Graco Husky 2150 Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1994, Graco Inc. is registered to I.S. EN ISO 9001
ALUMINUM, STAINLESS, AND DUCTILE IRON
Huskyt2150 Air–Operated
Diaphragm Pumps
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
*Model No. DF3 Aluminum Pumps
*Model No. DFH Aluminum Extended Pump
*Model No. DF4 Stainless Steel Pumps
*Model No. DF6 Ductile Iron Pumps
*Model No. DFC Aluminum BSPT Pumps
*Model No. DFD Stainless Steel BSPT Pumps
*Model No. DFF Ductile Iron BSPT Pumps
*Model No. DFJ Aluminum BSPT Extended Pump
Model No. 232503 Private-Label Aluminum
2150 Pump (See page 20.)
*NOTE: Refer to the Pump Matrix on page 20 to
determine the Model No. of your pump.
US and Foreign Patents Pending
308368W
Read warnings and instructions.
See page 2 for table of contents.
03940B
Aluminum Model Shown
Parts

2 308368
Table of Contents
Safety Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service
Repairing the Air Valve 12. . . . . . . . . . . . . . . . . . . . . .
Ball Check Valve Repair 14. . . . . . . . . . . . . . . . . . . . .
Diaphragm Repair 15. . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing and Air Gasket Removal 18. . . . . . . . . . . . .
Pump Matrix 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Kit Matrix 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Chart 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranties 30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
EQUIPMENT MISUSE HAZARD
Any misuse of the equipment or accessories, such as overpressurizing, modifying parts, using
incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and
result in splashing in the eyes or on the skin, other serious injury, or fire, explosion or property dam-
age.
DThis equipment is for professional use only. Observe all warnings. Read and understand all
instruction manuals, warning labels, and tags before operating the equipment.
DNever alter or modify any part of this equipment; doing so could cause it to malfunction. Use only
genuine Graco parts and accessories.
DCheck all equipment regularly and repair or replace worn or damaged parts immediately.
DNever exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the Technical Data on page 28.
DDo 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.
DBe sure that all fluids and solvents used are chemically compatible with the wetted parts shown in
the Technical Data on page 28. Always read the manufacturer’s literature before using fluid or
solvent in the pump.
DNever move or lift a pump under pressure. If dropped, the fluid section may rupture. Always
follow the Pressure Relief Procedure on page 9 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.
WARNING

308368 3
HAZARDOUS FLUIDS
Improper handling of hazardous 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.
DKnow what fluid you are pumping and its specific hazards. Take precautions to avoid a toxic fluid
spill.
DAlways wear appropriate clothing and equipment, such as eye protection and breathing appara-
tus, to protect yourself.
DStore hazardous fluid in an appropriate, approved container. Dispose of it according to all Local,
State and Federal guidelines for hazardous fluids.
DSecure the fluid outlet hose tightly into the receiving container to prevent it from coming loose
and improperly draining the fluid.
DPipe 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 8.
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.
DTo reduce the risk of static sparking, ground the pump and all other equipment used or located in
the work area. Check your local electrical code for detailed grounding instructions for your area
and type of equipment. Refer to Grounding on page 4.
DIf 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.
DPipe 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 8.
DDo 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.
WARNING

4 308368
Installation
General Information
DThe 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.
DAlways use Genuine Graco Parts and Accessories.
DReference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 22 to 23.
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 on page 9 before moving or
lifting the pump.
WARNING
DThe 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 7.
Tightening Screws Before First Use
After you unpack the pump, and before you use it for
the first time, check and retorque external fasteners.
Retorque the fluid cover screws first, then the manifold
screws. This keeps the manifolds from interfering with
tightening the fluid covers. See the Service section for
torque specifications.
After the first day of operation, check and retorque the
fasteners again. Although the recommended
frequency for retorquing fasteners varies with pump
usage, a general guideline is to retorque fasteners
every two months.
Grounding
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 3.
WARNING
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:
DPump: 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 mm@) 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.
02646
B
Fig. 1
Y
W
DAir and fluid hoses: Use only grounded hoses with
a maximum of 500 ft (150 m) combined hose
length to ensure grounding continuity.
DAir compressor: Follow the manufacturer’s recom-
mendations.
DAll 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.
DFluid 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 8.
DBe sure the mounting surface can support the
weight of the pump, hoses, and accessories, as
well as the stress caused during operation.
DFor all mountings, be sure the pump is bolted
directly to the mounting surface.
DFor 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.
DRubber Foot Mounting Kit 236452 is available to
reduce noise and vibration during operation.
Air Line
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 on a
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.
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 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 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/N195265) 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. 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 28 for maximum
suction lift (wet and dry).

6 308368
Installation
Fluid Outlet Line
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.
1. Use grounded fluid hoses (L). The pump fluid
outlet (S) is 2”npt(f). Screw the fluid fitting into the
pump outlet securely.
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.
Retorquing with TeflonRSeals or
Diaphragms
If your pump has TeflonRseals in the manifolds or if it
has TeflonRdiaphragms, retorque the manifold bolts
(106) and fluid cover bolts (106 & 112) according to the
torque notes in Fig. 3 on page 7.
03943B
KEY
A 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 valve
L Fluid hose
N 1/2 npt(f) air inlet port
R 2 npt(f) fluid inlet port
S 2 npt(f) fluid outlet port
Y Ground wire (required; see page 4
for installation instructions)
Fig. 2
FLOOR-MOUNT TYPICAL INSTALLATION
YJ
F
BE
C
A
D
KL
G
H
R
S
N

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 covers (101).
2. Reverse the manifold and reattach. Install the
screws and torque to 120 to 150 in-lb (14 to 17
N.m).
03940B
Fig. 3
1Apply medium-strength (blue) LoctiteRor equivalent
to the threads. Torque to 120 to 150 in-lb
(14 to 17 N.m).
KEY
N 1/2 npt(f) air inlet port
P Muffler. Air exhaust
port is 3/4 npt(f).
R 2 npt(f) fluid
inlet port
S 2 npt(f) fluid
outlet port
101 Covers
102 Fluid inlet manifold
103 Fluid outlet manifold
106 Manifold and cover
screws
112 Cover screws
(top and bottom)
N
P
R
S
1
Aluminum Model Shown
103
102
101
106
112
2Apply medium-strength (blue) LoctiteRor equivalent
to the threads. Torque to 190 to 220 in-lb
(22 to 25 N.m).
2
106
2
Fluid Pressure Relief Valve
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 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.
CAUTION
Fig. 4
1
2Connect fluid inlet line here.
KEY
R 2 npt(f) fluid inlet port
S 2 npt(f) fluid outlet port
V Pressure relief valve
Part No. 110134 (aluminum)
Part No. 112119 (stainless steel)
R
S
Connect fluid outlet line here.
1
2
3
Install valve between fluid inlet and outlet ports.
V
3
03941B

8 308368
Installation
Air Exhaust Ventilation
FIRE AND EXPLOSION HAZARD;
HAZARDOUS FLUIDS
Be sure to read and follow the warnings
and precautions regarding HAZ-
ARDOUS FLUIDS, and FIRE OR
EXPLOSION HAZARD on page 3,
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 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.
WARNING The air exhaust port is 3/4 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
erratic pump operation.
To provide a remote exhaust:
1. Remove the muffler (P) from the pump air exhaust
port.
2. 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.
3. Place a container (U) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures.
03942
Fig. 5
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 Grounded air exhaust hose
U Container for remote air exhaust
FBEC
A
D
VENTING EXHAUST AIR
P
T
U

308368 9
Operation
Flush the Pump Before First Use
The pump was tested in water. If the 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
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 4.
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 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.
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).
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
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 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.

10 308368
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 9
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
and retorque all threaded connections at least every
two months. Retorque the fluid cover screws first,
followed by the manifold screws.
The recommended frequency for retorquing of fasten-
ers varies with pump usage; a general guideline is to
retorque fasteners every two months.
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 leakage due to dia-
phragm failure.