations.
•All solvent pails used when flushing:Follow the local
code. Use only metal pails, which are conductive.
Do not place the pail on a non-conductive surface,
such as paper or cardboard, which interrupts the
grounding continuity.
•Fluid supply container: Follow the local code
Fig. 1
WARNING
FIRE AND EXPLOSION HAZARD This
pump must be grounded. Before
operating the pump, ground the system
as explained below. Also, read the sec-
tion FIRE AND EXPLOSION HAZARD,
on page 5.
Polypropylene and PVDF are not conductive.
Attaching the ground wire to the grounding lug will
ground only the air motor. When pumping conductive
flammable fluids, always ground the entire fluid
system by making sure the fluid has an electrical
path to a true earth ground. See Fig. 1.
Never use a polypropylene or a PVDF pump with
non-conductive flammable fluids as specified by your
local fire protection code.
US Code (NFPA 77 Static Electricity) recommends a
conductivity greater than 50 x 10-12 Siemans/meter
(mhos/meter) over your operating temperature range
to reduce the hazard of fire. Consult your fluid
supplier to determine the conductivity or resistivity
of your fluid. The resistivity must be less than
2x10
12 ohm-centimeters.
Y
W
02646
B
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8 308550
Installation
Air Line
1. Install the air line accessories as shown in Fig. 2.
Mount these accessories on the wall or on a
bracket. Be sure the air line supplying the acces-
sories is electrically conductive.
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.
b Locate one bleed-type master air valve (B)
close to the pump and use it to relieve trapped
air. See the WARNING at left. 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 an electrically conductive, 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.
3. Screw an air line quick disconnect coupler (D) onto
the end of the air hose (A); be sure the coupler
porting is large enough to not restrict the air flow,
which will affect pump performance. 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.
Fig. 2
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.
04614B
Y
J
FEB C
A
D
KL
G
H
R
S
N
TYPICAL FLOOR-MOUNT
INSTALLATION
KEY FOR Fig. 2
A Electrically conductive air supply hose
B Bleed-type master air valve (required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
G Fluid suction hose
H Fluid supply
J Fluid drain valve (required)
K Fluid shutoff valveD
l Fluid hose
N 1/2 npt(f) air inlet port
R 2” fluid inlet flange
S 2” fluid outlet flange
Y Ground wire (required; see page 6 for
installation instructions)
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308550 9
Installation
Installation of Remote 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 connectors
(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/N195265) controllers.
Mountings
• Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as well
as the stress caused during operation.
• For all mountings, be sure the pump is bolted
directly to the mounting surface.
• 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.
• Rubber Foot Mounting Kit 236452 is available to
reduce noise and vibration during operation.
• Prolonged exposure to UV radiation will degrade
natural polypropylene components of the pumps. To
prevent potential injury or equipment damage, do
not expose pump or the plastic components todirect
sunlight for prolonged periods.
Fluid Suction Line
1. The pump fluid inlet (R) is a 2” raised face flange.
Refer to Flange Connections on page 10.
2. 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.
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 36 for maximum
suction lift (wet and dry).
Fluid Outlet Line
1. The pump fluid outlet (S) is a 2” raised face flange.
Refer to Flange Connections on page 10.
2. Install a fluid drain valve (J) near the fluid outlet. See
the WARNING above.
3. Install a shutoff valve (K) in the fluid outlet line.
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 12
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.
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10 308550
Installation
Flange Connections
The fluid inlet and outlet ports are 2” raised face,
standard 150 lb class pipe flanges. Connect 2” flanged
plastic pipe to the pump as follows. You will need:
• Torque wrench
• Adjustable wrench
• 6” diameter, 1/8” thick PTFE gasket, with four 0.75”
diameter holes on a 4.75” diameter bolt circle, and a
2.20” diameter center
• Four 5/8” x 3” bolts
• Four 5/8” spring lockwashers
• Eight 5/8” flat washers
• Four 5/8” nuts
1. Place a flat washer (E) on each bolt (C). Refer to
Fig. 3.
2. Align the holes in the gasket (B) and the pipe flange
(A) with the holes in the pump outlet flange (S).
3. Lubricate the threads of the four bolts. Install the
bolts through the holes and secure with the wash-
ers (E), lockwashers (D), and nuts (F).
4. Hold the nuts with a wrench. Refer to the tighten-
ing sequence in Fig. 3 and torque the bolts to
20- 30 ft-lb (27- 41 N•m). Do not over-torque.
5. Repeat for the pump inlet flange (R).
Fig. 3
04405
1
F
E
S
B
A
E
D
C
R
1
1
2
3
4
1
04615B
BOLT TIGHTENING SEQUENCE
KEY
A Flanged plastic pipe
B PTFE gasket
C Bolt
D Lockwasher
E Flat washer
F Nut
R 2” fluid inlet flange
S 2” fluid outlet flange
Lubricate threads. Torque to 20- 30 ft-lb
(27- 41 N•m). Do not over-torque.
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308550 11
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. 4. To
change the orientation of the inlet and/or outlet port:
1. Remove the screws and washers (106, 112, 113
and 114) holding the inlet (102) and/or outlet (103)
manifold to the covers (101).
2. Reverse the manifold and reattach. Install the
screws and washers and torque to 150- 160 in- lb
(17- 18 N•m). See Torque Sequence, page 33.
Fig. 4
Fluid Pressure Relief Valve
Fig. 5
04613
B
1
N
P
R
S
1
103
102
101
1
106
112
113
114
KEY
N 1/2 npt(f) air inlet port
N 1/2 npt(f) air inlet port
P Muffler
Air exhaust port is 3/4
npt(f)
R 2” fluid inlet flange
S 2” fluid outlet flange
101 Fluid covers
102 Fluid inlet manifold
103 Fluid outlet manifold
106 Fluid outlet manifold
screws (top)
112 Fluid inlet manifold screws
(bottom)
113 Fluid outlet manifold
washer
114 Fluid inlet manifold washer
Torque to 150- 160 in- lb (17- 18 N•m). See
Torque Sequence, page 31.
CAUTION
Some systems may require installation of a
pressure relief valve at the pump outlet to prevent
overpressurization and rupture of the pump or
hose. See Fig. 5.
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 fluid to a piston pump,
and the intake valve of the piston pump does not
close, causing fluid to back up in the outlet line
1
2
R
S
1
2
3
V
3
04616B
KEY
R 2” fluid inlet flange
S 2” fluid outlet flange
V Pressure relief valve
Part No. 112119 (stainless steel)
Install valve between fluid inlet and outlet ports.
Connect fluid inlet line here.
Connect fluid outlet line here.
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12 308550
Installation
Air Exhaust Ventilation The air 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. Remove the muffler (P) from the pump air exhaust
port.
2. Install an electrically conductive air exhaust hose (T)
and connect 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. 6 .
3. Place a container (U) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures.
Fig. 6
WARNING
FIRE AND EXPLOSION HAZARD
Be sure to read and follow the warnings
and precautions regarding TOXIC FLUID
HAZARD, and FIRE AND EXPLOSION
HAZARD on page 5, before operating
this pump.
Be sure the system is properly ventilated for your
type of installation. You must vent the exhaust to a
safe place, away from people, animals, food handl-
ing 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. 6.
04617
FBEC
A
D
P
TU
KEY
A Air supply line
B Bleed-type master air valve (required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
P Muffler
T Electrically conductive air exhaust hose
U Container for remote air exhaust
VENTING EXHAUST AIR
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308550 13
Operation
Pressure Relief Procedure
1. Shut off the air to the pump.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve all fluid
pressure, having a container ready to catch the
drainage.
Flush the Pump Before First Use
The pump was tested in water. If water could
contaminate the fluid you are pumping, flush the pump
thoroughly with a compatible solvent. Follow the steps
under Starting and Adjusting the Pump.
Starting and Adjusting the Pump
1. Be sure the pump is properly grounded. Refer to
Grounding on page 7.
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
appropriate 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 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. Removethe suction tube from the solvent
and place it in the fluid to be pumped.
WARNING
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of serious injury
from pressurized fluid, accidental spray from the gun or
splashing fluid, follow this procedure whenever you:
• Are instructed to relieve pressure,
• Stop pumping,
• Check, clean or service any system equipment,
• Install or clean fluid nozzles.
WARNING
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause
serious injury or death if splashed in the
eyes or on the skin, inhaled, or
swallowed. Do not lift a pump under pressure. If
dropped, the fluid section may rupture. Always fol-
low the Pressure Relief Procedure above before
lifting the pump.
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Website: www.springerpumps.com
Int'l: +001 267 404 2910

14 308550
Operation
Operation of Remote Piloted Pumps
1. Fig. 2 and Parts Drawings. Follow preceding steps 1
through 7 of Starting and Adjusting the Pump on
page 13.
2. Open air regulator (C).
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, relieve the pressure.
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.
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. Flush with a fluid that is compatible withthe
fluid you are pumping and with the wetted parts in your
system. Check with your fluid manufacturer or supplier
for recommended flushing fluids and flushing frequency.
Always flush the pump and relieve the pressure before
storing it for any length of time.
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 33.
Preventive Maintenance Schedule
Establish a preventive maintenance schedule, based on
the pump’s service history. This is especially important
for prevention of spills or leakage due to diaphragm
failure.
WARNING
The pump may cycle once before the external sig- nal is
applied. Injury is possible. If pump cycles, wait until end
before proceeding.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 13.
CAUTION
Do not over-lubricate the pump. Oil is exhausted
through the muffler, which could contaminate your
fluid supply or other equipment. Excessive
lubrication can also cause the pump to
malfunction.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 13.
Tel: [phone]
Fax: [phone]
Springer Pumps, LLC
Website: www.springerpumps.com
Int'l: +001 267 404 2910

308550 15
Tel: [phone]
Fax: [phone]
Springer Pumps, LLC
Website: www.springerpumps.com
Int'l: +001 267 404 2910

16 308550
Troubleshooting
1. Relieve the pressure before checking or servicing
the equipment.
2. Check all possible problems and causes before
disassembling the pump.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 13.
PROBLEM CAUSE SOLUTION
Pump cycles at stall or fails to hold
pressure at stall. Worn check valve balls (301), seats
(201) or o-rings (202). Replace. See page 20.
Pump will not cycle, or cycles once
and stops. Air valve is stuck or dirty. Disassemble and clean air valve. See pages 18- 20. Use filtered air.
Check valve ball (301) severely
worn and wedged in seat (201) or
manifold (102 or 103).
Replace ball and seat. See page 20.
Check valve ball (301) is wedged
into seat (201), due to
overpressurization.
Install Pressure Relief Valve
(see page 11).
Dispensing valve clogged. Relieve pressure and clear valve.
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking balls (301). Clean or replace. See page 20.
Diaphragm ruptured. Replace. See pages 21- 24.
Restricted exhaust. Remove restriction.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace. See pages 21- 24.
Loose inlet manifold (102), damaged
seal between manifold and seat
(201), damaged o-rings (202).
Tighten manifold bolts (112) or
replace seats (201) or o-rings
(202). See page 20.
Loose fluid side diaphragm plate
(105). Tighten or replace. See pages
21- 24.
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Fax: [phone]
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Website: www.springerpumps.com
Int'l: +001 267 404 2910

308550 17
Troubleshooting
PROBLEM CAUSE SOLUTION
Fluid in exhaust air. Diaphragm ruptured. Replace. See pages 21- 24.
Loose fluid side diaphragm plate
(105). Tighten or replace. See pages 21- 24.
Pump exhausts excessive air at
stall. Worn air valve block (7), o-ring (6), plate (8), pilot block (18), u-cups
(10), or pilot pin o-rings (17).
Inspect; replace. See pages 18- 20.
Worn shaft seals (402). Replace. See pages 21- 24.
Pump leaks air externally. Air valve cover (2) or air valve cover
screws (3) are loose. Tighten screws. See page 18.
Air valve gasket (4) or air cover
gasket (22) is damaged. Inspect; replace. See pages 18- 20,
25- 26.
Air cover screws (25) are loose. Tighten screws. See pages 25- 26.
Pump leaks fluid externally from ball
check valves.
Loose manifolds (102, 103),
damagedseal betweenmanifoldand
seat (201), damaged o-rings (202).
Tighten manifold bolts (106 and 112)
or replace seats (201) or o-rings
(202). See page 18.
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Fax: [phone]
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Website: www.springerpumps.com
Int'l: +001 267 404 2910

18 308550
Service
Repairing the Air Valve
Tools Required
• Torque wrench
• Torx (T20) screwdriver or 7 mm (9/32”) socket
• Needle-nose pliers
• O-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 28. Parts included in
the kit are marked with a symbol, for example (4†).
Use all the parts in the kit for the best results.
Disassembly
1. Relieve the pressure.
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. 7.
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. 8.
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. 9.
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. 10.
6. Inspect the bearings (12, 15) in place. See Fig. 9.
The bearings are tapered and, if damaged, must be
removed from the outside. This requires
disassembly of the fluid section. See page 25.
7. Clean all parts and inspect for wear or damage.
Replace as needed. Reassemble as explained on
page 19.
Fig. 7
Fig. 8
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 13.
3
24{H
2
2
Torque to 50- 60 in-lb
(5.6- 6.8 N•m).
†
04900
18
5
1
2
3
1
7
6
5
2
3
3
11
16
†
†
See Detail at right.
Grease.
Grease lower face.
†
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Website: www.springerpumps.com
Int'l: +001 267 404 2910

308550 19
Service
Fig. 9
Reassembly
1. If you removed the bearings (12, 15), install new
ones as explained on page 25. Reassemble the
fluid section.
2. On aluminum center housing models, install the
valve plate seal (9†) into the groove at the bottom of
the valve cavity. The rounded side of the seal must
face down into the groove. See Fig. 10.
3. Install the valve plate (8) 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. 10.
4. Install an o-ring (17†) on each pilot pin (16).
Grease the pins and o-rings. Insert the pins into the
bearings (15), narrow end first. See Fig. 9.
5. Install a u-cup packing (10†) on each actuator
piston (11), so the lips of the packings face the
narrow end of the pistons. See Fig. 9.
Fig. 10
6. Lubricate the u-cup packings (10†) 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. 9.
7. Grease the lower face of the pilot block (18†) and
install so its tabs snap into the grooves on the ends
of the pilot pins (16). See Fig. 8.
8. Grease the o-ring (6†) and install it in the valve
block (7{H). Push the block onto the valve carriage
(5). Grease the lower face of the valve block. See
Fig. 8.
9. Install the valve carriage (5) so its tabs slip into the
grooves on the narrow end of the actuator pistons
(11). See Fig. 8.
10. 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- 60 in-lb
(5.6-6.8 N•m). See Fig. 7.
0490
1
17 16
11
10
12
15
1
2
3
4
1
2
3
4
2
†
†
Insert narrow end first.
Grease.
Install with lips facing narrow
end of piston (11).
†
Insert wide end first.
0394
7
1
2
8
9
3
1
2
Rounded side must face down.
Tighten screws until they bottom out on
the housing. 
†
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Fax: [phone]
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Website: www.springerpumps.com
Int'l: +001 267 404 2910

20 308550
Service
Ball Check Valve Repair
Tools Required
• Torque wrench
• 10 mm socket wrench
• O-ring pick
Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to
page 28 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.
1. Relieve the pressure. Disconnect all hoses.
2. Remove the pump from its mounting.
3. Using a 10 mm socket wrench, remove the eight
bolts (106), and four washers (113), holding the
outlet manifold (103) to the fluid covers (101). See
Fig. 11.
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 bolts (112),
washers (114), and 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. 11. 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). Fig. 11
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 13.
1
2
106
103
101
A
201*
301*
112
102
201*
301*
2
1
1
202*
202*
3
3
3
04619
C
113
114
Arrow (A) must point toward outlet manifold (103).
Torque to 150- 160 in- lb (17- 18 N•m).
See Torque Sequence, page 33.
Not used on some models.
Tel: [phone]
Fax: [phone]
Springer Pumps, LLC
Website: www.springerpumps.com
Int'l: +001 267 404 2910