II 2GD T5
SERVICE & OPERATING MANUAL
See pages 2, 16 & 17
for ATEX ratings
Model MHDF1 Type 1
Original Instructions
Mod e l MHDF25 Typ e 1
Table of Contents
Engineering Data, Temperature Limitations & Performance Curve ....................... 1
Explanation of Pump Nomenclature ...................................................................... 2
Dimensions ............................................................................................................ 3
Principle of Operation ............................................................................................ 4
Installation and Start-Up ........................................................................................ 4
Air Supply .............................................................................................................. 4
Installation Guide ................................................................................................... 5
Air Inlet & Priming .................................................................................................. 6
Air Exhaust ............................................................................................................ 6
Between Uses ....................................................................................................... 6
Flap Valve Servicing .............................................................................................. 6
Diaphragm Servicing ............................................................................................. 6
Air Valve Lubrication .............................................................................................. 7
Recommended Accessories .................................................................................. 7
ESADS+Plus
®
:
Externally Serviceable Air Distribution System ................................ 7
Pilot Valve .............................................................................................................. 8
Pilot Valve Actuator ................................................................................................8
Service Instructions: Troubleshooting ................................................................... 8
Warranty ................................................................................................................ 8
Important Safety Information ................................................................................. 9
Recycling ............................................................................................................... 9
Grounding The Pump .......................................................................................... 10
Material Codes .................................................................................................... 11
Composite Repair Parts List ...........................................................................12-13
Composite Repair Drawing.................................................................................. 14
CE Declaration of Conformity - Machinery .......................................................... 15
CE Declaration fo Conformity - ATEX .................................................................. 16
Explanation of ATEX Certication ........................................................................ 17
Warren Rupp, Inc. • A Unit of IDEX Corporation • 800 N. Main St., Manseld, Ohio 44902 USA
Telephone (419) 524-8388 • Fax (419) 522-7867 • www.warrenrupp.com
mhdf1dl1sm-rev0711
©Copyright 2010 Warren Rupp, Inc. All rights reserved.
II 2GD T5
Quality System
ISO9001 Certied
Environmental
Management System
ISO14001 Certied
See pages 2, 16 & 17
for ATEX ratings
MHDF1 Type 1
MHDF25 Type 1
Heavy Duty
Flap Valve
Air-Operated
Double Diaphragm Pump
ENGINEERING, PERFORMANCE
& CONSTRUCTION DATA
INTAKE/DISCHARGE PIPE SIZE
MHDF1: 1” NPT(F)
MHDF25: 1” BSP Tapered
PSI
BAR
7
100
10(17)
100 PSI
(6.8 Bar)
6
80
80 PSI
60
40
(5.44 Bar)
60 PSI
(4.08 Bar)
40 PSI
(2.72 Bar)
5
4
HEAD
3
2
CAPACITY
0 to 70 gallons per minute
(0 to 265 liters per minute)
AIR CONSUMPTION
SCFM (M3/hr)
20(34)
30(51)
AIR VALVE
No-lube, no-stall
design
40(68)
SOLIDS-HANDLING
1” (25.4mm)
MODEL HDF1 Performance Curve
water at ambient temperature. Average displacement per pump stroke: .10 Gallons (.38 Liters).
The use of other materials and varying hydraulic conditions may result in deviations in excess of 5%.
Performance based on the following: elastomer fitted pump, flooded suction,
50(85)
HEADS UP TO
125 psi or 289 ft. of water
2
(8.8 Kg/cm
or 88 meters)
DISPLACEMENT/STROKE
.10 Gallon / .38 liter
20
20 PSI Air Inlet Pressure
1
0
(1.36 Bar)
0
0 10 20 30 40 50 60 70 80
U.S. Gallons per minute
0 100755025 150125 200175 225 250 275 275
Liters per minute
CAPACITY
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 1
II 2GD T5
Explanation of Pump Nomenclature, MHDF1 & MHDF25
To order a pump or replacement parts, first enter the Model Number MHDF1, or MHDF25, followed by the Type Designation listed below in the far left column.
Type Manifold & Outer Inner Outer Inner Intermediate Diaphragm Valve Hard- Diaphragm Flap Seat/ Air Air Shipping
Elbow Chamber Chamber Diaphragm Diaphragm Housing Rod Seat ware Valve Manifold Valve Valve Wt. (lbs)
Plate Plate Material Seal Cap
DB1A. 356-T6AL 356-T6AL AL380DC AL380DC PS AL380DC 416SS SS PS B B B PE AL380DC 48
DI1A. 356-T6AL 356-T6AL AL380DC AL380DC PS AL380DC 416SS SS PS I I I PE AL380DC 48
DN1A. 356-T6AL 356-T6AL AL380DC AL380DC PS AL380DC 416SS SS PS N N N PE AL380DC 48
DV1A. 356-T6AL 356-T6AL AL380DC AL380DC PS AL380DC 416SS SS PS V V V PE AL380DC 48
DP1A. 356-T6AL 356-T6AL AL380DC AL380DC PS AL380DC 416SS SS PS S S I PE AL380DC 48
DR1A. 356-T6AL 356-T6AL AL380DC AL380DC PS AL380DC 416SS SS PS H H N PE AL380DC 48
DA1A. 356-T6AL 356-T6AL AL380DC AL380DC PS AL380DC 416SS SS PS N U N PE AL380DC 48
DB1I. CI CI AL380DC AL380DC PS AL380DC 416SS SS PS B B B PE AL380DC 61
DI1I. CI CI AL380DC AL380DC PS AL380DC 416SS SS PS I I I PE AL380DC 61
DN1I. CI CI AL380DC AL380DC PS AL380DC 416SS SS PS N N N PE AL380DC 61
DV1I. CI CI AL380DC AL380DC PS AL380DC 416SS SS PS V V V PE AL380DC 61
DP1I. CI CI AL380DC AL380DC PS AL380DC 416SS SS PS S S I PE AL380DC 61
DR1I. CI CI AL380DC AL380DC PS AL380DC 416SS SS PS H H N PE AL380DC 61
DA1I. CI CI AL380DC AL380DC PS AL380DC 416SS SS PS N U N PE AL380DC 61
DB1S. SS SS AL380DC AL380DC PS AL380DC 416SS SS PS B B B PE AL380DC 64
DI1S. SS SS AL380DC AL380DC PS AL380DC 416SS SS PS I I I PE AL380DC 64
DN1S. SS SS AL380DC AL380DC PS AL380DC 416SS SS PS N N N PE AL380DC 64
DV1S. SS SS AL380DC AL380DC PS AL380DC 416SS SS PS V V V PE AL380DC 64
DP1S. SS SS AL380DC AL380DC PS AL380DC 416SS SS PS S S I PE AL380DC 64
DR1S. SS SS AL380DC AL380DC PS AL380DC 416SS SS PS H H N PE AL380DC 64
DA1S. SS SS AL380DC AL380DC PS AL380DC 416SS SS PS N U N PE AL380DC 64
DB1II. CI CI CI CI PS CI 416SS SS PS B B B PE PE 76
DI1II. CI CI CI CI PS CI 416SS SS PS I I I PE PE 76
DN1II. CI CI CI CI PS CI 416SS SS PS N N N PE PE 76
DV1II. CI CI CI CI PS CI 416SS SS PS V V V PE PE 76
DP1II. CI CI CI CI PS CI 416SS SS PS S S I PE PE 76
DR1II. CI CI CI CI PS CI 416SS SS PS H H N PE PE 76
DA1II. CI CI CI CI PS CI 416SS SS PS N U N PE PE 76
DB1SI. SS SS CI CI PS CI 416SS SS PS B B B PE PE 79
DI1SI. SS SS CI CI PS CI 416SS SS PS I I I PE PE 79
DN1SI. SS SS CI CI PS CI 416SS SS PS N N N PE PE 79
DV1SI. SS SS CI CI PS CI 416SS SS PS V V V PE PE 79
DP1SI. SS SS CI CI PS CI 416SS SS PS S S I PE PE 79
DR1SI. SS SS CI CI PS CI 416SS SS PS H H N PE PE 79
DA1SI. SS SS CI CI PS CI 416SS SS PS N U N PE PE 79
Meaning of Abbreviations:
AL = Aluminum
B = Nitrile
CI = Cast Iron
DC = Die Cast
H = Hytrel
I = EPDM
N = Neoprene
PE = Conductive HDPE
PS = Plated Steel
S = Sanotprene
SS = Stainless Steel
U = Urethane
V = FKM
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.
Materials
Nitrile/FDA White Nitrile General purpose, oil-resistant. Shows good solvent, oil,
water and hydraulic fluid 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 oils. 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.
®
Good on acids, bases, amines and glycols at room temperature.
HYTREL
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.
Shows good resistance to abrasives. Has poor resistance to most
Urethane
solvents and oils.
®
Santoprene
Long mechanical flex life. Excellent abrasion resistance.
CF-8M Stainless Steel equal to or exceeding ASTM specification 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.
For specific applications, always consult “Chemical Resistance Chart" Technical Bulletin
Injection molded thermoplastic elastomer with no fabric layer.
II 1 G c T5
II 3/1 G c T5
II 1 D c T100oC
I M1 c
Models equipped with Cast Iron or Stainless
Steel wetted parts and Cast Iron midsection
parts. See page 17 for ATEX Explanation of
EC-Type Certicate.
II 2 G c T5
II 3/2 G c T5
II 2 D c T100oC
All models, including pumps equipped with Aluminum
wetted and midsection parts.
See page 17 for ATEX Explanation of Type Examination
Certicate.
Operating Temperatures
Maximum
190°F
88°C
280°F
138°C
200°F
93°C
220°F
104°C
350°F
177°C
150°F
66°C
275°F
135°C
I M2 c
Minimum
-10°F
-23°C
-40°F
-40°C
-10°F
-23°C
-20°F
-29°C
-40°F
-40°C
32°F
0°C
-40°F
-40°C
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 2
Dimensions: MHDF1 & MHDF25
10.80
AIR INLET
1/2" NPTF
16.73
425
8.56
217
DISCHARGE PORT
1" NPTF (HDF1)
1" BSPF (HDF25)
4X
AIR EXHAUST
3/4" NPTM
15.67
398
6.89
175
2.57
65
.28 [7] MOUNTING HOLE
274
5.80
147
2.38
60
5.54
141
Dimensions are 1/8"
Figures in parenthesis = millimeters
2.38
60
SUCTION PORT
1" NPTF (HDF1)
1" BSPF (HDF25)
(OPTIONAL 90
14.03
356
8.57
218
.72
18
PORT ROTATION)
16.41
417
9.00
229
Model MHDF1 features
NPT threaded connections.
Model MHDF25 features
British Standard Pipe
(BSP) Tapered threaded
connections.
Note:
Unit furnished with subbase plate and rubber feet
as standard. For stationary
bolt down use, rubber feet
can be removed.
MHDF1: 1" NPT(F) SUCTION AND DISCHARGE • ½" NPT (F) AIR INLET PORT • ¾" NPT (F) AIR EXHAUST PORT (NOT SHOWN)
MHDF25: 1" BSP(F) TAPERED SUCTION AND DISCHARGE • ½" NPT (F) AIR INLET PORT • ¾" NPT (F) AIR EXHAUST PORT (NOT SHOWN)
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 3
II 2GD T5
SERVICE & OPERATING MANUAL
See pages 2, 16 & 17
for ATEX ratings
Model MHDF1 Type 1
Mod e l MHDF25 Typ e 1
PLEASE NOTE!
The photos shown in this manual are for general instruction only. Your specic model
may not be shown. Always refer to the parts list and exploded view drawing for your
specic model when installing, disassembling or servicing your pump.
PRINCIPLE OF PUMP OPERATION
This ball valve pump is powered by compressed air and is a 1:1 pressure ratio design.
It alternately pressurizes the inner side of one diaphragm chamber, while simultaneously
exhausting the other inner chamber. This causes the diaphragms, which are connected
by a common rod, to move endwise. Air pressure is applied over the entire surface
of the diaphragm, while liquid is discharged from the opposite side. The diaphragm
operates under a balanced condition during the discharge stroke, which allows the unit
to be operated at discharge heads over 200 feet (61 meters) of water head.
Since the diaphragms are connected by a common rod, secured by plates to the
center of the diaphragms, one diaphragm performs the discharge stroke, while the other
is pulled to perform the suction stroke in the opposite chamber.
For maximum diaphragm life, keep the pump as close to the liquid being pumped
as possible. Positive suction head in excess of 10 feet of liquid (3.048 meters) is not
recommended. For applications with higher suction heads, consult the factory.
Alternate pressuring and exhausting of the diaphragm chamber is performed by
means of an externally mounted, pilot operated, four-way spool type air distribution
valve. When the spool shifts to one end of the valve body, inlet air pressure is applied to
one diaphragm chamber and the other diaphragm chamber exhausts. When the spool
shifts to the opposite end of the valve body, the porting of chambers is reversed. The air
distribution valve spool is moved by an internal pilot valve which alternately pressurizes
one side of the air distribution valve spool, while exhausting the other side. The pilot
valve is shifted at each end of the diaphragm stroke by the diaphragm plate coming in
contact with the end of the pilot valve spool. This pushes it into position for shifting of
the air distribution valve.
The chambers are manifolded together with a suction and discharge check valve for
each chamber, maintaining ow in one direction through the pump.
Original Instructions
INSTALLATION & START-UP
Locate the pump as close to the product being pumped as possible, keeping suction
line length and number of ttings to a minimum. Do not reduce line size.
For installations of rigid piping, short exible sections of hose should be installed
between pump and piping. This reduces vibration and strain to the piping system. A
MARATHON surge suppressor is recommended to further reduce pulsation in ow.
Tighten all fasteners before pump startup.
This pump was tested at the factory prior to shipment and is ready for operation. It
is completely self-priming from a dry start for suction lifts of 17 feet (5.8 meters) or less.
For suction lifts exceeding 17 feet of liquid, ll the chambers with liquid prior to priming.
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 4
Available from
Distributor
Available from
MARATHON
INSTALLATION GUIDE
Bottom Discharge Flap Valve Unit
CAUTION
The air exhaust should be
piped to an area for safe
disposition of the product
being pumped, in the event
of a diaphragm failure.
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 5
AIR SUPPLY
Air supply pressures cannot exceed 125 psi (8.61 bar). Connect the pump air inlet
to an air supply of sufcient capacity and pressure required for desired performance.
When the air line is solid piping, use a short length of exible hose (not less than 1/2"
(12.7 mm) in diameter) between pump and piping to eliminate strain to pipes.
AIR INLET & PRIMING
For start-up, open an air valve approximately 1/2" to 3/4" turn. After the unit primes,
an air valve can be opened to increase ow as desired. If opening the valve increases
cycling rate, but does not increase ow rate, cavitation has occurred, and the valve
should be closed slightly.
For the most efcient use of compressed air and the longest diaphragm life, throttle
the air inlet to the lowest cycling rate that does not reduce ow.
AIR EXHAUST
If a diaphragm fails, the pumped liquid or fumes can enter the air end of the pump,
and be exhausted into the atmosphere. When pumping hazardous or toxic materials,
pipe the exhaust to an appropriate area for safe disposition.
This pump can be submerged if materials of construction are compatible with the
liquid. The air exhaust must be piped above the liquid level. Piping used for the air
exhaust must not be smaller than 1" (2.54 cm). Reducing the pipe size will restrict air
ow and reduce pump performance. When the product source is at a higher level than
the pump (ooded suction), pipe the exhaust higher than the product source to prevent
siphoning spills.
Freezing or icing-up of the air exhaust can occur under certain temperature and
humidity conditions. Use of an air dryer should eliminate most icing problems.
BETWEEN USES
When used for materials that tend to settle out or transform to solid form, the pump
should be completely ushed after each use, to prevent damage. Product remaining
in the pump between uses could dry out or settle out. This could cause problems with
valves and diaphragms at re-start. In freezing temperatures, the pump must be drained
between uses in all cases.
FLAP VALVE SERVICING
Valve inspection requires removal of Capscrews 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.
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.
DIAPHRAGM SERVICING
Remove the eight bolts securing the elbows to the chamber. Remove the four nuts
and four capscrews securing the outer diaphragm chamber ange and remove the
chamber. Loosen the capscrew securing the diaphragm and plate to the rod by leaving
the diaphragm engaged with the capscrews around the outer ange, preventing rotation
of the rod. DO NOT USE A WRENCH ON THE DIAPHRAGM ROD. FLAWS ON THE
SURFACE MAY DAMAGE BEARINGS AND SEAL.
During reassembly make certain that the rubber bumper is on the rod on each side.
Install the diaphragm with the natural bulge outward as indicated on the diaphragm.
Install the outer plate on the outside of the diaphragm. Place the sealing washer between
the inner diaphragm plate and the end of the rod. Tighten the capscrew to approximately
25 ft. lbs. (33.9 Newton meters). Torque while allowing diaphragm to turn freely with
plates. Except for EPDM Rubber, use a lightweight oil between plates and diaphragm
when doing this procedure. For EPDM water can be used. Use a wrench on the Hex of
the opposite side to keep the rod from rotating. If the opposite chamber is assembled,
the rod need not be held. The Flap Valves can also be inspected for proper seating at
this point.
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 6
AIR VALVE LUBRICATION
The SANDPlPER pump’s pilot valve and main air valve assemblies are
designed to operate WITHOUT lubrication. This is the preferred mode of
operation. There may be instances of personal preference, or poor quality air
supplies when lubrication of the compressed air supply is required. The pump air
system will operate with properly lubricated compressed air supplies. Proper lubrication of the
compressed air supply would entail the use of an air line lubricator (available from
MARATHON) set to deliver one drop of 10 weight, non-detergent oil for every 20 SCFM
of air the pump consumed at its point of operation. Consult the pump’s published Performance Curve to determine this.
It is important to remember to inspect the sleeve and spool set routinely. It should
move back and forth freely. This is most important when the air supply is lubricated. If
a lubricator is used, oil accumulation will, over time, collect any debris from the compressed air. This can prevent the pump from operating properly.
Water in the compressed air supply can create problems such as icing or freezing
of the exhaust air causing the pump to cycle erratically, or stop operating. This can
be addressed by using a point of use air dryer to supplement a plant’s air drying
equipment. This device will remove excess water from the compressed air supply and
alleviate the icing or freezing problem.
ESADS+PLUS®:
EXTERNALLY SERVICEABLE AIR
DISTRIBUTION SYSTEM
Please
supplied with your pump. If you need replacement or additional copies, contact your local
MARATHON Distributor, or the MARATHON factory Literature Department. To receive
the correct manual, you must specify the MODEL and TYPE information found on the
name plate of the pump.
The main air valve sleeve and spool set is located in the valve body mounted on the
pump with four hex head capscrews. The valve body assembly is removed from the
pump by removing these four hex head capscrews.
With the valve body assembly off the pump, access to the sleeve and spool set is
made by removing a retaining ring (each end) securing the end cap on 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.
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, and retaining ring (see safety warning), 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.
Re-install the spool, opposite end cap and retaining ring (see safety warning), 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 capscrews evenly and in an alternating cross pattern, at 150 in./lbs. (16.94
Newton meters).
refer to the exploded view drawing and parts list in the Service Manual
RECOMMENDED MARATHON
ACCESSORIES TO MAXIMIZE
PUMP PERFORMANCE:
• Surge Suppressor.
For nearly pulse-free ow.
• MARATHON Filter/Regulator.
For modular installation and
service convenience.
• MARATHON Speed Control.
For manual or programmable
process control. Manual adjustment
or 4-20mA reception.
For more detailed information on
these accessories, contact your local
MARATHON Factory-Authorized
Distributor, or Warren Rupp corporate
headquarters or visit:
www.warrenrupp.com
SAFETY WARNING
To assure proper pump function and safe installation of the
retaining ring, check the gap “G”
dimension for full installation
into the valve body grooves.
> .232 "G"
Dimensions between lugs
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 7
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.
Mo st pr oblem s wit h the pilot valve can be co rrected by replac ing the
o-rings. Always grease t he spool prior to inserting it into the s leeve. 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 held in the inner chambers with
retaining rings. An o-ring is behind each bushing. If the plunger has any sideways motion,
check o-rings and bushing for deterioration or wear. 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.
TROUBLESHOOTING - For additional information, see the MARATHON Troubleshooting Guide.
PROBLEM
Pump cycles but will not pump.
(Note: higher suction lifts require faster
cycling speed for priming.)
PROBLEM
Pump will not cycle. (Note: Always
disconnect air supply to relieve air
pressure before disassembling any
portion of pump.)
PROBLEM
Uneven discharge ow. (Indicates one
chamber not operating properly.)
For additional information, see the MARATHON Troubleshooting Guide.
POSSIBLE CAUSES:
A. Air leak in suction line.
B. Excessive suction lift.
C. Flap valve not seating properly.
D. Leakage at joint of suction manifold or elbow ange.
E. Suction line or strainer plugged.
F. Diaphragm ruptured.
POSSIBLE CAUSES:
A. Discharge hose or line plugged, or discharge head requirement
greater than air supply pressure.
(Disconnect discharge line to check.)
B. Spool in air distribution valve not shifting.
(Remove end cap and check spool — must slide freely.)
C. Diaphragm ruptured.
(Air will escape out discharge line in this case.)
D. Blockage in diaphragm chamber preventing movement.
(Shut off air supply and reopen after pressure is relieved.)
POSSIBLE CAUSES:
A. Flap valve not sealing properly in one chamber.
B. Diaphragm failure in one chamber.
C. Air leak at suction manifold joint or elbow ange one side.
WARRANTY:
This unit is guaranteed for a period of ve years against defective material and workmanship.
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 8
IMPORTANT SAFETY
INFORMATION
IMPORTANT
Read these safety warnings
Read these safety warnings
an d in st ruction s in thi s
an d in st ruction s in thi s
manual completely, before
manual completely, before
in sta llati on an d sta rt- up
in sta llati on an d sta rt- up
of th e p ump . It is th e
responsibility of the purchaser to retain this
responsibility of the purchaser to retain this
manual for reference. Failure to comply with
manual for reference. Failure to comply with
the recommendations stated in this manual will
the recommendations stated in this manual will
damage the pump, and void factory warranty.
damage the pump, and void factory warranty.
prevent leakage. Follow recommended torques
stated in this manual.
pressurized and must be bled of its pressure.
pumping a product which is hazardous or toxic,
the air exhaust must be piped to an appropriate
area for safe disposition.
of th e p ump . It is th e
CAUTION
Be for e pump op era ti on,
i n s pect a l l g a sket ed
fa ste ne rs fo r loo senes s
caused by gasket creep. Retorque loose fasteners to
WARNING
Be fo re ma in tenan ce or
repair, shut off the compressed air line, bleed the
pressure, and disconnect
the air line from the pump.
The discharge line may be
WARNING
In the event of diaphragm
rupture, pumped material
may enter the air end of the
pump, and be discharged
in to the atm osphere . If
WARNING
Take action to prevent static
sparking. Fire or explosion
can result, especially when
handling ammable liquids.
containers or other miscellaneous equipment
must be grounded. (See page 10)
The pump, piping, valves,
WARNING
This pump is pressurized
internally with air pressure
during operation. Always
make certain that all bolting
is in good condition and
bolting is reinstalled during assembly.
th at a ll of t he co rre ct
WARNING
Wh en us ed fo r to xi c or
aggressive uids, the pump
should always be ushed
clean prior to disassembly.
WARNING
Be for e doi ng an y mai nten an c e o n th e pu mp,
be certain all pressure is
completely vented from the
pump, suction, discharge,
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
all times in the vicinity of the pump. Failure to
follow these recommendations may result in
serious injury or death.
p ipi ng , a nd a ll o t h er
WARNING
Airborne particles and
loud noise hazards.
Wear ear and eye
protection.
RECYCLING
Many components of MARATHON® AODD pumps are made
of recyclable materials (see chart on page 11 for material
specications). We encourage pump users to recycle worn out parts
and pumps whenever possible, after any hazardous pumped uids
are thoroughly ushed.
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 9
GROUNDING THE PUMP
WARNING
To be fully groundable, the pumps must be
ATEX Compliant. Refer to pump data sheet
for ordering.
One eyelet is fastened to the pump hardware.
One eyelet is installed to a true earth ground. (Requires a 5/16"
or 8mm maximum diameter bolt.
Take action t o prevent static sparki ng.
F i r e o r e x p l o s i o n c a n r e s u l t ,
esp ecia lly w hen hand lin g fla mmab le
liquids. T h e p u m p , p i p i n g , v a l v e s ,
c ontainers o r other m i s c e l l a n e ous
equipment must be grounded.
This 8 foot long (244 centimeters) Ground
Strap, part number 920-025-000 can be
ordered as a service item.
To reduce the risk of static electrical sparking, this pump must be grounded.
Check the local electrical code for detailed grounding instruction and the
type of equipment required, or in the absence of local codes, an industry
or nationally recognized code having jurisdiction over specic installations.
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 10
MATERIAL CODES
THE LAST 3 DIGITS OF PART NUMBER
000 Assembly, sub-assembly;
and some purchased items
010 Cast Iron
012 Powered Metal
015 Ductile Iron
020 Ferritic Malleable Iron
025 Music Wire
080 Carbon Steel, AISI B-1112
100 Alloy 20
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 Martensitic)
123 410 Stainless Steel
(Wrought Martensitic)
148 Hardcoat Anodized Aluminum
149 2024-T4 Aluminum
150 6061-T6 Aluminum
151 6063-T6 Aluminum
152 2024-T4 Aluminum (2023-T351)
154 Almag 35 Aluminum
155 356-T6 Aluminum
156 356-T6 Aluminum
157 Die Cast Aluminum Alloy #380
158 Aluminum Alloy SR-319
159 Anodized Aluminum
162 Brass, Yellow, Screw Machine Stock
165 Cast Bronze, 85-5-5-5
166 Bronze, SAE 660
170 Bronze, Bearing Type,
Oil Impregnated
175 Die Cast Zinc
180 Copper Alloy
305 Carbon Steel, Black Epoxy Coated
306 Carbon Steel, Black PTFE Coated
307 Aluminum, Black Epoxy Coated
308 Stainless Steel, Black PTFE Coated
309 Aluminum, Black PTFE Coated
310 PVDF Coated
313 Aluminum, White Epoxy Coated
330 Zinc Plated Steel
331 Chrome Plated Steel
332 Aluminum, Electroless Nickel Plated
333 Carbon Steel, Electroless
Nickel Plated
335 Galvanized Steel
336 Zinc Plated Yellow Brass
337 Silver Plated Steel
340 Nickel Plated
342 Filled Nylon
351 Food Grade Santoprene
353 Geolast; Color: Black
354 Injection Molded #203-40
Santoprene- Duro 40D +/-5;
Color: RED
355 Thermal Plastic
356 Hytrel
357 Injection Molded Polyurethane
358 Urethane Rubber
(Some Applications)
(Compression Mold)
359 Urethane Rubber
360 Nitrile Rubber Color coded: RED
361 Nitrile
363 FKM (Fluorocarbon).
Color coded: YELLOW
364 E.P.D.M. Rubber.
Color coded: BLUE
365 Neoprene Rubber.
Color coded: GREEN
366 Food Grade Nitrile
368 Food Grade EPDM
370 Butyl Rubber
Color coded: BROWN
371 Philthane (Tuftane)
374 Carboxylated Nitrile
375 Fluorinated Nitrile
378 High Density Polypropylene
379 Conductive Nitrile
405 Cellulose Fibre
408 Cork and Neoprene
425 Compressed Fibre
426 Blue Gard
440 Vegetable Fibre
465 Fibre
500 Delrin 500
501 Delrin 570
502 Conductive Acetal, ESD-800
503 Conductive Acetal, Glass-Filled
505 Acrylic Resin Plastic
506 Delrin 150
520 Injection Molded PVDF
Natural color
540 Nylon
541 Nylon
542 Nylon
544 Nylon Injection Molded
550 Polyethylene
551 Glass Filled Polypropylene
552 Unlled Polypropylene
553 Unlled Polypropylene
555 Polyvinyl Chloride
556 Black Vinyl
558 Conductive HDPE
570 Rulon II
580 Ryton
590 Valox
591 Nylatron G-S
592 Nylatron NSB
600 PTFE (virgin material)
Tetrauorocarbon (TFE)
601 PTFE (Bronze and moly lled)
602 Filled PTFE
603 Blue Gylon
604 PTFE
606 PTFE
607 Envelon
608 Conductive PTFE
610 PTFE Encapsulated Silicon
611 PTFE Encapsulated FKM
632 Neoprene/Hytrel
633 FKM/PTFE
634 EPDM/PTFE
635 Neoprene/PTFE
637 PTFE, FKM/PTFE
638 PTFE, Hytrel/PTFE
639 Nitrile/TFE
643 Santoprene®/EPDM
644 Santoprene®/PTFE
656 Santoprene Diaphragm and
Check Balls/EPDM Seats
661 EPDM/Santoprene
666 FDA Nitrile Diaphragm,
PTFE Overlay, Balls, and Seals
668 PTFE, FDA Santoprene/PTFE
Delrin is a registered
tradename of E.I. DuPont.
Gylon is a registered tradename
of Garlock, Inc.
Nylatron is a registered tradename
of Polymer Corp.
Santoprene is a registered tradename
of Exxon Mobil Corp.
Rulon II is a registered tradename
of Dixion Industries Corp.
Ryton is a registered tradename
of Phillips Chemical Co.
Valox is a registered tradename
of General Electric Co.
PortaPump and SludgeMaster
are registered tradenames
of Warren Rupp, Inc.
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 11
II 2GD T5
SERVICE & OPERATING MANUAL
See pages 2, 16 & 17
for ATEX ratings
Model MHDF1 Type 1
Original Instructions
Mod e l MHDF25 Typ e 1
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 031.030.558 Assembly, Air Valve 1
1.1 095.051.558 Body, Air Valve 1
1.2 031.039.000 Sleeve & Spool Set 1
1.3 560.058.360 O-Ring 8
1.4 165.038.558 Cap, End 2
1.5 675.043.115 Ring, Retaining 2
2 070.012.170 Bearing, Sleeve 2
3 095.074.001 Pilot Valve Assembly 1
3.1 095.071.557 Body, Pilot Valve 1
3.2 755.025.000 Sleeve Assembly (w/ O-Rings) 1
3.2.1 560.033.360 O-Ring 4
3.2.2 755.025.162 Sleeve, Pilot Valve 1
3.3 775.014.000 Spool Assembly (w/ O-Rings) 1
3.3.1 775.014.115 Spool, Pilot Valve 1
3.3.2 560.023.360 O-Ring 4
3.4 675.037.080 Ring, Retaining 1
4 114.007.157 Bracket, Intermediate (AL Center) 1
114.012.010 Bracket, Intermediate (CI Center) 1
5 115.071.330 Bracket, Mounting 1
6 132.019.360 Bumper 2
7 132.022.360 Bumper, Actuator 2
8 135.034.506 Bushing, Plunger 2
9 165.134.157 Cap, Air Inlet, Ass'y (AL Center) 1
165.134.558 Cap, Air Inlet, Ass'y (CI Center) 1
10 170.029.330 Capscrew, Hex HD 24
11 170.033.330 Capscrew, Hex HD 4
12 170.045.330 Capscrew, Hex HD 12
13 170.063.330 Capscrew, Hex HD 1
14 170.080.330 Capscrew, Hex HD 4
15 170.043.330 Capscrew, Hex HD (AL Center) 6
170.006.330 Capscrew, Hex HD (CI Center) 6
16 196.042.157 Chamber, Inner (AL Center) 1
196.084.010 Chamber, Inner (CI Center) 1
17 196.043.157 Chamber, Inner (AL Center) 1
196.090.010 Chamber, Inner (CI Center) 1
18 196.199.156 Chamber, Outer 2
196.199.010 Chamber, Outer 2
196.199.110 Chamber, Outer 2
19 255.012.335 Coupling, Pipe, 3/4 NPT 1
20 286.008.354 Diaphragm 2
286.008.356 Diaphragm 2
286.008.360 Diaphragm 2
286.008.363 Diaphragm 2
286.008.364 Diaphragm 2
286.008.365 Diaphragm 2
21 312.119.156 Elbow, Suction 2
312.119.010 Elbow, Suction 2
312.119.110 Elbow, Suction 2
22 312.120.156 Elbow, Discharge 2
312.120.010 Elbow, Discharge 2
312.120.110 Elbow, Discharge 2
23 338.014.354 Flap Valve 4
338.014.356 Flap Valve 4
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 12
ITEM NO. PART NUMBER DESCRIPTION QTY.
338.014.360 Flap Valve 4
338.014.363 Flap Valve 4
338.014.364 Flap Valve 4
338.014.365 Flap Valve 4
24 350.002.360 Foot, Rubber 4
25 360.056.379 Gasket 1
26 360.057.360 Gasket 1
27 360.058.360 Gasket 1
28 518.205.156 Manifold 2
518.205.156 E Manifold 2
518.205.010 Manifold 2
518.205.010 E Manifold 2
518.205.110 Manifold 2
518.205.110 E Manifold 2
29 530.036.000 Mufer 1
30 542.001.330 Nut, Square 1
31 545.004.330 Nut, Hex, 5/16-18 14
32 547.002.110 Nut, Stop 12
33 560.001.360 O-Ring 2
34 560.038.360 O-Ring 8
560.038.363 O-Ring 8
560.038.364 O-Ring 8
560.038.365 O-Ring 8
35 560.040.360 O-Ring 2
36 560.198.360 O-Ring 4
560.198.363 O-Ring 4
560.198.364 O-Ring 4
560.198.365 O-Ring 4
37 570.018.360 Pad, Hinge 4
570.018.363 Pad, Hinge 4
570.018.364 Pad, Hinge 4
570.018.365 Pad, Hinge 4
38 570.019.360 Pad, Wear 2
570.019.363 Pad, Wear 2
570.019.364 Pad, Wear 2
570.019.365 Pad, Wear 2
39 612.022.330 Plate, Diaphragm, Inner 2
40 612.108.157 Assembly, Diaphragm Plate 2
612.101.082 Assembly, Diaphragm Plate 2
612.101.110 Assembly, Diaphragm Plate 2
41 618.003.330 Plug, Pipe, 1/4 3
42 620.007.114 Plunger, Actuator 2
43 670.053.110 Retainer 4
44 675.040.360 Ring, Sealing 2
45 675.042.115 Ring, Retaining 2
46 675.065.360 Ring, Sealing 4
675.065.363 Ring, Sealing 4
675.065.364 Ring, Sealing 4
675.065.364 Ring, Sealing 4
47 685.039.120 Rod, Diaphragm 1
48 706.013.330 Screw, Machine 4
49 720.010.375 Seal, U-Cup 2
50 720.066.360 Seal, Seat 4
720.066.363 Seal, Seat 4
720.066.364 Seal, Seat 4
720.066.365 Seal, Seat 4
51 722.101.110 Seat, Flap 4
52 807.018.110 Stud, 1/4-20 8
53 900.004.330 Washer, Lock, 5/16 32
54 901.005.330 Washer, Flat, 3/8 4
55 901.012.180 Washer, Sealing 2
56 901.035.330 Washer, Flat 7
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 13
Composite Repair Drawing
41
53
3.3.1
2
52
11
13
55
9
27
1.3
45
7
40
10
1.21.2
1.4
1.5
1.3
10
17
52
31
48
54
6
33
8
44
20
38
39
29
19
1.1
26
3.1
3.4
15 55
16
4
40
32
24
47
12
5
18
10
34
36
51
50
16
15
25
3.2.1
43
35
45
46
49
23
37
42
55
4
35
2
28
32
42
37
32
34
36
17
48
45
23
50
49
22
52
46
30
3.2.2
3.3.2
28
31
51
21
14
41
7
CAST IRON MID-SECTION
ASSEMBLY CONFIGURATION
33
8
44
mhdf1dl1sm-rev0711 Models MHDF1 & MHDF25 Page 14
Declaration of Conformity
Manufacturer:
®
Warren Rupp, Inc.
Mansfield, Ohio, 44901-1568 USA
certifies that Air-Operated Double Diaphragm Pump Series:
M Non-Metallic, M Metallic, and Surge Suppressors comply
with the European Community Directive 2006/42/EC on Machinery,
according to Annex VIII. This product has used Harmonized Standard
EN 809, Pumps and Pump Units for Liquids - Common Safety
Requirements, to verify conformance.
Signature of authorized person
, 800 N. Main Street, P.O. Box 1568,
October 20, 2005
Date of issue
David Roseberry
Printed name of authorized person
Revision Level: E
Engineering Manager
Title
May 27, 2010
Date of revision
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 44901-1568 USA
EN 60079-25: 2004
For pumps equipped with Pulse Output ATEX Option
KEMA Quality B.V. (0344)
AODD Pumps and Surge Sppressors
For Type Examination Designations, see page 2 (back)
AODD (Air-Operated Double Diaphragm) Pumps
EC Type Examination Certificate No. Pumps: KEMA 09ATEX0071 X
KEMA Quality B.V.
Utrechtseweg 310
6812 AR Arnhem, The Netherlands
®
Applicable Standard:
EN13463-1: 2001,
EN13463-5: 2003
DATE/APPROVAL/TITLE:
27 MAY 2010
David Roseberry, Engineering Manager
EC Declaration of Conformity
ATEX Summary of Markings
Type Marking Listed In
Pump types, M05, M1F, M15,
M20 and M30 provided with the
pulse output option
Pump types, M05, M1F, M15
M20 and M30 provided with the
integral solenoid option
Pump types, MPB1/4, M05,
M1F, M15, M20, M30, MSB1,
MHDF1, MHDF2 without the
above listed options, no
aluminum parts
Pump types,
MPB1/4, M05, M1F, M15,
M20, M30, MSB1, MHDF1,
MHDF2, MHDF3
MT Series Surge Suppressors II 2 G T5
EC Type Certificate No. Pumps: KEMA 09ATEX0071 X
Type Certificate No. Pumps: KEMA 09ATEX0072 X
Type Certificate No. Suppressors: KEMA 09ATEX0073
II 2 G Ex ia c IIC T5
II 3/2 G Ex ia c IIC T5
II 2 D
Ex c iaD 20 IP67 T100oC
II 2 G EEx m c II T5
II 3/2 G EEx m c II T5
II 2 D c IP65 T100
II 1 G c T5
II 3/1 G c T5
II 1 D c T100
I M1 c
I M2 c
II 2 G c T5
II 3/2 G c T5
II 2 D c T100
II 3/2 G T5
II 2 D T100
Non-Conductive
Fluids
KEMA 09ATEX0071 X
CE 0344
KEMA 09ATEX0071 X
o
C
o
C
o
C
o
C
CE 0344
KEMA 09ATEX0071 X
KEMA 09ATEX0072 X
CE 0344
KEMA 09ATEX0072 X
CE
KEMA 09ATEX0073
CE
KEMA 09ATEX0071 X
KEMA 09ATEX0071 X
KEMA 09ATEX0071 X
KEMA 09ATEX0071 X
KEMA 09ATEX0071 X
KEMA 09ATEX0071 X
KEMA 09ATEX0071 X
KEMA 09ATEX0071 X
KEMA 09ATEX0071 X
KEMA 09ATEX0071 X
KEMA 09ATEX0072 X
KEMA 09ATEX0072 X
KEMA 09ATEX0072 X
KEMA 09ATEX0072 X
KEMA 09ATEX0073
KEMA 09ATEX0073
KEMA 09ATEX0073
No
Yes
Yes
No
Yes
Yes
No
Yes
Yes
No
Yes
No
Yes
Yes
No
Yes
Yes
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