IPM IP02 Series User manual

IP-02
2:1 RATIO TRANSFER PUMP
OPERATING MANUAL
IPM, INC.
Manufactured by International Pump Manufacturing, Inc.
Covers models: IP02, IP02S, IP02SST and IP02S-SST Manual Number: MIP11192008

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IP-02, IP-02S
IP02-SST, IP02S-SST
2:1 RATIO TRANSFER PUMP
OPERATION MANUAL
with
PARTS IDENTIFICATION
This manual contains IMPORTANT WARNINGS and INSTRUCTIONS. Read and retain for
reference.
International Pump Mfg, INC.
3107 142nd Avenue E Suite 106
Sumner, WA 98390
U.S.A.
TEL: [phone]
FAX: [phone]
Website : www.ipmpumps.com
For Technical Service Call Your Local Distributor
Copyright 2004 International Pump Mfg, Inc.
Printed: November 2008
WARNING: The equipment described herein must only be operated or serviced by properly
trained individuals, thoroughly familiar with the operating instructions and limitations of the
equipment.
Notice: All statements, information and data given herein are believed to be accurate and reliable but are presented without guarantee,
warranty or responsibility of any kind expressed or implied. Statements or suggestions concerning possible use of IPM equipment are made
without representation or warranty that any such use is free of patent infringement, and are not recommendations to infringe any patent. The
user should not assume that all safety measures are indicated or that other measures may not be required.

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CONTENTS:
1.0 SAFETY WARNINGS………………………………….. 4
2.0 INSTALLATION………………………………………… 7
2.1 MOUNTING CONFIGURATION………………………… 8
3.0 OPERATIONS………………………………………….. 9
4.0 MAINTENANCE AND REPAIR SECTIONS
4.1 AIR MOTOR DISASSEMBLY…………………………… 11
4.2 AIR MOTOR ASSEMBLY……………………………….. 13
4.3 DISASSEMBLY LOWER FLUID SECTION…………. 14
4.4 ASSEMBLY LOWER FLUID SECTION…………….. 16
5.0 PARTS IDENTIFICATION
5.1 PARTS DIAGRAM FOR AIR MOTORS (IP02/IP02S).. 17
5.2 PARTS LIST FOR AIR MOTORS (IP02/IP02S)……… 18
5.3 FLUID SECTION PARTS DIAGRAM IP02…………… 19
5.4 PARTS LIST IP-02………………………………………….20
5.5 FLUID SECTION PARTS DIAGRAM IP-02SST……….. 21
5.6 PARTS LIST IP-02SST……………………………………. 22
5.7 FLUID SECTION PARTS DIAGRAM IP02-S..….……. 23
5.8 PARTS LIST IP02S………………………………….. 24
5.9 FLUID SECTION PARTS DIAGRAM IP02S-SST…….. 25
5.10 PARTS LIST IP02-SST………………………………….. 26
6.0 REPAIR KITS………………………………………………… 27
7.0 TROUBLESHOOTING…………………………………. 28
8.0 TECHNICAL SPECIFICATIONS………………………. 29
9.0 WARRANTY AND DISCLAIMER………………………. 32

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1.0 SAFETY WARNINGS
Please read and observe all warnings contained in this operations manual before any attempt
to operate the equipment.
Misuse of Equipment
Misuse of the Equipment can cause serious injury. Use the equipment only for its intended
purpose. Care should be taken to prevent over pressurization of the pump or accessories
connected to it. Use only proper parts in good condition. Use the pump only with compatible
fluids. Improper use or misuse of this equipment could result in fluid being splashed on the skin
or in the eyes, serious bodily injury, property damage, fire or explosion.
Make daily check on the equipment and repair damaged or worn parts immediately.
Do not alter this equipment, doing so could cause it to function incorrectly and could cause
serious injury.
Material & Fluid compatibility
Always ensure the chemical compatibility of the fluids and solvents with the wetted parts in the
pump and any components. Check the fluid manufacturer’s data sheets and specifications
before using the fluids or solvents in this pump.
Pressurized Hoses
Because the hoses are pressurized, they present a danger should the fluid escape at high
pressure. This escaping fluid pressure can spray out and cause serious bodily injury or
property damage. Ensure that the hoses do not leak or rupture due to wear, misuse or
damage.
The hoses should be handled properly - do not pull on the hoses to move the equipment
around. Use the hoses only for fluids in which they are compatible both for the inner liner of the
hose and the outer covering. Use care not to exceed the temperature rating of the hose.
Before each use, ensure that the fluid couplings are tight and that the entire length of hose is
not worn or damaged. Check the entire hose for leaks, bulging cover, damage, abrasion or
cuts. These conditions may cause the hose to fail that could result in splashing of pressurized
fluid on the skin, or in the eyes and cause serious bodily injury or property damage.
Pressure Specification
The maximum working fluid pressure of this equipment is 180 psi (12.5bar) at the maximum
incoming air pressure of 180 psi (12.5bar). Ensure all equipment and accessories used with
this pump are rated to withstand the maximum working pressure of this pump. Never exceed
the maximum working pressure of the pump or any device attached to the pump.
Procedure for Pressure Relief
In order to avoid the risk of serious bodily injury such as splashing fluid on the skin or in the
eyes, or risk of injury from moving parts, the following procedure should be used. This
procedure should be used when shutting down the pump, when servicing or repairing the
pump or any part of the system, when replacing or cleaning components, or when pumping of
fluid is stopped.
1. Close the air valve to the pump.

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2. Use the air bleed down valve (see installation instructions) to relieve the air pressure in
the system.
3. Relieve the fluid pressure by holding a grounded metal pail in contact with the metal
part of the fluid dispense valve and slowly opening the valve.
4. With a container ready to catch the fluid open the drain valve (see installation
instructions).
5. It is a good practice to leave the drain valve open until it is time to dispense fluid again.
If you are unsure that the fluid pressure has been relieved (due to a blockage in a component
or a hose) be careful to relieve the pressure by slowly loosening the hose end coupling to allow
the fluid pressure to escape slowly. After the pressure has been relieved, the fitting can be
removed completely and any blockages removed.
Hazards from Fire or Explosion
Hazards exist when sparks can ignite vapors or fumes from flammable or combustible
materials or other hazardous conditions (explosive dusts, etc.). These sparks can be created
from plugging in or unplugging an electrical supply cord. Sparks can also be created from the
static electricity generated by the flow of fluid through the pump and hose.
Every part of the equipment must be properly grounded to prevent static electricity from
generating a spark and causing the pump or system to become hazardous. These sparks can
cause a fire, explosion, and serious bodily injury and property damage. Ensure that the pump
and all components and accessories are properly grounded and that electrical supply cords
are not plugged in or unplugged when these hazards exist.
Should any evidence of static electricity (sparks or small shocks while in contact with the
equipment) exists, discontinue the operation immediately. Investigate the source of the static
electricity and correct the grounding problem. Do not use the system until the grounding
problem is repaired.
Grounding Procedures
Grounding of the pump and all other dispensing equipment is necessary to minimize the
possibility of sparks due to static electricity. Grounding must be in compliance with local
electrical codes. Check with the local authorities for requirements in your area and with the
type of equipment being used. Ensure that all the following equipment is grounded:
1. Air Compressor: Follow the grounding procedures as recommended
by the manufacturer.
2. Air Hoses: Use grounded air hoses.
3. Fluid Container used to
supply the system: Grounding must be done according to local codes.
4. Pump: Follow the procedures included referring to Figure 1.
5. Fluid Hoses: Use grounded fluid hoses.
6. Dispensing Valve: The valve must be metal to conduct through the fluid hose to
the pump which must be properly grounded.
7. Dispensing Point: Grounding must be done according to local codes.

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8. Solvent Containers: Grounding must be done according to local codes. Use
metal conductive pails that are properly grounded.
9. Grounding while Maintain conductivity by firmly holding the metal part of the
dispensing, cleaning, dispensing valve to the side of a grounded metal container.
or relieving:
FIGURE 1
Grounding the Pump:
Follow these procedures for grounding the pump. Loosen the lock screw (W) to allow insertion
of one end of a 12 ga. (1.5 mm2) minimum size wire into the hole in the side of the lug (Z).
Insert the wire (Y) and tighten the lock screw securely. The other end of the ground wire must
be secured to a true earth ground.
Hose Grounding:
It is very important that the hoses used for both air and the fluid be a grounding type and that
this ground continuity is maintained. Regular checks of the hose ground resistance (with a
resistance meter using a suitable range) and a comparison to the Manufacturer’s Specification
will ensure the ground is within specifications. If it is not within specified limits it should be
replaced immediately.
Solvent Cleaning:
While cleaning the system with solvent, hold the metal part of the dispensing valve in contact
with a grounded metal pail to minimize the possibility of splashing fluid on the skin or in the
eyes or static sparks. Use low fluid pressure for additional safety.
Hazards From Moving Parts:
Use the Pressure Relief Procedure (page 9) to prevent the pump from starting unintentionally
when not desired. Please observe that moving parts present a pinching hazard to fingers or
other body parts. Always stay clear of moving parts when starting or operating the pump.
Safety Standards:
Safety standards have been established by the United States Government under the
Occupational Safety and Health Act. These standards should be consulted as they apply to the
hazards and type of equipment being used.

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2.0 INSTALLATION
FIGURE 2
Figure 2 depicts a typical installation provided as a guide for your reference. Select and install
optional accessories required. Feel free to call an IPM representative or the IPM Technical
Department for assistance.

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2.1 Mounting Configuration
Install the necessary accessories in sequence using Figure 2 as a guide. An Air Control Valve
(K) for Controlling air flow is required with the equipment. To minimize the risk of serious bodily
injury such as splashing fluid on the skin or in the eyes; or risk of injury from moving parts,
install the following accessories in your system.
1. Bleed-off master air valve (D)
This valve will relieve the air trapped within the system after the pump is stopped. Air
that is trapped between this valve and the pump can cause the pump to reciprocate
unintentionally, which may cause harm to the operator.
2. Fluid Drain Valve (G)
The fluid drain valve (use a metal valve for grounding purposes) is installed to relieve
fluid pressure in the pump, hose or the dispensing valve when the pump is stopped. The
relief of pressure by the dispensing valve, which at times is inadequate if there is a clog
or restriction in the hose or the dispensing valve, can be achieved by using the fluid
drain valve (G).
3. Low level cut-off valve or runaway safety valve
The low level cut-off valve should be installed at the fluid intake port of the pump. It
shuts off the fluid intake when the fluid level is too low, causing the pump to stall. This is
to prevent the pump from running empty. If not, then a runaway safety valve should be
installed. This valve shuts off the air supply to the pump if the pump accelerates beyond
the pre-set value when the fluid level is too low and the pump is pumping air, or there is
insufficient fluid for normal pump operation.
Connect an air lubricator (C). The lubricator provides proper lubrication to the air motor. (see
daily maintenance check). Next, install a bleed-off master air valve (D). This valve is required
in your system to relieve trapped air (as explained above).
Air Filter (E) helps to remove dirt and foreign particles from the supply air, water moisture also
will be trapped within this filter. Be sure to release the trapped water daily as a good
housekeeping practice (Also see daily maintenance check). Connect a grounded air supply
hose for the supply of air.
For the fluid section, connect one fluid drain valve (G) directly after the outlet of the pump. Be
sure to connect it pointing downwards for safety. Connect a grounded fluid hose (M) to the fluid
outlet 3/4” NPTF.
Grounding of the pump and accessories are to be ensured before operation. Observe all
OSHA regulations and other safety regulations.

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3.0 OPERATION
Start up and Adjustment of the Pump (Refer figure 2, page 7)
Ensure that installation is fully completed before proceeding to start up operations.
1. Ensure that the air control valve (K) is closed. Open the bleed-type master air valves
(D). Connect the quick disconnect coupler to the male fitting.
2. Into a grounded metal container, open the dispensing valve (G) slowly. Ensure metal-to-
metal contact between the container and the valve.
3. Adjust the pump air control valve (K) slowly for pressure just enough to start running the
pump. This is to prime all air within the system. After all the air has been expelled from
the lines, close the dispensing valve. During the priming of the pump, the pump runs
when the dispensing valve is opened and stop when the valve is closed.
4. Turn the air regulator slowly until sufficient flow from the dispensing valve is achieved.
Remember to run the pump always at the lowest possible speed necessary to achieve
what is desired. Never exceed the maximum working pressure of any component in the
system.
5. The pump should not be left to run dry of the fluid being pumped. When running empty,
the pump speed will become very fast and probably cause damage. During operation,
should the pump be found to run too fast, stop it immediately and check the fluid supply.
Is the fluid level in the drum too low or empty? If air has gone into the system, do a
priming procedure. Ensure that all air has been expelled from the lines before beginning
operations again. Flush the pump or leave it filled with a compatible solvent when not in
use.
6. Always follow the Pressure Relief Procedure should the pump be put away for any
period of time or during system shut off at the end of the day.
Daily Maintenance Check
1. Ensure sufficient lubricant in the air lubricator.
2. Drain the moisture trapped in the air pressure regulator.
Clean and flush the pump thoroughly with care and appropriate cleaning fluid to obtain
maximum service life of the equipment.
Procedure For Pressure Relief
In order to avoid the risk of serious bodily injury such as spraying fluid on the skin or in the
eyes, or risk of injury from the moving part, the following procedure should be used. This
procedure should be used when shutting down the pump, servicing or repairing the pump or
any part of the system, replacing or cleaning components, or if the pumping of fluid has
stopped.
1. Close the air valve (D) of the pump.
2. Use the air bleed down valve (see installation instructions) to relieve the air
pressure in the system.

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Warning
To reduce the risk of static sparking, splashing fluid in the eyes or on the
skin, follow the Pressure Relief Procedure before flushing.
For your safety, read the Fire or Explosion Hazard before flushing and
follow all the recommendations furnished.
3. Relieve the fluid pressure by holding a grounded metal pail in contact with metal
part of the fluid dispense valve (G) and slowly opening the valve.
4. With a container ready to catch the fluid open the drain valve (G) (see installation
instructions).
5. It is a good practice to leave the drain valve (G) open until it is time to dispense
fluid again.
If you are unsure that the fluid pressure has been relieved due to a blockage in a component
or a hose, relieve pressure by slowly loosening the hose end coupling to allow the fluid
pressure to escape. After the pressure has been relieved, the fitting can be removed
completely and any blockages removed.
Flush the Pump before Using It
1. The pump is tested with lightweight DOP oil, which is left in to protect the pump parts. If
the fluid you are pumping may contaminated by oil, Flush out the oil with a compatible
solvent before using the pump. Follow the Flushing Instruction below:
2. If you are pumping fluid that dries, hardens or sets up, flush the system with a
compatible solvent as often as necessary to prevent build-up of dried fluid in the pump
or hoses.
3. If the pump is being used to supply a circulating system, allow the solvent to circulate
through the entire system for at least 30 minutes every 48 hours- more often if
necessary to prevent any undesired settling.
4. Always fill the wet-cup 1/2 full of Throat Seal Liquid (TSL) or a compatible solvent to
keep the fluid from drying on the displacement rod and/or damaging the pump throat
packing.
5. Lubricate the throat packing frequently when you are pumping a non-lubricating fluid, or
are shutting down for more than a few days.
Shut down & care of the Pump
For overnight shut down, follow the Pressure Relief Procedure on page 9. Always stop the
pump at bottom of the stroke to prevent the fluid from drying on the exposed displacement rod,
which could damage the throat packing.

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4.0 IP-02 Maintenance & Repair Section
4.1 Air Motor Disassembly Procedure
1. Follow the Procedure For Pressure Relief on page 9. It is very important to relieve
all air and fluid line pressure, as well as pump pressure before proceeding to the
next step or injury can occur.
2. Remove inlet and outlet hoses. Place the pump in a vise or other holding device.
If you know that you just need to work on the air motor, the pump can simply be left
in the drum it is operating in.
3. Clamp on the housing with the outlet hole against one of the jaws of the vice.
When clamping the housing- either the air motor assembly or the lower tube and/or
foot valve can be removed.
Use a strap wrench to remove the air motor assembly.
The pump assembly can be removed from the air motor by disengaging the Piston Rod.

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Remove the air cylinder either by hand or by using a strap wrench.
Air piston assembly with the Air Cylinder removed.
Place a pair of channel-lock pliers on the knurled area and a crescent wrench on the flats to
remove the air piston assembly. Examine the spring in the air motor cap to ensure that it is not
damaged or loose. Examine the gasket in the air motor cap, and replace as needed. This
gasket seals the cylinder cap to the air cylinder. Also inspect the lower return spring to ensure
it is secured correctly into the air motor base assembly.

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4.2 Air Motor Assembly Procedure:(Reference numbers come from Page 20, Air Motor Section)
Assemble the Air Piston assembly (12). Includes parts (13A through 13G). The Air
Exhaust Valve Plate (13E) and the screws (13A) require the use of Loctite-222 on
the threads to ensure they do not vibrate loose. Tighten the screws to 10-14 inch
pounds. Note: Inspect the Air Exhaust Valve Plate to make sure that the gasket is still securely
attached to the center as shown (far left, in the photo below).
1. Assemble the Air Piston assembly (use Loctite-222), with washer (5) onto Piston Rod (11).
Hand-tighten only.
2. Place O-ring (1) inside the groove in the Air Motor Base. Place gasket (6) in the top of the
Air Motor Base, with spring (4) centered inside the gasket resting on the Air Motor Base.
Slide the Piston Rod and Air Valve assembly in to the Air Motor Base (7).
Air Piston assembly (12)
Air Intake
Valve Plate
Spacers, screws
and o-rings
Air Piston
Air Exhaust
Valve Plate
O-ring (1) inserted
in to the groove.
Gasket (6)

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3. Place the conical spring (2) into the groove in the Air Cylinder Cap (10) followed by Gasket
(6). Clamp the Air Motor Base in to a vice and use a strap wrench to assemble the Air
Cylinder (3) and the Air Cylinder Cap to the Air Motor Base. Hand-tighten the Air Cylinder
cap.
4. Place the Connecting Ring (9) around the Connecting Rod Housing (8) and hand-tighten.
4.3 Disassembly Lower Fluid Section
1. Remove the foot valve while holding the cylinder with a strap wrench.
2. With the upper air motor assembly already removed, you should be able to simply push
from the upper ball end, the complete assembly out the bottom of the lower section.
3. Use two wrenches and dismantle the upper pump section. Note the orientation of the
Teflon cups. One goes up, followed by a wear ring in the center, and one goes down
followed by a lower support washer. Use Loctite-222 when re-installing.
Upper portion of the Lower Connecting Rod assembly.
Spring must be pushed
under the lip inside the cap

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Internal foot valve of an IP-02 pump.
Internal foot valve disassembled. Clean, inspect or replace (if necessary) these
components before re-assembly. Use Loctite-222 when re-installing.
After the lower piston rod is inspected and proper parts replaced/cleaned as needed,
inspect the lower body assembly and make sure that they are also clean and free from
any rough scratches. Grease and push this assembly back up from the bottom into the
pump’s cylinder. Just push it in far enough to re attach the foot valve.
IP-02 lower foot valve parts. On the stubby version there are ¾” female pipe threads
under the Foot Valve- on the drum length IP02 there are not. Should you need to extend
in to your container farther, it is recommended to install a proper Cylinder Extension Tube
to keep the foot valve at the lowest possible point.
Be sure to clean and inspect and replace any of the above items if needed.
You will need to re-assemble the foot valve assembly the same way that you removed it.

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4.4 Attaching lower fluid assembly to the Air Motor assembly
The Piston Rod is actually inside the Air Motor assembly- which has been removed so you can
see more detail.
Notice how the Upper Connecting Rod is being inserted at an angle. This is to ensure that the
ball on the end correctly engages the slot or notch in the photo on the left.
You will need to “hook” the ball in to the slot by moving at an angle- and then press it towards
the center of the notch.
Note: the lower section will need to have the Piston Rod extended, and the Air Motor will need
to be in the down position in order for you to have enough length to hook these two
components together.
Connect the assembly to the lower section as shown.
You should now be ready to re-install the pump into your container. Attach the fluid hose first
and tighten before attaching the air line and turning the air supply back on.

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5.0 PARTS IDENTIFICATION:
5.1 Parts Drawing for AIR MOTOR IP-02 (Drum Length)
Parts Drawing for AIR MOTOR IP02S (Stubby)
14A: Complete
air motor assy.
for IP02.
14B: Complete
air motor assy.
for IP02S

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5.2 Parts List for AIR MOTOR IP-02 (Drum Length)
Parts List for AIR MOTOR IP02S (Stubby)
Ref
No.
New Part
Number
Old Part
Number
Description
QTY
1*
500206
02-156-698
O-ring
1
2
500284
02-157-630
SPRING, conical
1
3
500203
02-157-632
Air cylinder
(IP02)
1
500241
02-186-565
Air cylinder
(IP02S)
1
4
500204
02-157-633
SPRING,
compression
1
5
500104
02-157-872
WASHER, valve
1
6*
500236
02-158-109
GASKET, rubber
2
7
500205
02-161-770
BASE, air motor
1
8
500207
02-161-771
HOUSING,
connecting rod
1
9
500212
02-161-772
RING, connecting
1
10
500200
02-204-465
Air cylinder cap
1
11
700027
02-204-723
ROD, piston
1
12
700055
02-220-168
Air valve & piston
assembly.
(Includes 13a-13g)
1
13a
500288
02-220-884
SCREW, SHCS
(6-32X1” with copper
gasket)
3
13b
500140
02-181-485
SPACER
3
13c
500137
02-189-210
PISTON, air
1
13d
500139
02-181-487
Air intake valve plate
1
13e
500138
02-162-729
Air exhaust
valve plate
1
13f*
500141
02-108-357
O-Ring
1
13g*
500144
02-108-358
O-Ring
3
14A
700038
02-204-722
IP02 complete
air motor
1
14B
700046
02-223-953
IP02S complete
air motor
1
* Supplied in the air motor repair kit 601011.

19
5.3 Parts drawing for IP-02 Fluid Section for C/Steel (Drum Length)

20
5.4 Parts List for IP-02 Fluid Section for C/Steel (Drum Length)
Ref
No.
New Part
Number
Old Part
Number
Description
QTY
1
700038
02-204-722
AIR MOTOR
1
2
700047
02-208-197
Displacement pump
assy.
(includes items 3-31)
1
3*
500213
02-102-596
O-Ring, Teflon
1
4
500268
02-101-750
BALL, piston valve
1
5
500269
02-101-917
BALL, intake valve
1
6*
500221
02-161-788
CUP PACKING, Teflon
2
7*
500222
02-186-647
BEARING, Piston
1
8*
500227
02-161-793
CUP PACKING, Teflon
2
9*
500228
02-186-648
BEARING, Piston
1
10
500107
02-104-029
LUG, grounding
1
11
500230
02-164-250CS
PIN, ball stop
1
12
500210
02-166-564
BEARING
1
13
500225
02-169-293
HOUSING, Piston valve
1
14
500224
02-169-294
ROD, lower connecting
1
15
500226
02-169-295
WASHER, back-up
1
16
500223
02-169-296
WASHER, back-up
1
17
700017
02-990-017
FRAME, displacement
pump
1
18
700028
02-208-198
Rod, upper connecting
1
19
500211
02-169-298
RETAINER, packing
1
20
500229
02-208-201
BODY, piston
1
21
500289
02-208-202X
Foot Valve
1
22
500233
02-100-040
PLUG, pipe, 3/8" NPT
1
23
500232
02-103-147
PLUG. Pipe, 1/16" NPT
1
24
500108
02-104-582
SCREW, M5X10
1
25
500238
02-990-359-A
ADAPTER,BUNG
1
26
500239
02-990-359-B
CAP, bung adapter
1
27
500053
02-990-359-C
GASKET
1
28
500240
02-990-359-D
O-RING
1
(25-28)
700019
02-990-359
Complete Bung Assy.
1
29*
500237
02-990-032
O-RING
1
30
500220
02-990-017-5
CYLINDER
1
31*
500066
02-990-038
O-RING
1
32
810201
02-208-177
Complete IP02 Pump
1
*Supplied in the repair kit P/N 601009.