4X .75 HOLES EQUALLY SPACED ON A 6.00 B.C. AIR INLET 3/4" NPT 18.32 465 32.65 829 DISCHARGE PORT SERVICE & OPERATING MANUAL Original Instructions 1: PUMP SPECS 4" 150# ANSI FLANGE 8X .75 HOLES EQUALLY SPACED ON A 7.50 B.C. 19.66 499 HDB3/HDB4 18.62 473 11.00 279 Quality System 15.00 381 ISO 9001 Certified 6.26 159 SUCTION PORT 4" 150# ANSI FLANGE 8X .75 HOLES EQUALLY SPACED ON A 6.00 B.C. 1.18 30 17.50 445 8X .56 14 MOUNTING HOLE 4: AIR END AIR EXHAUST 1" NPT 8X .
Safety Information IMPORTANT WARNING When used for toxic or aggressive fluids, the pump should always be flushed clean prior to disassembly. Read the safety warnings and instructions in this manual before pump installation and start-up. Failure to comply with the recommendations stated in this manual could damage the pump and void factory warranty. Before maintenance or repair, shut off the compressed air line, bleed the pressure, and disconnect the air line from the pump.
1: PUMP SPECS Table of Contents 2: INSTAL & OP SECTION 1: PUMP SPECIFICATIONS.................1 • Explanation of Nomenclature • Performance • Materials • Dimensional Drawings SECTION 2: INSTALLATION & OPERATION.......7 • Principle of Pump Operation • Recommended Installation Guide • Troubleshooting Guide 3: EXP VIEW SECTION 3: EXPLODED VIEW..........................10 • Composite Repair Parts Drawing • Composite Repair Parts List • Material Codes 4: AIR END SECTION 4: AIR END.........................
1: PUMP SPECS Explanation of Pump Nomenclature Your Model #: __ __ Pump Series Pump Design (fill in from pump nameplate) Model #: XX HD Heavy Duty Pump Design Soilid Ball Pump Size 3 4 3" 4" Discharge Porting Position D T __ Pump Size Options and Options X XXXXXX, X Pump Series B _____ ___ __ __ __ Discharge Porting Diaphragm/ Valve Design Level Construction XX XXX X XX Diaphragm Check Valve Materials B Nitrile C FKM with PTFE GN Neoprene Backup with PTFE Overlay and PTFE C
Performance 7 CAPACITY • 0 to 260 gallons per minute (0 to 988 liters per minute) 6 AIR DISTRIBUTION VALVE • No-lube, no-stall design 5 HEAD SOLIDS-HANDLING • Up to .875 in. (22.2mm) HEADS UP TO • 125 psi or 289 ft. of water (8.8 Kg/cm2 or 88 meters) MAXIMUM OPERATING PRESSURE • 125 psi (8.6 bar) DISPLACEMENT/STROKE • 1.8 Gallon / 6.8 liter SHIPPING WEIGHT • Cast Iron 460 lbs. (207 kg) • Stainless Steel 480 lbs.
1: PUMP SPECS Dimensional Drawings HDB3 Heavy Duty Ball Valve - 3" Top Ported Dimensions in inches (metric dimensions in brackets). Dimensional Tolerance .125" (3mm). 13.50 343 1.22 31 DISCHARGE PORT 26.06 662 AIR INLET 3/4" NPT 3" 150# ANSI FLANGE 4X .75 HOLES EQUALLY SPACED ON A 6.00 B.C. SUCTION PORT 3" 150# ANSI FLANGE 4X .75 HOLES EQUALLY SPACED ON A 6.00 B.C. 32.65 829 36.40 925 19.66 499 16.25 413 18.63 473 AIR EXHAUST 1" NPT 8X .56 MOUNTING HOLE 11.00 279 15.00 381 17.
Dimensional Drawings HDB4 Heavy Duty Ball Valve - 4" Top Ported 1: PUMP SPECS Dimensions in inches (metric dimensions in brackets). Dimensional Tolerance .125" (3mm). DISCHARGE PORT 4" 150# ANSI FLANGE 8X .75 HOLES EQUALLY SPACED ON A 7.50 B.C. 19.50 495 4.22 107 26.06 662 AIR INLET 3/4" NPT SUCTION PORT 4" 150# ANSI FLANGE 8X .75 HOLES EQUALLY SPACED ON A 7.50 B.C. 32.65 829 37.15 944 19.66 499 18.63 473 16.25 413 AIR EXHAUST 1" NPT 8X .56 MOUNTING HOLE 11.00 279 15.00 381 17.
1: PUMP SPECS Dimensional Drawings HDB3 Heavy Duty Ball Valve - 3" Bottom Ported Dimensions in inches (metric dimensions in brackets). Dimensional Tolerance .125" (3mm). 26.06 662 24.07 611 AIR INLET 3/4" NPT 15.32 389 DISCHARGE PORT 3" 150# ANSI FLANGE 4X .75 HOLES EQUALLY SPACED ON A 6.00 B.C. 31.19 792 31.07 789 19.25 489 6.26 159 18.62 473 SUCTION PORT 3" 150# ANSI FLANGE 4X .75 HOLES EQUALLY SPACED ON A 6.00 B.C. 1.82 46 17.50 445 8X .56 14 MOUNTING HOLE 15.00 381 11.
Dimensional Drawings HDB4 Heavy Duty Ball Valve - 4" Bottom Ported 26.06 662 1: PUMP SPECS Dimensions in inches (metric dimensions in brackets). Dimensional Tolerance .125" (3mm). 27.07 688 AIR INLET 3/4" NPT 18.32 465 DISCHARGE PORT 4" 150# ANSI FLANGE 8X .75 HOLES EQUALLY SPACED ON A 7.50 B.C. 31.19 792 19.25 489 6.26 159 18.62 473 SUCTION PORT 4" 150# ANSI FLANGE 8X .75 HOLES EQUALLY SPACED ON A 6.00 B.C. 1.18 30 17.50 445 8X .56 14 MOUNTING HOLE 15.00 381 11.
Principle of Pump Operation Air-Operated Double Diaphragm (AODD) pumps are powered by compressed air or nitrogen. 2: INSTAL & OP The main directional (air) control valve ① distributes compressed air to an air chamber, exerting uniform pressure over the inner surface of the diaphragm ②. At the same time, the exhausting air ③ from behind the opposite diaphragm is directed through the air valve assembly(s) to an exhaust port ④.
Recommended Installation Guide Available Accessories: 1. Surge Suppressor 2. Filter/Regulator 3.
Troubleshooting Guide Symptom: Pump Cycles Once 2: INSTAL & OP Pump Will Not Operate / Cycle Pump Cycles and Will Not Prime or No Flow Pump Cycles Running Sluggish / Stalling, Flow Unsatisfactory Product Leaking Through Exhaust Premature Diaphragm Failure Unbalanced Cycling Potential Cause(s): Deadhead (system pressure meets or exceeds air supply pressure). Air valve or intermediate gaskets installed incorrectly. Bent or missing actuator plunger. Pump is over lubricated.
Composite Repair Parts Drawing BOTTOM PORTING is recommended for pumping material containing solids which could settle out in the pumping chambers. TOP PORTING is recommended if there is a possibility of entrapped air vapors inhibiting the pumping action. Convert from one configuration to the other by rotating the outer chambers as indicated and substituting the proper pump base (low base for top porting, high base for bottom porting).
3: EXP VIEW Service and Repair Kits Conversion Kits Service Kits 475.292.360 475.292.363 475.292.364 475.292.365 475.292.608 475.293.360 475.293.363 475.293.364 475.293.365 475.293.366 475.293.608 476.252.000 476.327.354 476.327.360 476.327.364 476.327.365 476.327.633 476.327.635 476.327.636 476.327.
Composite Repair Parts List Description Assembly, Main Air Valve Ball, Check Ball, Check Ball, Check Ball, Check Base, Pump (Top Ported) Base, Pump (Bottom Ported) Bearing, Sleeve Assembly, Pilot Valve Bracket, Intermediate Bumper 2 Bushing, Threaded Capscrew, Hex Hd, 5/8-11 X 2.75 Capscrew, Hex Head 1/2-13 Unc X 2.00 Capscrew, Hex Head 5/16-18 X 1 1/4 Capscrew, Hex Hd, 5/8-11 Unc X 2.25 Capscrew, Hex Hd, 3/4-10 X 2.25 Capscrew, Hex, 1/2-13 X 2.
3: EXP VIEW Material Codes 000 ����Assembly, sub-assembly; and some purchased items 010 ����Cast Iron 015 ����Ductile Iron 020 ����Ferritic Malleable Iron 080 ����Carbon Steel, AISI B-1112 110 �����Alloy Type 316 Stainless Steel 111 �����Alloy Type 316 Stainless Steel (Electro Polished) 112 �����Alloy C 113 �����Alloy Type 316 Stainless Steel (Hand Polished) 114 �����303 Stainless Steel 115 �����302/304 Stainless Steel 117 �����440-C Stainless Steel (Martensitic) 120 ����416 Stainless Steel (Wrought Marten
Air Distribution Valve Assembly 1-G 1-F 1-E 1-C 1-A 1-B 1-C 1-E 1-F 1-G 4: AIR END 1-D Air Distribution Valve Servicing See repair parts drawing, remove screws. Step 1: Remove Hex Head Cap Screws (1-G). Step 2: Remove end cap (1-F), gasket (1-E) and bumper (1-C). Step 3: Remove spool part of (1-B) (caution: do not scratch). Step 4: Press sleeve (1-B) from body (1-A). Step 5: Inspect O-Ring (1-D) and replace if necessary. Step 6: Lightly lubricate O-Rings (1-D) on sleeve (1-B).
Pilot Valve Assembly 5-A 5-D 5-B 4: AIR END 5-F 5-E 5-C Pilot Valve Servicing With Pilot Valve removed from pump. Step 1: Remove snap ring (5F). Step 2: Remove sleeve (5B), inspect O-Rings (5C), replace if required. Step 3: Remove spool (5D) from sleeve (5B), inspect O-Rings (5E), replace if required. Step 4: Lightly lubricate O-Rings (5C) and (5E). PILOT VALVE ASSEMBLY PARTS LIST Item 5 5-A 5-B 5-C 5-D 5-E 5-F Part Number 095.073.001 095.070.558 755.025.000 560.033.360 775.026.000 560.023.360 675.
Diaphragm Servicing Step 1: With manifolds and outer chambers removed, remove diaphragm assemblies from diaphragm rod. DO NOT use a pipe wrench or similar tool to remove assembly from rod. Flaws in the rod surface may damage bearings and seal. Soft jaws in a vise are recommended to prevent diaphragm rod damage. Step 1.A: NOTE: Not all inner diaphragm plates are threaded. Some models utilize a through hole in the inner diaphragm plate.
Written Warranty 5 - YEAR Limited Product Warranty Quality System ISO 9001 Certified • Environmental Management Systems ISO 14001 Certified Warren Rupp, Inc. (“Warren Rupp”) warrants to the original end-use purchaser that no product sold by Warren Rupp that bears a Warren Rupp brand shall fail under normal use and service due to a defect in material or workmanship within five years from the date of shipment from Warren Rupp’s factory.
EC Declaration of Conformity In accordance with ATEX Directive 94/9/EC, Equipment intended for use in potentially explosive environments. Manufacturer: Warren Rupp, Inc.®, A Unit of IDEX Corportion 800 North Main Street, P.O. Box 1568, Mansfield, OH 44902 USA EN 60079-25: 2004 For pumps equipped with Pulse Output ATEX Option KEMA Quality B.V.