Graco Husky 2150 User manual

Instructions – Parts List
ALUMINUM, STAINLESS, AND DUCTILE IRON
HuskyTM 2150 Air-Operated
Diaphragm Pumps 308368ZAM
EN
2-inch AODD pump for fluid transfer applications. For professional use only.
See Models on page 3 for a list of pump models and descriptions.
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8bar) Maximum Air Input Pressure
Aluminum Model Shown
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
03940B

2 308368
Table of Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Repairing the Air Valve . . . . . . . . . . . . . . . . . . . 15
Ball Check Valve Repair . . . . . . . . . . . . . . . . . . 18
Diaphragm Repair . . . . . . . . . . . . . . . . . . . . . . . 19
Bearing and Air Gasket Removal . . . . . . . . . . . 22
Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Repair Kit Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Torque Instructions . . . . . . . . . . . . . . . . . . . . . . . . 32
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Performance Chart . . . . . . . . . . . . . . . . . . . . . . . . 37
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 38

308368 3
Models
* Refer to the Pump Matrix on page 24 to determine the Model No. of your pump.
NOTE: Plus Models include stainless steel center sections.
Model No. Description
*DF3______ Aluminum Pumps
*DG3______ Aluminum Pumps, Remote
*DFH______ Aluminum Extended Pump
*DGH______ Aluminum Extended Pump, Remote
*DF4______ Stainless Steel Pumps
*DG4______ Stainless Steel Pumps, Remote
*DF6______ Ductile Iron Pumps
*DG6______ Ductile Iron Pumps, Remote
*DFC______ Aluminum BSPT Pumps
*DGC______ Aluminum BSPT Pumps, Remote
*DFD______ Stainless Steel BSPT Pumps
*DGD______ Stainless Steel BSPT Pumps, Remote
*DFF______ Ductile Iron BSPT Pumps
*DGF______ Ductile Iron BSPT Pumps, Remote
*DFG______ Aluminum BSPT Extended Pump
*DGG______ Aluminum BSPT Extended Pump, Remote
*DFP______ Stainless Steel, center flange, vertical outlet
*DFR______ Stainless Steel, center flange, horizontal outlet
*DV4______ Stainless Steel Plus Pumps
*DVD______ Stainless Steel BSPT Plus Pumps
*DVP______ Stainless Steel, center flange, vertical outlet
*DVR______ Stainless Steel, center flange, horizontal outlet
24B782 Aluminum Pump with overmolded diaphragms
24B783 Stainless Steel Plus Pump with overmolded diaphragms
24B801 Stainless Steel Pump with overmolded diaphragms
24G413 Aluminum BSPT with overmolded diaphragms
24J360 Aluminum Pump with overmolded diaphragms
25A018 Aluminum Pump with overmolded diaphragms, SST balls
25A149 Ductile Iron Pump with overmolded diphragms, PTFE balls
25A150 Ductile Iron Pump with overmolded diphragms, Geolast balls
25A151 Ductile Iron Pump with overmolded diphragms, Santoprene balls
25C658 Stainless Steel Pump with SST Center Section, Flanged Manifold Ports
(Horizontal Outlet), and overmolded diaphragms
25C659 Stainless Steel Pump with Aluminum Center Section, Flanged Manifold
Ports (Horizontal Outlet), and overmolded diaphragms
25C660 Stainless Steel Pump with SST Center Section, Flanged Manifold Ports
(Vertical Outlet), and overmolded diaphragms
25C661 Stainless Steel Pump with Aluminum Center Section, Flanged Manifold
Ports (Vertical Outlet), and overmolded diaphragms

4 308368
Symbols
Warning Symbol Caution Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
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 damage.
•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 36.
•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 36. 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 12 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 5
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 following
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 apparatus,
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 11.
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 outdoors,
and can cause a fire or explosion and serious injury and property damage.
•To 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 6.
•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 11.
•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.
WARNING

6 308368
Installation
General Information
The Typical Installation shown in 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.
Reference numbers and letters in parentheses refer to
the callouts in the figures and the parts lists on pages
27 to 28.
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 10.
Tightening Screws Before First Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque
Instructions, page 32. After the first day of operation,
retorque the fasteners. Although pump use varies, a
general guideline is to retorque fasteners every two
months.
Tips to Reduce Cavitation
Cavitation in a diaphragm pump is the formation and col-
lapse of bubbles in the pumped liquid. Frequent or exces-
sive cavitation can cause serious damage, including
pitting and early wear of fluid chambers, balls, and seats.
It may result in reduced efficiency of the pump. Cavitation
damage and reduced efficiency both result in increased
operating costs.
Cavitation depends on the vapor pressure of the pumped
liquid, the system suction pressure, and the velocity pres-
sure. It can be reduced by changing any of these factors.
1. Reduce vapor pressure: Decrease the temperature
of the pumped liquid.
2. Increase suction pressure:
a. Lower the installed position of the pump relative
to the liquid level in the supply.
b. Reduce the friction length of the suction piping.
Remember that fittings add friction length to the
piping. Reduce the number of fittings to reduce
the friction length.
c. Increase the size of the suction piping.
NOTE: Be sure the inlet fluid pressure does not
exceed 25% of the outlet working pressure.
3. Reduce liquid velocity: Slow the cyclic rate of the
pump.
Pumped liquid viscosity is also very important but nor-
mally is controlled by factors that are process dependent
and cannot be changed to reduce cavitation. Viscous liq-
uids are more difficult to pump and more prone to cavita-
tion.
Graco recommends taking all the above factors into
account in system design. To maintain pump efficiency,
supply only enough air pressure to the pump to achieve
the required flow.
Graco distributors can supply site specific suggestions to
improve pump performance and reduce operating costs.
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:
Pump: 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
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 on
page 12 before moving or lifting the pump.
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.

308368 7
a true earth ground. Order Part No. 238909 Ground
Wire and Clamp.
FIG. 1 ___________________________________________
Air and fluid hoses: Use only grounded hoses with a
maximum of 500 ft (150 m) combined hose length to
ensure grounding continuity.
Air compressor: Follow the manufacturer’s
recommendations.
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.
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.
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 accessories 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 coupler (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 connectors
(14) on air motor of pump.
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 11.
02646
B
Y
W
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.

8 308368
Installation
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. 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. 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.
WARNING
A fluid drain valve (J) is requiredto relieve pressure in
the hose if it is plugged. The drain valve reduces the
risk of serious injury, including splashing 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.

308368 9
Installation
FIG. 2 _________________________________________________________________________________________________
03943B
YJ
F
BE
C
A
D
KL
G
H
R
S
N
FLOOR-MOUNT TYPICAL INSTALLATION
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
LFluidhose
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 6
for installation instructions)

10 308368
Installation
Changing the Orientation of the Fluid Inlet
and Outlet Ports
Remove and rotate the center manifold(s) to change the
orientation of inlet or outlet port(s). Follow Torque
Instructions, page 32.
Pumps have npt, bspt, or ANSI/DIN flange fluid ports.
KEY
Apply medium-strength (blue) thread locker to the threads.
See Torque Instructions, page 32.
Apply medium-strength (blue) thread locker to the threads.
See Torque Instructions, page 32.
FIG. 3 ___________________________________________
Fluid Pressure Relief Valve
KEY
R 2 in. npt(f) fluid inlet port
S 2 in. npt(f) fluid outlet port
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.
FIG. 4___________________________________________
N Air inlet port
P Muffler. Air exhaust
port is 3/4 npt(f).
101 Covers
102 Fluid inlet manifold
103 Fluid outlet manifold
106 Manifold and cover
screws
112 Cover screws
(top and bottom)
1
2
03940B
N
P
1
103
102
101
106
112
2
106
2
Aluminum Model Shown
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. 4
Thermal expansion of fluid in the outlet line can
cause overpressurization. This can occur when using
long fluid lines exposed to sunlight or ambient 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
3
R
S
1
2
V
3
03941B

308368 11
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 a grounded 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. 5.
3. Place a container (U) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures.
FIG. 5 _________________________________________________________________________________________________
WARNING
FIRE AND EXPLOSION HAZARD;
HAZARDOUS FLUIDS
Be sure to read and follow the warnings
and precautions regarding HAZARDOUS
FLUIDS, 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 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 appropriate
container at the end of the air exhaust line to catch
the fluid. See Fig. 5.
03942
FBEC
A
D
P
T
U
VENTING EXHAUST AIR
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
PMuffler
T Grounded air exhaust hose
U Container for remote air exhaust

12 308368
Operation
Flush the Pump Before First Use
The pump was tested in water. If water could
contaminate the fluid you are pumping, flush it 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 6.
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. 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 the Pump.
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 and before checking,
adjusting, cleaning or repairing the system, follow the
Pressure Relief Procedure below.
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.
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.
WARNING
The pump may cycle once before the external signal
is applied. Injury is possible. If pump cycles, wait until
end before proceeding.
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.

308368 13
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. Always flush the pump and follow the
Pressure Relief Procedure Warning on page 12 before
storing it for any length of time. Use a compatible 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 Instructions on page 32.
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.
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.

14 308368
Troubleshooting
NOTE: Check all possible problems and causes before disassembling the pump.
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 12 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.
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 18.
Pump will not cycle, or cycles once and
stops. Air valve is stuck or dirty. Disassemble and clean air valve. See pages 15 to 16. 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 18.
Check valve ball (301) is wedged into
seat (201), due to overpressurization. Install Pressure Relief Valve (see page 10).
Dispensing valve clogged. Relieve pressure and clear valve.
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking check valve balls (301). Clean or replace. See page 18.
Diaphragm ruptured. Replace. See pages 19 to 21.
Restricted exhaust. Remove restriction.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace. See pages 19 to 21.
Loose inlet manifold (102), damaged
seal between manifold and seat (201), or
damaged o-rings (202).
Tighten manifold bolts (106) or replace
seats (201) or o-rings (202). See page
18.
Loose diaphragm shaft bolt (107). Tighten or replace. See pages 19 to 21.
Damaged o-ring (108). Replace. See pages 19 to 21.
Fluid in exhaust air. Diaphragm ruptured. Replace. See pages 19 to 21.
Loose diaphragm shaft bolt (107). Tighten or replace. See pages 19 to 21.
Damaged o-ring (108). Replace. See pages 19 to 21.
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).
Repair or replace. See pages 15 to 16.
Worn shaft seals (402). Replace. See pages 19 to 21.
Pump leaks air externally. Air valve cover (2) or air valve cover
screws (3) are loose. Tighten screws. See page 16.
Air valve gasket (4) or air cover gasket
(22) is damaged. Inspect; replace. See pages 15 to 16, 22 to 23.
Air cover screws (3) are loose. Tighten screws. See pages 22 to 23.
Pump leaks fluid externally from ball
check valves. Loose manifolds (102, 103), damaged seal between manifold and seat (201), or
damaged o-rings (202).
Tighten manifold bolts (106) or replace
seats (201) or o-rings (202).
See page 18.

308368 15
Service
Repairing the Air Valve
Tools Required
Torque wrench
Torx (T20) screwdriver or 7 mm (9/32”) socket wrench
Needle-nose pliers
O-ring pick
Lithium base grease
NOTE: Air Valve Repair Kits 236273 (aluminum center
housings) and 255061 (stainless steel center housings)
are available. Refer to page 27. 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. Follow the Pressure Relief Procedure Warning on
page 12.
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 bearings
(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 disassembly
of the fluid section. See page 22.
7. Clean all parts and inspect for wear or damage.
Replace as needed. Reassemble as explained on
page 16.
FIG. 6 ___________________________________________
FIG. 7 ___________________________________________
03944
3
2
4
2
Torque to 50 to 60 in-lb (5.6 to 6.8 Nm).
2
03945
18
51
7
6
5
2
3
3
11
16
See Detail at right.
Grease
Grease lower face.
1
2
3

16 308368
Service
FIG. 8 ___________________________________________
FIG. 9 ___________________________________________
Reassembly
1. If you removed the bearings (12, 15), install new
ones as explained on page 22. 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. 9.
3. Install the valve plate (8) in the cavity. On aluminum
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.
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. 8.
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. 8.
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. 8.
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. 7.
8. Grease the o-ring (6†) and install it in the valve
block (7†). Push the block onto the valve carriage
(5). Grease the lower face of the valve block. See
FIG. 7.
9. Install the valve carriage (5) so its tabs slip into the
grooves on the narrow end of the actuator pistons
(11). See FIG. 7.
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 to50 to 60 in-lb (5.6 to
6.8 N•m). See FIG. 6.
03946
17 16
11
10
12
15 1
2
3
4
2
Insert narrow end first.
Grease
Install with lips facing narrow end of piston (11).
Insert wide end first.
1
2
3
4
03947
8
9
3
1
2
Rounded side must face down (aluminum center
housing models only).
Tighten screws until they bottom
out on the housing.
1
2

308368 17
Notes

18 308368
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 26 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), always replace o-rings (116) when
replacing the balls.
1. Follow the Pressure Relief Procedure Warning on
page 12. 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).
FIG. 10__________________________________________
TI0352B
106
103
101
A
*201
*301
106
102
201*
301*
2
1
1
*202
202*
3
3
4
4
113 5
117
103
*301
*201
*202
115
116
101
TI2233A
Apply medium-strength (blue) thread locker to the
threads. Torque to 120 to 150 in-lb (14 to 17 Nm) on
aluminum pumps. Torque to 190-220 in-lb (22-25 Nm)
on ductile iron and stainless steel pumps. See Torque
Instructions on page 32.
Arrow (A) must point toward outlet manifold (103).
Not used on some models.
Beveled seating surface must face ball (301).
Used on stainless steel model only.
1
2
3
4
2
5
Extension
Models Only

308368 19
Service
Diaphragm Repair
Tools Required
Torque wrench
10 mm socket wrench
13 mm socket wrench
15 mm socket wrench (aluminum models) or 1” socket
wrench (stainless steel models)
19 mm open-end wrench
O-ring pick
Lithium-base grease
Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to
page 26 to order the correct kit for your pump. Parts
included in the kit are marked with an asterisk, for
example (401*). Use all the parts in the kit for the best
results.
1. Follow the Pressure Relief Procedure Warning on
page 12.
2. Remove the manifolds and disassemble the ball
check valves as explained on page 16.
3. Using 10 and 13 mm socket wrenches, remove the
screws (106 and 112) holding the fluid covers (101)
to the air covers (23). Pull the fluid covers (101) off
the pump. See FIG. 11.
FIG. 11 ________________________________________________________________________________________________
23
101
A2
B
1
106
112 1
03949B
Apply medium-strength (blue) thread locker 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 Nm). See Torque
Instructions on page 32.
Arrow (A) must point toward air valve (B)
1
2

20 308368
Service
4. 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.
5. 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 air side diaphragm plate
(104). See FIG. 12.
For overmolded diaphragms: Grip both diaphragms
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.
6. Pull the other diaphragm 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 bolt (107) from the shaft.
Disassemble the remaining diaphragm assembly.
For overmolded diaphragms: Pull the other
diaphragm 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.
7. 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
22.
8. 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.
9. Clean all parts and inspect for wear or damage.
Replace parts as needed.
Reassembly
1. Install the shaft u-cup packings (402*) so the lips face
out of the housing (1). Lubricate the packings. See
FIG. 12.
2. Install the diaphragm assembly on one end of the
shaft (24) as follows. For pumps with overmolded
diaphragms, go directly to step g.
a. Install 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).
c. On PTFE Models only, install the PTFE
diaphragm (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) thread locker 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) thread
locker to the threads of the diaphragm assembly.
Screw the assembly into the shaft (24) hand
tight.
3. Grease the length and ends of the diaphragm shaft
(24), and slide it through the housing (1).
4. Assemble the other diaphragm assembly to the shaft
as explained in step 2.
5. Hold one shaft bolt (107) with a wrench and torque
the other bolt to 20 to 25 ft-lb (27 to 34 Nm) at 100
rpm maximum. NOTE: This step does not apply to
pumps with overmolded diaphragms.
6. 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 with
the screws (106 and 112), handtight. Install the
longer screws (112) in the top and bottom holes of
the covers. See FIG. 11.
7. First, torque the longer screws (112) oppositely and
evenly to 190 to 220 in-lb (22 to 25 Nm), using a 13
mm socket wrench. Then torque the shorter screws
(106), using a 10 mm socket wrench. See Torque
Instructions on page 32.
8. Reassemble the ball check valves and
manifolds as explained on page 18.