Graco 308441ZAB, Husky 1590 AODD Pumps, Aluminum and Stainless Steel Instructions
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Instructions – Parts List
ALUMINUM AND STAINLESS STEEL
Husky
t
1590 Air-Operated
Diaphragm Pumps
308441ZAB
ENG
1.5–inch AODD pump for fluid transfer applications.
For professional use only.
See Models on page 2 for a list of pump models and descriptions.
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
Patent No.
CN ZL94102643.4
FR 9408894
JA 3517270
US 5,386,452
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Model No. DB3777 shown
03263B
Table of Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
Symbols
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
12
Troubleshooting
Service
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Repairing the Air Valve
Ball Check Valve Repair
. . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . 18
Diaphragm Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bearing and Air Gasket Removal
Pump Matrix
. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
24
Repair Kit Matrix
Parts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
24
Torque Sequence
Dimensions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
31
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
33
Graco Warranties
Graco Information
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Models
Model No.
*DB3______
*DC3______
*DB4______
*DC4______
*DBC______
*DCC______
*DBD______
*DCD______
*DT4______
*DU4______
*DTD______
*DUD______
253485
232502
24B780
24B781
Description
Aluminum Pumps
Aluminum Pumps, Remote
Stainless Steel Pumps
Stainless Steel Pumps, Remote
Aluminum BSPT Pumps
Aluminum BSPT Pumps, Remote
Stainless Steel BSPT Pumps
Stainless Steel BSPT Pumps, Remote
Stainless Steel Plus Pumps
Stainless Steel Plus Pumps, Remote
Stainless Steel BSPT Plus Pumps
Stainless Steel BSPT Plus Pumps, Remote
Aluminum Pump
Private–Label Aluminum Pump
Stainless Steel Plus Pump with overmolded diaphragms
Stainless Steel Pump with overmolded diaphragms
* Refer to the Pump Matrix on page 24 to determine the Model No. of your pump.
NOTE: Plus Models include stainless steel center sections.
2 308441
Symbols
Warning Symbol
WARNING
Caution Symbol
CAUTION
This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 120 psi (0.8 MPa, 8 bar) maximum working pressure at 120 psi (0.8
MPa, 8 bar) maximum incoming air pressure.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use could result in a chemical reaction, with the possibility of explosion.
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 82 C (180 F) or below –40 C (–40 F).
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
308441 3
WARNING
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.
Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas.
If the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 9.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury.
Ground the equipment. Refer to Grounding on page 5.
If there is any static sparking or you feel an electric shock while using this equipment, stop
pumping immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.
Pipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 9.
Keep the work area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the work area.
Extinguish all open flames or pilot lights in the work area.
Do not smoke in the work area.
Do not turn on or off any light switch in the work area while operating or if fumes are present.
Do not operate a gasoline engine in the work area.
4 308441
General Information
Installation
Grounding
The typical installation shown in Fig. 2 is only a guide for selecting and installing system components. Contact your Graco distributor for assistance in planning a system to suit your needs.
Always use Genuine Graco Parts and Accessories.
Refer to Product Data Sheet 305646.
WARNING
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before operating the pump, ground the system as explained below. Also, read the section FIRE AND EXPLOSION HAZARD, on page 4.
Reference numbers and letters in parentheses refer to the callouts in the figures and the parts lists on pages 27–26.
Lift the pump by grasping the outlet manifold (1) securely. See Fig. 3 on page 8.
To reduce the risk of static sparking, ground the pump and all other equipment used or located in the pumping area. Check your local electrical code for detailed grounding instructions for your area and type of equipment. Ground all of this equipment:
Pump: Connect a ground wire and clamp as shown in Fig. 1. Loosen the grounding screw (W). Insert one end of a 12 ga (1.5 mm ) minimum ground wire
(Y) behind the grounding screw and tighten the screw securely. Connect the clamp end of the ground wire to a true earth ground. Order Part
No. 222011 Ground Wire and Clamp.
WARNING swallowed.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or
1.
Read TOXIC FLUID HAZARD on page 4.
2.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
Y
Tightening Screws Before First Use
Before using the pump for the first time, check and retorque all external fasteners. See Torque Se-
quence, page 30. After the first day of operation, retorque the fasteners. Although pump use varies, a general guideline is to retorque fasteners every two months.
W
02646B
Fig. 1
Air and fluid hoses: Use only grounded hoses with a maximum of 500 ft (150 m) combined hose length to ensure grounding continuity.
Air compressor: Follow the manufacturer’s recommendations.
All solvent pails used when flushing: Follow the local code. Use only metal pails, which are conductive. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts the grounding continuity.
Fluid supply container: Follow the local code.
308441 5
Mountings
Installation
c.
The air line filter (F) removes harmful dirt and moisture from the compressed air supply.
CAUTION
The pump exhaust air may contain contaminants.
Ventilate to a remote area if the contaminants could affect your fluid supply. See Air Exhaust
Ventilation on page 9.
2.
Install a grounded, flexible air hose (A) between the accessories and the 1/2 npt(f) pump air inlet
(N). See Fig. 3. Use a minimum 1/2 in. (13 mm) ID air hose. Screw an air line quick disconnect coupler (D) onto the end of the air hose (A), and screw the mating fitting into the pump air inlet snugly. Do not connect the coupler (D) to the fitting until you are ready to operate the pump.
1.
Be sure the mounting surface can support the weight of the pump, hoses, and accessories, as well as the stress caused during operation.
2.
For all mountings, be sure the pump is bolted directly to the mounting surface.
3.
For ease of operation and service, mount the pump so the air valve cover (2), air inlet, and fluid inlet and outlet ports are easily accessible.
4.
Rubber Foot Mounting Kit 236452 is available to reduce noise and vibration during operation.
Installation of Remote Pilot Air Lines
1.
Refer to Parts Drawings. Connect air line to pump as in preceding steps.
2.
Connect 1/4 in. O.D. tubing to push type connectors (14) on air motor of pump.
Air Line
WARNING
A bleed-type master air valve (B) is required in your system to relieve air trapped between this valve and the pump. Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury, including splashing in the eyes or on the skin, injury from moving parts, or contamination from hazardous fluids. See Fig. 2.
NOTE: by replacing the push type connectors, other sizes or types of fittings may be used. The new fittings will require 1/8 in. npt threads.
3.
Connect remaining ends of tubes to external air signal, such as Graco’s Cycleflo (P/N 195264) or
Cycleflo II (P/N195265) controllers.
NOTE: the air pressure at the connectors must be at least 30% of the air pressure to the air motor for the pump to operate.
Fluid Suction Line
1.
Use grounded fluid hoses (G). The pump fluid inlet (R) is 1–1/2 in. npt(f). Screw the fluid fitting into the pump inlet securely.
1.
Install the air line accessories as shown in Fig. 2.
Mount these accessories on the wall or on a bracket. Be sure the air line supplying the accessories is grounded.
a.
Install an air regulator (C) and gauge to control the fluid pressure. The fluid outlet pressure will be the same as the setting of the air regulator.
b.
Locate one bleed-type master air valve (B) close to the pump and use it to relieve trapped air. See the WARNING above. Locate the other master air valve (E) upstream from all air line accessories and use it to isolate them during cleaning and repair.
2.
If the fluid inlet pressure to the pump is more than
25% of the outlet working pressure, the ball check valves will not close fast enough, resulting in inefficient pump operation.
3.
At inlet fluid pressures greater than 15 psi
(0.1 MPa, 1 bar), diaphragm life will be shortened.
4.
See the Technical Data on page 32 for maximum suction lift (wet and dry).
6 308441
Fluid Outlet Line
Installation
1.
Use grounded fluid hoses (L). The pump fluid outlet (S) is 1–1/2 in. npt(f). Screw the fluid fitting into the pump outlet securely.
WARNING
A fluid drain valve (J) is required to relieve pressure in the hose if it is plugged. The drain valve reduces the risk of serious injury, including splashing in the eyes or on the skin, or contamination from hazardous fluids when relieving pressure.
Install the valve close to the pump fluid outlet. See
Fig. 2.
2.
Install a fluid drain valve (J) near the fluid outlet.
See the WARNING above.
3.
Install a shutoff valve (K) in the fluid outlet line.
TYPICAL FLOOR-MOUNT INSTALLATION
KEY
A Air supply hose
B Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
G Fluid suction hose
H Fluid supply
J Fluid drain valve (required)
K Fluid shutoff valve
L Fluid hose
R 1.5 npt(f) fluid inlet port
S 1.5 npt(f) fluid outlet port
Y Ground wire (required; see page 5 for installation instructions)
Y
D
A
B
S
K
C F
E
L
R
J
H
G
Muffler not included on Model No. 253485
03265B
Fig. 2
308441 7
Installation
Fluid Pressure Relief Valve Changing the Orientation of the Fluid Inlet and Outlet Ports
The pump is shipped with the fluid inlet (R) and outlet
(S) ports facing the same direction. See Fig. 3. To change the orientation of the inlet and/or outlet port:
1.
Remove the screws (106) holding the inlet (102) and/or outlet (103) manifold to the covers (101).
2.
Reverse the manifold and reattach. Install the screws, and torque according to the torque notes in Fig. 3.
CAUTION
Some systems may require installation of a pressure relief valve at the pump outlet to prevent overpressurization and rupture of the pump or hose. See Fig. 4.
Thermal expansion of fluid in the outlet line can cause overpressurization. This can occur when using long fluid lines exposed to sunlight or ambient heat, or when pumping from a cool to a warm area (for example, from an underground tank).
Overpressurization can also occur if the Husky pump is being used to feed fluid to a piston pump, and the intake valve of the piston pump does not close, causing fluid to back up in the outlet line.
KEY
N 1/2 npt(f) air inlet port
P Muffler. Air exhaust port is 3/4 npt(f) . (Not included on Model No. 253485)
R 1.5 npt(f) fluid inlet port
S 1.5 npt(f) fluid outlet port
101 Covers
102 Fluid inlet manifold
103 Fluid outlet manifold
106 Manifold and cover screws
112 Bottom cover screws
1
2
Apply medium-strength (blue) Loctite or equivalent to the threads. Torque to 120–150 in-lb (14–17 N m). See Torque
Sequence, page 30.
Apply medium-strength (blue) Loctite or equivalent to the threads. Torque to 190–220 in-lb (22–25 N m). See Torque
Sequence, page 30.
103
106 1
KEY
R 1.5 npt(f) fluid inlet port
S 1.5 npt(f) fluid outlet port
V Pressure relief valve (Order Part No. 112119 for stainless steel pumps)
1 Install valve between fluid inlet and outlet ports.
2 Connect fluid inlet line here.
3 Connect fluid outlet line here.
4 Muffler not included on Model No. 253485
S 3
S
N
106 2
V 1
P
102
8
Aluminum Model Shown
Fig. 3
308441
101
112 2
R
03263B
Fig. 4
4
R
2
03461B
Air Exhaust Ventilation
Installation
The air exhaust port is 3/4 npt(f). Do not restrict the air exhaust port. Excessive exhaust restriction can cause erratic pump operation.
WARNING
FIRE AND EXPLOSION HAZARD
Be sure to read and follow the warnings and precautions regarding TOXIC
FLUID HAZARD, and FIRE OR EXPLO-
SION HAZARD on page 4, before operating this pump.
Be sure the system is properly ventilated for your type of installation. You must vent the exhaust to a safe place, away from people, animals, food handling areas, and all sources of ignition when pumping flammable or hazardous fluids.
Diaphragm failure will cause the fluid being pumped to exhaust with the air. Place an appropriate container at the end of the air exhaust line to catch the fluid. See Fig. 5.
If the muffler (P) is installed directly to the air exhaust port, apply PTFE thread tape or anti–seize thread lubricant to the muffler threads before assembly.
To provide a remote exhaust:
1.
Remove the muffler (P) from the pump air exhaust port.
2.
Install a grounded air exhaust hose (T) and connect the muffler (P) to the other end of the hose.
The minimum size for the air exhaust hose is 3/4 in. (19 mm) ID. If a hose longer than 15 ft (4.57 m) is required, use a larger diameter hose. Avoid sharp bends or kinks in the hose. See Fig. 5.
3.
Place a container (U) at the end of the air exhaust line to catch fluid in case a diaphragm ruptures.
VENTING EXHAUST AIR
E F C B
A
KEY
A Air supply line
B Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
P Muffler (not included on
Model No. 253485)
T Grounded air exhaust hose
U Container for remote air exhaust
D
T
U
P
03267A
Fig. 5
308441 9
Pressure Relief Procedure
Operation
NOTE: If the fluid inlet pressure to the pump is more than 25% of the outlet working pressure, the ball check valves will not close fast enough, resulting in inefficient pump operation.
WARNING
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is manually relieved. To reduce the risk of serious injury from pressurized fluid, accidental spray from the gun or splashing fluid, follow this procedure whenever you:
Are instructed to relieve pressure,
Stop pumping,
Check, clean or service any system equipment,
Install or clean fluid nozzles.
4.
Place the end of the fluid hose (L) into an appropriate container.
5.
Close the fluid drain valve (J). See Fig. 2.
6.
Close the pump air regulator (C). Open all bleedtype master air valves (B, E).
7.
If the fluid hose has a dispensing device, hold it open while continuing with the following step.
1.
Shut off the air to the pump.
8.
Slowly open the air regulator (C) until the pump starts to cycle. Allow the pump to cycle slowly until all air is pushed out of the lines and the pump is primed.
2.
Open the dispensing valve, if used.
3.
Open the fluid drain valve to relieve all fluid pressure, having a container ready to catch the drainage.
If you are flushing, run the pump long enough to thoroughly clean the pump and hoses. Close the air regulator. Remove the suction tube from the solvent and place it in the fluid to be pumped.
Flush the Pump Before First Use
The pump was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, flush the pump with a compatible solvent before using the equipment. Follow the steps under Starting and Adjusting the Pump.
Operation of Remote Piloted Pumps
1.
Follow preceding steps 1 through 7 of Starting
and Adjusting Pump.
2.
Open air regulator (C).
Starting and Adjusting the Pump
WARNING
The pump may cycle once before the external signal is applied. Injury is possible. If pump cycles, wait until end before proceeding.
WARNING
TOXIC FLUID HAZARD
To reduce the risk of serious injury, splashing in the eyes or on the skin, and toxic fluid spills, never move or lift a pump under pressure. If dropped, the fluid section may rupture. Always follow the Pressure Relief
Procedure above before lifting the pump.
1.
Be sure the pump is properly grounded. Refer to
Grounding on page 5.
3.
Pump will operate when air pressure is alternately applied and relieved to push type connectors (14).
NOTE: Leaving air pressure applied to the air motor for extended periods when the pump is not running may shorten the diaphragm life. Using a 3–way solenoid valve to automatically relieve the pressure on the air motor when the metering cycle is complete prevents this from occurring.
Pump Shutdown
2.
Check all fittings to be sure they are tight. Be sure to use a compatible liquid thread sealant on all male threads. Tighten the fluid inlet and outlet fittings securely.
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
3.
Place the suction tube (if used) in the fluid to be
10 pumped.
308441
At the end of the work shift, relieve the pressure.
Notes
308441 11
Maintenance
Flushing and Storage Lubrication
The air valve is designed to operate unlubricated, however if lubrication is desired, every 500 hours of operation (or monthly) remove the hose from the pump air inlet and add two drops of machine oil to the air inlet.
CAUTION
Do not over-lubricate the pump. Oil is exhausted through the muffler, which could contaminate your fluid supply or other equipment. Excessive lubrication can also cause the pump to malfunction.
Flush the pump often enough to prevent the fluid you are pumping from drying or freezing in the pump and damaging it. Use a compatible solvent.
Always flush the pump and relieve the pressure before storing it for any length of time.
Tightening Threaded Connections
Before each use, check all hoses for wear or damage, and replace as necessary. Check to be sure all threaded connections are tight and leak–free.
Check fasteners. Tighten or retorque as necessary.
Although pump use varies, a general guideline is to retorque fasteners every two months. See Torque
Sequence, page 30.
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
12 308441
Troubleshooting
Relieve the pressure before checking or servicing the equipment.
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
Check all possible problems and causes before disassembling the pump.
PROBLEM
Pump cycles at stall or fails to hold pressure at stall.
Pump will not cycle, or cycles once and stops.
Pump operates erratically.
Air bubbles in fluid.
CAUSE
Worn check valve balls (301), seats
(201) or o-rings (202).
Air valve is stuck or dirty.
SOLUTION
Replace. See page 18.
Check valve ball (301) severely worn and wedged in seat (201) or manifold (102 or 103).
Check valve ball (301) is wedged into seat (201), due to overpressurization.
Dispensing valve clogged.
Clogged suction line.
Sticky or leaking balls (301).
Diaphragm ruptured.
Restricted exhaust.
Disassemble and clean air valve.
See pages 15–16. Use filtered air.
Replace ball and seat. See page
18.
Install Pressure Relief Valve
(see page 8).
Relieve pressure and clear valve.
Inspect; clear.
Clean or replace. See page 18.
Replace. See pages 19–21.
Remove restriction.
Suction line is loose.
Diaphragm ruptured.
Loose inlet manifold (102), damaged seal between manifold and seat (201), damaged o-rings (202).
Tighten.
Replace. See pages 19–21.
Tighten manifold bolts (106) or replace seats (201) or o-rings (202).
See page 18.
Loose diaphragm shaft bolt (107).
Tighten or replace. See pages
19–21.
Damaged o-ring (108).
Replace. See pages 19–21.
308441 13
Troubleshooting
PROBLEM
Fluid in exhaust air.
Pump exhausts excessive air at stall.
CAUSE
Diaphragm ruptured.
SOLUTION
Replace. See pages 19–21.
Loose diaphragm shaft bolt (107).
Tighten or replace. See pages
19–21.
Damaged o-ring (108).
Replace. See pages 19–21.
Worn air valve block (7), o-ring (6), plate (8), pilot block (18), u-cups
(10), or pilot pin o-rings (17).
Repair or replace. See pages
15–16.
Pump leaks air externally.
Worn shaft seals (402).
Air valve cover (2) or air valve cover screws (3) are loose.
Air valve gasket (4) or air cover gasket (22) is damaged.
Air cover screws (25) are loose.
Replace. See pages 19–21.
Tighten screws. See page 16.
Inspect; replace. See pages 15–16,
22–23.
Tighten screws. See pages 22–23.
Pump leaks fluid externally from ball check valves.
Loose manifolds (102, 103), damaged seal between manifold and seat (201), damaged o-rings (202).
Tighten manifold bolts (106) or replace seats (201) or o-rings (202).
See page 18.
14 308441
Service
Repairing the Air Valve
Tools Required
Torque wrench
Torx (T20) screwdriver or 7 mm (9/32 in.) socket wrench
Needle-nose pliers
O-ring pick
Lithium base grease
NOTE: Air Valve Repair Kits 236273 (aluminum center housing models) and 255061 (sst center housing models) are available. Refer to page 25. Parts included in the kit are marked with a symbol, for example (4 ).
Use all the parts in the kit for the best results.
Disassembly
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
1
1
Muffler not included on
Model No. 253485
2
Torque to 50–60 in-lb
(5.6–6.8 N m).
Fig. 6
1.
Relieve the pressure.
2.
With a Torx (T20) screwdriver or 7 mm (9/32 in.) socket wrench, remove the six screws (3), air valve cover (2), and gasket (4). See Fig. 6.
3.
Move the valve carriage (5) to the center position and pull it out of the cavity. Remove the valve block (7 ) and o-ring (6 ) from the carriage.
Using a needle-nose pliers, pull the pilot block (18) straight up and out of the cavity. See Fig. 7.
4.
Pull the two actuator pistons (11) out of the bearings (12). Remove the u-cup packings (10) from the pistons. Pull the pilot pins (16) out of the bearings (15). Remove the o-rings (17) from the pilot pins. See Fig. 8.
5.
Inspect the valve plate (8 ) in place. If damaged, use a Torx (T20) screwdriver or 7 mm (9/32 in.) socket wrench to remove the three screws (3).
Remove the valve plate (8 ) and, on aluminum center housing models only, remove the seal (9).
See Fig. 9.
6.
Inspect the bearings (12, 15) in place. See Fig. 8.
The bearings are tapered and, if damaged, must be removed from the outside. This requires disassembly of the fluid section. See page 22.
7.
Clean all parts and inspect for wear or damage.
Replace as needed. Reassemble as explained on page 16.
1
2
3
Fig. 7
See Detail at right.
Grease.
Grease lower face.
2
3
5
6
7
3
2
2
4
18
3 5 1
11
03268B
308441
03269
15
Service
1 Insert narrow end first.
2 Grease.
3 Install with lips facing narrow end of piston (11).
4 Insert wide end first.
1
2
Rounded side must face down
(aluminum center housing models only).
Tighten screws until they bottom out on the housing.
10 2 3
11 4
12
3
2
8
9
1
Fig. 8
2
17 15 16 1
03270
03271
Fig. 9
Reassembly
1.
If you removed the bearings (12, 15), install new ones as explained on page 22. Reassemble the fluid section.
2.
On aluminum center housing models, install the valve plate seal (9 ) into the groove at the bottom of the valve cavity. The rounded side of the seal must face down into the groove. See Fig. 9.
3.
Install the valve plate (8 ) in the cavity. On aluminum center housing models, the plate is reversible, so either side can face up. Install the three screws
(3), using a Torx (T20) screwdriver or 7 mm (9/32 in.) socket wrench. Tighten until the screws bottom out on the housing. See Fig. 9.
4.
Install an o-ring (17 ) on each pilot pin (16).
Grease the pins and o-rings. Insert the pins into the bearings (15), narrow end first. See Fig. 8.
5.
Install a u-cup packing (10 ) on each actuator piston (11), so the lips of the packings face the
narrow end of the pistons. See Fig. 8.
16 308441
6.
Lubricate the u-cup packings (10 ) and actuator pistons (11). Insert the actuator pistons in the bearings (12), wide end first. Leave the narrow end of the pistons exposed. See Fig. 8.
7.
Grease the lower face of the pilot block (18 ) and install so its tabs snap into the grooves on the ends of the pilot pins (16). See Fig. 7.
8.
Grease the o-ring (6 ) and install it in the valve block (7). Push the block onto the valve carriage
(5). Grease the lower face of the valve block. See
Fig. 7.
9.
Install the valve carriage (5) so its tabs slip into the grooves on the narrow end of the actuator pistons
(11). See Fig. 7.
10. Align the valve gasket (4 ) and cover (2) with the six holes in the center housing (1). Secure with six screws (3), using a Torx (T20) screwdriver or 7 mm (9/32 in.) socket wrench. Torque to 50–60 in-lb
(5.6–6.8 N m). See Fig. 6.
308441 17
Service
Ball Check Valve Repair
Tools Required
Torque wrench
13 mm socket wrench
O-ring pick
Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to page 25 to order the correct kit for your pump. Parts included in the kit are marked with an asterisk, for example (201*). Use all the parts in the kit for the best results.
NOTE: To ensure proper seating of the balls (301), always replace the seats (201) when replacing the balls. Also, on some models, replace the o-rings (202).
1
Apply medium-strength (blue) Loctite or equivalent to the threads. Torque to 120–150 in-lb (14–17 N m). See Torque
Sequence, page 30.
2
Arrow (A) must point toward outlet manifold (103).
3 Not used on some models.
4
Beveled seating surface must face ball (301).
1 106
103
301*
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
201* 4
202*
3
101
A
2 1.
Relieve the pressure. Disconnect all hoses.
2.
Remove the pump from its mounting.
3.
Using a 13 mm socket wrench, remove the four bolts (106) holding the outlet manifold (103) to the fluid covers (101). See Fig. 10.
4.
Remove the o-rings (202, not used on some
models), seats (201), and balls (301) from the manifold.
5.
Turn the pump over and remove the inlet manifold
(102). Remove the o-rings (202, not used on some
models), seats (201), and balls (301) from the fluid covers (101).
Reassembly
1.
Clean all parts and inspect for wear or damage.
Replace parts as needed.
2.
Reassemble in the reverse order, following all notes in Fig. 10. Be sure the ball checks are assembled exactly as shown. The arrows (A) on the fluid covers (101) must point toward the outlet manifold (103).
3
Fig. 10
106 1
301*
201*
4
202*
3
102
03272B
18 308441
Service
Diaphragm Repair
Tools Required
Torque wrench
13 mm socket wrench
15 mm socket wrench (aluminum models) or
1 in. socket wrench (stainless steel models)
19 mm open–end wrench
O-ring pick
Lithium-base grease
Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to page 25 to order the correct kit for your pump. Parts included in the kit are marked with an asterisk, for example (401*). Use all the parts in the kit for the best results.
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
1.
Relieve the pressure.
2.
Remove the manifolds and disassemble the ball check valves as explained on page 18.
3.
Using a 13 mm socket wrench, remove the screws
(106 and 112) holding the fluid covers (101) to the air covers (23). Pull the fluid covers (101) off the pump. See Fig. 11.
1
2
Apply medium-strength (blue) Loctite or equivalent to the threads. Torque to 190–220 in-lb (22–25 N m).
See Torque Sequence, page 30.
Arrow (A) must point toward air valve (B).
3 Muffler not included on Model No. 253485.
B
23
101
A 2
106 1
3
Fig. 11
112 1
03273C
308441 19
Service
4.
Loosen but do not remove the diaphragm shaft bolts (107), using a 15 mm socket wrench (1 in. on stainless steel models) on both bolts. NOTE: This step does not apply to pumps with overmolded diaphragms.
5.
Unscrew one bolt from the diaphragm shaft (24) and remove the o-ring (108), fluid side diaphragm plate (105), PTFE diaphragm (403, used on PTFE
models only), diaphragm (401), and air side diaphragm plate (104). See Fig. 12.
For overmolded diaphragms: Grip both diaphragms securely around the outer edge and rotate counterclockwise. One diaphragm assembly will come free and the other will remain attached to the shaft. Remove the freed diaphragm and air side plate.
6.
Pull the other diaphragm assembly and the diaphragm shaft (24) out of the center housing (1).
Hold the shaft flats with a 19 mm open–end wrench, and remove the bolt (107) from the shaft.
Disassemble the remaining diaphragm assembly.
For overmolded diaphragms: Pull the other diaphragm assembly and the diaphragm shaft (24) out of the center housing (1). Hold the shaft flats with a 19 mm open–end wrench and remove the diaphragm and air side plate from the shaft.
7.
Inspect the diaphragm shaft (24) for wear or scratches. If it is damaged, inspect the bearings
(19) in place. If the bearings are damaged, refer to page 22.
8.
Reach into the center housing (1) with an o-ring pick and hook the u-cup packings (402), then pull them out of the housing. This can be done with the bearings (19) in place.
9.
Clean all parts and inspect for wear or damage.
Replace parts as needed.
Reassembly
1.
Install the shaft u-cup packings (402*) so the lips face out of the housing (1). Lubricate the packings. See Fig. 12.
2.
Install the diaphragm assembly on one end of the shaft (24) as follows. For pumps with overmolded diaphragms, go directly to step g.
a.
Install the o-ring (108*) on the shaft bolt (107).
b.
Install the fluid side diaphragm plate (105) on the bolt so the rounded side faces in, toward the diaphragm (401).
c.
On PTFE models only, install the PTFE diaphragm (403*). Make certain the side marked
AIR SIDE faces the center housing (1).
d.
Install the diaphragm (401*) on the bolt. Make certain the side marked AIR SIDE faces the center housing (1).
e.
Install the air side diaphragm plate (104) so the recessed side faces the diaphragm (401).
f.
Apply medium-strength (blue) Loctite or equivalent to the bolt (107) threads. Screw the bolt (107) into the shaft (24) hand tight.
g.
For overmolded diaphragms: Assemble the air side plate (104) onto the diaphragm (403). The wide, radiused side of the plate must face the diaphragm. Apply medium–strength (blue)
Loctite or equivalent to the threads of the diaphragm assembly. Screw the assembly into the shaft (24) hand tight.
3.
Grease the length and ends of the diaphragm shaft
(24), and slide it through the housing (1).
4.
Assemble the other diaphragm assembly to the shaft as explained in step 2.
5.
Hold one shaft bolt (107) with a wrench and torque the other bolt to 20–25 ft-lb (27–34 N m) at 100 rpm maximum. NOTE: This step does not apply to pumps with overmolded diaphragms.
6.
Align the fluid covers (101) and the center housing
(1) so the arrows (A) on the covers face the same direction as the air valve (B). Apply mediumstrength (blue) Loctite or equivalent to the threads of screws (106) and (112), and secure the covers with the screws handtight. Install the longer screws (112) in the bottom holes of the covers. See Fig. 11. Using a 13 mm socket wrench, torque the screws oppositely and evenly to 190–220 in-lb (22–25 N m). See Torque Se-
quence, page 30.
7.
Reassemble the ball check valves and manifolds as explained on page 18.
20 308441
Service
105
2
107 5
19 402* 1
1
24
4
104
7
401*
3
03274A
Cutaway View, with Diaphragms in Place
24
4
403*
3 6
1
03275A
Cutaway View, with Diaphragms Removed
104 7
401*
3
403* 3 5
105
2
1
24
4 108*
107
6
8
Fig. 12
3
4
5
1
2
6
7
8
Lips face out of housing (1).
Rounded side faces diaphragm (401).
Air Side must face center housing (1).
Grease.
Used on pumps with PTFE diaphragms only.
Apply medium-strength (blue) Loctite or equivalent. Torque to 20 to 25 ft-lb (27 to 34 N-m) at 100 rpm maximum.
Recessed side faces diaphragm (401).
Muffler not included on Model No. 253485.
03276C
308441 21
Bearing and Air Gasket Removal
Tools Required
Torque wrench
10 mm socket wrench
Bearing puller
O-ring pick
Press, or block and mallet
Disassembly
NOTE: Do not remove undamaged bearings.
1.
Relieve the pressure.
Service
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
7.
Use a bearing puller to remove the diaphragm shaft bearings (19), air valve bearings (12) or pilot pin bearings (15). Do not remove undamaged bearings.
8.
If you removed the diaphragm shaft bearings (19), reach into the center housing (1) with an o-ring pick and hook the u-cup packings (402), then pull them out of the housing. Inspect the packings. See Fig. 12.
Reassembly
1.
If removed, install the shaft u-cup packings (402*) so the lips face out of the housing (1).
2.
The bearings (12, 15, and 19) are tapered and can only be installed one way. Insert the bearings into the center housing (1), tapered end first. Using a press or a block and rubber mallet, press-fit the bearing so it is flush with the surface of the center housing.
3.
Reassemble the air valve as explained on page
16.
4.
Align the new air cover gasket (22) so the pilot pin
(16) protruding from the center housing (1) fits through the proper hole (H) in the gasket.
2.
Remove the manifolds and disassemble the ball check valves as explained on page 18.
3.
Remove the fluid covers and diaphragm assemblies as explained on page 19.
NOTE: If you are removing only the diaphragm shaft bearing (19), skip step 4.
4.
Disassemble the air valve as explained on page
15.
5.
Using a 10 mm socket wrench, remove the screws
(25) holding the air covers (23) to the center housing (1). See Fig. 13.
6.
Remove the air cover gaskets (22). Always replace the gaskets with new ones.
5.
Align the air cover (23) so the pilot pin (16) fits in the middle hole (M) of the three small holes near the center of the cover. Apply medium-strength
(blue) Loctite or equivalent to the threads of screws (25), and install the screws handtight. See
Fig. 13. Using a 10 mm socket wrench, torque the screws oppositely and evenly to 130–150 in-lb
(15–17 N m).
6.
Install the diaphragm assemblies and fluid covers as explained on page 19.
7.
Reassemble the ball check valves and manifolds as explained on page 18.
22 308441
Service
1
2
3
4
Insert bearings tapered end first.
Press-fit bearings flush with surface of center housing (1).
Apply medium-strength (blue) Loctite or equivalent. Torque to 130–150 in-lb (15–17 N m).
Muffler not included on Model No. 253485.
12
1 2
1
16
19 2 1
H
22
03277
15 1 2
Detail of Air Valve Bearings
M
23
25
3
Fig. 13
4
03278B
308441 23
Pump Matrix
Husky 1590 Aluminum and Stainless Steel Pumps, Series A
Your Model No. is marked on the pump’s serial plate. To determine the Model No. of your pump from the following matrix, select the six digits which describe your pump, working from left to right. The first digit is always D, designating Husky diaphragm pumps. The remaining five digits define the materials of construction. For example, a pump with an aluminum air motor, aluminum fluid section, polypropylene seats, PTFE balls, and PTFE diaphragms is Model No.
D B 3 9 1 1.
To order replacement parts, refer to the part lists on pages 27–26. The digits in the matrix do not correspond to the ref. nos. in the parts drawing and lists.
Diaphragm
Pump
232502*
253485*
D (for all pumps)
24B780*
24B781*
Air Motor aluminum aluminum
Fluid Section – Seats aluminum – TPE aluminum – Buna–N
– 1 (not used) B aluminum
(standard)
C aluminum
(remote)
1 (not used)
2 (not used)
T sst (standard) 3 (aluminum)
U sst (remote) 4 (sst)
–
–
–
2 (not used)
3 (316 sst)
4 (17–4 PH sst)
5 (not used)
C (aluminum
BSPT)
D (sst BSPT)
– 5 (TPE)
– 6 (Santoprene )
Balls acetal
Buna–N
1 (PTFE)
2 (acetal)
3 (not used)
4 (440C sst)
5 (TPE)
6 (Santoprene )
Diaphragms
TPE
Buna–N
1 (PTFE)
2 (not used)
3 (not used)
4 (not used)
5 (TPE)
6 (Santoprene )
– 7 (Buna–N) 7 (Buna–N) 7 Buna–N)
– 8 (Fluoroelastomer) 8 (Fluoroelastomer) 8 (Fluoroelastomer)
– 9 (polypropylene)
– A (PVDF)
– G (Geolast )
9 (not used)
A (not used)
G (Geolast )
9 (not used)
A (not used)
G (Geolast )
* 232502, Aluminum 1590 Pump, Series D
Model No. 232502 is a private-label aluminum 1590 pump. This pump is the same as Model No. DB3525 except for the label and:
Ref. Nos. 10 and 402 are 115666 Packing, U–cup,
Fluoroelastomer
Ref. No. 17 is 168518 O–ring, Fluoroelastomer
Use 243492 as the Air Valve Repair Kit
Ref. 106 is 112416 SCREW, SST; M10 x 1.5, 30 mm
Ref. 112 is 112417 SCREW, SST; M10 x 1.5; 90 mm
* 24B780 Stainless Steel Plus Pump
This pump is the same as Model DT4311 except for the serial plate and parts listed in the chart below.
* 24B781 Stainless Steel Pump
This pump is the same as Model DB4311 except for the serial plate and parts listed in the chart below.
* 253485, Aluminum 1590 Pump, Series A
Model No. 253485 is an aluminum 1590 pump. This pump is the same as Model No. DB3777 except for the label and that 253485 does not include Ref. No. 111
Muffler.
246451 Stainless Steel Air Motor Conversion Kit
Use kit 246451 and refer to manual 309643 (included with kit) to convert from aluminum air motor to stainless steel air motor.
Ref.
No.
104
105
107
108
401
Part No.
Description
15H810 PLATE, air side; alum.
––– not used
––– not used
––– not used
15G745 DIAPHRAGM, HD, overmolded;
PTFE/EPDM
0
0
2
Qty
2
0
24 308441
Repair Kit Matrix
For Husky 1590 Aluminum and Stainless Steel Pumps, Series A
Repair Kits may be ordered separately. To repair the air valve, order Part No. 236273 for aluminum center housing models or Part No. 255061 for stainless steel center housing models (see page 26). Parts included in the Air Valve
Repair Kit are marked with a symbol in the parts list, for example (3).
To repair your pump, select the six digits which describe your pump from the following matrix, working from left to right. The first digit is always D, the second digit is always 0 (zero), and the third is always B. The remaining three digits define the materials of construction. Parts included in the kit are marked with an asterisk in the parts list, for example (201*). For example, if your pump has polypropylene seats, PTFE balls, and PTFE diaphragms, order
Repair Kit
D 0 B 9 1 1.
If you only need to repair certain parts (for example, the diaphragms), use the 0 (null) digits for the seats and balls, and order Repair Kit
D 0 B 0 0 1.
The digits in the matrix do not correspond to the ref. nos. in the parts drawing and lists on pages 26–27.
Diaphragm
Pump Null Shaft O-ring
D (for all pumps) 0 (for all pumps) B (PTFE)
– Seats
– 0 (null)
– 1 (not used)
– 2 (not used)
– 3 (316 sst)
– 4 (17–4 PH sst)
– 5 (TPE)
– 6 (Santoprene )
– 7 (Buna–N)
Balls
0 (null)
1 (PTFE)
2 (acetal)
3 (not used)
4 (440C sst)
5 (TPE)
6 (Santoprene )
7 (Buna–N)
Diaphragms
0 (null)
1 (PTFE)
2 (not used)
3 (not used)
4 (not used)
5 (TPE)
6 (Santoprene )
7 (Buna–N)
– 8 (Fluoroelastomer) 8 (Fluoroelastomer) 8 (Fluoroelastomer)
– 9 (polypropylene) 9 (not used) 9 (not used)
– A (PVDF)
– G (Geolast )
A (not used)
G (Geolast )
A (not used)
G (Geolast )
Part No. 253627: Husky 1590 HD Overmolded PTFE/EPDM Diaphragm Repair Kit.
Part No. 289225: Husky 1590 HD Overmolded PTFE/EPDM Diaphragm Repair Kit, with new air side diaphragm plates.
308441 25
Parts Drawing
11
10
17
16
18
3
2
4
3
5
6
7
8
9
16
17
1
12
10
11
22
14 }
110
20
23
15
25
1
111
1 402* 19
13 }
24
Aluminum Model Shown
104
1 Not used on some models.
2 Used on PTFE models only.
401*
3 Used on stainless steel models only.
1 403*
}
These parts are unique to remote piloted air motor, DC––––, DT––––
* These parts are included in the Pump Repair Kit, which may be purchased separately.
Refer to the Repair Kit Matrix on page 25 to determine the correct kit for your pump.
These parts are included in Air Valve Repair Kit 236273 (aluminum center housing models), which may be purchased separately.
These parts are included in Air Valve Repair Kit 255061 (stainless steel center housing models), which may be purchased separately.
Replacement Danger and Warning labels, tags and cards are available at no cost.
105
108*
107
3
113
*301
*201
106
106
103
301*
201*
202* 1
106
101
112
202*
1
102
03279C
26 308441
Parts
Air Motor Parts List (Matrix Column 2)
20
22
23
17
18
19
24
25
Digit
Ref.
No.
Part No.
Description
B 1
2
188838 HOUSING, center; aluminum
188854 COVER, air valve; aluminum
3
4
116344 SCREW, mach, hex flange hd; M5 x 0.8;
12 mm (0.47 in.)
188618 GASKET, cover; foam
5
6
7
188855
108730
CARRIAGE; aluminum
O-RING; nitrile
1
9
1
1
1
188616 BLOCK, air valve; acetal 1
Qty
1
8
9
10
188615
188617
112181
PLATE, air valve; sst
SEAL, valve plate; buna-N
PACKING, u-cup; nitrile
1
1
2
11 188612 PISTON, actuator; acetal 2
12 188613 BEARING, piston; acetal 2
13 } 104765 PLUG, pipe; headless
14
}
115671 FITTING, connector; male
2
2
15
16
188611 BEARING, pin; acetal 2
188610 PIN, pilot; stainless steel 2
157628 O-RING; buna-N
188614 BLOCK, pilot; acetal
188609 BEARING, shaft; acetal
116343 SCREW, grounding 1
188603 GASKET, air cover; foam 2
189400 COVER, air; aluminum 2
189245 SHAFT, diaphragm; sst
115643 SCREW; M8 x 1.25;
25 mm (1 in.), aluminum
2
1
2
1
12
Digit
C
Ref.
No.
Part No.
Description
Same as B with the following exceptions
1 195921 HOUSING, center; remote, aluminum
23 195918 COVER, air; remote
T Same as B with the following exceptions
1
2
15K009 HOUSING, center; stainless steel
15K696 COVER, air valve; stainless steel
8
9
15H178 PLATE, air valve; stainless steel
– –
U
23
25
15A739 COVER, air; stainless steel
112178 SCREW; M8 x 1.25;
25 mm (1 in.), stainless steel
Same as B with the following exceptions
1
2
8
9
23
25
15K011 HOUSING, center; remote, stainless steel
15K696 COVER, air valve; stainless steel
15H178 PLATE, air valve; stainless steel
– –
15B795 COVER, air; remote, stainless steel
112178 SCREW; M8 x 1.25;
25 mm (1 in.), stainless steel
Qty
1
2
1
–
2
12
1
1
1
–
2
12
1
1
308441 27
Parts
Fluid Section Parts List (Matrix Column 3)
Digit
3
Ref.
No.
101
102
103
Part No.
Description Qty
15A615 COVER, fluid; aluminum 2
1 189402 MANIFOLD, inlet; aluminum
15A616 MANIFOLD, outlet; aluminum
1
2 104
105
15K448 PLATE, air side; aluminum
189843 PLATE, fluid side; carbon steel
106
107
115644 SCREW; M10 x 1.25;
35 mm (1.38 in.)
189410 BOLT; M12 x 1.75;
55 mm (2.17 in.); 316 sst
108* 104319 O-RING; PTFE
2
24
2
2
1
1
4
110
111
112
101
102
103
188970 LABEL, warning
102656 MUFFLER (not used on
Model No. 253485)
115645 SCREW; M10 x 1.50;
90 mm (3.54 in.)
194169
194170
COVER, fluid; sst
MANIFOLD, inlet; sst
194221 MANIFOLD, outlet; sst
104 15K448 PLATE, air side; aluminum
189309 PLATE, fluid side; sst 105
106 112416 SCREW; M10 x 1.25;
30 mm (1.18 in.); sst
107 189410 BOLT; M12 x 1.75;
55 mm (2.17 in.); 316 sst
108* 104319 O-RING; PTFE
4
2
1
1
2
2
24
2
2
1 110
111
112
188621 LABEL, warning
102656 MUFFLER
112417 SCREW; M10 x 1.50;
90 mm (3.54 in.); sst
1
4
Digit
C
Ref.
No.
101
Part No.
Description Qty
15A615 COVER, fluid; aluminum 2
1 102
103
104
105
192078 MANIFOLD, inlet; aluminum; BSPT
15A658 MANIFOLD, outlet; aluminum; BSPT
15K448 PLATE, air side; aluminum
189843 PLATE, fluid side; carbon steel
106
107
115644 SCREW; M10 x 1.25;
35 mm (1.38 in.)
189410 BOLT; M12 x 1.75;
55 mm (2.17 in.); 316 sst
108* 104319 O-RING; PTFE
1
2
2
24
2
2
1
1
4
D
110
111
112
188970 LABEL, warning
102656 MUFFLER
115645 SCREW; M10 x 1.50;
90 mm (3.54 in.)
194169 COVER, fluid; sst 101
102
103
195574 MANIFOLD, inlet; sst;
BSPT
195575 MANIFOLD, outlet; sst;
BSPT
104 15K448 PLATE, air side; aluminum
189309 PLATE, fluid side; sst 105
106
107
112416 SCREW; M10 x 1.25;
30 mm (1.18 in.); sst
189410 BOLT; M12 x 1.75;
55 mm (2.17 in.); 316 sst
108* 104319 O-RING; PTFE
110 188621 LABEL, warning
111
112
113
102656 MUFFLER
112417 SCREW; M10 x 1.50;
90 mm (3.54 in.); sst
114862 NUT, hex, M10, fhn
2
1
1
2
2
24
2
8
1
4
2
1
28 308441
Seat Parts List (Matrix Column 4)
Digit
3
Ref.
No.
Part No.
Description
201* 189318 SEAT; 316 stainless steel
202* 112418 O-RING; PTFE
4 201* 189319 SEAT; 17-4 stainless steel
202* 112418 O-RING; PTFE
5
6
7
8
201* 189322 SEAT; TPE
202 None Not Used
201* 189320 SEAT; Santoprene
202* 112418 O-RING; PTFE
201* 15B266 SEAT; Buna–N
202 None Not used 0
201* 15B264 SEAT; Fluoroelastomer 4
202 None Not used
4
4
0
4
4
0
4
4
4
Qty
4
9
A
G
201* 193417 SEAT; polypropylene
202* 112418 O-RING; PTFE
201* 189732 SEAT; PVDF
202* 112418 O-RING; PTFE
201* 194213 SEAT; Geolast
202* 112418 O-RING; PTFE
4
4
4
4
4
4
Parts
Ball Parts List (Matrix Column 5)
5
6
7
8
Digit
1
2
Ref.
No.
Part No.
Description
301* 112419 BALL; PTFE
301* 112423 BALL; acetal
4 301* 112420 BALL; 440C stainless steel
301* 112831 BALL; TPE
301*
301*
301*
112421
15B490
15B489
BALL; Santoprene
BALL; Buna–N
BALL; Fluoroelastomer
G 301* 114752 BALL; Geolast 4
Diaphragm Parts List (Matrix Column 6)
Digit
Ref.
No.
Part No.
Description Qty
1 2 401* Not sold separately
DIAPHRAGM, backup; polychloroprene (CR)
402* 112181 PACKING, u-cup; nitrile
403* 15K312 DIAPHRAGM; PTFE
2
2
4
4
4
4
Qty
4
4
4
5
6
7
401* 189425 DIAPHRAGM; TPE
402* 112181 PACKING, u-cup; nitrile
401* 189426 DIAPHRAGM; Santoprene
402* 112181 PACKING, u-cup; nitrile
401* 15B312 DIAPHRAGM; Buna–N
2
2
2
2
2
8
402* 112181 PACKING, u-cup; nitrile
401* 15B501 DIAPHRAGM;
Fluoroelastomer
402* 112181 PACKING, u-cup; nitrile
2
2
2
G 401* 194214 DIAPHRAGM;
Geolast
402* 112181 PACKING, u-cup; nitrile
2
2
* These parts are included in the pump repair kit, purchased separately. See Repair Kit Matrix on page 25 to determine the correct kit for your pump.
308441 29
Torque Sequence
Always follow torque sequence when instructed to torque fasteners.
1.
Left/Right Fluid Covers
Torque bolts to 190–220 in–lb (22–25 N m).
3.
Outlet Manifold
Torque bolts to 120–150 in–lb (14–17 N
15 18 m).
1
3
8
5
17 16
10 9
TOP VIEW
6
4 2
7
SIDE VIEW
2.
Inlet Manifold
Torque bolts to 120–150 in–lb (14–17 N m).
11 14
13 12
BOTTOM VIEW
30 308441
1/2 npt(f)
Air Inlet
3/4 npt(f)
Air Exhaust
268 mm
FRONT VIEW
197 mm
Dimensions
PUMP MOUNTING HOLE PATTERN
6.0 in.
(152.5 mm)
6.0 in.
(152.5 mm)
A
B
C
1
152.5 mm
379.5 mm
SIDE VIEW
5.23 in.
(132.5 mm)
38 mm 1
Muffler not included on Model No. 253485.
Dim.
A
B
C
Alum. Pumps
16.81 in. (427 mm)
18.31 in. (465 mm)
19.56 in. (497 mm)
SST Pumps
16.25 in. (412.5 mm)
17.75 in. (451 mm)
19.0 in. (482.5 mm)
1.5 npt(f) Outlet Port
45
°
1.5 npt(f) Inlet Port
1
.45 in.
(11.5 mm)
6.0 in.
(152.5 mm)
10.46 in.
(265.5 mm) 7438B
308441 31
Technical Data
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 psi
Air pressure operating range
(0.8 MPa, 8 bar)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–120 psi
Maximum air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air consumption at 70 psi/60 gpm
(0.14 –0.8 MPa, 1.4–8 bar)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
125 scfm
50 scfm (see chart)
Maximum free-flow delivery
Maximum pump speed
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 gpm (378.5 l/min)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 cpm
Gallons (Liters) per cycle
Maximum suction lift
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.5 (1.9)
18 ft (5.48 m) wet or dry
Maximum size pumpable solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* Maximum noise level at 100 psi, full flow
3/16 in. (4.8 mm)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 dBa
* Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* Noise level at 70 psi, 50 cycles/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108 dBa
72 dBa
Maximum operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 F (65.5
C);
200 F (93.3
C) for models with PTFE diaphragms
Air inlet size
Fluid inlet size
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-wetted external parts
Weight
0.5 npt(f)
1.5 npt(f)
Fluid outlet size
Wetted parts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 npt(f)
Vary by Model. See pages 24–26.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aluminum, 302, 316 stainless steel, polyester (labels)
Aluminum pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stainless steel pumps with aluminum center section
33.5 lb (15.2 kg)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 lb (32.7 kg)
Stainless steel pumps with stainless steel center section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 lb (40 kg)
Geolast is a registered trademarks of the ExxonMobil Chemical Co.
Santoprene is a registered trademarks of the Monsanto Co.
Loctite r is a registered trademark of the Loctite Corporation.
* Noise levels measured with the pump mounted on the floor, using Rubber Foot Kit 236452. Sound power measured per ISO Standard 9216.
32 308441
Performance Chart
Example of Finding Pump Air Consumption and Air Pressure at a Specific Fluid Delivery and Discharge Head:
To supply 60 gpm (227 liters) fluid flow (horizontal scale) at 40 psi (0.28 MPa, 2.8 bar) discharge head pressure (vertical scale) requires approximately 50 scfm (1.40 m /min) air consumption at 70 psi (0.49 MPa, 4.9 bar) inlet air pressure.
feet
(meters)
280
(85.3) psi
(MPa, bar)
120
(0.8, 8) A
240
(73.2)
200
(61.0)
100
(0.7, 7.0) B
E
INLET AIR PRESSURES
A 120 psi air (0.8, 8 bar)
B 100 psi air (0.7, 7 bar)
C 70 psi air (0.49, 4.9 bar)
D 40 psi air (0.28, 2.8 bar)
80
(0.56, 5.6)
160
(48.8)
120
(36.6)
60
(0.42, 4.2)
C
F
G
80
(24.4)
40
(12.2)
40
(0.28, 2.8)
20
(0.14, 1.4)
D
0
0
0 15
(57)
30
(114)
45
(170)
60
(227)
75
(284)
FLUID FLOW GPM (lpm)
TEST CONDITIONS
Pump tested in water with PTFE diaphragm and inlet submerged.
KEY
AIR CONSUMPTION
E 20 scfm (0.56 m /min)
F 40 scfm (1.12 m /min)
G 60 scfm (1.68 m /min)
H 80 scfm (2.24 m /min)
90
(341)
H
105
(397)
120
(454)
FLUID PRESSURE AND FLOW
SCFM AIR CONSUMPTION
308441 33
Graco Warranties
Graco Standard Husky Pump Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco,
Graco will, for a period of five years from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within six years of the date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Extended Product Warranty
Graco warrants all Husky 205, 307, 515, 716, 1040, 1590, 2150, and 3275 air valve center sections to be free from defects in material and workmanship for a period of fifteen years from date installed in service by the original purchaser. Normal wear of items such as packings or seals are not considered to be defects in material and workmanship.
Five years
Six to Fifteen years
Graco will provide parts and labor.
Graco will replace defective parts only.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor, or call to identify the nearest distributor.
1–800–328–0211 Toll Free, 612–623–6921, 612–378–3505 Fax
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 308441
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 1995, Graco Inc. is registered to ISO 9001 www.graco.com
Revised 02/2010
34 308441
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