Pentair HYPRO 2100 Series Use and care manual

Installation, Operation, Repair And Parts Manual
Rev. B
Series 2100 Diaphragm
and Plunger Pumps Form L-1493
Description
Plunger Pump Models:
2120P-P18DC 2.7 PM Max., 150 PSI Max., 18 Amp VDC, Continuous Duty Motor
2120P-P35DC 2.9 PM Max., 300 PSI Max., 35 Amp VDC, 75% Duty Cycle Motor
2120P-P39DC 2.9 PM Max., 300 PSI Max., 39 Amp VDC, Continuous Duty Motor
2120P-P05AC 2.5 PM Max., 300 PSI Max., 1/2 HP, 60 Hz, 115 VAC, Continuous Duty Motor
2120P-P05EU 1.6 PM Max., 300 PSI Max., 1/2 HP, 50 Hz, 230 VAC, Continuous Duty Motor
2120P-P55 E 2.9 PM Max., 300 PSI Max., 5.5 HP PowerPro as Engine
Diaphragm Pump Models:
2150P-D35DC 7.0 PM Max., 100 PSI Max., 35 Amp, 12 VDC, 75% Duty Cycle Motor
2150P-D39DC 8.3 PM Max., 100 PSI Max., 39 Amp, 12 VDC, Continuous Duty Motor
2150P-D05AC 6.7 PM Max., 100 PSI Max., 1/2 HP, 60 Hz, 115 VAC, Continuous Duty Motor
2150P-D55 E 7.0 PM Max., 100 PSI Max., 5.5 HP PowerPro as Engine
DC Version as Engine Version
AC Version
HYPRO®®

-2-
The following special attention notices are used to noti-
fy and advise the user of this product of procedures that
may be dangerous to the user or result in damage to
the product.
NOTE: Notes are used to notify of installation,
operation, or maintenance information that is
important but not safety related.
CAUTION: Caution is used to indicate the presence
of a hazard, which will or can cause minor injury or
property damage if the notice is ignored.
WARNIN : Warning denotes that a potential haz-
ard exists and indicates procedures that must be
followed exactly to either eliminate or reduce the
hazard, and to avoid serious personal injury, or pre-
vent future safety problems with the product.
DAN ER: Danger is used to indicate the presence
of a hazard that will result in severe personal injury,
death, or property damage if the notice is ignored.
*************************
DAN ER: DO NOT pump flammable or explosive
fluids such as gasoline, fuel oil, kerosene, etc. DO
NOT use in explosive atmospheres. The pump
should be used only with liquids compatible with
the pump component materials. Failure to follow
this warning may result in personal injury and/or
property damage and will void the product warranty.
A pressure relief device; such as an unloader, relief
valve or balancing regulator, must be installed on
the outlet side of the pump. Failure to do so could
result in personal injury and/or void the warranty.
•Be sure all exposed moving parts such as shafts,
couplers and adapters are properly shielded or
guarded and that all coupling devices are securely
attached before applying power.
•Do not exceed recommended speed, pressure and
temperature for pump and equipment being used.
•Before servicing, disconnect all power, make sure
all pressure in the system is relieved, drain all
liquids from the system and flush.
•Secure the discharge lines before starting the
pump. An unsecured line may whip, causing
personal injury and/or property damage.
•Check hose for weak or worn condition before each
use. Make certain that all connections are tight and
secure.
•Periodically inspect the pump and the system
components. Perform routine maintenance as
required (see Maintenance section).
•Protect pump from freezing conditions by draining
liquid and pumping rust inhibiting solution, such as
antifreeze, through the system, coating the pump
interior.
•Use only pipe, hose and fittings rated for the
maximum (or greater) PSI rating of the pump.
•Do not use these pumps for pumping water or other
liquids for human or animal consumption.
Safety Information
System Installation
Figure 1
Tank
Strainer
Flexible Hose
Remote-Mounted
Pressure Regulator
Pulsation
Dampener
California Proposition 65 Warning -- This product and related accessories contain chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm.

Pump Installation
Accessories should be installed with flex hose and be
mounted as close to the pump as possible. The hose
must be used right after accessories.
NOTE: If remaining installation is solid piping, a two
to four foot length of hose must be installed
between accessories and solid piping for vibration
isolation.
Hose
Selection of the right size and type of hose is vital for
good performance. Be sure to hook up to the proper
ports on the pump (note markings “IN” and “OUT” on
pump).
Suction Hose
Always use a suction hose compatible with the fluids
being pumped and at least the same inside diameter as
pump ports. If the suction hose is over 5 feet long, use
one size larger hose. Keep the suction hose as short as
possible and restrictions such as elbows, check valves,
etc. at a minimum. Use both inlet ports if the flow is to
exceed 6 gpm. Suction lift not to exceed 5 feet.
Discharge Hose
High pressure pumps require the use of special high
pressure discharge hose (2 rayon braid or equivalent).
Use a hose rated at least 50% greater than the highest
operating pressure required of pump. Example: If
required pump pressure is 300 psi, use discharge hose
rated at minimum of 450 psi working pressure.
Unloader Valve
The unloader has a very important safety function in
your plunger pump hookup. The unloader valve pro-
tects the pump by unloading pressure when the gun is
shut off or discharge is otherwise blocked. This saves
the pump and power because the liquid is bypassed at
a very low pressure. If the gun is to be shut off for more
than 5 minutes, install a thermal relief valve in the inlet
side or stop the pump to prevent heat buildup. The
length of time may vary due to the original temperature
of the fluid being pumped.
Bypass Valve
Bypass valves incorporate an adjustable spring-loaded
poppet that opens to protect the pump from over pres-
surizing when the pump outlet is shut off. The overflow
is diverted back to the inlet of the pump or back to tank.
Its main difference from an unloader valve is that it
does not reduce the power requirements or pump pres-
sure when the outlet is turned off. Instead, the pressure
stays at whatever the set operating pressure is that the
pump is working at. Bypass valves must be rated for
the max. flow of the pump because they return the full
amount of flow when the outlet is shut off. If the pump is
to run in shut-off condition for more than five minutes at
a time, it is recommended that the bypass flow goes
back to tank.
Strainers
Use a suction line strainer with at least 3 to 5 times the
suction port area in open screen area. or example, an
area of approximately 1.1 to 1.9 square inches for a
1/2" suction port. Be sure the screen is suitable for the
liquid being pumped. Keep the filter clean. A clogged
strainer will cause cavitation, which usually leads to
poor performance and wear of the pump parts.
Compound auge (Optional)
The pump should not be subjected to high suction line
vacuums. To check on this, install a compound gauge
at pump inlet. or ultimate performance and life, the
vacuum should be limited to 5 inches of mercury. High
vacuum conditions may cause premature product
failure and void warranty.
Pulsation Dampener
This device absorbs the shock and smooths out the
pump discharge pulsations, providing smoother opera-
tion. or the proper operation of many unloader valves,
the pulsation dampener should be installed on the
discharge side downstream from the unloader valve.
However, for maximum system protection, the pulsation
dampener may be installed upstream from the unloader
valve, provided the unloader valve will function properly.
The dampener can be mounted vertically or horizontally.
Pressure auge/Dampener
Use gauge capable of reading double the pump work-
ing pressure. Use a silicone-filled gauge or a gauge
dampener to protect the gauge needle against pressure
surges and provide easier reading.
Inlet/Outlet Ports
This pump has dual inlet and outlet ports for your
convenience. Use only one outlet port, and cap the
other outlet port for best performance. or flows over 6
gpm, use both inlet ports to reduce cavitation in the
diaphragm pump.
Pressure Switch/Demand Switch
A pressure switch is used to turn the motor and pump
off when the pressure at the discharge of the pump
reaches maximum operating pressure and when spray
nozzles or spray gun
have been turned off.
Pressure switches are
wired through the
normally closed (NC)
circuit. A normally
closed circuit allows
power to flow through
the switch contacts until
it reaches the switching
pressure, whereby the
contacts open and the
-3-
System Installation

-4-
pump is turned off. A pressure switch conserves ener-
gy in a DC voltage system by eliminating current draw
when output from the pump is not required. The dis-
advantage of a pressure switch, when used with a
positive displacement pump, is that the flow being
used by the spray gun or system must exceed the
pump’s capacity at whatever pressure the pump is
operating at. If the flow rate used by the spray gun is
too low, the pump will cycle on and off, producing an
undesirable effect to the user and harming the motor.
Solenoid DC Power Contacts for 12-Volt
Systems
A solenoid contact switch is used in low voltage,
direct current (VDC) systems where the current (mea-
sured in amperes or amps) of the motor is too high for
the rated capacity of a switch or relay. Low voltage
systems with high inductive current requirements arc
across the contacts and "burn" the switch out as the
switch is turned on and off. It is recommended that a
solenoid contact switch,
the same type that is
used in the automotive
industry for starters, be
used. The switch
should be rated for 12
VDC applications with a
minimum of 50 amps
continuous duty. (White
Rogers 70-111244 or
equivalent.)
Automotive Fuse
It is important to always use an inline fuse or circuit
breaker rated for 12 VDC in direct current applications. It
is best to place the inline fuse near the source of power
(battery) to safeguard the whole system (wires and
motor). ailure to do so can lead to a vehicle fire should
a short occur, or extended high amp condition caused by
pump over-pressuriza-
tion. Blade-type, easy-
to-install fuses are the
industry standard for
low-voltage automotive
rated for 32 VDC and
are UL listed. The Maxi
(time delay) fuse is the
preferred choice to pro-
tect higher current cir-
cuits than mini and
standard fuses. These
fuses will not blow when
exposed to harmless,
temporary overload currents as the mini and standard
fuses do. usible links and automotive circuit breakers
are also available to be used in this type of application.
(Maxi use Types: MAX, A 3, MAX/299.)
Figure 2
Start/Stop
Toggle Switch
Automotive Fuse
To Vehicle Power Source
Use Battery Isolator
Starter Solenoid
50 Amp, 12 Volt
Deep Cycle
12 Volt Battery
Heavy-duty Wire
Pressure Switch
Red Lead (+)
Black Lead (-)

-5-
DC Electrical Installation
Remember, the motor and electrical wire must always be fused to protect the electrical system. Use an automotive
fuse at or slightly above the motor-rated amps.
When the motor leads are not identified, the pump can operate in either rotation.
Positive Motor Lead (+) to Positive Power Lead (Red, +).
Negative Motor Lead (-) to Negative Power Lead (Black, -).
igure 4 shows a typical application of a high current draw pump. Note that a
solenoid is used for switching the motor on and off. The solenoid has four termi-
nals. The two large diameter posts are for the DC electrical current being
switched as it goes to the motor, and the two smaller terminals are for energizing
the coil inside the solenoid that pulls the main contacts to the on position ( igure
3). The solenoid permits a low-amp rated on/off switch, or pressure switch, to
control the motor and operation of the pump.
Incorrect sizing of the wire may limit the performance of the pump output. If the
gauge of wire is undersized, there will be too much resistance in the wire which leads to lower voltage at the motor
and lower performance from the pump. or 40 amp applications, 8 gauge wire or larger should be used. If lengths
over 25 feet are needed, use 4 gauge wire. or 20 amp applications, 10 gauge or larger should be used.
A time-delayed fuse should be located near the power source (battery) to protect the wire and the motor from
exceeding their rated loads. If other systems are also powered on the same line as the pump, it is recommended
that the motor be fused separately. Minimize wire length where possible to achieve the best possible performance
from the pump.
Battery isolators are recommended to protect both the alternator and battery of your vehicle. Not all vehicles have
high amp alternators. An alternator may be damaged if it is overloaded. Be sure to check the output rating of the
vehicle or implement, and use battery isolators with a deep cycle battery, or bank of batteries, to protect system
from overloading or draining vehicle battery.
PRESSURE SWITCH
DEEP CYCLE
12 VOLT BATTERY
AUTOMOTIVE FUSE
START/STOP
TOGGLE SWITCH
HEAVY DUTY WIRE
BLACK LEAD (-)
RED LEAD (+) STARTER SOLENOID
50 AMP, 12 VOLT
MAIN
12 VOLT BATTERY
ALTERNATOR
BATTERY
ISOLATOR
Figure 3
Figure 4
Duty Cycle
Duty cycle is the ratio of motor-on time to total cycle time in one hour. It is used to determine the acceptable level of
running time so that the thermal limits of the motor are not exceeded. Inefficiencies cause a temperature rise in a
system, and when the temperature reaches a critical point, components can fail. Letting the system rest idle during
the cycle allows the motor windings to cool. The duty cycle is limited by the motor thermal internal limits.
Use the following equation and example to determine Duty Cycle:
Duty Cycle = ON TIME / [Cycle ON TIME + (60 Minutes - Cycle ON TIME)] * 100.
(ON TIME cannot exceed 60 minutes.)
An example of a 75% Duty Cycle Motor is = 45/ [45+ (60-45)]*100 = 75% or 45 minutes on time per hour of opera-
tion at maximum rated pressure and flow. ON TIME can be extended by reducing the maximum pressure the pump
operates at.
To round (-)
Power OUT (+)
To Motor
Power IN (+)
From Battery
From On/Off
Switch or
Pressure Switch
(+)

-6-
Make sure the power source conforms to the requirements of the equipment being installed.
When wiring an electrically-driven pump, follow all electrical and safety codes, including the most
current National Electrical Code (NEC) and the Occupational Safety and Health Act (OSHA)
requirements in the United States.
To reduce the risk of electric shock, all motors must be adequately grounded to a grounded metal
raceway system, or by using separate grounding wire connected to the bare metal on the motor
frame or to the grounding screw inside the motor terminal box. Refer to the National Electric
Code (NEC) Article 250 (grounding) for further information.
AC Electrical Connections
Operation
Electrical Connections for Single Phase
Never connect the green (or green and yellow) wire to a
live terminal. Doing so may result in severe electrical
shock and/or damage to the equipment.
1. Make all electrical connections according to the
instructions provided on the electric motor. Select
models can be used for 115V or 230V (single
phase) 50/60 Hz and can be wired for either
portability with a flexible 3-wire cord, or permanent
installation using a grounded power supply.
2. To reduce the risk of electrical shock, the motor must
be properly grounded. This is accomplished by:
• Inserting a plug (portable installations only) directly
into a properly installed and grounded 3-prong
grounding type (G CI) receptacle.
• Permanently wiring the unit to a grounded metal
frame.
• Using a separate ground wire connected to the
bare metal of the motor frame.
3. Voltage should be within 5% of the motor rating.
4. Motor starters may be used.
5. The green, or green and yellow, conductor in the cord
is the grounding wire. The motor must be grounded
for your protection against electrical shock.
6. Where a 2-prong receptacle is encountered, it must
be replaced with a properly grounded 3-prong
receptacle installed in accordance with the National
Electrical Code and local codes and ordinances.
7. Use wire of adequate size to minimize voltage drop
at the motor. The pump motor should be powered
by a separate branch circuit.
8. Connections should be made with flexible conduit to
minimize vibration transmission.
9. After making electrical connections, jog the motor
momentarily to verify correct rotation (CCW when
viewed from front of pump).
Priming
If the liquid is below the level of the pump, some means
should be provided in installation to prime the pump,
such as a foot valve or check valve to hold prime. Keep
suction lift to a minimum and avoid unnecessary bends
in the suction line. Before starting pump, make sure air
bleeder valve or spray gun is open, or unloader valve is
adjusted to its lowest pressure. After starting pump,
open and close gun several times if necessary to aid
priming the pump. If pump does not prime within a few
seconds, stop motor and inspect installation for suction
line leaks or obstructions. Make sure that strainer is not
clogged. Be sure that suction line is not obstructed,
kinked or blocked. Suction lift not to exceed 5 feet.
If the pump is to operate hours at a time, check
frequently for:
1. Adequate liquid supply. Plunger pumps must not
run dry for more than 30 seconds.
2. Temperature rise. Overheating is harmful to bear-
ings, cups and ceramic plungers.
Care of Pump
Your pump will last longer and give best performance
when properly taken care of. Proper pump care
depends on the liquid being pumped and when pump
will be used again.
After each use, flush pump with a neutralizing solution
for the liquid just pumped. ollow with a clean water
rinse. This is especially important for corrosive
chemicals.
While this flushing is not absolutely necessary for short
periods of idleness (as overnight), it is good practice to
clean the pump after each use to prevent deposits from
forming and damaging the pump. Using antifreeze not
only coats the interior of the pump with an inhibitor, but
acts as a lubricant as well, keeping valves from sticking
- and protecting against any remaining moisture
freezing in cold weather.

-7-
Recommended Shop Tools:
3/16” and 5/32” Allen wrench
7/16” Socket
Blade screwdriver
Bar clamp
High temperature wheel bearing grease
Inverted pliers or seal puller
WARNIN : Before disassembly, be sure to follow
all precautions to relieve pressure from the pump,
and properly flush the pump of all chemicals.
1. Remove pump head from motor. Pry nameplate
loose from front of pump. Locate the four socket
head cap screws inside the dry crankcase of the
pump. With a long 3/16” hex allen wrench, remove
the four cap screws. Remove pump head.
2. Disassemble pump head. With a 7/16” socket,
loosen the eight flanged nuts that hold the two body
halves together. Remove bolts and gently pry the
pump body halves apart. With a flat screwdriver,
pry the internal connecting rod and valve casings
from the body.
3. Inspection of Pump Parts
When disassembling pump, thoroughly inspect all
parts and replace if necessary, with special consid-
eration given to the following areas:
a. Cam Bearing: Rotate bearing. It should turn
smooth without a rough or loose feeling to it.
Replace if necessary. If bearing has been
flooded with solution due to failure of
diaphragm, it most likey will need to be
replaced.
b. Connecting Rod: Check clearance on the
wear surface with feeler gauge between
bearing and flat surface. It should be less than
0.010". Excessive noise and loss of
performance will occur if clearance is too great.
c. Elastomers: O-rings, U-cup, and diaphragms
should always be replaced when pump is
serviced. Elastomers take a set with age and
do not energize in a dynamic condition as new
parts will. Reusing these parts may cause leaks
or premature failure to occur. Running a
plunger pump dry for excessive amount of time
will cause the U-cup to fail due to the high heat
generated by friction on non-lubricated surfaces.
d. Valves: Inspect for pitting and general wear in the
valve assembly. Poppets wear against the valve
seat. Valves will leak if worn unevenly or pitted,
resulting in loss of performance and increased
vibration accompanied by reduced flow.
e. Carbon Plunger uide/ Brass Diaphragm
uide: Inspect guides for wear and replace if
necessary. Worn guides and spacers put
stress on U-cup or diaphragms and will cause
early failure of these parts.
f. Plunger / Diaphragm: Plungers may show
discoloration due to the solutions being
pumped. Inspect for pits, fissures & cracks.
Replace if any are found. Ceramic material
cracks from thermal shock are usually caused
by running the pump dry followed by a sudden
shock of cold solution. Inspect diaphragms on
the back side where the backing plate wears
against it. If more than 1/8” is worn off, replace
diaphragm.
g. Body and Valve Casing Polyester Polymer
Parts (PBT): Inspect parts for cracks, worn
surfaces or chemical attack.
Operation
Plunger & Diaphragm Pump Disassembly, Repair & Assembly Instructions
or infrequent use and before long periods of storage,
drain pump thoroughly. Open any drain plugs, remove
suction hose from liquid, and run pump “dry” from 0 to
30 seconds (not longer). A rust inhibitor should be
injected into the pump before both ports are plugged
and the pump is stored. Plug all ports to keep out air
until pump is used again.
Lubrication
The lubrication of this pump unit has been done at the
factory prior to shipping. No further lubrication is
required. If the pump unit is to be repaired or reworked,
see work instructions on initial lubrication.

-8-
Figure 10
1. Plunger / Connecting Rod Assembly: (Fig. 5)
Skip this step if assembly was left untouched,
otherwise assemble stainless steel washer on shoulder bolt and
slide ceramic plunger over bolt. Lubricate o-ring, and roll
it over the end of the bolt threads until tight against the plunger.
Spray Loctite activator on threads and then apply
blue Loctite to threads. (Stainless steel requires
activator for Loctite to adhere. Thread bolt into connecting rod
and tighten with 3/16" Allen wrench, while holding connecting
rod with a crescent wrench or in a vise ( ig. 6). Shoulder bolt
should be tightened to approximately 100 to 115 in-lbs.
2. Plunger uide / Vacuum Seal Assembly: (Fig. 7)
Assemble vacuum seal by lubricating o-ring with oil, then
slipping Teflon® seal ring inside o-ring. Carefully insert vacuum
seal assembly into brass plunger guide retainer at an angle and
part way in ( ig. 8). Align carbon plunger guide with the brass
retainer cup and start it into retainer. With a constant force, push
carbon guide all the way down. This will align and locate the
vacuum seal correctly against the bottom. Carbon guide should
be even with the top of the brass plunger guide retainer when
fully assembled.
3. U-Cup / Valve Casing Assembly: (Fig. 9)
Lubricate o-ring on valve with oil and push valve in casing
as shown in igure 9. Note: The cage should always be on the
upper side of the assembly. Solution enters the valve
through the stainless steel metal seat of the valve and exits
through the plastic cage. On the plunger side of the
casing, insert the U-cup with the open side facing in.
This allows the pressure of the liquid to spread the lips
of the U-Cup and engergize it to seal against the ceramic
plunger. Insert metal backup ring and then
the o-ring to finish assembly.
4. Assemble Sub-Assemblies:
Push vacuum seal/plunger guide over ceramic plunger.
Groove for o-ring on retainer should be facing outward. Next slip
valve/U-cup casing onto plunger and mate it up to the retainer
cup. Repeat for other side of plunger. Check orientation: inlet
valve side of valve casing (metal seat side of valve) towards the
bottom and the blue plastic cage side up. The connecting rod
cupped face should be orientated to face the motor pilot of the
body half ( ig. 10).
Figure 5
Figure 7
Figure 6
Figure 8
Plunger Assembly Instructions
Figure 9

-9-
Plunger Assembly Instructions
5. Final Pump Head Assembly:
Lubricate and insert o-ring No. 1720-0076 into the bottom of the
pump body’s two circular cavities ( ig.11). Use grease or
vacuum seal grease to hold o-rings in place. Carefully place
sub-assembly into pump body’s lower half. Slide or reposition
parts to get the assembly to fit into place ( ig. 12).
Extra care is usually necessary for positioning
of the brass plunger guide. Next, place lubricated
o-rings in upper body half and squeeze lower body with sub-
assembly into upper body. Some lateral pressure will have to be
applied to the two valve casings to get them to feed into the
pump body. Once the two identical body halves are together,
drop the bolts in so that the flanged nuts are
positioned on the bottom (inlet) side. Tighten nuts 35 to 40 in-
lbs. inally, lubricate connecting rod with wheel bearing grease
(three pumps of grease gun). Pump head is now ready for
assembly onto motor or gas engine.
Figure 11
Figure 12
Diaphragm Assembly Instructions
1. Diaphragm / Connecting Rod Assembly: (Fig. 13)
To assemble diaphragm / connecting rod assembly, first slide
spacer onto pilot of connecting rod. Then slide bushing onto
spacer. Be sure to orientate the bushing properly (smaller diam-
eter faces outward) when assembling this part. Thread shoulder
bolt through front diaphragm support, diaphragm, (smooth, flat
surface faces inward towards the connecting rod) backing plate,
(smooth curved surface against diaphragm) and diaphragm
clamp (grooved-side facing diaphragm). Spray Loctite activator
on threads, then apply blue Loctite to threads. inish by insert-
ing bolt into spacer and tightening shoulder screw onto connect-
ing rod with a 3/16" Allen wrench, while holding connecting rod
with a crescent wrench or in a vise ( ig 14). Shoulder bolt
should be tightened to approximately 100 to 115 in-lbs. Repeat
procedure for second half of assembly.
Note: Applying grease between the backing plate and
diaphragm will prolong the life of the diaphragms.
2. Diaphragm / Valve Casing Assembly: (Fig. 15)
Lubricate o-ring on valve with oil and push valve in casing as
shown to the lower right. Note: The cage should always be on
the upper side of the configuration. Solution enters the valve
through the stainless steel metal seat and exits through the
plastic cage. Note arrow on side of valve casing showing the
direction of flow. The valve cage can only assemble into the
valve casing from this side.
Figure 13
Figure 14
Figure 15

-10-
3. Assemble Sub-Assemblies: (Fig. 16)
Place oiled o-rings No. 1720-0076 (2) into pockets
at the bottom half of pump body. One o-ring is
placed on each side. With both hands, assemble
the two valve casing parts to the connecting rod
assembly. Orientate valve casing in the correct
position relative to the connecting rod, as shown to
the right (valve cages facing upward and connect
ing rod cupped face facing the motor pilot). Set the
assembly into the body half.
With your index fingers, align the bushing into the
groove of the body as indicated ( ig. 17). At this
point, make sure the diaphragm is properly mated
with the valve casing and diaphragm clamp. You
may need to roll or stuff the diaphragm into the
groove ( ig. 18).
Figure 16
Figure 17
Figure 18
Diaphragm Assembly Instructions

-11-
Diaphragm Assembly Instructions
4. Final Pump Head Assembly:
Lubricate and insert o-ring No. 1720-0076 into the
bottom of the pump body's two circular cavities
( ig. 11). Use grease or vacuum seal grease to
hold o-rings in place. Next, work lower body with
sub-assembly into upper body. Some lateral
pressure will need to be applied to the two valve
casings to compress the diaphragms and allow the
valve casing to feed into the upper pump body.
A bar clamp is a very helpful aid for this task ( ig. 19).
Once the two identical body halves are together,
drop the bolts in so that the flanged nuts are
positioned on the bottom (inlet) side. Tighten bolts
and nuts 35 to 40 in-lbs. inally, lubricate connect-
ing rod with wheel bearing grease (three pumps of
grease gun). (See ig. 20.) Pump head is now
ready for assembly onto motor or gas engine.
1. Shaft Eccentric and Bearing:
Be sure the correct eccentric is assembled onto
your motor. Over-sizing the eccentric may cause
damage to the motor. Check with parts breakdown
for correct sizing.
Press bearing onto shaft eccentric using an arbor
press. Assemble eccentric shaft onto motor shaft
with the flat surface aligned with the set screw.
Tighten set screw down onto the shaft using 5/32”
Allen wrench. ront face of bearing should be no
further than 1.34” (1-11/32”) distance from the
mounting face that the pump mates up with. If the
bearing distance is too great, interference can pre-
vent the motor from turning or decrease bearing
life. Next, align pump head with pilot on motor.
Check that bearing is not interferring with connect-
ing rod. Adjust eccentric shaft further back if neces-
sary. Using 1/4” hex cap screw (2220-0041) and a
long 3/16” Allen wrench, bolt pump head onto
motor. Tighten screws to approximately 35 to 40
in-lbs. If your motor has a 56C face on it, you will
need to use an adapter flange as well as a 3/32” X
3/16” rectangular key to create the flat for the set
screw to lock on.
Figure 19
Figure 20
Motor / Pump Assembly

ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
2210-0137
2250-0077
2840-0083
2102030
G40013
2000-0015
2230-0003
0550-2145
26 0551-2175
9
20
30
32
33
7
6
14
13
11
10
2
8
5
4
3
19
16
2
12
15
1
17
24
26
23
18
28
31
22
21
29
36
31
35
24
27
23
23
24
25
23
24
26
34
37
38
ITEM
NO .
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
2210-0137
2250-0077
2840-0083
2102030
G40013
2000-0015
2230-0003
0550-2145
26 0551-2175
9
20
30
32
33
7
6
14
13
11
10
2
8
5
4
3
19
16
2
12
15
1
17
24
26
23
18
28
31
22
21
29
36
31
35
24
27
23
23
24
25
23
24
26
34
37
38
9
20
30
32
33
7
6
14
13
11
10
2
8
5
4
3
19
16
2
12
15
1
17
24
26
23
18
28
31
29
36
31
35
24
27
23
23
24
25
23
24
26
34
37
38
-12-
Ref. Qty. P rt No. Description Ref. Qty. P rt No. Description
No. Req’d. No. Req’d.
12 0101-2100 M ump Body ( olyester BT) 21 2 2102030 End Cap
26 1720-0076 O-ring 22 2 G40013 End Cap Washer
31 0500-2100 Connecting Rod 23 1 2000-0015 Bearing
42 1720-0033 O-ring 24 1 2230-0003 Set Screw
52 3500-0070 Ceramic lunger (3/4” in. Dia.) 25 1 0550-2145 Shaft Eccentric (2120 - 18DC)
6 2 2270-0015 Seal Washer 26 1 0551-2175 Shaft Eccentric (2120 - 35DC, 50AC)
72 2220-0104 Shoulder Screw 27 1 0552-2190 Shaft Eccentric (Gas Engine)
82 1830-0171 Guide Retainer 28 1 2570-0025 DC Motor (20 Amp)
92 1720-0202 O-ring 29 1 2570-0026 DC Motor (36 Amp)
10 2 1440-0010 Seal Ring 30 1 2560-0013 Motor (1/2 H , 56C Frame AC, 50 Hz)
11 2 1440-0086 lunger Guide (Carbon) 30 1 2570-0027 Motor (1/2 H , 56C Frame DC, 39 Amp)
12 2 0717-2100 Valve Retainer 30 1 24878-SHU Motor (1/2 H , 56C Frame AC, 60 Hz)
13 2 2150-0091 U-Cup Seal (Viton) 31 1 2549-0052 Gas Engine (2:1 Gear Reduced)
14 2 2270-0095 U-Cup Backup Ring 32 1 1610-0061 Key
15 4 3400-0088 Valve Assembly 33 1 0706-2100A Adapter Flange (56C Motor)
16 4 1720-0007 O-ring 34 4 2210-0020 Bolts
17 4 2220-0041 Hex Head Cap Screw 35 1 0708-2100A Adapter Flange (Gas Engine)
18 8 2210-0137 Bolts 36 4 2210-0146 Bolts
19 8 2250-0077 Flanged Nuts 37 1 2000-0017 Bearing
20 1 2840-0083 Nameplate
Plunger Pump V lve Kit Engine Fl nge Mounting
No. 3430-0632 Includes: Kit No. 3430-0658 Includes:
Ref. No. Qty. Ref. No. Qty.
24 32 1
15 4 35 1
16 4 36 4
37 1
Plunger P cking Kit
No. 3430-0631 Includes:
Ref. No. Qty.
2 6
4 2
6 2
9 2
10 2
11 2
13 2
Pump He d Only No. 2120PX
Consists of P rt Numbers
1 thru 22.
Note: When ordering parts, give
quantity, part number, description
and complete model number.
Reference numbers are used
ONLY to identify parts in the
drawing and NOT to be
used as order numbers.

2150 Diaphragm Series
8
16
25
27
28
6
5
12
11
910
7
4
3
17
2
13
1
14
21
22
20
15
26
19
24
26
30
21
23
20
20
21
22
18
29
33
32
31
-13-
Ref. Qty. P rt No. Description Ref. Qty. P rt No. Description
No. Req’d. No. Req’d.
12 0101-2100 M ump Body ( olyester BT) 19 2 2102030 3/4” End Cap
24 1720-0076 O-ring 20 1 2000-0015 Bearing
31 0500-2100 Connecting Rod 21 1 2230-0003 Set Scew
42 1440-0087 Bushing 22 1 0551-2145 Motor Eccentric Bushing (1/2 H )
52 1430-0029 Spacer 23 1 0552-2145 Motor Eccentric Bushing (Gas Engine)
62 1410-0113 Backing late 24 1 2570-0026 DC Motor (36 Amp)
72 1830-0172 Diaphragm Clamp 25 1 2570-0027 Motor (1/2 H , 56C Frame DC, 39 Amp)
82 2535-0009 Diaphragm 25 1 2560-0013 Motor (1/2 H , 56C Frame AC, 50 Hz)
92 1410-0114 Front Support Washer 25 1 24878-SHU Motor (1/2 H , 56C Frame AC, 60 Hz)
10 2 2220-0104 Shoulder Screw 26 1 2549-0052 Gas Engine 5.5 H (2:1 Gear Reduced)
11 2 0718-2100 Diaphragm/Valve Casing 27 1 1610-0061 Shaft Key
12 4 3400-0168 Valve Assy. (includes 1720-0007) 28 1 0706-2100A Adapter Flange (56C Motor)
13 4 1720-0007 O-ring 29 4 2210-0020 Adapter Bolts
14 4 2220-0041 Bolts 30 1 0708-2100A Adapter Flange (Gas Engine)
15 8 2210-0137 Head Bolts 31 4 2210-0146 Hex Head Cap Screw
16 1 2840-0083 Shield and Nameplate 32 1 1520-0087 Label Bracket
17 8 2250-0077 Flanged Nuts 33 1 2000-0017 Bearing
18 2 G40013 Gasket for End Cap
Di phr gm Pump V lve Kit Engine Fl nge Mounting
No. 3430-0634 Includes: Kit No. 3430-0658 Includes:
Ref. No. Qty. Ref. No. Qty.
24 27 1
12 4 30 1
13 4 31 4
33 1
Di phr gm P cking Kit
No. 3430-0633 Includes:
Ref. No. Qty.
2 4
6 2
7 2
8 2
92
Pump He d Only No. 2150PX
Consists of P rt Numbers
1 thru 19.
Note: When ordering parts, give
quantity, part number, description
and complete model number.
Reference numbers are used
ONLY to identify parts in the
drawing and NOT to be used as
order numbers.
24
25
27
28
29
22
14
26
21
21
20
20
22
15
1
12
13
10
34
56789
2
16 17
18 19
11
20 23 31
27
30
33
21
32

Troubleshooting
Performance Data
-14-
Symptom Prob ble C use(s) Corrective Action(s)
No flow or low flow. ump not primed. Refer to riming in the Operation Section.
Air leaks in suction line. Check and reseal inlet fittings.
Blocked or clogged line strainer. Inspect strainer and clear any debris from screen.
Undersize suction line or collapsed hose. Suction line should be the same diameter as inlet
port of pump or larger.
Nozzle clogged. Clear nozzle or replace.
Low voltage at motor. Increase wire size.
Unloader or relief valve not functioning properly. Repair or replace relief valve.
ump incorrectly rebuilt. Dissassemble and rebuild per instructions.
Low pressure. Debris in valves. Remove debris. See Repair section.
Valves worn. Replace Valves. See Repair section.
Unloader or relief valve not functioning properly. Repair or replace relief valve.
ump not primed. See priming in Operation section.
ump leaking. Seals worn. Replace seals. See Repair section.
Body cracked. Replace body. See Repair section.

-15-
B
A
C
4 1/2"
9 3/4"
3/4" NPT PORTS
FLYNUT READY
E
GF
3 1/2"
3"
D
1 1/2"
2100 Outline Drawing
-15-

Hypro (1/13)
Printed in USA
375 Fifth Avenue NW •New Brighton, MN 55112 USA
Phone: [phone] •800-424-9776 •Fax: [phone]
www.hypropumps.com
Hypro/SHURflo (hereafter, “Hypro”) agricultural products are warranted to be free of defects in material and workmanship under
normal use for the time periods listed below, with proof of purchase.
- Pumps: one (1) year from the date of manufacture, or one (1) year of use. This limited warranty will not
exceed two (2) years, in any event.
- Accessories: ninety (90) days of use.
This limited warranty will not apply to products that were improperly installed, misapplied, damaged, altered, or incompatible with
fluids or components not manufactured by Hypro. All warranty considerations are governed by Hypro’s written return policy.
Hypro’s obligation under this limited warranty policy is limited to the repair or replacement of the product. All returns will be tested
per Hypro’s factory criteria. Products found not defective (under the terms of this limited warranty) are subject to charges paid by the
returnee for the testing and packaging of “tested good” non-warranty returns.
No credit or labor allowances will be given for products returned as defective. Warranty replacement will be shipped on a freight
allowed basis. Hypro reserves the right to choose the method of transportation.
This limited warranty is in lieu of all other warranties, expressed or implied, and no other person is authorized to give any other
warranty or assume obligation or liability on Hypro’s behalf. Hypro shall not be liable for any labor, damage or other expense, nor
shall Hypro be liable for any indirect, incidental or consequential damages of any kind incurred by the reason of the use or sale of
any defective product. This limited warranty covers agricultural products distributed within the United States of America. Other world
market areas should consult with the actual distributor for any deviation from this document.
Return Procedures
All products must be flushed of any chemical (ref. OSHA section 1910.1200 (d) (e) (f) (g) (h)) and hazardous chemicals must be
labeled/tagged before being shipped* to Hypro for service or warranty consideration. Hypro reserves the right to request a Material
Safety Data Sheet from the returnee for any pump/product it deems necessary. Hypro reserves the right to “disposition as scrap”
products returned which contain unknown fluids. Hypro reserves the right to charge the returnee for any and all costs incurred for
chemical testing, and proper disposal of components containing unknown fluids. Hypro requests this in order to protect the environ-
ment and personnel from the hazards of handling unknown fluids.
Be prepared to give Hypro full details of the problem, including the model number, date of purchase, and from whom you purchased
your product. Hypro may request additional information, and may require a sketch to illustrate the problem.
Contact Hypro Service Department at 800-468-3428 to receive a Return Merchandise Authorization number (RMA#).
Returns are to be shipped with the RMA number clearly marked on the outside of the package. Hypro shall not be liable for freight
damage incurred during shipping. Please package all returns carefully. All products returned for warranty work should be sent
shipping charges prepaid to:
HYPRO / PENTAIR
Attention: Service Department
375 ifth Avenue NW
New Brighton, MN 55112
or technical or application assistance, call the Hypro Technical/Application number: 800-445-8360, or send an email to:
[e-mail]. To obtain service or warranty assistance, call the Hypro Service and Warranty number: 800-468-3428;
or send a fax to the Hypro Service and Warranty FAX: [phone].
*Carriers, including U.S.P.S., airlines, UPS, ground freight, etc., require specific identification of any hazardous material being shipped. ailure to do
so may result in a substantial fine and/or prison term. Check with your shipping company for specific instructions.
Limited Warranty on Hypro/SHURflo Agricultural Pumps & Accessories
Visit www.hypropumps.com/register today to register
your product and stay up-to-date on new products
and promotional offers.
The following information is required:
Model # _______________ Serial # _______________