Graco SaniForce BV Series User manual

3A8983A
EN
Instructions
SaniForce® Diaphragm
Pumps, BV-Series
Air-operated double-diaphragm (AODD) pumps for sanitary fluid transfer applications. For
professional use only.
1050, 1590, and 2150 Models
See page 2 for model information, including approvals.
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working
Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.
1050 Pump
1590 Pump
2150 Pump

2 3A8983A
Contents
Models and Approvals . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Configuration Matrix . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Information . . . . . . . . . . . . . . . . . . . . . . . 6
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Before First Use . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mount the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ventilate Air Exhaust . . . . . . . . . . . . . . . . . . . . . . 8
Install Accessories . . . . . . . . . . . . . . . . . . . . . . . . 9
Tips to Reduce Cavitation . . . . . . . . . . . . . . . . . 10
Orient Fluid Inlet and Outlet Ports . . . . . . . . . . . 10
Fluid Pressure Relief Valve. . . . . . . . . . . . . . . . . 11
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 12
Before Each Use . . . . . . . . . . . . . . . . . . . . . . . . 12
Start and Adjust the Equipment. . . . . . . . . . . . . 13
Shut Down the Equipment. . . . . . . . . . . . . . . . . 13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lubricate the Equipment . . . . . . . . . . . . . . . . . . 14
Flush the Equipment . . . . . . . . . . . . . . . . . . . . . 15
Store the Equipment . . . . . . . . . . . . . . . . . . . . . 15
Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 15
End of Product Life . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Repair the Check Valve . . . . . . . . . . . . . . . . . . . 18
Repair the Diaphragm . . . . . . . . . . . . . . . . . . . . 19
Repair the Air Valve for 1050 Pumps. . . . . . . . . 22
Repair the Air Valve for 1590 and 2150 Pumps. 24
Replace the Bearing and Air Gasket . . . . . . . . . 26
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Center Section and Air Section Parts for 1050
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Center Section and Air Section Parts for 1590 and
2150 Pumps. . . . . . . . . . . . . . . . . . . . . . . . . 30
Fluid Section Parts . . . . . . . . . . . . . . . . . . . . . . . 32
Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . 34
Part Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Accessory Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Torque Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Torque Instructions. . . . . . . . . . . . . . . . . . . . . . . 36
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . 36
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 38
Performance Charts for 1050 Pumps. . . . . . . . . 39
Performance Chart for 1590 Pumps . . . . . . . . . 40
Performance Chart for 2150 Pumps . . . . . . . . . 41
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Dimensions for 1050 Pumps . . . . . . . . . . . . . . . 42
Dimensions for 1590 Pumps . . . . . . . . . . . . . . . 43
Dimensions for 2150 Pumps . . . . . . . . . . . . . . . 44
Technical Specifications . . . . . . . . . . . . . . . . . . . . 45
Technical Specifications for 1050 Pumps . . . . . 45
Technical Specifications for 1590 Pumps . . . . . 46
Technical Specifications for 2150 Pumps . . . . . 47
Fluid Temperature Range . . . . . . . . . . . . . . . . . . 48
California Proposition 65 . . . . . . . . . . . . . . . . . . . . 48
Graco Standard Warranty. . . . . . . . . . . . . . . . . . . . 50
Graco Information. . . . . . . . . . . . . . . . . . . . . . . . . . 50
Models and Approvals
Pump Model Part Number Approvals
1050 26D635
ATEX T-code rating depends on the
temperature of the fluid being dispensed.
Fluid temperature is limited by the materials
of the pump interior wetted parts. See
Technical Specifications for the maximum
fluid operating temperature for your specific
pump model.
1590 26D631
EC 1935/2004
2150 26D634 II 2 GD
Ex h IIC 66°C...135°C Gb
Ex h IIIC T135°C Db

Warnings
3A8983A 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks.
When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.
Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this
manual where applicable.
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) from distributor or
retailer.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route fluid lines and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over-bend fluid lines, cords, or cables. Do not use fluid lines, cords, or cables to pull
equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
• Use equipment only in well-ventilated area.
• Eliminate all ignition sources, such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Use only conductive, grounded fluid lines.
•Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
• Route exhaust away from all ignition sources. If diaphragm ruptures, fluid may be exhausted with air.

Warnings
4 3A8983A
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause
serious injury.
• Follow the Pressure Relief Procedure when you stop spraying/dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check fluid lines and connections daily. Replace worn or damaged parts immediately.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious
chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious
injury, or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
• Do not use chlorine bleach.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read Safety Data Sheets (SDSs) to know the specific hazards of the fluids you are using.
• Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into the air.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not
limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNING

Configuration Matrix
3A8983A 5
Configuration Matrix
Record the model part number and configuration
sequence found on your equipment identification plate
(ID) to assist you when ordering replacement parts.
Model Part Number:
_______________________________________________
Configuration Sequence:
_______________________________________________
NOTE: Some combinations are not possible. Check with your local distributor.
ID
Sample Configuration Sequence: 1050BVPA01AS16SSCWSPEP
1050 BV P A01A S16 SS CW SP EP
Pump
Model
Wetted
Section
Material
Drive Center
Section and
Air Valve
Material
Manifolds Seats Checks Diaphragms Gaskets
Pump Wetted Section
Material
Drive Type Center Section and Air
Valve Material
Manifolds
1050 1.5 in.
fluid ports
BV Stainless Steel P Pneumatic A01A Aluminum S16 316 Stainless
Steel
1590 2 in. fluid
ports
2150 2.5 in.
fluid ports
Seat Material Checks Diaphragm Material Gaskets
SS Stainless Steel CW Polychloroprene, weighted
ball
SP Santoprene®EP EPDM

Typical Installation
6 3A8983A
Typical Installation
General Information
A typical installations is shown in FIG. 1. The figure is
only a guide for selecting and installing system
components. Contact your local distributor 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 requirements of the system.
Reference letters in the text, for example, (A), refer to
the callouts in the figures.
Typical Installation
KEY:
A Air supply line
B Bleed-type master air valve (for pump) (required,
not supplied)
C Air regulator (required, not supplied)
E Master air valve (for accessories)
F Air line filter
G Flexible, conductive fluid supply line
J Fluid drain valve (required, not supplied)
K Fluid shutoff valve
L Flexible, conductive fluid outlet line
N* Air inlet port
R◆Fluid inlet port
S◆Fluid outlet port
Y Ground wire
Z Pump
*1/2 in. npt(f) port.
◆ Can be oriented to be on the left or right side. See Orient
Fluid Inlet and Outlet Ports, page 10.
FIG. 1: Typical Installation
A
B
C
E
F
G
J
KL
N
R
S
Y
Z

Installation
3A8983A 7
Installation
Before First Use
Tighten Fasteners
Before using the equipment for the first time, check and
torque all fasteners. Follow Torque Fasteners,
page 36.
After the first day of operation, re-torque the fasteners.
Tighten Connections
Check and tighten all fluid connections before operating
the equipment. Replace worn or damaged parts as
needed.
Flush the Equipment
Before using the equipment for the first time, flush the
equipment. Follow Flush the Equipment, page 15.
The equipment was tested using a food grade lubricant.
If a food grade lubricant could contaminate the fluid
being dispensed, flush the equipment thoroughly with a
sanitizing solution before first use.
Grounding
•Pump: Connect a ground wire and clamp to the
grounding screw (W). To order a ground wire and
clamp, order part number 222011.
1. Loosen the grounding screw (W).
2. Insert one end of a 12-gauge (1.5 mm2) or thicker
ground wire behind the grounding screw and
tighten the screw securely.
3. Connect the clamp end of the ground wire to a true
earth ground.
•Air and fluid lines: Use only conductive lines with a
maximum of 500 ft (150 m) combined line length to
ensure grounding continuity. Check electrical
resistance of lines. If total resistance to ground
exceeds 29 megohms, replace line immediately.
•Air compressor: Follow manufacturer’s
recommendations.
•Fluid supply container: Follow local codes and
regulations.
•Solvent pails used when flushing: Follow local
codes and regulations. Use only conductive metal
pails, placed on a grounded surface. Do not place
the pail on a nonconductive surface, such as paper
or cardboard, which interrupts grounding continuity.
NOTICE
To avoid pump damage, do not over-torque the
fasteners on the equipment.
NOTICE
Firmly tighten all connections to avoid leaks and
damage to equipment parts.
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes to
ignite or explode. Grounding provides an escape wire
for the electric current. Follow local codes and
regulations.
FIG. 2: Ground the Pump
W

Installation
8 3A8983A
Mount the Pump
Rubber Foot Mounting Kit 236452 is available to reduce
noise and vibration during operation (purchase
separately).
1. Ensure that the mounting surface is level and can
support the weight of the equipment, lines, and
accessories, as well as the stress caused during
operation.
2. Mount the equipment on a level surface and secure
the equipment to the mounting surface. For all
mountings, ensure that the equipment is fastened
directly to the mounting surface. See Dimensions,
page 42, for dimensions of the mounting holes for
your equipment.
NOTE: For ease of operation and service, mount
the equipment so the air valve cover, air inlet, and
fluid inlet and outlet ports are easily accessible.
Ventilate Air Exhaust
NOTE: The air exhaust port is 3/4 npt(f). Do not restrict
the air exhaust port. Excessive exhaust restriction can
reduce equipment performance.
To provide a remote exhaust:
1. Remove the muffler (P) from the air exhaust port.
See FIG. 3.
2. Install a conductive, grounded air exhaust line (T)
and connect the muffler (P) to the other end of the
line. The minimum size for the air exhaust line is
3/4 in. (19 mm) inner-diameter. If a line longer than
15 ft (4.57 m) is required, use a larger diameter line.
Avoid sharp bends or kinks in the line.
3. Place a conductive, grounded container (U) at the
end of the air exhaust line to catch fluid in case of a
diaphragm rupture. See FIG. 3.
The equipment is heavy (see Technical
Specifications for specific weights). If the equipment
must be moved, follow the Pressure Relief
Procedure, page 12, and have two people lift the
equipment by grasping the outlet manifold securely,
or use appropriate lifting equipment to lift by the
outlet manifold. Never have one person move or lift
the equipment.
Be sure the system is properly ventilated for your
type of installation. Exhaust must be vented to a safe
place, away from people, animals, food handling
areas, and all sources of ignition when pumping
flammable or hazardous fluids. Diaphragm rupture
can cause the fluid being pumped to exhaust with
the air. Place a grounded container at the end of the
air exhaust line to catch the fluid. See FIG. 3.
FIG. 3: Air Exhaust Ventilation
KEY:
A Air supply line
B Bleed-type master air valve (for pump)
(required, not supplied)
C Air regulator (required, not supplied)
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
P Muffler
T Conductive air exhaust line
U Conductive container for air exhaust
A
B
C
D
E
F
P
T
U

Installation
3A8983A 9
Install Accessories
Install the following accessories in the order shown in
FIG. 1, using adapters as necessary.
Install Air Line Accessories
•Bleed-type master air valve (B): Required in your
system to relieve air trapped between it and the air
motor when the valve is closed.
Be sure the valve is easily accessible from the
equipment and located downstream from the air
regulator.
•Air regulator (C): To control pump speed and fluid
outlet pressure. Locate it close to the equipment.
•Air line filter (F): Removes harmful dirt and
moisture from compressed air supply.
•Master bleed-type air valve (E): Isolates air line
accessories for servicing. Locate upstream from all
other air line accessories.
1. Install the air line accessories as shown in FIG. 1.
Verify that the air line supplying the accessories is
grounded.
2. Install a conductive, flexible air line (A) between the
accessories and the air inlet (N). Use a minimum
1/2 in. (13 mm) inner-diameter air line.
Install Fluid Supply and Outlet Lines
•Fluid drain valve (J): Required in your system,
relieves fluid pressure in the fluid line.
•Fluid pressure relief valve (V): Relieves fluid
pressure in the fluid line. See FIG. 5.
•Fluid shutoff valve (K): Shuts off fluid flow.
1. Install flexible, conductive fluid lines (G and L).
2. Install a fluid drain valve (J) in the fluid outlet line (L)
close to the fluid outlet. See FIG. 1.
3. Install a fluid shutoff valve (K) in the fluid outlet line
(L) downstream from the fluid drain valve (J).
4. If needed, install a fluid pressure relief valve (V). See
Fluid Pressure Relief Valve, page 11.
NOTE: For best results, always install the pump as
close as possible to the material source. See the
Technical Specifications, page 45, for maximum
suction lift (wet and dry).
Trapped air can cause the equipment to cycle
unexpectedly, which could result in serious injury
from splashing fluid. To help prevent serious injury,
install a bleed-type master air valve (B). See FIG. 1.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury
when relieving pressure, such as splashing fluid,
install a fluid drain valve (J). See FIG. 1.
NOTICE
The equipment can be damaged if flexible fluid lines
are not used. If hard-plumbed fluid lines are used in
the system, use a short length of flexible, conductive
fluid line to connect to the equipment.

Installation
10 3A8983A
Tips to Reduce Cavitation
Cavitation is the formation and collapse of air pockets
in the fluid. Cavitation depends on the vapor pressure
of the fluid, the system suction pressure, and the
velocity pressure. Viscous fluids are more difficult to
pump and more prone to cavitation than non-viscous
fluids.
To improve equipment efficiency and reduce the
cavitation:
1. Reduce vapor pressure: Decrease the
temperature of the fluid.
2. Increase suction pressure:
a. Position the equipment lower than the fluid
level in the supply.
b. Reduce the number of fittings on the suction
lines to reduce friction length.
c. Increase the diameter of the suction lines.
d. Reduce the fluid inlet pressure. An inlet
pressure supply of 3–5 psi (21–35 kPa,
0.2–0.3 bar) is adequate for most materials.
e. Increase the Net Positive Suction Head (NPSH).
See Performance Charts, page 38.
3. Reduce liquid velocity: Slow the equipment cyclic
rate.
Consider all the previously listed factors in system
design. To maintain efficiency, operate the equipment
at the lowest speed and pressure setting needed for the
required flow.
Contact your local distributor for site-specific
suggestions to improve equipment performance and
reduce operating costs.
Orient Fluid Inlet and Outlet
Ports
The inlet and outlet fluid port can be rotated. To change
the fluid port orientation of the manifold (102, 103):
1. Remove the manifold fasteners (106).
2. Rotate the manifold (102, 103) to the applicable
position.
3. Install the manifold fasteners (106) and torque. See
Torque Fasteners, page 36.
NOTICE
Frequent or excessive cavitation can cause serious
damage, including pitting and early wear of wetted
parts, and may result in reduced efficiency of the
equipment. Cavitation damage and reduced efficiency
both result in increased operating costs.
NOTICE
To avoid pump damage and inefficient operation, do
not use a fluid inlet pressure greater than 25 percent of
the outlet working pressure.
FIG. 4: Fluid Inlet and Outlet Port Orientation, 1590
model shown
Apply medium-strength (blue) thread locker to the
threads and torque. See Torque Fasteners, page 36.
1
1106
103
1106
102

Installation
3A8983A 11
Fluid Pressure Relief Valve
A fluid pressure relief valve is available (purchase
separately). See Kits and Accessories, starting on
page 34.
KEY:
R Fluid inlet port
S Fluid outlet port
V Fluid pressure relief valve
Install valve between fluid inlet and outlet ports.
Connect fluid inlet line here.
Connect fluid outlet line here.
Some systems may require installation of a pressure
relief valve (V) at the pump outlet to prevent
overpressurization and rupture of the pump or fluid
lines.
Thermal expansion of fluid in the outlet line can
cause overpressurization. Thermal expansion 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 also can occur if the pump is
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.
The pressure relief valve reduces the risk of serious
injury, including splashing in the eyes or on the skin.
FIG. 5: Fluid Pressure Relief Valve
1
2
3
R
S
2
3
1
V

Operation
12 3A8983A
Operation
Pressure Relief Procedure
1. Close the bleed-type master air valve (B) to shut off
the air to the equipment.
2. Open outbound fluid valve to relieve fluid pressure
from the equipment.
a. For simple transfer applications, open either
the fluid shutoff valve (K) or the fluid drain
valve (J).
b. For circulating applications, ensure that the
fluid shutoff valve (K) is closed and open the fluid
drain valve (J).
Before Each Use
Tighten Fasteners
Check and tighten all fasteners before operating the
equipment. Re-torque as needed. Follow Torque
Fasteners, page 36.
Tighten Connections
Check and tighten all fluid connections before operating
the equipment. Replace worn or damaged parts as
needed.
Flush the Equipment
Flush the equipment before each use. Determine
whether to disassemble and clean individual parts or
simply flush the equipment with a compatible solvent or
sanitizing solution.
To simply flush the equipment with a compatible
solvent or sanitizing solution, follow Start and Adjust
the Equipment, page 13, and Flush the Equipment,
page 15.
To disassemble and clean individual parts, see the
applicable repair procedure. See Repair, starting on
page 18.
Follow the Pressure Relief Procedure
whenever you see this symbol.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as splashing fluid, follow the
Pressure Relief Procedure when you stop
dispensing and before cleaning, checking, or
servicing the equipment.
NOTICE
To avoid pump damage, do not over-torque the
fasteners on the equipment.
NOTICE
Firmly tighten all connections to avoid leaks and
damage to equipment parts.

Operation
3A8983A 13
Start and Adjust the Equipment
1. Confirm that the equipment is properly grounded.
See Grounding, page 7.
2. Check and tighten all fasteners, air connections,
and fluid connections before operating the
equipment. Replace worn or damaged parts as
needed.
3. Connect a flexible, conductive fluid supply line (G)
from the fluid to be pumped to the fluid inlet
port (R).
4. Connect the flexible, conductive fluid outlet line (L)
to the fluid outlet port (S) and route the line to the
end container.
5. Close the fluid drain valve (J).
6. Turn the air regulator (C) to the lowest air pressure
setting and open the bleed-type master air
valve (B).
7. If the fluid outlet line (L) has a dispensing device,
hold it open while continuing with the following
step.
8. To prime the pump, slowly increase air pressure
with the air regulator (C) until pump starts to cycle.
Do not exceed the maximum operating air pressure
listed in the Technical Specifications, page 45.
Allow the pump to cycle slowly until all air is pushed
out of the fluid lines and fluid exits the fluid outlet
line (L).
Shut Down the Equipment
1. Follow Pressure Relief Procedure, page 12.
2. Follow Flush the Equipment, page 15.
NOTICE
Firmly tighten all fasteners and connections to avoid
air or fluid leaks. To avoid equipment damage, do
not over-torque the fasteners on the equipment. See
Torque Fasteners, page 36.

Maintenance
14 3A8983A
Maintenance
Establish a Preventive
Maintenance Schedule
Establish a preventive maintenance schedule based on
the equipment service history.
Inspect the Equipment
Regularly inspect the equipment for worn or damaged
parts. Replace as needed.
Torque Fasteners
Regularly check and torque all fasteners. Follow
Torque Fasteners, page 36.
Tighten Connections
Check and tighten all fluid connections before operating
the equipment. Replace worn or damaged parts as
needed.
Lubricate the Equipment
The equipment is lubricated at the factory. It is
designed to require no further lubrication for the life of
the equipment. There is no need to add an inline
lubricator under normal operating conditions.
The air valve is designed to operate unlubricated. If
lubrication is desired, remove the line from the
equipment air inlet and add two drops of machine oil to
the air inlet every 500 hours of operation (or monthly).
NOTICE
Regularly maintain the equipment to avoid pump
damage due to spills, leaks, or diaphragm failure.
NOTICE
To avoid pump damage, do not over-torque the
fasteners on the equipment.
NOTICE
Firmly tighten all connections to avoid leaks and
damage to equipment parts.
NOTICE
Do not over-lubricate the equipment. Lubricant is
exhausted through the muffler and could
contaminate your fluid supply or other equipment.
Excessive lubrication can also cause the equipment
to malfunction.

Recycling and Disposal
3A8983A 15
Flush the Equipment
•Flush before changing fluid materials, before fluid
can dry or freeze in the equipment, at the end of the
day, before storing, and before repairing equipment.
•Flush at the lowest pressure possible. Check and
tighten all fasteners and fluid connections. Replace
worn or damaged parts as needed.
•Flush with a solvent that is compatible with the fluid
being dispensed and the equipment wetted parts.
•Flushing schedule will vary based on particular
uses.
•Always cycle the equipment during the entire
flushing process.
1. Perform the Pressure Relief Procedure, page 12.
2. Insert the suction end of the supply line (G) into a
compatible solvent.
3. Open the air regulator (C) to supply low pressure air
to the equipment.
4. Run the equipment for enough time to thoroughly
clean the equipment and lines.
5. Close the air regulator (C).
6. Remove the suction end of the supply line (G) from
the compatible solvent and drain the equipment.
Store the Equipment
Always relieve the pressure and flush the equipment
before storing the equipment for any length of time.
1. Follow Pressure Relief Procedure, page 12.
2. Follow Flush the Equipment, page 15.
Recycling and Disposal
End of Product Life
At the end of the product’s useful life, dismantle and
recycle it in a responsible manner.
• Perform the Pressure Relief Procedure, page 12.
• Drain and dispose of fluids according to applicable
regulations. Refer to the material manufacturer’s
Safety Data Sheet.
• Deliver remaining product to a recycling facility.
To avoid fire and explosion, always ground
equipment and waste container. To avoid static
sparking and injury from splashing, always flush at
the lowest possible pressure. NOTICE
Store the equipment at 32°F (0°C) or higher.
Exposure to extreme low temperatures may result in
damage to plastic parts.

Troubleshooting
16 3A8983A
Troubleshooting
1. Follow Pressure Relief Procedure, page 12,
before checking or repairing the equipment.
2. Check all possible problems and causes before
disassembling 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 22–26. 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 the fluid pressure relief valve.
See page 11.
Dispensing valve clogged. Relieve pressure and clear valve.
Reduced pump performance. Clogged suction line. Inspect; clear.
Sticky or leaking balls (301). Clean or replace. See page 18.
Diaphragm ruptured. Replace. See page 19.
Restricted exhaust. Remove restriction.
Air bubbles in fluid. Suction line is loose Tighten.
Diaphragm ruptured. Replace. See page 19.
Loose inlet manifold (102), damaged
seal between manifold and seat
(201), damaged o-rings (202).
Tighten manifold fasteners (106) or
replace seats (201) or o-rings (202).
See page 18.
Loose diaphragm shaft fastener
(107).
Tighten or replace. See page 19.
Damaged o-ring (108). Replace. See page 19.
Fluid in exhaust air. Diaphragm ruptured. Replace. See page 19.
Loose diaphragm shaft fastener
(107).
Tighten or replace. See page 19.
Damaged o-ring (108). Replace. See page 19.
Pump exhausts excessive air at
stall.
Worn air section parts. Repair or replace. See pages 22–26.
Worn shaft seals (402). Replace. See page 19.

Troubleshooting
3A8983A 17
Pump leaks air externally. Loose, worn, or damaged air
section parts.
Tighten fasteners on air section.
See pages 22–26.
Repair or replace parts. See pages
22–26.
Pump leaks fluid externally from ball
check valves.
Loose manifolds (102, 103),
damaged seal between manifold
and seat (201), damaged o-rings
(202).
Tighten manifold fasteners (106) or
replace seats (201) or o-rings (202).
See page 18.
Problem Cause Solution

Repair
18 3A8983A
Repair
Repair kits available (purchase separately). Use all parts in the kits for best results. See Parts, starting on page 28.
Repair the Check Valve
Tools Required:
• Torque wrench
• O-ring pick
•For 1050 Pumps: 10 mm socket wrench
•For 1590 and 2150 Pumps: 13 mm socket wrench
Repair kits are available (purchase separately). Use all
parts in the kit for best results. See Kits and
Accessories, starting on page 34.
Service the check valves as follows.
See FIG. 6.
Remove the Check Valves
1. Perform the Pressure Relief Procedure, page 12.
2. Disconnect all air and fluid lines from the
equipment.
3. Remove fasteners (106) from manifolds (102, 103).
Remove manifolds from fluid covers (101).
NOTE: Use care while removing manifolds to avoid
damage to check valve components.
4. Remove balls (301), seats (201), and o-rings (202).
5. Clean and inspect for wear or damage. Replace as
needed.
NOTE: To ensure proper seating, always replace all
seat and check valve components when performing
check valve repairs.
Install the Check Valves
1. Install the o-rings (202), seats (201), and balls (301).
See FIG. 6.
NOTE: Ensure that the check valves and seating
areas are clean.
2. Align manifolds (102, 103) with fluid covers (101).
3. Insert fasteners (106) and torque. See Torque
Fasteners, page 36.
4. Reconnect air and fluid lines to equipment.
To avoid severe burns, do not touch hot fluid or hot
equipment.
FIG. 6: Check Valve Section
1
Apply medium-strength (blue) thread locker to the
threads and torque. See Torque Fasteners, page
36.
1
101
103
301
106
201
202
113
102

Repair
3A8983A 19
Repair the Diaphragm
Tools Required:
• Torque wrench
• 13 mm socket wrench
• 15 mm socket wrench
• 1 in. socket wrench
• 19 mm open-end wrench
• O-ring pick
• Lithium-base grease
Repair kits are available (purchase separately). Use all
parts in the kit for best results. See Kits and
Accessories, starting on page 34.
Service the diaphragms as follows. See FIG. 7–FIG. 9.
Remove the Diaphragms
1. Perform the Pressure Relief Procedure, page 12.
2. Disconnect all air and fluid lines from the
equipment.
3. Perform Remove the Check Valves, page 18.
4. Remove fasteners (106, 106b) from fluid covers
(101). Remove fluid covers from air covers (23).
5. Use an applicable wrench to loosen the diaphragm
shaft fasteners (107). Do not remove the fastener.
6. Remove one diaphragm assembly (401). See FIG. 7.
7. Remove the other diaphragm assembly (401) with
the shaft (24). See FIG. 9.
8. Disassemble the diaphragm plates (104, 105),
diaphragms (401), packing o-rings (108), and
fastener (107).
9. Clean and inspect for wear or damage. Replace as
needed.
Install the Diaphragms
1. Assemble the diaphragm plates (104, 105), packing
o-ring (108), and diaphragm (401) onto the
diaphragm shaft fastener (107). See FIG. 9.
NOTE: Install diaphragms (401) with the side
marked AIR SIDE facing toward the center housing
(1). See FIG. 8.
2. Screw the diaphragm assembly onto one side of
the shaft (24). Torque to 20–25 in-lb (3.5–4.4 N•m).
3. Grease the length of the shaft (24) and slide through
the center housing (1).
4. Repeat steps 1–2 for the other diaphragm
assembly.
5. Apply medium-strength (blue) thread locker to the
threads of the fluid cover fasteners (106, 106b).
6. Align fluid covers (101) with center housing (1) and
insert fluid cover fasteners (106, 106b). Torque the
fasteners (106, 106b). See Torque Fasteners,
page 36.
7. Perform Install the Check Valves, page 18.
8. Reconnect air and fluid lines to equipment.
To avoid severe burns, do not touch hot fluid or hot
equipment.
NOTICE
After reassembly, allow the thread locker to cure for
12 hours, or per manufacturer’s instructions, prior to
operating the equipment. Damage to the equipment
will occur if the diaphragm shaft fastener loosens.

Repair
20 3A8983A
FIG. 7: Diaphragm Section, 1590 model shown
Apply medium-strength (blue) thread locker to
the threads and torque. Torque to 20–25 in-lb
(3.5–4.4 N•m)
1
106,
106b
401
107
108
105
23 104
101
112
1
2
2Torque. See Torque Fasteners, page 36.
2