Warren rupp SANDPIPER RHDF2 Parts list manual

rhdf2dl1-rev0413
SAFETY PRECAUTIONS
Engineering, Performance and Construciton Data............................................................................ 1
Explanation of Pump Nomenclature.................................................................................................. 2
Performance Curve ........................................................................................................................... 3
Dimensions........................................................................................................................................ 4
Important Installation Information ...................................................................................................... 5
Principle of Pump Operation.............................................................................................................. 7
Principle of AirVantage ...................................................................................................................... 7
Installation and Start-Up.................................................................................................................... 7
Air Supply .......................................................................................................................................... 7
Air Line Moisture................................................................................................................................ 7
Air Valve Lubrication.......................................................................................................................... 7
Air Inlet and Priming .......................................................................................................................... 7
Between Uses ................................................................................................................................... 7
Pump Troubleshooting....................................................................................................................... 9
AirVantage Troubleshooting ...................................................................................................... 10-11
Composite Repair Parts List ........................................................................................................... 12
Composite Repair Parts Kits ........................................................................................................... 13
Composite Repair Parts Drawing: Wetted Side............................................................................... 14
Diaphragm and Check Valve Servicing ........................................................................................... 15
Composite Repair Parts Drawing: Air Side...................................................................................... 16
Intermediate and AirVantage Sensor Servicing............................................................................... 17
Air Valve Servicing, Assembly Drawings and Parts List .................................................................. 18
Air Valve Servicing with Stroke Indicators, Assembly Drawings and Parts List .............................. 19
Pilot Valve and Actuator Plunger Servicing .................................................................................... 20
Pulse Output Kits and Drawing ....................................................................................................... 21
Composite Repair Parts Drawing - AirVantage Unit ........................................................................ 23
AirVantage Servicing - Solenoid Valve and Pressure Regulator ..................................................... 24
AirVantage Servicing - Power Generation Module .......................................................................... 25
AirVantage Servicing - Control Module ........................................................................................... 26
AirVantage Servicing - Sensor Assembly ....................................................................................... 27
AirVantage Servicing - Poppet Valve Drawing................................................................................. 28
AirVantage Servicing - Poppet Valve .............................................................................................. 29
AirVantage Servicing - Check Valve ............................................................................................... 30
Grounding the Pump ...................................................................................................................... 31
Pumping Hazardous Liquids - Shutdown Procedure ...................................................................... 32
Converting the Pump for Piping Exhaust Air ................................................................................... 32
Material Codes for the Last 3 Digits of the Part Number ................................................................ 33
CE Declaration of Conformity.......................................................................................................... 34
RHDF2
Heavy Duty Flap Valve
AirVantage Design Level 1
Table of Contents
SERVICE & OPERATING MANUAL
©Copyright 2013 Warren Rupp, Inc. All rights reserved.
Warren Rupp, Inc.® • A Unit of IDEX Corporation • 800 N. Main St., Manseld, Ohio 44902 USA
Telephone [phone] • Fax [phone] • www.warrenrupp.com
US Patent # 6,241,487
US Patent # 7,521,921 Pending

Recycling
Warren Rupp, Inc. is committed to protecting the environment and preventing pollution for the benet of our employees, as well as local and global communities, now and in the future.
Many components of SANDPIPER® Metallic AODD pumps are made of recyclable materials (see chart on page 32 for material specications). We encourage pump users to recycle worn out parts
and pumps whenever possible. Follow all applicable guidelines if hazardous material has been pumped.
Cautions - Read Operating and Safety Precautions First
This pump is pressurized
internally with air during
operation. Always make
certain that all bolts are in
good condition and that
all of the correct bolts are
reinstalled during assembly.
Before pump operation,
inspect all gasketed
fasteners for looseness
caused by gasket creep. Re-
torque loose fasteners to
prevent leakage. Follow recommended torques
stated in this manual.
When used for toxic or
aggressive uids, the pump
should always be ushed
clean prior to disassembly.
Before maintenance
or repair, shut off the
compressed air line,
bleed the pressure, and
disconnect the air line from
the pump. The discharge line may be pressurized
and must be bled of its pressure.
Before doing any
maintenance on the pump,
be certain all pressure is
completely vented from the
pump, suction, discharge,
piping, and all other openings and connections.
Be certain the air supply is locked out or made
non-operational, so that it cannot be started
while work is being done on the pump. Be certain
that approved eye protection and protective
clothing are worn at all times in the vicinity of the
pump. Failure to follow these recommendations
may result in serious injury or death.
Airborne particles and
loud noise hazards.
Wear ear and eye
protection.
In the event of diaphragm
rupture, pumped material
may enter the air end of the
pump, and be discharged
into the atmosphere. If
pumping a product which is hazardous or toxic,
the air exhaust must be piped to an appropriate
area for safe disposition.
IMPORTANT
Before installation and
start-up of the pump read
these safety warnings and
instructions in this manual
completely. It is the responsibility of the
purchaser to retain this manual for reference.
Failure to comply with the recommendations
stated in this manual will damage the pump,
and void factory warranty.
Take action to prevent static
sparking. Fire or explosion
can result, especially when
handling ammable liquids.
The pump, piping, valves,
containers or other miscellaneous equipment
must be grounded. (See page 30)
WARNING WARNING
WARNING
WARNING WARNING
WARNING
WARNING
CAUTION

rhdf2dl1sm-rev0413 Model RHDF2 Page 1
Nitrile: General purpose, oil-resistant. Shows good solvent, oil, water and hydraulic uid resistance. Should not be used with highly polar
solvents like acetone and MEK, ozone, chlorinated hydrocarbons and nitro hydrocarbons.
EPDM: Shows very good water and chemical resistance. Has poor resistance to oil and solvents, but is fair in ketones and alcohols.
Neoprene: All purpose. Resistant to vegetable oil. Generally not affected by moderate chemicals, fats, greases and many oils and solvents. Generally
attacked by strong oxidizing acids, ketones, esters, nitro hydrocarbons and chlorinated aromatic hydrocarbons.
Santoprene®::Injection molded thermoplastic elastomer with no fabric layer. Long mechanical ex life.
Excellent abrasion resistance.
Virgin PTFE: Chemically inert, virtually impervious. Very few chemicals are known to react chemically with PTFE- molten alkali metals, turbulent liquid or
gaseous uorine and a few uoro-chemicals such as chlorine triuoride or oxygen diuoride which readily liberate free uorine at elevated temperatures.
FKM (Fluorocarbon): Shows good resistance to a wide range of oils and solvents; especially all aliphatic, aromatic and halogenated hydrocarbons,
acids, animal and vegetable oils. Hot water or hot aqueous solutions (over 70°F) will attack FKM.
Polypropylene:
UHMW Polyethylene:
HYTREL®Good on acids, bases, amines and glycols at room temperature.
Materials Maximum Minimum
Quality System
ISO9001 Certied
Environmental
Management System
ISO14001 Certied
Operating Temperatures
INTAKE/DISCHARGE PIPE SIZE
2" NPT (internal)
CAPACITY
0 to 165 gallons per minute
(0 to 624 liters per minute)
AIR VALVE
No-lube, no-stall
design
SOLIDS-HANDLING
Up to 2 in. (50mm)
HEADS UP TO
125 psi or 289 ft. of water
(125 psi or 8.6 bar inlet) (8.6 bar or 88 meters)
DISPLACEMENT/STROKE
.48 Gallon / 1.81 liter
CAUTION! Operating temperature limitations are as follows:
190° F
88° C
-10° F
-23° C
280° F
138° C
-40° F
-40° C
200° F
93° C
-10° F
-23° C
275° F
135° C
-40° F
-40° C
220° F
104° C
-35° F
-37° C
350° F
177° C
-40° F
-40° C
180° F
82° C
32° F
0° C
180° F
82° C
32° F
0° C
For specic applications, always consult The Warren Rupp Chemical Resistance Chart
SANDPIPER®pumps are designed to be powered only by compressed air.
RHDF2
AirVantage
Design Level 1
Heavy Duty Flap
Air-Operated
Double Diaphragm Pump
ENGINEERING, PERFORMANCE
& CONSTRUCTION DATA
190° F
88° C
-10° F
-23° C
US Patent # 6,241,487
US Patent # 7,521,921 Pending
Maximum and Minimum Temperatures are the limits for which these
materials can be operated. Temperatures coupled with pressure affect the
longevity of diaphragm pump components. Maximum life should not be
expected at the extreme limits of the temperature ranges.

rhdf2dl1sm-rev0413 Model RHDF2 Page 2
Explanation of Pump Nomenclature, RHDF2 · Flap Valve
Santoprene is a registered tradename of Exxon Mobil Corp.
Hytrel is a registered tradename of E.I. du Pont.
Meanings of
Abbreviations:
A = Compressed Fibre DC = Die Cast PS = Plated Steel SS/I = Stainless Steel seat w/EPDM O-Ring
AL = Aluminum H = Hytrel®S = Santoprene®T = PTFE
B = Nitrile I = EPDM SS = Stainless Steel U = Urethane
CI = Cast Iron N = Neoprene V = FKM (Fluorocarbon) F = FDA Accepted White Nitrile
‡ CF-8M Stainless Steel equal to or exceeding ASTM specication A743 for corrosion resistant iron chromium, iron chromium nickel, and nickel based alloy castings for
general applications. Commonly referred to as 316 Stainless Steel in the pump industry.
Inner Flap
Type AirVantage Manifold Outer Inner Diaphragm Diaphragm Intermediate Diaphragm Valve Hard- Diaphragm Valve Sealing Shipping
Designation Options Elbow Chamber Chamber Plate Plate Housing Rod Seat ware Material Rings Wt. lbs.
DA6A S. AL AL AL PS PS AL SS SS PS N U N 107
DB6A S. AL AL AL PS PS AL SS SS PS B B B 107
DV6A S. AL AL AL PS PS AL SS SS PS V V V 107
DN6A S. AL AL AL PS PS AL SS SS PS N N N 107
DI6A S. AL AL AL PS PS AL SS SS PS I I I 107
DP6A S. AL AL AL PS PS AL SS SS/I PS S S I 107
DR6A S. AL AL AL PS PS AL SS SS PS H H N 107
DA6I S. CI CI AL PS PS AL SS SS PS N U N 150
DB6I S. CI CI AL PS PS AL SS SS PS B B B 150
DV6I S. CI CI AL PS PS AL SS SS PS V V V 150
DN6I S. CI CI V PS PS AL SS SS PS N N N 150
DI6I S. CI CI AL PS PS AL SS SS PS I I I 150
DR6I S. CI CI AL PS PS AL SS SS PS H H N 150
DP6I S. CI CI AL PS PS AL SS SS/I PS S S I 150
DA6S S. ‡SS ‡SS AL ‡SS PS AL SS SS PS N U N 157
DB6S S. ‡SS ‡SS AL ‡SS PS AL SS SS PS B B B 157
DF6S S. ‡SS ‡SS AL ‡SS PS AL SS SS PS F F F 157
DV6S S. ‡SS ‡SS AL ‡SS PS AL SS SS PS V V V 157
DN6S S. ‡SS ‡SS AL ‡SS PS AL SS SS PS N N N 157
DI6S S. ‡SS ‡SS AL ‡SS PS AL SS SS PS I I I 157
DP6S S. ‡SS ‡SS AL ‡SS PS AL SS SS/I PS S S I 157
DR6S S. ‡SS ‡SS AL ‡SS PS AL SS SS PS H H N 157
S = Self Contained
Electrical Generator
P = 100 VAC Electrical
Conneciton
To order a pump or replacement parts, rst enter the Model Number RHDF2, followed by Type Designation listed below in the far left columns.

rhdf2dl1sm-rev0413 Model RHDF2 Page 3
Performance Curve, RHDF2 Design Level 1
0 20 40 60 80 100 120 140 160 180
500400300200100
100
90
80
70
60
50
40
30
20
10
0
BAR PSI
1
2
3
4
5
6
7
0
10
(17)
20
(34)
30
(51)
40
(68)
50 (85)
60 (102)
(119)70
100 PSI (6.9 Bar)
80 PSI (5.5 Bar)
60 PSI (4.1 Bar)
40 PSI (2.8 Bar)
20 PSI (1.4 Bar)
SCFM (M3/hr)
600
U.S. Gallons per minute
Liters per minute
HEAD
Model RHDF2 Performance Curve
CAPACITY
Performace based on the following: elastomer fitted pump, flooded suction, water at ambient conditions.
The use of other materials and varying hydraulic conditions may result in deviations in excess of 5%.

rhdf2dl1sm-rev0413 Model RHDF2 Page 4
Dimensions: RHDF2
Dimensions are ± 1/8"
Figures in parenthesis = millimeters
19.87
505
21.64
550
1" NPT AIR INLET
8.48
215
20.30
OPTIONAL
VERTICAL
SUCTION
PORT
516
2.57
65
17.68
449
15.37
390
15.62
397
24.29
617
2.62
67
2.62
67
.25
6
9.81
249
SUCTION PORT
2" NPT
DISCHARGE PORT
2" NPT
3/4" NPT EXHAUST
8.88
226
11.00
279
14.00
355
10.25
260
8X
.50 [13] MTG. HOLE
BOTH SUCTION AND DISCHARGE PORTS ARE
AVAILABLE WITH 2" BSP CONNECTIONS

rhdf2dl1sm-rev0413 Model RHDF2 Page 5
Warren Rupp Tranquilizer
Limited to 125 psi
(Optional)
Flexible Connector
Pipe Connection
(Style Optional)
Shut-O Valve
Pressure Gauge
Drain Port
Muer
(Optional Piped Exhaust)
Flexible
Connection
Dessicant Dryer
(Optional)
Unregulated Air
Supply to Tranquilizer
Filter Regulator
PN: 020.107.000
Shut O
Valve
Flexible Connector
Pipe Connection
(Style Optional
Drain Port
Shut-O Valve
Vacuum
Gauge
Note: Pipe weight should not be supported
by pump connections.
Suction Port
Discharge Port
Suggested Installation Guide
Important Installation Information
Use of the standard AODD Installation Guide is recommended for pumps
tted with AirVantage technology. Install shut-off valves on both the suction and
discharge of the pump. (This will help limit the amount of product that enters the center section
of the pump in the event of a diaphragm failure.) Using shut-off valves in conjunction with a drain
port also provides a means of allowing the lines to be drained when maintenance needs to
be conducted.
WARNING
In the event of diaphragm
rupture, pumped material
may enter the air end of the
pump, and be discharged
into the atmosphere. If
pumping a product which is hazardous or toxic,
the air exhaust must be piped to an appropriate
area for safe disposition.
When the supply liquid level is above the air inlet of the pump, and a
diaphragm fails, the pumped liquid or fumes can enter the air end through
the point of failure. When a diaphragm failure is detected, it is best to close
the shut-off valves and bleed the lines of product. This will limit the ability
of the material being pumped to enter the AirVantage. Failure to do so may
result in damage to the AirVantage and air distribution components.
If a diaphragm failure has been detected in pumps
tted with AirVantage, the following procedure for
shut-down must be used:
1. Close the suction shut-off valve
(this will limit any new product from
entering the pump)
2. Close the discharge shut-off valve
(this will stop any product from
reentering the pump)
3. Close the air supply shut-off valve
4. Drain the discharge line
5. Drain the suction line
6. Perform maintenance
Caution: When performing a direct spray washdown, a
plug must be installed in place of the AirVantage mufer.
Failure to do so may damage internal components.
(See page 23)

rhdf2dl1sm-rev0413 Model RHDF2 Page 6
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rhdf2dl1sm-rev0413 Model RHDF2 Page 7
PRINCIPLE OF PUMP OPERATION
This ball valve tted pump has been equipped with IDEX’s patented AirVantage equipment. To fully understand the
operation of the AirVantage, one must rst understand the basics of Air Operated Double Diaphragm (AODD) pumps.
AODD’s are powered by compressed air. The compressed air is directed behind each of the exible diaphragms by a
Main Air Valve. Once the diaphragm has reached the end of its stroke, a Pilot Valve is mechanically actuated, sending
an air signal back to the Main Air Valve which redirects air to the opposite diaphragm. This causes the diaphragm
assemblies, which are connected by a common Diaphragm Rod, to move in a reciprocating action.
Air is directed to the inboard side of the diaphragm, which is closest to the center of the pump. This is referred to
as the air side of the diaphragm. The opposite side is commonly called the uid side. Most AODD pumps have a 1:1
ratio design. This means, when the discharge of the pump is closed completely (dead headed), the maximum pressure
the pump will create will be equal to the air pressure being applied to the pump. At this point, and only at this point, the
diaphragm will be completely balanced. The air pressure is equivalent to the uid pressure and there will be no movement
of the diaphragm. If the pump is stroking, then the system is not balanced. There will be more pressure applied to the air
side than uid pressure on the uid side.
During each stroke of the pump there are two distinct operations that occur. One diaphragm is moving away from
the center of the pump, moving uid out of the Discharge Manifold, while the other diaphragm is moving toward the
center, bringing uid into the Suction Manifold. Considering that the pump has a common suction and discharge port,
these two operations are separated from each other through a series of Check Valves.
PRINCIPLE OF AIRVANTAGE
AirVantage is a special air side device which uses equipment that can accurately monitor the operation of the pump.
Based on the monitored information, air is metered to the correct amount to perform the work required, and
NOTHING MORE.
Once the pump starts up, and the AirVantage is turned on, the LED indicator light will go through a series of patterns.
Initially the light will be solid green. This indicates the AirVantage is allowing the pump to reach a steady state. Next,
the light will pulse at a very rapid rate. This is called the learn phase. Learn is where the AirVantage monitors the pump
in non-AirVantage mode. This will set the parameters for operation in AirVantage mode. In less than one minute, the
pump will change tones. The LED indicator light will start an uneven blink when optimization has started. Optimization
will be completed once the LED light is blinking in unison with the stroke rate of the pump. All this is completed without
sacricing a signicant amount of ow.
INSTALLATION AND START-UP
The pump should be located near the product being pumped, in order to keep the suction line as short as possible.
Minimize the number of ttings between the product and the pump and maintain the line size, if possible. Better results
will always be realized if the line size of the suction line is increased by one size. It's not recommended to hook up
rigid pipe directly to the pump. Some method of expansion joint or vibration isolator should be used. A Warren Rupp
Tranquilizer® is recommended to reduce the pulsation in the ow. If the uid level is more than 10 feet (3 meters) above
the level of the pump, a pressure regulating device may need to be added to the exhaust of the pump (Consult the factory
for recommendations).
AIR SUPPLY
The air supply pressure cannot exceed 125 psi (8.6 bar). The air line and associated components (lters,
regulators, solenoid valves, etc.) should not be less than ½” (13 mm). However, 3/4" (19mm) or greater is preferred. An
air line lter-regulator is necessary for the AirVantage installation. The required component (PN: 020.107.000) is available
through the distributor. Rigid pipe should not be hooked directly to the air inlet of the AirVantage. A exible hose should be
installed to reduce the strain. Do not let the weight of the air line components be supported by the air inlet of the pump.
Failure to provide a means of supporting the weight may result in damage to the pump. If the pump will be shut down for
any extended length of time, it is recommended that the air supply to the pump should be shut off.
AIR LINE MOISTURE
Water in the compressed air supply can create problems such as icing and freezing of the exhaust air. The
formation of ice in the exhaust can cause the pump to cycle erratically, degrade efciency, or even stop the pump. Fitting
the pump with the AirVantage technology reduces the exhaust temperature. This is due to more energy being extracted
from every pulse of air. When more energy is extracted, the temperature of the air is reduced. Some method of air drying
will be necessary. Most refrigerant dryers installed on compressors can reduce the dewpoint to about 40° F. This is
normally adequate for most pumping applications. If further drying needs to occur due to internal ice build-up, a desiccant
dryer can be installed. These air line dryers can lower the dewpoint to around -40° F.
AIR VALVE LUBRICATION
The air valve and pilot valve are designed to operate without lubrication. There may be instances of personal
preference or when extremely dry air is being used (instrument quality or nitrogen) that a small amount of lubrication will
improve the life of the rubber components being used on the air side of the pump. The lubrication may be added using an
air line lubricator (¾” PN: 020.051.001 – 1” PN: 020.052.001). At the point of operation use SAE 10 weight, non detergent
oil at a maximum rate of 1 drop per hour for every 20 scfm (9.4 liters/sec) of air consumption. Consult the pump curve to
determine this value. The smallest amount needed is preferred.
AIR INLET AND PRIMING
To start the pump, make sure the AirVantage switch is in the off position. Increase the pressure until the pump starts
to cycle. The pump stroke rate should slow slightly when the pump is primed. Once the pump is fully primed, increase
the pressure at the regulator until the desired ow rate is achieved. Again, the pump curve can be used to derive this
value. If increasing the pressure to the pump does not generate a higher ow rate, then cavitation has occurred. Back the
regulator off slightly. To gain the most efciency from the pump, try to run the pump fully primed at all times.
BETWEEN USES
When the pump is being used to move materials that tend to settle out or solidify, the pump should be ushed to
prevent damage. The product that remains in the pump could dry and settle out. This could potentially cause damage
to the diaphragms and/or check valves during restart. In freezing temperatures the pump must be completely drained
between uses. Due to the addition of the new technology, it is recommended the air supply to the pump be shut off if the
pump is going to be shut down for an extended length of time.

rhdf2dl1sm-rev0413 Model RHDF2 Page 8
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rhdf2dl1sm-rev0413 Model RHDF2 Page 9
PUMP TROUBLESHOOTING
CAUTION! WHENEVER TROUBLESHOOTING OR PERFORMING ANY
REPAIRS ON ANY WARREN RUPP, INC. EQUIPMENT, ALWAYS REMOVE
THE AIR SUPPLY LINE TO THE PUMP AND WEAR PROPER PERSONAL
PROTECTIVE EQUIPMENT.
PUMP WILL NOT CYCLE
What to Check: • The system head exceeds the air supply pressure to the pump.
Corrective Action: • Increase the air inlet pressure to the pump. Most diaphragm pumps are
designed for 1:1 pressure at zero ow.
What to Check:• Check ESADS+, including pilot valve assembly and main air valve assembly.
Corrective Action: • Disassemble and inspect the main air distribution valve, pilot valve, and
pilot valve actuator pins. Check for scores, wear, or damaged o-rings. Replace parts as necessary.
Refer to the exploded view drawing and air valve section (P.18 & 20).
What to Check: • Blocked discharge line.
Corrective Action: • Check for obstruction or closed discharge line.
What to Check: • Blocked pumping chamber.
Corrective Action: • Disassemble and inspect wetted chambers of the pump. Remove or ush
any obstructions. Refer to page 14 for disassembly.
PUMP CYCLES, BUT WILL NOT FLOW OR FLOW RATE IS UNSATISFACTORY
What to Check: • Restricted or undersized air line.
Corrective Action: • Make sure there are no obstructions or restrictions in the air inlet to the
pump. Install proper size air line and/or air line equipment. Refer to air supply section (p.7) air inlet
plumbing recommendations.
What to Check: • Restricted or undersized suction piping.
Corrective Action: • Make sure there are no obstructions or restrictions in the suction line or
related suction components such as screens or strainers. Install the proper size suction line and/
or equipment. It is recommended that any suction line components and pipe size be at least the
same size as the suction line thread size to the pump. Though best results will always be realized
if the line size of the suction line is increased by one size. Refer to the installation section (p.5) for
recommended suction plumbing recommendations.
What to Check: • Blocked air exhaust mufer.
Corrective Action: • Remove mufer, clean or de-ice and reinstall.
What to Check: • Excessive Suction Lift.
Corrective Action: • For lifts exceeding 20 feet (6 meters), lling the pump chambers with liquid
will prime the pump in most cases. If not, place pump closer to uid level.
What to Check: • Suction line cavitation.
Corrective Action: • If no obstructions are in the suction line of the pump, decrease the inlet
air pressure and/or volume to the pump. This will slow down the diaphragm speed and reduce the
cavitation.
What to Check: • Partially blocked exhaust mufer.
Corrective Action: • Remove mufer and make sure that some of the material being pumped has
not migrated into the mufer element. If it has, replace the element or clean it and reinstall. If product
has made it to the mufer, then the diaphragm assembly will need to be inspected. Refer to the
Diaphragm Replacement section (p.15).
What to Check: • Suction side air leakage or air in the product.
Corrective Action: • Visually inspect all suction side gaskets, seals, as well as pipe and pipe
connections.
PUMP CYCLE SEEMS UNBALANCED OR PRODUCES EXCESSIVE VIBRATION
What to Check: • Excessive ooded suction in system.
Corrective Action: • Check height of uid above pump. For ooded conditions, exceeding 10 feet
(3 meters) of liquid, install a back pressure device in the exhaust side of the pump.
What to Check: • Worn or misaligned check valve or check valve seat.
Corrective Action: • Disassemble the wet end of the pump and inspect check valves and seats
for wear and proper seating. Replace them if necessary. Refer to the Check Valve section (p.15) for
disassembly instructions.
What to Check: • Obstructed check valves.
Corrective Action: • Disassemble the wet end of the pump and look for obstructions that may
prevent the check valve from seating on the seat. Look for damage on the valve and the seat. Replace
them as necessary. Refer to the Check Valve section for disassembly (p.15).
What to Check: • Rigid pipe connections.
Corrective Action: • Install exible pipe isolators or expansion joints between the plumbing and
the pump.
What to Check: • Pulsation in the discharge line.
Corrective Action: • Excessive pulsation in the discharge line may be corrected by installing a
Warren Rupp Tranquilizer Surge Suppressor.

rhdf2dl1sm-rev0413 Model RHDF2 Page 10
Caution! Whenever troubleshooting or performing any repairs on any
Warren Rupp, Inc. equipment, always remove air supply line to the pump
and wear proper personal protective equipment.
LED OUTPUT FOR AirVantage UNIT
STATE LED OUTPUT
Startup/Settle/Deadhead Solid
Standby/Low Flow 1 Second ON / 1 Second OFF
Learn Mode 0.1 Seconds ON / 0.1 Seconds OFF
Seek/Optimize 1 Second ON / 0.1 Seconds OFF
Steady State/Air Savings OFF / ON in rhythm with Cycle Rate of Pump
AirVantage LED DOES NOT LIGHT UP AT ALL
What to Check:
• Make sure power switch on the control module is turned on, (depressed to the left)
• Make sure air is being supplied to pump or make sure 110 VAC unit has power
being supplied to it
Corrective Action:
• Cycle power switch off/on
• Unplug patch cable and cycle power switch off/on
• Consult Factory After Sales Support team
AirVantage LED LIGHTS UP AND STAYS ON SOLID
What to Check:
• Make sure patch cable is plugged in and locked
Corrective Action:
• Consult Factory After Sales Support team
VALVE FIRES ONCE AND IMMEDIATELY RESETS
Corrective Action:
• Consult Factory After Sales Support team
AirVantage Troubleshooting
VALVE LED NEVER LEAVES SEEK MODE - AirVantage LED PULSING IN TIME TO
PUMP, BUT VALVE NOT ACTUATING AND THE PUMP IS NOT SAVING AIR
Corrective Action:
• Consult Factory After Sales Support team
UNEXPECTED OPERATING CONDITION (AIR SAVINGS OR FLOW RATE)
What to Check:
• Check for varying environmental pumping conditions (changing head or suction)
• Check ice buildup in exhaust area
• Inspect sleeve and spool set for damage
Corrective Action:
• Consult Factory After Sales Support team
PUMP CYCLING IS UNSTABLE OR ERRATIC
What to Check:
• Run pump without AirVantage and check pump operation
• Make sure pump has correct sleeve and spool set installed
• Make sure patch cable plug is connected and locked
• Make sure power wire connectors are tight
Corrective Action:
• Consult Factory After Sales Support team
PUMP RUNNING SLOWLY
What to Check:
• Run pump without AirVantage and check operation
• Cycle the power off/on to the control module to reset controller
• Check ice buildup in exhaust area
• Inspect sleeve and spool set for damage
Corrective Action:
• Consult Factory After Sales Support team
• Cycle the power switch on the control module off/on

rhdf2dl1sm-rev0413 Model RHDF2 Page 11
AirVantage Troubleshooting Continued
AirVantage RESETS AND ENTERS LEARN MODE TOO FREQUENTLY
What to Check:
• Check for excessive varying environmental pumping conditions
(changing head or suction)
• Check ice buildup in exhaust area
• Inspect sleeve and spool set for damage
• Make sure patch cable plug is connected and locked
Corrective Action:
• Consult Factory After Sales Support Team
PUMP STALLS, RESETS, LEARNS, SEEKS AND REPEATS
What to Check:
• Make sure patch cable plug is connected and locked
• Check ice buildup in exhaust area
Corrective Action:
• Consult Factory After Sales Support Team
PUMP MOVES OUT OF STEADY STATE AND NEVER
ATTEMPTS TO RELEARN (LED ON)
What to Check:
• Make sure patch cable plug is connected and locked
• Cycle the power off/on to the control module
Corrective Action:
• Consult Factory After Sales Support Team
• Cycle the power switch on the control module off/on
WHAT TO DO IN THE EVENT OF A DIAPHRAGM FAILURE
If a diaphragm failure has been detected in pumps tted with AirVantage,
see page 5 for shut-down procedure.
What to Check:
• Has product migrated to the sensor?
Corrective Action:
• If the sensor has been submerged in product, the sensor will need to be
replaced. Consult the AirVantage servicing section of the manual for detailed instructions.
What to Check:
• Has product contaminated the check valve cartridge?
Correct Action:
• If a signicant amount of product has made it into the check valve assembly, then the unit will need to
be disassembled for inspection. If the check valve assembly is damaged, then it will need to be replaced.
Consult parts list for information.
SEAL, O-RING
(Purchased Separately)
VALVE, POPPET
VALVE, SOLENOID
CAPSCREW, HEX SOC HD, 10-32 X .50
COVER
SEAL, O-RING
SEAL, O-RING
MUFFLER
SEAL, O-RING
ASSEMBLY, POWER GENERATOR
CAPSCREW, HEX SOC HD, 10-32 X 2.25
CAPSCREW, HEX SOC HD, 10-32 X 1.00
CAPSCREW, HEX SOC HD, 10-32 X .50
O-RING
O-RING
CONTROL MODULE
REGULATOR
Optional 1/4" NPT Pipe Plug (P/N 618.011.330)
Must be installed if performing direct spray
wash-down of pump

rhdf2dl1sm-rev0413 Model RHDF2 Page 12
Composite Repair Parts List
Item Part Number Description Qty
1 031.019.004 Ass’y - Air Valve 1
031.098.001 Ass’y - Air Valve (Pulse Output Application) 1
2 032.058.000 Ass’y - AirVantage 1
3 070.006.170 Bearing 2
4 095.073.001 Pilot Valve Assembly 1
5 114.032.156 F Intermediate 1
6 115.158.080 Bracket, Leg 2
7 115.159.080 Bracket, Leg 2
8 115.172.159 Bracket, Mounting, R.H. 1
9 115.173.159 Bracket, Mounting, L.H. 1
10 132.002.360 Bumper, Diaphragm Plate 2
11 135.016.162 Bushing, Threaded, W/ O-Ring 560.001.360 2
12 165.138.150 Cap, End, Sensor 1
13 170.024.330 Capscrew, Hex Hd, 7/16-14 X 1 8
14 170.026.330 Capscrew, Hex Head 3/8-16 X 3 1/2 2
15 170.031.330 Capscrew, Soc Hd, 7/16-14 x 2 1/2 4
16 170.035.330 Capscrew, Hex Hd, 7/16-14 X 2 8
17 170.045.330 Capscrew, Hex Head 5/16-18 X 1 1/4 4
18 170.052.330 Capscrew, Hex Head 3/8-16 X 2 1/2 2
19 170.060.330 Capscrew, Hex Hd, 7/16-14 X 1 1/2 4
20 170.061.330 Capscrew, Hex Head 3/8-16 X 2 16
21 170.121.330 Capscrew, Hex Head 5/16-18 X 5 1/2 4
22 171.002.330 Capscrew, Socket Head 2
171.002.110 Capscrew, Socket Head (Stainless Steel Only) 2
23 171.100.115 Capscrew, Soc Hd, 5/16-18 x 2 1/2 4
24 196.001.157 Chamber, Inner 2
25 196.002.010 NS Chamber, Outer 2
196.002.110 NS Chamber, Outer 2
196.002.157 NS Chamber, Outer 2
26 258.023.147 Cover, Sensor 1
27 286.007.354 Diaphragm 2
286.007.356 Diaphragm 2
286.007.360 Diaphragm 2
286.007.363 Diaphragm 2
286.007.364 Diaphragm 2
286.007.365 Diaphragm 2
286.007.366 Diaphragm 2
28 312.012.010 Elbow Suction 2
312.012.110 Elbow Suction 2
312.012.156 Elbow Suction 2
29 312.013.010 Elbow, Discharge 2
312.013.110 Elbow, Discharge 2
312.013.156 Elbow, Discharge 2
30 338.005.360 Flap Valve 4
338.005.363 Flap Valve 4
338.005.364 Flap Valve 4
338.005.365 Flap Valve 4
338.005.366 Flap Valve 4
338.010.354 Flap Valve 4
338.010.356 Flap Valve 4
338.010.357 Flap Valve 4
31 360.041.379 Gasket, Pilot Valve 1
32 360.048.425 Gasket, Main Air Valve 1
33 518.001.010 Manifold 2
518.001.110 Manifold 2
518.001.157 Manifold 2
Item Part Number Description Qty
34 530.041.000 Mufer 1
35 538.108.110 Nipple, Pipe 1
36 545.007.330 Nut, Hex - 7/16-14 8
37 547.002.110 Nut, Stop 8
38 560.001.360 O-Ring 2
39 560.011.360 O-Ring 2
40 560.022.360 O-Ring 2
41 560.033.360 O-Ring 2
42 560.046.360 O-Ring (Stainless Steel Units Only) 2
43 560.200.360 O-Ring 1
44 560.201.360 O-Ring 2
45 560.203.360 O-Ring 2
46 570.001.360 Pad, Hinge-Flap Valve 4
570.001.363 Pad, Hinge-Flap Valve 4
570.001.364 Pad, Hinge-Flap Valve 4
570.001.365 Pad, Hinge-Flap Valve 4
570.001.366 Pad, Hinge-Flap Valve 4
47 570.009.360 Pad, Wear 2
570.009.363 Pad, Wear 2
570.009.364 Pad, Wear 2
570.009.365 Pad, Wear 2
48 612.047.330 Plate, Inner Diaphragm 2
49 612.008.330 Plate, Outer Diaphragm 2
612.096.110 Plate, Outer Diaphragm (SST Units Only) 2
50 612.241.147 Plate, Adapter 1
51 618.003.330 Plug, Pipe, 1/4 4
52 618.003.330 Plug, Pipe, 1/4 2
618.003.110 Plug, Pipe, 1/4 (Stainless Steel Only) 2
53 620.011.114 Plunger, Actuator 2
54 670.005.110 Retainer, Flap Valve 4
55 675.013.360 Ring, Sealing 4
675.013.363 Ring, Sealing 4
675.013.364 Ring, Sealing 4
675.013.365 Ring, Sealing 4
675.013.366 Ring, Sealing 4
56 685.007.120 Rod, Diaphragm 1
57 720.004.360 Seal, U-Cup 2
58 722.070.360 Seat, Flap Valve 4
722.070.363 Seat, Flap Valve 4
722.070.364 Seat, Flap Valve 4
722.070.365 Seat, Flap Valve 4
59 724.008.000 Sensor, Feed Back 1
60 770.005.330 Spacer (Aluminum Only) 2
61 770.074.159 Spacer 4
62 807.018.110 Stud, 1/4-20 8
63 846.001.167 Probe Tip 2
64 894.014.000 Valve, Check 1
64a 031.206.000 Cartridge, Check Valve 1
65 900.005.330 Washer, Lock, 3/8 20
66 900.006.330 Washer, Lock - 7/16 (Aluminum) 16
67 901.022.330 Washer, Flat 7/16 8
68 902.003.000 Washer, Sealing 2
69 920.028.000 Cable, Patch 1
70 P126-0011 Foam Bumper, Sensor 2
71 P126-0032 Capscrew, Socket Head, 8/32 x 7/16 8

rhdf2dl1sm-rev0413 Model RHDF2 Page 13
Composite Repair Parts Kits
Available Service And Conversion Kits
Air End Kit - 476.247.162
Seals, O-rings, Gaskets, Air Valve Sleeve and Spool Set, and Pilot Valve Assembly
Wet End Kit – 476.270.356 (RHDF2, HDF2)
Hytrel Diaphragms, Flap Valves and Neoprene Hinge Pads, Wear Pads, Sealing Rings
Wet End Kit – 476.270.360 (RHDF2, HDF2)
Nitrile Diaphragms, Flap Valves, Hinge Pads, Wear Pads, and Sealing Rings
Wet End Kit – 476.270.364 (RHDF2, HDF2)
EPDM Diaphragms, Flap Valves, Hinge Pads, Wear Pads, and Sealing Rings
Wet End Kit – 476.270.365 (RHDF2, HDF2)
Neoprene Diaphragms, Flap Valves, Hinge Pads, Wear Pads, and Sealing Rings
Wet End Kit – 476.270.632 (RHDF2, HDF2)
Neoprene Diaphragms, Hinge Pads, Wear Pads, and Sealing Rings, and Hytrel Flap Valves
Wet End Kit – 476.270.643 (RHDF2, HDF2)
Santoprene Diaphragms, Flap Valves and EPDM Hinge Pads, Wear Pads, Sealing Rings
Sensor Kit - 476.304.000
(Sensor, Probe Tips and O-rings)
Poppet Valve Kit – 476.271.000
(Poppet Valve Assembly, O-ring)
Poppet Valve Assembly Kit – 476.272.000
(Poppet Valve Assembly, O-ring, Regulator and Solenoid Valve)
Cover Kit – 476.273.000
(Enclosures, Hardware and O-rings)
Control Module Kit – 476.298.000 (Power Gen AirVantage Only)
(Control Module Assembly, Gaskets, Hardware and O-rings)
Control Module Kit – 476.299.000 (Power Supply AirVantage Only)
(Control Module Assembly, Gaskets, Hardware and O-rings)
Power Gen Kit – 476.278.000 (Power Gen AirVantage Only)
(Power Gen, Gasket, Hardware and O-ring)
Power Supply Kit – 476.279.000 (Power Supply AirVantage Only)
(Power Supply, Gasket, Hardware and O-ring
Seal Kit – 476.280.000
O-rings and Gaskets
Probe Tip Kit – 476.283.000
(Probe Tips and O-rings)
Midsection Upgrade Kit – 475.XXX.000 Consult Factory
(Replaces S20 Metallic Midsection with AirVantage Components)
Electronic Leak Detector Kits
032.037.000 100-120/220-240 VAC
032.045.000 12-32 VDC
RING, SEALING
PAD, HINGE
FLAP VALVE
DIAPHRAGM
PAD, WEAR
WETTED END KIT
GASKET, AIR VALVE
BUMBER, AIR VALVE
GASKET, MAIN AIR VALVE
PILOT VALVE
PLUNGER, ACTUATOR
BUSHING
SEAL, U-CUP
O-RING
O-RING
GASKET, PILOT VAVLVE
AIR END KIT

rhdf2dl1sm-rev0413 Model RHDF2 Page 14
20
18
55
33
37
54
46
58
30
54 37
58 30 46
60 65 14
55
15
62
62
16
7
61
21
2
55
65
65 20
25
29
28
36
65
69
34
52
52
66
8
9
39
43
23
64
67
Composite Repair Parts Drawing: Wetted Side
Note: Refer to Composite Repair Parts List
on page 12 for part numbers

rhdf2dl1sm-rev0413 Model RHDF2 Page 15
Read these instructions
completely, before
installation and start-up.
It is the responsibility of
the purchaser to retain
this manual for reference. Failure to
comply with the recommendations stated
in this manual will damage the pump, and
void factory warranty.
IMPORTANT
FLAP VALVE SERVICING
Valve inspection requires removal of 3/8" hex nuts and elbows. When the top suction elbows are
removed, the valve and seat are connected as an assembly. When the bottom discharge elbows are
removed, the valve and seat stay with the outer chamber. Visual inspection and cleaning is possible. If
parts are to be replaced, remove the self-locking nuts and all parts are accessible.
DIAPHRAGM SERVICING
Diaphragms can be inspected or the diaphragm assembly removed without removing the suction and
discharge anges. Remove (8) nuts around the chamber ange, and the housing assembly will pull
off. Flap valves can be inspected for proper seating at this point as well as the diaphragm. Use care to
keep foreign matter from behind the diaphragm. The opposite diaphragm may be inspected by the same
procedure. If either diaphragm has to be replaced, follow closely these steps: Pull the outer diameter
of one diaphragm off the (8) capscrews. NOTE: One side only! On the free diaphragm assembly, use
a 3/8" allen wrench to turn the assembly (diaphragm, plates and screw) loose from the shaft. Once the
assembly has turned, it will turn out by hand by use of the diaphragm. Now the opposite diaphragm
assembly and the drive shaft will pull free from the capscrews and pump intermediate assembly. The
interior components consisting of sleeve bearings, rod seals, and pilot valve actuator bushings are now
accessible for service if required. Hold the shaft in a clamping device making sure to protect surface of
shaft so as not to scratch or mar it in any way. The diaphragm assembly will turn loose. To disassemble
the components, turn a 1/4"-20 capscrew by hand into the tapped hole in the inner plate. This keeps the
plate from turning while the socket head capscrew is removed. To do this, place assembly in a vise so
the two protruding ends of screws are loose in the vise jaws (about 3/4" apart). Turn the center screw
loose from the back plate and the assembly will come apart.
“AirVantage CAUTION” – If product is observed on the air side of the diaphragm, refer to the “Air-
Vantage Servicing” section of the service manual.
REASSEMBLY
All procedures for reassembling the pump are the reverse of the previous
instructions with further instructions as shown:
The diaphragm assemblies are to be installed with the natural bulge outward or toward the head
of the center screw. Make sure both plates are installed with outer radii against the diaphragm. After
all components are in position in a vise and hand tight, set a torque wrench for 480 inch pounds (40 ft.
pounds) (54.23 Newton
meters) or, 600 inch pounds (50 ft. pounds) (67.79 Newton meters) for Santoprene, using a (3/8") allen
head socket. After each diaphragm sub assembly has been
completed, thread one assembly into the shaft (held near the middle in a vise having soft jaws to protect
the nish) making sure the stainless steel washer is in place on the capscrew.
Make sure 1/4"-20 mounting screw has been removed and that the bumper (Item #19 on drawing) is
in place in the shaft.
Install this sub assembly into the pump and secure by placing the outer chamber housing and
capscrews on the end with the diaphragm. This will hold the assembly in place while the opposite side is
installed. Make sure the last diaphragm assembly is torqued to 30 ft. lbs. (40.67 Newton meters) before
placing the outer diaphragm over the capscrews. If the holes in the diaphragm ange do not line up with
the holes in the chamber ange, turn the diaphragm assembly in the direction of tightening to align the
holes so that the capscrews can be inserted. This nal torquing of the last diaphragm assembly will lock
the two diaphragm assemblies together. Place
remaining outer chamber on the open end and tighten down the securing nuts
gradually and evenly on both sides.
Caution should be used while reassembling Flap valves. The valves are designed for some preload
over the retainer hinge pad. This is done to insure proper face contact with the seat. After all parts are
in place, tighten the lock nuts down on the assembly to the point where visual inspection shows that
seat and valve face mate without gap. This is important for dry prime. However, after priming action has
started, valves will function due to differential pressure without concern or trouble.
PILOT VALVE
The pilot valve assembly is accessed by removing the main air distribution valve body from the
pump and lifting the pilot valve body out of the intermediate housing.
Most problems with the pilot valve can be corrected by replacing the o-rings. Always grease the
spool prior to inserting it into the sleeve. If the sleeve is removed from the body, reinsertion must be
at the chamfered side. Grease the o-rings to slide the sleeve into the valve body. Securely insert the
retaining ring around the sleeve. When reinserting the pilot valve, push both plungers (located inside the
intermediate bracket) out of the path of the pilot valve spool ends to avoid damage.
PILOT VALVE ACTUATOR
Bushings for the pilot valve actuators are threaded into the intermediate bracket from the outside.
The plunger may be removed for inspection or replacement. First remove the air distribution valve body
and the pilot valve body from the pump. The plungers can be located by looking into the intermediate. It
may be necessary to use a ne piece of wire to pull them out. The bushing can be turned out through the
inner chamber by removing the outer chamber assembly. Replace the bushings if pins
have bent.

rhdf2dl1sm-rev0413 Model RHDF2 Page 16
Composite Repair Parts Drawing: Air Side
Note: Refer to Composite Parts List on
page 12 for part numbers
66
13
56
40
24
27
48
68
10
51
11
38
53
57
1
32
4
31
47
49
22
17 44 63
42
41
70
59
26
71
45 12 71

rhdf2dl1sm-rev0413 Model RHDF2 Page 17
Page 17
PROBE TIP
O-RING
SENSOR, FEED BACK
WASHER, SEALING
PLATE, DIAPHRAGM
DIAPHRAGM
PAD, WEAR
PLATE,
OUTER DIAPHRAGM
CAPSCREW
SENSOR COVER
CAPSCREW
END CAP
FEED BACK SENSOR
O-RING
CAPSCREW
INTERMEDIATE
JAM NUT
O-RING
FOAM BUMPER
BEARING
SEAL
Note: Refer to Composite Repair Parts
List on page 12 for part numbers
A
BRACKET, INTERMEDIATE, ASSEMBLY SENSOR, FEEDBACK
NUT
SEAL
DIAPHRAGM
PLATE,
OUTER DIAPHRAGM
PLATE,
INNER DIAPHRAGM
PROBE TIP
O-RING
SENSOR, FEEDBACK
BUMPER
DETAIL A
FLAT EDGE
Step#8: Reinstallation
• Slide the new sensor assembly in the intermediate.
• “AirVantageCAUTION”–Makesurethecableassemblytsintothegroovemachinedinthe
intermediate. Failure to do so may damage the cable during assembly.
• Feed the connector through the hole in the intermediate, making sure the gasket is on the connector
before installation. The at edge on the connector should line up with the inside of the intermediate.
Install the nut and hand tighten it using a 13/16" socket.
• The inner chambers and gaskets can now be reinstalled. Use blue thread locker on the inner chamber
bolts and torque them to 300 in-lbs.
• Refer to the “Diaphragm Servicing” section of the manual to nish the diaphragm installation procedure.
INTERMEDIATE AND AirVantage SENSOR SERVICING
• To service the intermediate and AirVantage sensor, rst shut off and bleed the air being supplied to the
pump. For safety purposes, the air supply line should be disconnected from the pump. Shut off both the
suction and discharge lines to the pump. Consult the “Composite Repair Parts Drawing”.
Step #1: Remove the Patch Cable
• Twist the ribbed portion of the patch cable connector in a counterclockwise direction, until it unthreads
from the connector. The cable can either be removed from the intermediate or from the control module.
Step #2: Remove the AirVantage from the Pump
• Use a ½” socket and remove the four 5/16-18 x 5 ½cap screws that hold the AirVantage to the pump.
Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage
is removed from the pump, set the unit down on the plastic cover located on the bottom.
Step #3: Remove the Manifolds, Chambers, and Diaphragms (See Diaphragm
Servicing Section)
Step #4: Remove the Diaphragm Assemblies
• Refer to the “Diaphragm Servicing” section of the manual to remove diaphragm assembly from the
pump.
• “AirVantage CAUTION” – When the diaphragm assembly is removed, watch for the brass probe
tips located on the end of the sensor rod. There is one brass probe tip and one o-ring per
side. Inspect the probe tips and o-rings for wear. For every diaphragm service, these parts should be
replaced and are available in kit form. Consult the “Composite Repair Parts Drawing” for part numbers
and quantities.
• Note: For AirVantage sensor servicing, refer to page 27.
Step #5: Remove the End Caps
• Use an Allen wrench and remove the two screws from the End Caps on either side of the intermediate.
• Use two small at-head screw drivers to simultaneously pry the End Caps up at the ends.
• “AirVantage CAUTION” – Remove the End Caps from the intermediate with caution, taking care
not to damage the sensor. Inspect the gaskets and u-cup seals under each End Cap and replace
them as necessary.
Step #6: Accessing the Actuator Plunger Bushings and O-rings
• The actuator plunger pin bushings and o-rings can now be accessed. If it is determined that these parts
need to be replaced, use a small screwdriver and remove the retaining rings.
• NOTE: It is recommended that new retaining rings be installed after disassembly. The bushing
and o-ring can now be removed and inspected.
Step #7: Accessing the AirVantage Sensor
• If the sensor needs to be replaced, use a 13/16” socket and remove the plastic nut securing the
connector to the intermediate. Slide the connector out of the hole, taking care not to lose/misplace the
gasket on the connector.
• The sensor can now be removed from the intermediate assembly.

rhdf2dl1sm-rev0413 Model RHDF2 Page 18
Air Valve Servicing, Assembly Drawing & Parts List
Read these instructions
completely, before
installation and
start-up. It is the
responsibility of the
purchaser to retain this
manual for reference. Failure to comply
with the recommendations stated in this
manual will damage the pump, and void
factory warranty.
IMPORTANT
AIR VALVE ASSEMBLY PARTS LIST
Item Part Number Description Qty
1 031-183-003 Air Valve Assembly 1
1-A 031.012.162 Sleeve and Spool Set 1
1-B 095.043.156 Description 1
1-C 132-014.358 Bumper, Air Valve 2
1-D 165.011.157 Cap, End 2
1-E 170.032.330 Capscrew, Hex Head 1/4-20 x 3/4 8
1-F 360.010.427 Body, Air Valve 2
1-F 560.020.360 O-ring 6
1.B
1.A1.A
1.C
1.F
1.D
1.E
1.F
1.C
1.F
1.D
Note to Trent: Do not paste this table in S/M. Only use to modify on
on page 18
Page 18
ITEM
NO.
PART NUMBER DESCRIPTION QTY.
1.A
031.012.162
SLEEVE & SPOOL SET 1
1.B 095.043.156 DESCRIPTION 1
1.C 132.014.358 BUMBER, AIR VALVE 2
1.D 165.011.157 CAP, END 2
1.E 170.032.330 CAPSCREW, HEX HEAD 1/4-20 X 3/4 8
1.F 360.010.427 BODY, AIR VALVE 2
1.F 560.020.360 O-RING 6
AIR DISTRIBUTION VALVE SERVICING
STEP #1: Remove Air Valve
The main air valve sleeve and spool set is located in the valve body mounted on the pump with four
hex head cap-screws. The valve body assembly is removed from the pump by removing these four hex
head cap-screws.
STEP #2: Disassembly of the Air Valve
With the valve body assembly off the pump, access to the sleeve and spool set is made by removing four
hex head cap-screws (each end) on the end caps of the valve body assembly.
With the end caps removed, slide the spool back and forth in the sleeve. The spool is closely sized
to the sleeve and must move freely to allow for proper pump operation. An accumulation of oil, dirt or other
contaminants from the pump’s air supply, or from a failed diaphragm, may prevent the spool from moving
freely. This can cause the spool to stick in a position that prevents the pump from operating. If this is the
case, the sleeve and spool set should be removed from the valve body for cleaning and further inspection.
Remove the spool from the sleeve.
Using an arbor press or bench vise (with an improvised mandrel), press the sleeve from the valve
body. Take care not to damage the sleeve.
At this point, inspect the o-rings on the sleeve for nicks, tears or abrasions. Damage of this sort could
happen during assembly or servicing. A sheared or cut o-ring can allow the pump’s compressed air supply
to leak or bypass within the air valve assembly, causing the pump to leak compressed air from the pump
air exhaust or not cycle properly. This is most noticeable at pump dead head or high discharge pressure
conditions.
Replace any of these o-rings as required or set up a routine, preventive maintenance schedule to
do so on a regular basis. This practice should include cleaning the spool and sleeve components with a
safety solvent or equivalent, inspecting for signs of wear or damage, and replacing worn components.
Reassembly of the Air Valve
To re-install the sleeve and spool set, lightly lubricate the o-rings on the sleeve with an o-ring
assembly lubricant or lightweight oil (such as 10 wt. air line lubricant).
Re-install one end cap, gasket and bumper on the valve body.
Using the arbor press or bench vise that was used in disassembly, carefully press the sleeve back
into the valve body, without shearing the o-rings. You may have to clean the surfaces of the valve body
where the end caps mount. Material may remain from the old gasket. Old material not cleaned from this
area may cause air leakage after reassembly.
Take care that the bumper stays in place allowing the sleeve to press in all the way.
Reinstall the spool, opposite end cap, gasket and bumper on the valve body.
After inspecting and cleaning the gasket surfaces on the valve body and intermediate, reinstall the
valve body on the pump using new gaskets.
Tighten the four hex head cap-screws evenly and in an alternating cross pattern.