Product Manual

Operating Instructions and Parts Manual 2D AND 3D Series
4
Operation
Operate the
diaphragm pump
in an upright
position only.
1. This diaphragm pump is capable of
priming "dry" up to fifteen feet; it will
prime much faster when it is filled
with clean water through priming cap
(Ref. No. W6). Primed, it can lift to
25 feet.
2. Activate unit following engine or air
motor manual or turning unit on if
electrical.
Do not control
discharge
capacity with a
valve or similar device.
CLEARING JAM-UP
If large solids or an accumulation of
sand or other sediment becomes lodged
in the pump well (Ref. No. A3)
preventing the plunger arm (Ref. No.
A2) from making a full stroke, the pump
will either stall or the crank (Ref. No. P5)
will slip on the output shaft (Ref. No.
G8). The pump is designed to react this
way to prevent severe internal damage.
If such a jam-up does occur, the pump
should be thoroughly cleaned as
described in "If Pump Stalls" shown
below. Refer to parts list and illustration
for parts identification.
If pump has
stopped or stalled
for any unknown reason, clean out
pump cavity thoroughly. Failure to
comply with the "caution" could
result in damage to crank (Ref. No.
P5/P9), plunger arm (Ref. No. P1) or
other parts of assembly.
1. IF PUMP STALLS:
a. Remove handle (Ref. No.
A35).
b. Remove four bolts (Ref. No. A9
& A10).
c. Clean obstruction and all debris
from pump well (Ref. No. A3).
d. Reassemble pump in reverse
order of disassembly and return
to service.
2. IF PLUNGER ARM (Ref. No. P1)
SEIZES AND GEAR BOX OUTPUT
SHAFT (Ref. No. G8) TURNS IN
CRANK (Ref. No. P5):
a. Remove sheet metal guard (Ref.
No. A4) by loosening hand knob
screws (Ref. No. A5).
b. Disassemble pump and clean as
described in steps (a) through
(d) listed for stalled engine
jam-up.
c. Torque the crank lock screw
(Ref. No. P6) to 70 foot
pounds with an appropriate
torque wrench (see Figure 3).
Figure 3
d. Reassemble the pump in
reverse order of disassembly
and return to service.
Pump jamming
with an over-
torqued lock
screw may cause internal damage.
Under torquing may allow the
output shaft to spin and wear parts
necessitating replacement.
MAINTENANCE
Make certain that
unit is
disconnected from power source
before attempting to service or
remove any component.
1. Check gear box oi level every 20
hours of operation or at least
once a week; more often if any
leakage is detected around the
gear box. Change gearbox oil
after the first 40 hours of
operation. Fill to the oil level plug.
Change gearbox oil every 350
hours of operation.
2. The plunger bearing (Ref. No.
P3) must be greased (any
automotive grease) after every 8
hours of use. This is done by
rotating plunger bearing to the 12
o’clock position. At this point,
grease fitting will be visible
through hole in guard (Ref. No.
A4). Bearing may be cleaned and
kept well lubricated by pumping
grease slowly into fitting until new
grease oozes out between
bearing and journal.
3. During freezing weather, be sure
to drain the pump when it is not
running. Remove discharge hose
and tip unit towards discharge
side.
4. Keep pump clean. After use with
liquids containing foreign
materials, flush with clean water.
REPLACEMENT OF FLAPPER
VALVES (Ref. No. W15)
1. Remove two bolts (Ref. No. W3)
and remove suction priming
chamber (Ref. No. W2). Replace
flapper (Ref. No. W15) on flapper
pin to locate on priming chamber.
2. Remove two bolts (Ref. No. W8)
and remove discharge plate (Ref.
No. W7). Replace flapper valve on
flapper pin to locate valve on pump
well (Ref. No. W1).
REPLACEMENT OF DIAPHRAGM
(Ref. No. P17)
1. Remove sheet metal guard (Ref.
No. A4) by loosening hand knob
screws (Ref. No. A5).
2. Rotate pump until plunger arm
(Ref. No. A2) is in the down
position.
3. Remove handle (Ref. No.
A35).
4. Remove pump well (Ref. No. A3)
by removing screws, (Ref. No.
A9/A10).
5. Remove diaphragm by removing
three nuts (Ref. No. P12) from
bolts (Ref. No. P11).
6. Replace diaphragm and reverse
steps 1 through 5 for reassembly.
GEAR BOX OVERHAULING
A completely assembled gear box is
available as a replacement part (Ref.
No. G28).
DISASSEMBLY
1. Remove diaphragm (Ref. No. P13)
as described in "Replacement of
Diaphragm".
2. Remove crank (Ref. No. P5) by
removing machine screw (Ref. No.
P6). Use screwdriver in slot of
crank to release clamp on output
shaft (Ref. No. G8).
3. Drain oil from gear box by
removing drain plug (Ref. No. G4).
4. Remove driver (Ref. Nos.
A28/A32) from adapter (Ref. No.
G26) by removing four bolts (Ref.
No. A27) plus 4 additional bolts
(Ref. No. A29) from engine mount
bracket (Ref. No. A16) for gas
driver models. Slide driver back
from adapter until driver shaft
disengages pinion (Ref. No. G20).
5. Remove adapter by removing four
bolts (Ref. No. G27).
6. Remove gear box from pump base
(Ref. No. A8) by removing four
bolts (Ref. No. A9 & A10).
7. Remove pinion/bearing assembly
(Ref. Nos. G15, G24, G20, G16)