Graco 308441ZAE User Manual
Instructions – Parts List
ALUMINUM AND STAINLESS STEEL
Huskyt 1590 Air-Operated
308441ZAE
Diaphragm Pumps
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
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
EN
Model No. DB3777 shown
03263B
Table of Contents
Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service
Repairing the Air Valve 14. . . . . . . . . . . . . . . . . . . . . .
Ball Check Valve Repair 16. . . . . . . . . . . . . . . . . . . . .
Diaphragm Repair 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing and Air Gasket Removal 20. . . . . . . . . . . . .
Models
Model No. Description
*DB3______ Aluminum Pumps
*DC3______ Aluminum Pumps, Remote
*DB4______ Stainless Steel Pumps
Pump Matrix 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Kit Matrix 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Sequence 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Chart 33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranties 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*DC4______ Stainless Steel Pumps, Remote
*DBC______ Aluminum BSPT Pumps
*DCC______ Aluminum BSPT Pumps, Remote
*DBD______ Stainless Steel BSPT Pumps
*DCD______ Stainless Steel BSPT Pumps, Remote
*DT4______ Stainless Steel Plus Pumps
*DU4______ Stainless Steel Plus Pumps, Remote
*DTD______ Stainless Steel BSPT Plus Pumps
*DUD______ Stainless Steel BSPT Plus Pumps, Remote
253485 Aluminum Pump
232502 Private–Label Aluminum Pump
24B780 Stainless Steel Plus Pump with overmolded diaphragms
24B781 Stainless Steel Pump with overmolded diaphragms
24G411 Aluminum BSPT Pump with overmolded diaphragms
24J358 Aluminum Pump with overmolded diaphragms
24J359 Aluminum Pump with overmolded diaphragms
* Refer to the Pump Matrix on page 22 to determine the Model No. of your pump.
NOTE: Plus Models include stainless steel center sections.
2 308441
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death 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.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
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 ex-
pose Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
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
Installation
General Information
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.
Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 25–24.
Lift the pump by grasping the outlet manifold (1)
securely. See Fig. 3 on page 8.
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.
Grounding
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.
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.
Y
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.
Tightening Screws Before First Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque Se-
quence, page 28. After the first day of operation,
retorque the fasteners. Although pump use varies, a
general guideline is to retorque fasteners every two
months.
W
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 recom-
mendations.
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.
02646B
Fluid supply container: Follow the local code.
308441 5
Installation
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
c. The air line filter (F) removes harmful dirt and
moisture from the compressed air supply.
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.
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.
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.
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.
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.
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).
6 308441
Installation
Fluid Outlet Line
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.
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
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.
3. Install a shutoff valve (K) in the fluid outlet line.
BE
F
C
A
K
D
S
H
J
L
Fig. 2
Muffler not included
on Model No. 253485
R
G
03265B
308441 7
Installation
s
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.
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
Apply medium-strength (blue) Loctite or equivalent to the
1
threads. Torque to 120–150 in-lb (14–17 Nm). See Torque
Sequence, page 28.
Apply medium-strength (blue) Loctite or equivalent to the
2
threads. Torque to 190–220 in-lb (22–25 Nm). See Torque
Sequence, page 28.
N
101Covers
102 Fluid inlet manifold
103 Fluid outlet manifold
106 Manifold and cover screw
112 Bottom cover screws
103
1
106
S
Fluid Pressure Relief Valve
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
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.
Connect fluid outlet line here.
3
4 Muffler not included on Model No. 253485
S
3
P
102
Aluminum Model Shown
Fig. 3
8 308441
106
112
2
101
R
03263B
1
V
2
4
R
2
03461B
Fig. 4
Installation
Air Exhaust Ventilation
WARNING
FIRE AND EXPLOSION HAZARD
Be sure to read and follow the warnings
and precautions regarding TOXIC
FLUID HAZARD, and FIRE OR EXPLOSION 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 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.
VENTING EXHAUST AIR
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 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.
Fig. 5
FBEC
D
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
A
P Muffler (not included on
Model No. 253485)
T Grounded air exhaust hose
U Container for remote air exhaust
T
U
P
03267A
308441 9
Operation
Pressure Relief Procedure
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.
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 pressure, having a container ready to catch the drainage.
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 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.
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.
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.
Starting and Adjusting the Pump
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.
Operation of Remote Piloted Pumps
1. Follow preceding steps 1 through 7 of Starting
and Adjusting Pump.
2. Open air regulator (C).
WARNING
The pump may cycle once before the external signal 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
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.
3. Place the suction tube (if used) in the fluid to be
pumped.
10 308441
WARNING
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 lubrication 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. See Torque
Sequence, page 28.
Flushing and Storage
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
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.
308441 11
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