Instructions – Parts List

POLYPROPYLENE AND PVDF

Huskyt 1590 Air-Operated

308549ZAE
Diaphragm Pumps EN

1.5–inch AODD pump for fluid transfer applications. For professional

use only.
Not approved to European explosive atmosphere requirements.
See Models on page 2 for a list of pump models and descriptions.
120 psi (0.84 MPa, 8.4 bar) Maximum Fluid Working Pressure
120 psi (0.84 MPa, 8.4 bar) Maximum Air Input Pressure

Important Safety Instructions

Read all warnings and instructions in
this manual. Save these instructions.

04700B
 Table of Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Repair Kit Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Technical Data and Performance Chart . . . . . . . . . . . 35
Service Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 36
Repairing the Air Valve . . . . . . . . . . . . . . . . . . . . . . 16 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ball Check Valve Repair . . . . . . . . . . . . . . . . . . . . . 18
Diaphragm Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bearing and Air Gasket Removal . . . . . . . . . . . . . 23

Models
Model No. Description
*DB2______ Polypropylene Pumps
*DC2______ Polypropylene Pumps, Remote
*DB5______ PVDF Pumps
*DC5______ PVDF Pumps, Remote
*DT2______ Polypropylene Plus Pumps
*DU2______ Polypropylene Plus Pumps, Remote
*DT5______ PVDF Plus Pumps
*DU5______ PVDF Plus Pumps, Remote
24B758 PVDF Plus Pump with overmolded diaphragms
24B759 Polypropylene Plus Pump with overmolded diaphragms
24B760 Polypropylene Pump with overmolded diaphragms
24B761 Polypropylene Pump with overmolded diaphragms and sst seats
24B832 PVDF Pump with overmolded diaphragms

* See the Pump Matrix on page 26 to determine the Model No. of your pump.

NOTE: Plus Models include stainless steel center sections.

2 308549
 Symbols
Warning Symbol Caution Symbol

WARNING CAUTION
This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to
injury or death if you do not follow the instructions. 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

D This equipment is for professional use only.

D Read all instruction manuals, tags, and labels before operating the equipment.

D Use the equipment only for its intended purpose. If you are not sure, call Graco your Graco
distributor.

D Do not alter or modify this equipment.

D Check equipment daily. Repair or replace worn or damaged parts immediately.

D Do not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 120 psi (0.84 MPa, 8.4 bar) maximum working pressure at 120 psi
(0.84 MPa, 8.4 bar) maximum incoming air pressure.

D 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.

D Do not use hoses to pull equipment.

D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-
pose Graco hoses to temperatures above 82_ C (180_ F) or below –40_ C (–40_ F).

D Do not lift pressurized equipment.

D Wear hearing protection when operating this equipment.

D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

308549 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.

D Know the specific hazards of the fluid you are using.

D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.

D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.

D 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 11.

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.

D Ground the equipment. Refer to Grounding on page 6.

D Never use a polypropylene or PVDFR pump with non-conductive flammable fluids as specified
by your local fire protection code. Refer to Grounding on page 6 for additional information.
Consult your fluid supplier to determine the conductivity or resistivity of your fluid.

D 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.

D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed, dispensed, or transferred.

D 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 11.

D Keep the work area free of debris, including solvent, rags, and gasoline.

D Electrically disconnect all equipment in the work area.

D Extinguish all open flames or pilot lights in the work area.

D Do not smoke in the work area.

D Do not turn on or off any light switch in the work area while operating or if fumes are present.

D Do not operate a gasoline engine in the work area.

4 308549
 Installation
General Information Tighten Screws Before First Use
D The Typical Installation shown in Fig. 2 is only a Before using the pump for the first time, check and
guide for selecting and installing system compo- retorque all external fasteners. See Torque Se-
nents. Contact your Graco distributor or Graco quence, page 32. After the first day of operation,
Technical Assistance (see back page) for assis- retorque the fasteners. Although pump use varies, a
tance in planning a system to suit your needs. general guideline is to retorque fasteners every two
D Always use Genuine Graco Parts and Accessories. months.
Be sure all accessories are adequately sized and
pressure-rated to meet the system’s requirements.
D Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 30 to 31.
D Variations in color between the plastic components
of this pump are normal. Color variation does not
affect the performance of the pump.

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.

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 manu-
als. Read the fluid and solvent manufacturer’s
warnings.

308549 5
 Installation
Grounding Ground all of this equipment:

D 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
WARNING ground wire to a true earth ground. Order Part
FIRE AND EXPLOSION HAZARD No. 237569 Ground Wire and Clamp.
This pump must be grounded. Before
operating the pump, ground the system NOTE: When pumping conductive flammable fluids
as explained below. Also, read the sec- with a polypropylene or a PVDF pump, always ground
tion FIRE AND EXPLOSION HAZARD, the entire fluid system. See the WARNING on
on page 4. page 6.

Polypropylene and PVDF are not conductive. D Air and fluid hoses: Use only electrically conductive
Attaching the ground wire to the grounding lug hoses.
grounds only the air motor. When pumping conduc-
D Air compressor: Follow the manufacturer’s recom-
tive flammable fluids, always ground the entire
mendations.
fluid system by making sure the fluid has an electri-
cal path to a true earth ground. See Fig. 1.
D All solvent pails used when flushing: Follow your
local code. Use only metal pails, which are conduc-
Never use a polypropylene or a PVDF pump with
tive. Do not place the pail on a non-conductive
non-conductive flammable fluids as specified by
surface, such as paper or cardboard, which inter-
your local fire protection code.
rupts the grounding continuity.
US Code (NFPA 77 Static Electricity) recommends
D Fluid supply container: Follow your local code.
a conductivity greater than 50 x 10–12 Siemans/me-
ter (mhos/meter) over your operating temperature
range to reduce the hazard of fire. Consult your
fluid supplier to determine the conductivity or
resistivity of your fluid. The resistivity must be less
than 2 x 1012 ohm-centimeters.
Y

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 W
grounding instructions for your area and type of equip-
02646B
ment. Fig. 1

6 308549
 Installation
Air Line b. Locate one bleed-type master air valve (B)
close to the pump and use it to relieve trapped
air. See the WARNING at left. Locate the other
WARNING master air valve (E) upstream from all air line
accessories and use it to isolate them during
A bleed-type master air valve (B) is required in cleaning and repair.
your system to relieve air trapped between this
valve and the pump. Trapped air can cause the c. The air line filter (F) removes harmful dirt and
pump to cycle unexpectedly, which could result in moisture from the compressed air supply.
serious injury, including splashing in the eyes or on
the skin, injury from moving parts, or contamination 2. Install an electrically conductive, flexible air hose
from hazardous fluids. See Fig. 2. (A) between the accessories and the 1/2 npt(f)
pump air inlet (N). See Fig. 2. Use a minimum 1/2”
(13 mm) ID air hose.
1. Install the air line accessories as shown in Fig. 2.
Mount these accessories on the wall or on a 3. Screw an air line quick disconnect coupler (D) onto
bracket. Be sure the air line supplying the acces- the end of the air hose (A); be sure the coupler
sories is electrically conductive. porting is large enough to not restrict the air flow,
which will affect pump performance. Screw the
a. Install an air regulator (C) and gauge to control mating fitting into the pump air inlet snugly. Do not
the fluid pressure. The fluid outlet pressure will connect the coupler (D) to the fitting until you are
be the same as the setting of the air regulator. ready to operate the pump.

Floor Mount Typical Installation

KEY FOR FIG. 2 B C F E
A Electrically conductive 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) A
F Air line filter
G Fluid suction hose
H Fluid supply
J Fluid drain valve (required)
K Fluid shutoff valve D
L Fluid hose S K L
N 1/2 npt(f) air inlet port
R 1–1/2” fluid inlet flange
S 1–1/2” fluid outlet flange
Y Ground wire (required; see page 6
for installation instructions)
N
Y J
H
R G

04701B
Fig. 2

308549 7
 Installation
Installation of Remote Pilot Air Lines 4. Rubber Foot Mounting Kit 236452 is available to
reduce noise and vibration during operation.
1. Refer to Parts Drawings. Connect air line to pump
as in preceding steps. Fluid Suction Line
2. Connect 1/4 in. O.D. tubing to push type connec- 1. The pump fluid inlet (R) is a 1–1/2 in. raised face
tors (14) on air motor of pump. flange. Refer to Flange Connections on page 9.

NOTE: by replacing the push type connectors, other 2. If the fluid inlet pressure to the pump is more than
sizes or types of fittings may be used. The new fittings 25% of the outlet working pressure, the ball check
will require 1/8 in. npt threads. valves will not close fast enough, resulting in
inefficient pump operation.
3. Connect remaining ends of tubes to external air
signal, such as Graco’s Cycleflo (P/N 195264) or
3. At inlet fluid pressures greater than 15 psi
Cycleflo II (P/N195265) controllers.
(0.1 MPa, 1 bar), diaphragm life will be shortened.
NOTE: the air pressure at the connectors must be at
4. See the Technical Data on page 35 for maximum
least 30% of the air pressure to the air motor for the suction lift (wet and dry).
pump to operate.
Mountings Fluid Outlet Line

CAUTION WARNING
The pump exhaust air may contain contaminants. A fluid drain valve (J) is required to relieve pres-
Ventilate to a remote area if the contaminants sure in the hose if it is plugged. The drain valve
could affect your fluid supply. See Air Exhaust reduces the risk of serious injury, including splash-
Ventilation on page 11. ing 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
1. Be sure the mounting surface can support the Fig. 2.
weight of the pump, hoses, and accessories, as
well as the stress caused during operation.
1. The pump fluid outlet (S) is a 1–1/2 in. raised face
2. For all mountings, be sure the pump is bolted flange. Refer to Flange Connections on page 9.
directly to the mounting surface.
2. Install a fluid drain valve (J) near the fluid outlet.
3. For ease of operation and service, mount the See the WARNING above.
pump so the air valve cover (2), air inlet, and fluid
inlet and outlet ports are easily accessible. 3. Install a shutoff valve (K) in the fluid outlet line.

8 308549
 Installation
Flange Connections 1. Place a flat washer (E) on each bolt (C). Refer to
Fig. 3.
The fluid inlet and outlet ports are 1–1/2 in. raised
face, standard 150 lb class pipe flanges. Connect
1–1/2 in. flanged plastic pipe to the pump as follows. 2. Align the holes in the gasket (B) and the pipe
You will need: flange (A) with the holes in the pump outlet flange
(S).
D Torque wrench
D Adjustable wrench 3. Lubricate the threads of the four bolts. Install the
bolts through the holes and secure with the wash-
D a 5 in. diameter, 1/8 in. thick PTFE gasket, with ers (E), lockwashers (D), and nuts (F).
four 0.63 in. diameter holes on a 3.88 in. diameter
bolt circle, and a 1.75 in. diameter center
4. Hold the nuts with a wrench. Refer to the tighten-
D four 1/2 in. x 3 in. bolts
ing sequence in Fig. 3 and torque the bolts to 10 to
D four 1/2 in. spring lockwashers 15 ft-lb (14 to 20 NSm). Do not over-torque.
D eight 1/2 in. flat washers
D four 1/2 in. nuts. 5. Repeat for the pump inlet flange (R).

BOLT TIGHTENING SEQUENCE 1

3 1

F
D
E 2 4
S

B 04405

C 1

KEY FOR FIG. 3

A Flanged plastic pipe
B PTFE gasket
C Bolt
D Lockwasher
E Flat washer
F Nut
R 1–1/2” fluid inlet flange
S 1–1/2” fluid outlet flange

Lubricate threads. Torque to 10 to 15 ft-lb

1
(14–20 N-m). Do not over-torque. 04703B
Fig. 3
308549 9
 Installation
Changing the Orientation of the Fluid Inlet Fluid Pressure Relief Valve
and Outlet Ports
The pump is shipped with the fluid inlet (R) and outlet CAUTION
(S) ports facing the same direction. See Fig. 4. To
change the orientation of the inlet and/or outlet port: Some systems may require installation of a pres-
sure relief valve at the pump outlet to prevent
1. Remove the screws (106 and 112) holding the inlet overpressurization and rupture of the pump or
(102) and/or outlet (103) manifold to the covers hose. See Fig. 5.
(101).
Thermal expansion of fluid in the outlet line can
2. Reverse the manifold and reattach. Install the cause overpressurization. This can occur when
screws and torque to 80 to 90 in-lb (9 to 10 NSm). using long fluid lines exposed to sunlight or ambi-
See Torque Sequence, page 32. ent heat, or when pumping from a cool to a warm
area (for example, from an underground tank).
KEY
N 1/2 npt(f) Air Inlet Port 101 Fluid Covers Overpressurization can also occur if the Husky
P Muffler; Air Exhaust Port 102 Fluid Inlet Manifold pump is being used to feed fluid to a piston pump,
is 3/4 npt(f) 103 Fluid Outlet Manifold and the intake valve of the piston pump does not
R 1–1/2” Fluid Inlet Flange 106 Fluid Outlet Manifold close, causing fluid to back up in the outlet line.
S 1–1/2” Fluid Outlet Flange Screws (Top)
112 Fluid Inlet Manifold
Screws (Bottom)
1 Torque to 80 to 90 in-lb (9 to 10 NSm).
KEY
See Torque Sequence, page 32.
R 1–1/2” fluid inlet flange
103 S 1–1/2” fluid outlet flange
V Pressure relief valve
106 1 Part No. 112119 (stainless steel)

S
1 Install valve between fluid inlet and outlet ports.
2 Connect fluid inlet line here.

3 Connect fluid outlet line here.

N S 3

101
R V 1

2
P

102 04700B
112 1
R
04702B
Fig. 4 Fig. 5

10 308549
 Installation
Air Exhaust Ventilation 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 If the muffler (P) is installed directly to the air exhaust
Be sure to read and follow the warnings port, apply PTFE thread tape or anti–seize thread
and precautions regarding TOXIC lubricant to the muffler threads before assembly.
FLUID HAZARD, and FIRE OR EXPLO-
SION HAZARD on page 4, before op- To provide a remote exhaust:
erating this pump.
1. Remove the muffler (P) from the pump air exhaust
Be sure the system is properly ventilated for your port.
type of installation. You must vent the exhaust to a
safe place, away from people, animals, food handl- 2. Install an electrically conductive air exhaust hose
ing areas, and all sources of ignition when pumping (T) and connect the muffler (P) to the other end of
flammable or hazardous fluids. the hose. The minimum size for the air exhaust
hose is 3/4 in. (19 mm) ID. If a hose longer than 15
Diaphragm failure will cause the fluid being ft (4.57 m) is required, use a larger diameter hose.
pumped to exhaust with the air. Place an appropri- Avoid sharp bends or kinks in the hose. See Fig. 6.
ate container at the end of the air exhaust line to
catch the fluid. See Fig. 6. 3. Place a container (U) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures.

Venting Exhaust Air

KEY
A Air supply line
B Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E F C B E Master air valve (for accessories)
F Air line filter
P Muffler
T Electrically conductive air exhaust hose
U Container for remote air exhaust

T
U

04704
Fig. 6

308549 11
 Operation
Pressure Relief Procedure 1. Be sure the pump is properly grounded. Refer to
Grounding on page 6.

WARNING
PRESSURIZED EQUIPMENT HAZARD 2. Check all fittings to be sure they are tight. Be sure
The equipment stays pressurized until pressure is to use a compatible liquid thread sealant on all
manually relieved. To reduce the risk of serious male threads. Tighten the fluid inlet and outlet
injury from pressurized fluid, accidental spray from fittings securely.
the gun or splashing fluid, follow this procedure
whenever you:
3. Place the suction tube (if used) in the fluid to be
D Are instructed to relieve pressure, pumped.
D Stop pumping,
D Check, clean or service any system equipment,
D Install or clean fluid nozzles. 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
1. Shut off the air to the pump. pump operation.

2. Open the dispensing valve, if used.

4. Place the end of the fluid hose (L) into an appropri-
3. Open the fluid drain valve to relieve all fluid pres- ate container.
sure, having a container ready to catch the drain-
age.
5. Close the fluid drain valve (J). See Fig. 2.
Flush the Pump Before First Use
The pump was tested in water. If water could contami- 6. With the pump air regulator (C) closed, open all
nate the fluid you are pumping, flush the pump thor- bleed-type master air valves (B, E).
oughly with a compatible solvent. Follow the steps
under Starting and Adjusting the Pump.
7. If the fluid hose has a dispensing device, hold it
Starting and Adjusting the Pump open while continuing with the following step.

WARNING 8. Slowly open the air regulator (C) until the pump
TOXIC FLUID HAZARD starts to cycle. Allow the pump to cycle slowly until
Hazardous fluid or toxic fumes can all air is pushed out of the lines and the pump is
cause serious injury or death if splashed primed.
in the eyes or on the skin, inhaled, or
swallowed. Do not lift a pump under pressure. If If you are flushing, run the pump long enough to
dropped, the fluid section may rupture. Always fol- thoroughly clean the pump and hoses. Close the
low the Pressure Relief Procedure above before air regulator. Remove the suction tube from the
lifting the pump. solvent and place it in the fluid to be pumped.

12 308549
 Operation
Operation of Remote Piloted Pumps NOTE: Leaving air pressure applied to the air motor for
extended periods when the pump is not running may
1. Follow preceding steps 1 through 7 of Starting shorten the diaphragm life. Using a 3–way solenoid
and Adjusting Pump. valve to automatically relieve the pressure on the air
motor when the metering cycle is complete prevents
this from occurring.
2. Open air regulator (C).
Pump Shutdown
WARNING WARNING
The pump may cycle once before the external sig-
nal is applied. Injury is possible. If pump cycles, To reduce the risk of serious injury whenever you
wait until end before proceeding. are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
3. Pump will operate when air pressure is alternately
applied and relieved to push type connectors (14). At the end of the work shift, relieve the pressure.

Maintenance
Lubrication Flush the pump often enough to prevent the fluid you
are pumping from drying or freezing in the pump and
The air valve is designed to operate unlubricated. damaging it. Flush with a fluid that is compatible with
However, if lubrication is desired, every 500 hours of the fluid you are pumping and with the wetted parts in
operation (or monthly) remove the hose from the pump your system. Check with your fluid manufacturer or
air inlet and add two drops of machine oil to the air supplier for recommended flushing fluids and flushing
inlet. frequency.

Always flush the pump and relieve the pressure before

storing it for any length of time.
CAUTION Tightening Threaded Connections
Do not over-lubricate the pump. Oil is exhausted
through the muffler, which could contaminate your Before each use, check all hoses for wear or damage,
fluid supply or other equipment. Excessive lubrica- and replace as necessary. Check to be sure all
tion can also cause the pump to malfunction. 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,
Flushing and Storage page 32.

WARNING Preventive Maintenance Schedule

To reduce the risk of serious injury whenever you Establish a preventive maintenance schedule, based
are instructed to relieve pressure, always follow the on the pump’s service history. This is especially impor-
Pressure Relief Procedure on page 12. tant for prevention of spills or leakage due to dia-
phragm failure.

308549 13
 Troubleshooting
1. Relieve the pressure before checking or servicing
WARNING the equipment.

To reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12. 2. Check all possible problems and causes before
disassembling the pump.

PROBLEM CAUSE SOLUTION

Pump cycles at stall or fails to hold Worn check valve balls (301), seats Replace. See page 18.
pressure at stall. (201) or o-rings (202).
Pump will not cycle, or cycles once Air valve is stuck or dirty. Disassemble and clean air valve.
and stops. See pages 16 to 17. Use filtered air.
Check valve ball (301) severely Replace ball and seat. See page
worn and wedged in seat (201) or 18.
manifold (102 or 103).
Check valve ball (301) is wedged Install Pressure Relief Valve
into seat (201), due to overpressur- (see page 10).
ization.
Dispensing valve clogged. Relieve pressure and clear valve.
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking balls (301). Clean or replace. See page 18.
Diaphragm ruptured. Replace. See pages 19 to 22.
Restricted exhaust. Remove restriction.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace. See pages 19 to 22.
Loose inlet manifold (102), dam- Tighten manifold bolts (112) or re-
aged seal between manifold and place seats (201) or o-rings (202).
seat (201), damaged o-rings (202). See page 18.
Loose fluid side diaphragm plate Tighten or replace. See pages
(105). 19 to 22.

14 308549
 Troubleshooting
PROBLEM CAUSE SOLUTION
Fluid in exhaust air. Diaphragm ruptured. Replace. See pages 19 to 22.
Loose fluid side diaphragm plate Tighten or replace. See pages
(105). 19 to 22.
Pump exhausts excessive air at Worn air valve block (7{H), o-ring Inspect; replace. See pages
stall. (6{H), 16 to 17.
plate (8H), pilot block (18), u-cups
(10), or pilot pin o-rings (17).
Worn shaft seals (402). Replace. See pages 19 to 22.
Pump leaks air externally. Air valve cover (2) or air valve cover Tighten screws. See page 17.
screws (3) are loose.
Air valve gasket (4{H) or air cover Inspect; replace. See pages 16
gasket (22) is damaged. to 17 and 23 to 24.
Air cover screws (25) are loose. Tighten screws. See pages
23 to 24.
Pump leaks fluid externally from ball Loose manifolds (102, 103), dam- Tighten manifold bolts (106 and
check valves. aged seal between manifold and 112) or replace seats (201) or o-
seat (201), damaged o-rings (202). rings (202). See page 18.

308549 15
 Service
Repairing the Air Valve 3 2

Tools Required 2
D Torque wrench 4{H
D Torx (T20) screwdriver or 7 mm (9/32 in.) socket
wrench
D Needle-nose pliers
D O-ring pick
D Lithium base grease

NOTE: Air Valve Repair Kits 236273 (aluminum center

housing models) and 255061 (SST center housing
models) are available. Refer to page 30. 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 Torque to 50–60 in-lb
Pressure Relief Procedure on page 12. 2
(5.6–6.8 N-m).
04705B
Fig. 7
1. Relieve the pressure.

2. With a Torx (T20) screwdriver or 7 mm (9/32 in.)

socket wrench, remove the six screws (3), air 1 See Detail at right. 5
valve cover (2), and gasket (4{H). See Fig. 7. 2 Grease.
2 H{6
3 Grease lower face.
3. Move the valve carriage (5{H) to the center posi-
tion and pull it out of the cavity. Remove the valve 3 H{7
block (7{H) and o-ring (6{H) from the carriage.
Using a needle-nose pliers, pull the pilot block (18)
straight up and out of the cavity. See Fig. 8.

4. Pull the two actuator pistons (11) out of the bear-

ings (12). Remove the u-cup packings (10{H) from H{18 3
the pistons. Pull the pilot pins (16) out of the
5 1
bearings (15). Remove the o-rings (17) from the
pilot pins. See Fig. 9.
11
5. Inspect the valve plate (8H) 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, remove the seal (9{). See
Fig. 10.

6. Inspect the bearings (12, 15) in place. See Fig. 9.

The bearings are tapered and, if damaged, must
be removed from the outside. This requires disas-
sembly of the fluid section. See page 23.

7. Clean all parts and inspect for wear or damage. 16

04898
Replace as needed. Reassemble as explained on Fig. 8
page 17.
16 308549
 Service
Install with lips facing 1
1 Insert narrow end first. 3 Rounded side must face down (aluminum 3
narrow end of piston (11). 2
center housing models only).
2 Grease. 4 Insert wide end first. 2 Tighten screws until
they bottom out on the 8H
housing.

9{ 1

10{H 2 3

11 4

12

2 17{H 15 16 1 03271
Fig. 10
04899
Fig. 9

Reassembly
1. If you removed the bearings (12, 15), install new 6. Lubricate the u-cup packings (10{H) and actuator
ones as explained on page 23. Reassemble the pistons (11). Insert the actuator pistons in the
fluid section. bearings (12), wide end first. Leave the narrow
end of the pistons exposed. See Fig. 9.
2. On aluminum center housing models, install the
valve plate seal (9{) into the groove at the bottom 7. Grease the lower face of the pilot block (18{) and
of the valve cavity. The rounded side of the seal install so its tabs snap into the grooves on the
must face down into the groove. See Fig. 10. ends of the pilot pins (16). See Fig. 8.

3. Install the valve plate (8H) in the cavity. On alumi- 8. Grease the o-ring (6{H) and install it in the valve
num center housing models, the plate is reversible, block (7{H). Push the block onto the valve carriage
so either side can face up. Install the three screws (5). Grease the lower face of the valve block. See
(3), using a Torx (T20) screwdriver or 7 mm Fig. 8.
(9/32 in.) socket wrench. Tighten until the screws
bottom out on the housing. See Fig. 10. 9. Install the valve carriage (5) so its tabs slip into the
grooves on the narrow end of the actuator pistons
4. Install an o-ring (17{H) on each pilot pin (16). (11). See Fig. 8.
Grease the pins and o-rings. Insert the pins into
the bearings (15), narrow end first. See Fig. 9. 10. Align the valve gasket (4{H) and cover (2) with the
six holes in the center housing (1). Secure with six
5. Install a u-cup packing (10{H) on each actuator screws (3), using a Torx (T20) screwdriver or 7
piston (11), so the lips of the packings face the mm (9/32 in.) socket wrench. Torque to 50–60 in-lb
narrow end of the pistons. See Fig. 9. (5.6–6.8 NSm). See Fig. 7.
308549 17
 Service
Ball Check Valve Repair 1 Torque to 80 to 90 in-lb (9 to 10 NSm). See Torque Se-
quence, page 32.
Tools Required
2 Arrow (A) must point toward outlet manifold (103).
D Torque wrench
3 Not used on some models.
D 10 mm socket wrench

D O-ring pick 106 1

Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to
103
page 27 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. 301*

NOTE: To ensure proper seating of the balls (301), 201*

always replace the seats (201) when replacing the
balls. 202* 3

101
WARNING A 2
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.

1. Relieve the pressure. Disconnect all hoses.

301*
2. Remove the pump from its mounting.
201*
3. Using a 10 mm socket wrench, remove the eight
bolts (106) holding the outlet manifold (103) to the 202* 3
fluid covers (101). See Fig. 11.

4. Remove the seats (201), balls (301), and o-rings

102
(202) from the manifold.

NOTE: Some models do not use o-rings (202).

5. Turn the pump over and remove the bolts (112)

and inlet manifold (102). Remove the seats (201),
balls (301), and o-rings (202) from the fluid covers
112 1 04706B
(101).
Fig. 11
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. 11. Be sure the ball checks are as-
sembled exactly as shown. The arrows (A) on the
fluid covers (101) must point toward the outlet
manifold (103).

18 308549
 Service
Diaphragm Repair
WARNING
Tools Required
D Torque wrench To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
D 13 mm socket wrench Pressure Relief Procedure on page 12.

D Adjustable wrench

D 19 mm open–end wrench
1. Relieve the pressure.
D O-ring pick

D Lithium-base grease 2. Remove the manifolds and disassemble the ball

check valves as explained on page 18.
Disassembly
NOTE: A Fluid Section Repair Kit is available. Refer to
page 27 to order the correct kit for your pump. Parts 3. Using 13 mm socket wrenches, remove the
included in the kit are marked with an asterisk, for screws (107 and 108) holding the fluid covers
example (401*). Use all the parts in the kit for the best (101) to the air covers (23). Pull the fluid covers
results. (101) off the pump. See Fig. 12.

You must torque the eight long screws (108) first, then the short
1
screws (107). Torque to 190 to 220 in-lb (21 to 25 NSm). See
Torque Sequence, page 32.

2 Arrow (A) must point toward air valve (B).

B
23

101

A 2

107 1

108 1

04707B
Fig. 12

308549 19
 Service
4. Unscrew one outer plate (105) from the diaphragm Reassembly – Standard Diaphragms
shaft (24). Remove one diaphragm (401), and the 1. Grease the shaft u-cup packings (402*) and install
inner plate (104). See Fig. 13. them so the lips face out of the housing (1). See
Fig. 13.
For overmolded diaphragms: Grip both dia-
phragms securely around the outer edge and
2. Grease the length and ends of the diaphragm shaft
rotate counterclockwise. One diaphragm assembly
will come free and the other will remain attached to (24) and slide it through the housing (1).
the shaft. Remove the freed diaphragm and air
side plate. 3. Assemble the inner diaphragm plates (104), dia-
phragms (401*), PTFE diaphragms (403*, if pres-
NOTE: PTFE models include a PTFE diaphragm (403) ent), and outer diaphragm plates (105) exactly as
in addition to the backup diaphragm (401). shown in Fig. 13. These parts must be assembled
correctly.
5. Pull the other diaphragm assembly and the dia-
phragm shaft (24) out of the center housing (1).
Hold the shaft flats with a 19 mm open–end 4. Apply medium-strength (blue) LoctiteR or equiva-
wrench, and remove the outer plate (105) from the lent to the threads of the fluid-side plates (105).
shaft. Disassemble the remaining diaphragm Hold one of the outer plates (105) with a wrench,
assembly. and torque the other outer plate to 20 to 25 ft-lb
(27 to 34 NSm) at 100 rpm maximum. Do not
For overmolded diaphragms: Pull the other dia- over-torque.
phragm assembly and the diaphragm shaft (24)
out of the center housing (1). Hold the shaft flats
5. Align the fluid covers (101) and the center housing
with a 19 mm open–end wrench and remove the
(1) so the arrows (A) on the covers face the same
diaphragm and air side plate from the shaft.
direction as the air valve (B). Secure the covers
6. Inspect the diaphragm shaft (24) for wear or with the screws (107 and 108), handtight. Install
scratches. If it is damaged, inspect the bearings the longer screws (108) in the top and bottom
(19) in place. If the bearings are damaged, refer to holes of the covers. See Fig. 12.
page 23.
6. First, torque the longer screws (108) oppositely
7. Reach into the center housing (1) with an o-ring and evenly to 190–220 in-lb (21–25 NSm), using a
pick and hook the u-cup packings (402), then pull 13 mm socket wrench. Then torque the shorter
them out of the housing. This can be done with the screws (107). See Torque Sequence, page 32.
bearings (19) in place.

8. Clean all parts and inspect for wear or damage. 7. Reassemble the ball check valves and manifolds
Replace parts as needed. as explained on page 18.

20 308549
Reassembly – Overmolded Diaphragms 5. Assemble the other diaphragm assembly to the
shaft as explained in step 2. This diaphragm will
be lifted off the air cover at this point.
WARNING
6. Supply the pump with low pressure air (less than 7
To reduce the risk of serious injury, including psi [0.05 MPa, 0.5 bar]). The diaphragm will very
amputation, do not put your fingers or hand be- slowly pull onto the air cover. Find the pressure
tween the air cover and the diaphragm. that keeps the diaphragm close enough to secure
with the screws, but does not let it contact the pilot
pin.
1. Lubricate and install the shaft u–cup packings
(402*) so the lips face out of the housing (1). See
NOTE: Do not deform the diaphragm manually. The
Fig. 13.
diaphragm needs uniform pressure to deform properly
2. Assemble the air side plate (104) onto the dia- for maximum life.
phragm (403). The wide, radiused side of the plate
must face the diaphragm. Apply medium–strength 7. Align the fluid cover (101) and the center housing
(blue) Loctite or equivalent to the threads of the (1) so the arrow (A) faces the same direction as
diaphragm assembly. Screw the assembly into the the air valve. Secure the cover with two of the
shaft (24) hand–tight. longer screws (108), handtight.

3. Grease the length and ends of the diaphragm shaft NOTE: If the diaphragm contacts the pilot pin and is
(24). Insert the shaft/diaphragm assembly into one forced away from the air cover, try Step 5 again. If
side of the pump. Align the fluid cover (101) and necessary, return to Step 3.
the center housing (1) so the arrow (A) faces the
same direction as the air valve. Secure the cover 8. Torque the longer screws (108) oppositely and
with the screws (107 and 108), handtight. evenly to 190–220 in–lb (21–25 NSm), using a
13mm socket wrench. Then torque the shorter
4. Torque the longer screws (108) oppositely and screws (107). See Torque Sequence, page 32.
evenly to 190–220 in–lb (21–25 NSm), using a
13mm socket wrench. Then torque the shorter 9. Reassemble the ball check valves and manifolds
screws (107). See Torque Sequence, page 32. as explained on page 18.

308549 21
 Service

5 105 19 402* 1

403* 1
1 24 104 401*
2 4
3 2
04708
03275
Cutaway View, with Diaphragms in Place Cutaway View, with Diaphragms Removed

24 3
104
401* 2

403* 2 4

105 5

24 3

1 Lips face out of housing (1).

2 Air Side must face center housing (1).

3 Grease.
4 Used on Models with PTFE diaphragms only.
5 Apply medium-strength (blue) LoctiteR or
equivalent. Torque to 20 to 25 ft-lb (27 to 34
NSm) at 100 rpm maximum.
Fig. 13 04709B

22 308549
 Service
Bearing and Air Gasket Removal 7. Use a bearing puller to remove the diaphragm
shaft bearings (19), air valve bearings (12) or pilot
Tools Required pin bearings (15). Do not remove undamaged
D Torque wrench bearings.

D 10 mm socket wrench 8. If you removed the diaphragm shaft bearings (19),

reach into the center housing (1) with an
D Bearing puller o-ring pick and hook the u-cup packings (402),
then pull them out of the housing. Inspect the
D O-ring pick packings. See Fig. 13.

D Press, or block and mallet Reassembly

1. If removed, install the shaft u-cup packings (402*)
Disassembly so the lips face out of the housing (1).
NOTE: Do not remove undamaged bearings.
2. The bearings (19, 12, and 15) are tapered and can
only be installed one way. Insert the bearings into
WARNING the center housing (1), tapered end first. Using a
press or a block and rubber mallet, press-fit the
To reduce the risk of serious injury whenever you
bearing so it is flush with the surface of the center
are instructed to relieve pressure, always follow the
housing.
Pressure Relief Procedure on page 12.
3. Reassemble the air valve as explained on page
1. Relieve the pressure. 17.

2. Remove the manifolds and disassemble the ball 4. Align the new air cover gasket (22) so the pilot pin
check valves as explained on page 18. (16) protruding from the center housing (1) fits
through the proper hole (H) in the gasket.
3. Remove the fluid covers and diaphragm assem-
blies as explained on page 19. 5. Apply medium-strength (blue) LoctiteR or equiva-
lent to the threads of screws (25). Align the air
NOTE: If you are removing only the diaphragm shaft cover (23) so the pilot pin (16) fits in the middle
bearing (19), skip step 4. hole (M) of the three small holes near the center of
the cover. Install the screws (25), handtight. See
4. Disassemble the air valve as explained on page Fig. 14. Using a 10 mm socket wrench, torque the
16. screws oppositely and evenly to 130 to 150 in-lb
(15 to 17 NSm).
5. Using a 10 mm socket wrench, remove the screws
(25) holding the air covers (23) to the center 6. Install the diaphragm assemblies and fluid covers
housing (1). See Fig. 14. as explained on page 19.

6. Remove the air cover gaskets (22). Always replace 7. Reassemble the ball check valves and manifolds
the gaskets with new ones. as explained on page 18.

308549 23
 Service

1 Insert bearings tapered end first.

12
2 Press-fit bearings flush with surface of center housing (1).
1 2
3 Apply medium-strength (blue) LoctiteR or equivalent. Torque
to 130 to 150 in-lb (15 to 17 NSm). 1

1 15 1 2
16
H 22 M Detail of Air Valve Bearings
23
03277

25 3

19 1 2

03278B
Fig. 14

24 308549
Notes

308549 25
 Pump Matrix
Husky 1590 Polypropylene and PVDF 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 a Husky 1590 aluminum air motor, polypropylene fluid section, polypropylene seats, PTFE balls, and
PTFE diaphragms is Model D B 2 9 1 1. To order replacement parts, refer to the part lists on pages 30 and 31.
The digits in the matrix do not correspond to the ref. nos. in the parts drawing and lists.

Diaphragm
Pump Air Motor Fluid Section – Seats Balls Diaphragms
D (for all pumps) B Aluminum 1 (not used) – 1 (not used) 1 (PTFE) 1 (PTFE)
(standard)
24B758* C Aluminum 2 (polypropylene) – 2 (not used) 2 (acetal) 2 (not used)
(remote)
24B759* T SST (standard) 3 (Aluminum; see – 3 (316 SST) 3 (not used) 3 (not used)
manual 308441)
24B760* U SST (remote) 4 (SST; see – 4 (17–4 PH SST) 4 (440C SST) 4 (not used)
manual 308441)
24B761* 5 (PVDF) – 5 (TPE) 5 (TPE) 5 (TPE)
24B832* – 6 (Santoprener) 6 (Santoprener) 6 (Santoprener)
– 7 (Buna–N) 7 (Buna–N) 7 (Buna–N)
– 8 (fluoroelastom- 8 (fluoroelastom- 8 (fluoroelastom-
er) er) er)
– 9 (polypropylene)
– A (PVDF)
– G (Geolastr) G (Geolastr) G (Geolastr)

246451 Stainless Steel Air Motor Conversion Kit * 24B761 Polypropylene Pump
Use kit 246451 and refer to instruction manual 309643 This pump is the same as Model DB2311 except for
(included with kit) to convert from aluminum air motor the serial plate and parts listed in the chart below.
to stainless steel air motor.
* 24B832 PVDF Pump
* 24B758 PVDF Plus Pump This pump is the same as Model DB5A11 except for
This pump is the same as Model DT5A11 except for the serial plate and parts listed in the chart below.
the serial plate and parts listed in the chart at right.

* 24B759 Polypropylene Plus Pump Ref.

No. Part No. Description Qty
This pump is the same as Model DT2911 except for
the serial plate and parts listed in the chart at right. 104 15H810 PLATE, air side; alum. 2
105 ––– not used 0
* 24B760 Polypropylene Pump
This pump is the same as Model DB2911 except for 401 15G745 DIAPHRAGM, HD, overmolded; 2
the serial plate and parts listed in the chart at right. PTFE/EPDM

26 308549
 Repair Kit Matrix
For Husky 1590 Polypropylene and PVDF 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 30). Parts included in the Air Valve
Repair Kit are marked with a symbol in the parts list, for example (4{H).

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 C. 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 C 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 C 0 0 1. The digits in the matrix do not correspond to the
ref. nos. in the parts drawing and lists on pages 30 and 31.

Diaphragm Fluid Section

Pump Null Material – Seats Balls Diaphragms
D (for all pumps) 0 (for all pumps) C (plastic) – 0 (null) 0 (null) 0 (null)
– 1 (not used) 1 (PTFE) 1 (PTFE)
– 2 (not used) 2 (acetal) 2 (not used)
– 3 (316 SST) 3 (not used) 3 (not used)
– 4 (17–4 PH SST) 4 (440C SST) 4 (not used)
– 5 (TPE) 5 (TPE) 5 (TPE)
– 6 (Santoprener) 6 (Santoprener) 6 (Santoprener)
– 7 (Buna–N) 7 (Buna–N) 7 (Buna–N)
– 8 (fluoroelastom- 8 (fluoroelastom- 8 (fluoroelastom-
er) er) er)
– 9 (polypropylene)
– A (PVDF)
– G (Geolastr) G (Geolastr) G (Geolastr)

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.

Part No. 24F397: Husky 1590 PTFE/Santoprene Backer Diaphragm Repair Kit,
for plastic pumps.

308549 27
 Parts
Air Motor Parts List (Matrix Column 2)
Ref. Ref.
Digit No. Part No. Description Qty Digit No. Part No. Description Qty
B 1 188838 HOUSING, center; 1 C Same as B with the following exceptions
aluminum
1 195921 HOUSING, center; 1
2 188854 COVER, air valve; 1 remote, aluminum
aluminum
23 195919 COVER, air; remote, 2
3 116344 SCREW, mach, hex 9 aluminum
flange hd; M5 x 0.8;
12 mm (0.47 in.) T Same as B with the following exceptions
4{H 188618 GASKET, cover; foam 1 1 15K009 HOUSING, center; 1
stainless steel
5 188855 CARRIAGE; aluminum 1
2 15K696 COVER, air valve; 1
6{H 108730 O-RING; nitrile 1 stainless steel
7{H 188616 BLOCK, air valve; acetal 1 8H 15H178 PLATE, air valve, 1
8 188615 PLATE, air valve; sst 1 stainless steel

9{ 188617 SEAL, valve plate; buna-N 1 9 – – –

10{H 112181 PACKING, u-cup; nitrile 2 23 15A739 COVER, air; stainless 2

steel
11 188612 PISTON, actuator; acetal 2
25 112178 SCREW; M8 x 1.25; 12
12 188613 BEARING, piston; acetal 2 25 MM (1 in.) stainless
steel
13} 104765 PLUG, pipe; headless 2
U Same as B with the following exceptions
14} 115671 FITTING, connector; 2
male 1 15K011 HOUSING, center; 1
remote, stainless steel
15 188611 BEARING, pin; acetal 2
2 15K696 COVER, air valve; 1
16 188610 PIN, pilot; stainless steel 2 stainless steel
17{H 157628 O-RING; buna-N 2 8H 15H178 PLATE, air valve, 1
stainless steel
18{H 188614 BLOCK, pilot; acetal 1
9 – – –
19 188609 BEARING, shaft; acetal 2
23 15B795 COVER, air; remote, 2
20 116343 SCREW, grounding 1
stainless steel
22 188603 GASKET, air cover; foam 2
25 112178 SCREW; M8 x 1.25; 12
23 189400 COVER, air; aluminum 2 25 MM (1 in.) stainless
steel
24 189245 SHAFT, diaphragm; sst 1
25 115643 SCREW; M8 x 1.25; 12
25 mm (1 in.), aluminum

28 308549
 Parts
Fluid Section Parts List (Matrix Column 3) Ref.
Digit No. Part No. Description Qty
Ref.
Digit No. Part No. Description Qty 5 101 189741 COVER, fluid; PVDF 2
2 101 189739 COVER, fluid; 2 102 192073 MANIFOLD, inlet; PVDF 1
polypropylene
103 192075 MANIFOLD, outlet; 1
102 192072 MANIFOLD, inlet; 1 PVDF
polypropylene
104 15K448 PLATE, air side; 2
103 192074 MANIFOLD, outlet; 1 aluminum
polypropylene
105 189744 PLATE, fluid side; 2
104 15K448 PLATE, air side; alum. 2 PVDF
105 189742 PLATE, fluid side; 2 106 112560 SCREW; M8 x 1.25; 8
polypropylene 70 mm (2.76 in.); sst
106 112560 SCREW; M8 x 1.25; 8 107 112368 SCREW; M10 x 1.50; 12
70 mm (2.76 in.); sst 60 mm (2.36 in.); sst
107 112368 SCREW; M10 x 1.50; 12 108 114118 SCREW; M10 x 1.50; 8
60 mm (2.36 in.); sst 90 mm (3.54 in.); sst
108 114118 SCREW; M10 x 1.50; 8 110 188621 LABEL, warning 1
90 mm (3.54 in.); sst Y
110 188621 LABEL, warning 1 111 102656 MUFFLER 1
Y
112 112559 SCREW; M8 x 1.25; 8
111 102656 MUFFLER 1 40 mm (1.57 in.); sst
112 112559 SCREW; M8 x 1.25; 8
40 mm (1.57 in.); sst

308549 29
 Parts
106

3
2 103
11 10{H

4{H Y110

H{17 5
104
16 6{H 401*
H{18 301*
3 7{H
403* 1
8H 201*
9{ 1 105
16 202* 1
17{H
1 14 } 107
12 23
10{H
11 22 25

24
15

*402 108
19 101
20
111 *301

13 } *201

202* 1

102
1 Not used on some models.

* These parts are included in the Pump Repair Kit, which may be purchased separately.
Refer to the Repair Kit Matrix on page 27 to determine the correct kit for your pump.

{ These parts are included in Air Valve Repair Kit 236273 (aluminum center housing mod- 04622C

els) which may be purchased separately. 112

H These parts are included in Air Valve Repair Kit 255061 (stainless steel center housing
models) which may be purchased separately.

Y Replacement Danger and Warning labels, tags and cards are available at no cost.

} These parts are unique to remote piloted air motor, DC––––, DT––––

30 308549
 Parts
Seat Parts List (Matrix Column 4) Diaphragm Parts List (Matrix Column 6)
Ref. Ref.
Digit No. Part No. Description Qty Digit No. Part No. Description Qty
3 201* 189318 SEAT; 316 stainless steel 4 1 401* not sold DIAPHRAGM, backup; 2
separately polychloroprene (CR)
202* 112418 O-RING; PTFE 4
402* 112181 PACKING, u-cup; nitrile 2
4 201* 189319 SEAT; 17–4 stainless 4
steel 403* 15K312 DIAPHRAGM; PTFE 2
202* 112418 O-RING; PTFE 4 5 401* 189425 DIAPHRAGM; TPE 2
5 201* 189322 SEAT; TPE 4 402* 112181 PACKING, u-cup; nitrile 2
202 None Not Used 0 6 401* 189426 DIAPHRAGM; Santo- 2
preneR
6 201* 189320 SEAT; SantopreneR 4
402* 112181 PACKING, u-cup; nitrile 2
202* 112418 O-RING; PTFE 4
7 401* 15B312 DIAPHRAGM; Buna–N 2
7 201* 15B266 SEAT; Buna–N 4
402* 112181 PACKING, u-cup; nitrile 2
202 None Not used 0
8 401* 15B501 DIAPHRAGM; fluoroelas- 2
8 201* 15B264 SEAT; fluoroelastomer 4
tomer
202 None Not used 0 402* 112181 PACKING, u-cup; nitrile 2
9 201* 193417 SEAT; polypropylene 4 G 401* 194214 DIAPHRAGM; GeolastR 2
202* 112418 O-RING; PTFE 4 402* 112181 PACKING, u-cup; nitrile 2
A 201* 189732 SEAT; PVDF 4
* These parts are included in the pump repair kit, purchased
202* 112418 O-RING; PTFE 4 separately. See Repair Kit Matrix on page 27 to determine
the correct kit for your pump.
G 201* 194213 SEAT; GeolastR 4
202* 112418 O-RING; PTFE 4

Ball Parts List (Matrix Column 5)

Ref.
Digit No. Part No. Description Qty
1 301* 112419 BALL; PTFE 4
2 301* 112423 BALL; acetal 4
4 301* 112420 BALL; 440C stainless 4
steel
5 301* 112831 BALL; TPE 4
6 301* 112421 BALL; SantopreneR 4
7 301* 15B490 BALL; Buna–N 4
8 301* 15B489 BALL; fluoroelastomer 4
G 301* 114752 BALL; GeolastR 4

308549 31
 Torque Sequence
Always follow torque sequence when instructed to torque fasteners.

1. Left/Right Fluid Covers 3. Outlet Manifold

Torque bolts to 190–220 in–lb (21–25 NSm) Torque bolts to 80–90 in–lb (9–10 NSm)
21 20 26
23
1
3

8 5

25 19 22 24
10 9

TOP VIEW
6 7
4 2

SIDE VIEW

2. Inlet Manifold
Torque bolts to 80–90 in–lb (9–10 NSm)
13 12 18
15

17 11 14 16

BOTTOM VIEW

32 308549
 Dimensions
FRONT VIEW SIDE VIEW

B outlet port I.D.:

5.23 in. 1.75 in. (44.5 mm)
(133 mm)
flange diameter:
5.5 in. (139.7 mm)
1/2 npt(f)
air inlet
four 0.73 in.
3/4 npt(f) (18.5 mm) slots
air exhaust

F G H

C 45_ inlet port I.D.:

1.75 in.
(44.5 mm)

J
four 0.73 in.
(18.5 mm) slots
6.0 in.
D M (152.5
K mm)
10.45 in.
E (265.5 mm)
7439B

PUMP MOUNTING HOLE PATTERN

Dimensions B, C, F, G, H and M can

vary by up to 1/4 in. (6.3 mm) depending
L on the seat and diaphragm material
fitted in the pump.
D

308549 33
 Dimensions
Aluminum
SST Center Center Aluminum
Polypropylene SST Center Polypropylene Center
Cover PVDF Cover Cover PVDF Cover
Dimension in. mm in. mm in. mm in. mm
B 10.0 255 10.0 255 10.0 255 10.0 255
C 12.1 306 11.9 302 12.1 306 11.9 302
D 6.0 152 6.0 152 6.0 152 6.0 152
E 17.6 447 17.5 445 17.6 447 17.5 445
F 16.3 414 16.1 408 16.3 414 16.1 408
G 19.3 490 19.1 484 19.3 490 19.1 484
H 22.0 560 21.8 554 22.0 560 21.8 554
J 3.0 76 3.0 76 3.0 76 3.0 76
K 0.25 6 0.3 6 0.25 6 0.3 6
L 6.0 152 6.0 152 6.0 152 6.0 152
M 7.0 178 7.0 178 7.0 178 7.0 178

34 308549
 Technical Data
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . 120 psi
(0.84 MPa, 8.4 bar) Non-wetted external parts . aluminum, 302 and 316 stainless
Air pressure operating range . . . . . . . . . . . . . . . . 20 to 120 psi steel polyester (labels)
(1.4 to 8.4 bar, 0.14 to 0.84 MPa) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . Polypropylene Pumps:
Maximum air consumption . . . . . . . . . . . . . . . . . . . . . 125 scfm . . . . . . . . . . . . . . . . with aluminum center section 35 lb (16 kg)
Air consumption at 70 psi/60 gpm . . . . . 50 scfm (see chart) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PVDF Pumps:
Maximum free flow delivery . . . . . . . . . 100 gpm (378.5 l/min) . . . . . . . . . . . . . . . . with aluminum center section 49 lb (22 kg)
Maximum pump speed . . . . . . . . . . . . . . . . . . . . . . . . . 200 cpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Polypropylene Plus Pumps:
Gallons (liters) per cycle . . . . . . . . . . . . . . . . . . . . . . . . 0.5 (1.9) . . . . . . . . . . . . . with stainless steel center section 49 lb (23 kg)
Maximum suction lift . . . . . . . . . . . . . 18 ft (5.48 m) wet or dry
Maximum size pumpable solids . . . . . . . . . . 3/16 in. (4.8 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PVDF Pumps:
* Maximum noise level at 100 psi, 50 cpm . . . . . . . . 94 dBa . . . . . . . . . . . . . with stainless steel center section 63 lb (30 kg)
Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . 108 dBa
* Noise level at 70 psi, 50 cycles/min . . . . . . . . . . . . 72 dBa Geolastr and Santoprener are registered trademarks of the
Maximum operating temperature . . . . . . . . . . 150_ F (65.5_ C) Monsanto Co.
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt(f)
Fluid inlet size. . . . . . . . . . . . . . . . . 1–1/2 in. raised face flange Loctiter is a registered trademark of the Loctite Corporation.
Fluid outlet size. . . . . . . . . . . . . . . . 1–1/2 in. raised face flange * Noise levels measured with the pump mounted on the floor,
Wetted parts . . . . . . . . . . Vary by model. See pages 28 to 31 using Rubber Foot Kit 236452. Sound power measured per
ISO Standard 9216.

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) re-
quires approximately 50 scfm (1.40 m#/min) air consumption at 70 psi (0.49 MPa, 4.9 bar) inlet air pressure.
feet psi
(meters) (bar, MPa)
280 120
(85.3) (0.84, 8.4) A Inlet Air Pressures
A 120 psi air (0.84 MPa, 8.4 bar)
240 B 100 psi air (0.7 MPa, 7 bar)
100 E
(73.2)
(0.7, 7.0) B C 70 psi air (0.49 MPa, 4.9 bar)
D 40 psi air (0.28 MPa, 2.8 bar)
200
(61.0) 80 Air Consumption
(0.56, 5.6)
E 20 scfm (0.56 m#/min)
160 F
C
(48.8) F 40 scfm (1.12 m#/min)
60
(0.42, 4.2) G 60 scfm (1.68 m#/min)
120 H 80 scfm (2.24 m#/min)
(36.6)
G
40
D
80 (0.28, 2.8)
(24.4)

20
40 (0.14, 1.4)
(12.2)
H
0
0 0 15 30 45 60 75 90 105 120
(57) (114) (170) (227) (284) (341) (397) (454)

FLUID FLOW GPM (lpm)

TEST CONDITIONS KEY FLUID PRESSURE AND FLOW
Pump tested in water with PTFE diaphragm and inlet SCFM AIR CONSUMPTION
submerged.

308549 35
Graco Standard Husky Pump Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from de-
fects 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 equip-
ment 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 sub-
stitution 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 (6) 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 reconnais-
sent 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 procédures concernées.

Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the distributor closest to you:
Phone: 612–623–6921 or Toll Free: 1–800–328–0211 Fax: 612–378–3505

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 308549
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 1994, Graco Inc. is registered to ISO 9001
www.graco.com
Revision ZAE, January 2015

36 308549