Graco Diaphragm Pump HUSKY 1590 DB4311

FIRE AND EXPLOSION HAZARD

This pump must be grounded. Before operating the pump, ground the system as explained below. Also, read the sec- tion FIRE AND EXPLOSION HAZARD,on page 4.

 

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 equip- ment. 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 mm²) 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.

 

 

 

 

•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 recom- mendations.

 

•All solvent pails used when flushing: Follow the local code. Use only metal pails, which are conduc- tive. Do not place the pail on a non-conductive surface, such as paper or cardboard, which inter- rupts the grounding continuity.

 

Fluid supply container: Follow the local code.

 

Mountings

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.

 

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.

Air Line

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.

 

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 acces- sories 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.

 

c.The air line filter (F) removes harmful dirt and moisture from the compressed air supply.

 

1. 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 cou- pler (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.

 

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 connec- tors (14) on air motor of pump.

 

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.

 

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).

 

Fluid Outlet Line

A fluid drain valve (J) is required to relieve pres- sure in the hose if it is plugged. The drain valve reduces the risk of serious injury, including splash- 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 Fig. 2.

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.

 

2.Install a fluid drain valve (J) near the fluid outlet. See the WARNING above.

 

1. 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)

 

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).

 

1. Reverse the manifold and reattach. Install the screws, and torque according to the torque notes in Fig. 3.

 

 

 

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

 

101Covers

102Fluid inlet manifold 103 Fluid outlet manifold

106 Manifold and cover screws 112 Bottom cover screws

 

Apply medium-strength (blue) Loctite® or equivalent to the threads. Torque to 120–150 in-lb (14–17 N•m). See Torque Sequence, page 28.

Apply medium-strength (blue) Loctite® or equivalent to the threads. Torque to 190–220 in-lb (22–25 N•m). See Torque Sequence, page 28.

 

Fluid Pressure Relief Valve

CAUTION

Some systems may require installation of a pres- sure 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 ambi- ent 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

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)

 

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

Connect fluid outlet line here.

Muffler not included on Model No. 253485

 

 

Air Exhaust Ventilation

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 op- erating 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 handl- ing 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 appropri- ate container at the end of the air exhaust line to catch the fluid. See Fig. 5.

 

The air exhaust port is 3/4 npt(f). Do not restrict the air exhaust port. Excessive exhaust restriction can cause erratic pump operation.

 

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 con- nect 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.

 

 

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 onModel No. 253485)

T Grounded air exhaust hose

U Container for remote air exhaust

 

 

Operation

Pressure Relief Procedure

 

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.

 

1.Shut off the air to the pump.

2.Open the dispensing valve, if used.

3.Open the fluid drain valve to relieve all fluid pres- sure, having a container ready to catch the drain- age.

 

Flush the Pump Before First Use

The pump was tested in water. If water could contami- nate the fluid you are pumping, flush the pump thor- oughly with a compatible solvent. Follow the steps under Starting and Adjusting the Pump.

 

Starting and Adjusting the Pump

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.

 

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.

 

1. Place the suction tube (if used) in the fluid to be pumped.

 

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.

 

4.Place the end of the fluid hose (L) into an appropri- ate container.

 

5.Close the fluid drain valve (J). See Fig. 2.

 

6.Close the pump air regulator (C). Open all bleed- type master air valves (B, E).

 

7.If the fluid hose has a dispensing device, hold it open while continuing with the following step.

 

1. 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.

 

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.

 

Operation of Remote Piloted Pumps

1.Follow preceding steps 1 through 7 of Starting and Adjusting Pump.

2.Open air regulator (C).

 

The pump may cycle once before the external sig- nal is applied. Injury is possible. If pump cycles, wait until end before proceeding.

 

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

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure at left.

At the end of the work shift, relieve the pressure.

 

Maintenance

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 lubrica- tion can also cause the pump to malfunction.

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.

 

Flushing and Storage

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.

 

Troubleshooting

•Relieve the pressure before checking or servicing the equipment.

•Check all possible problems and causes before disassembling the pump.

PROBLEM	CAUSE	SOLUTION
Pump cycles at stall or fails to hold pressure at stall.	Worn check valve balls (301), seats (201) or o-rings (202).	Replace. See page 16.
Pump will not cycle, or cycles once and stops.	Air valve is stuck or dirty.	Disassemble and clean air valve. See pages 14–15. Use filtered air.
	Check valve ball (301) severely worn and wedged in seat (201) or manifold (102 or 103).	Replace ball and seat. See page 16.
	Check valve ball (301) is wedged into seat (201), due to overpressur- ization.	Install Pressure Relief Valve (see page 8).
	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 16.
	Diaphragm ruptured.	Replace. See pages 17–19.
	Restricted exhaust.	Remove restriction.
Air bubbles in fluid.	Suction line is loose.	Tighten.
	Diaphragm ruptured.	Replace. See pages 17–19.
	Loose inlet manifold (102), dam- aged seal between manifold and seat (201), damaged o-rings (202).	Tighten manifold bolts (106) or re- place seats (201) or o-rings (202). See page 16.
	Loose diaphragm shaft bolt (107).	Tighten or replace. See pages 17–19.
	Damaged o-ring (108).	Replace. See pages 17–19.

 

 

 

PROBLEM	CAUSE	SOLUTION
Fluid in exhaust air.	Diaphragm ruptured.	Replace. See pages 17–19.
	Loose diaphragm shaft bolt (107).	Tighten or replace. See pages 17–19.
	Damaged o-ring (108).	Replace. See pages 17–19.
Pump exhausts excessive air at stall.	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 14–15.
	Worn shaft seals (402).	Replace. See pages 17–19.
Pump leaks air externally.	Air valve cover (2) or air valve cover screws (3) are loose.	Tighten screws. See page 15.
	Air valve gasket (4) or air cover gasket (22) is damaged.	Inspect; replace. See pages 14–15, 20–21.
	Air cover screws (25) are loose.	Tighten screws. See pages 20–21.
Pump leaks fluid externally from ball check valves.	Loose manifolds (102, 103), dam- aged seal between manifold and seat (201), damaged o-rings (202).	Tighten manifold bolts (106) or re- place seats (201) or o-rings (202). See page 16.

 

 

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 23. 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

 

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 bear- ings (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 disas- sembly of the fluid section. See page 20.

 

1. Clean all parts and inspect for wear or damage. Replace as needed. Reassemble as explained on page 15.

 

 

 

Reassembly

1.If you removed the bearings (12, 15), install new ones as explained on page 20. Reassemble the fluid section.

 

2.On aluminum center housing models, install the valve plate seal (9†■) into the groove at the bot- tom 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 alumi- num 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.

 

1. 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.

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.

 

1. 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.

 

 

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 23 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.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.

 

1. 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.

 

1. 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).

 

Apply medium-strength (blue) Loctite® or equivalent to the threads. Torque to 120–150 in-lb (14–17 N•m). See Torque Sequence, page 28.

Arrow (A) must point toward outlet manifold (103).

Not used on some models.

Beveled seating surface must face ball (301).

 

 

 

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 23 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.

1.Relieve the pressure.

 

2.Remove the manifolds and disassemble the ball check valves as explained on page 16.

 

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.

 

 

Apply medium-strength (blue) Loctite® or equivalent to the threads. Torque to 190–220 in-lb (22–25 N•m).

See Torque Sequence, page 28.

 

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

 

3Muffler not included on Model No. 253485.

 

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 dia- phragm plate (104). See Fig. 12.

 

For overmolded diaphragms: Grip both dia- phragms 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 dia- phragm shaft (24) out of the center housing (1). Hold the shaft flats with a 19 mm open–end wrench, and remove the b