Graco 308441ZAD manual

Instructions – Parts List ALUMINUM AND ST AINLESS STEEL Husky t 1590 Air-Operated 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 Pres[...]

2 308441 T able of Contents Models 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety W arnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbols 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 5 . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

308441 3 Symbols W arning Symbol W ARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions. Caution Symbol CAUTION This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions. EQUIPMENT MISUSE HAZARD Equipment misuse can cause the [...]

4 308441 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. ?[...]

308441 5 Installation General Information  The typical installation shown in Fig. 2 is only a guide for selecting and installing system compo- nents. 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 [...]

6 308441 Installation Mountings CAUTION The pump exhaust air may contain contaminants. V entilate to a remote area if the contaminants could af fect your fluid supply . See Air Exhaust V entilation 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.[...]

308441 7 Installation Fluid Outlet Line W ARNING 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 outl[...]

8 308441 Installation 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. T o 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[...]

308441 9 Installation Air Exhaust V entilation 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. Y ou must vent the exhaust to a safe place, aw[...]

10 308441 Operation Pressure Relief Procedure PRESSURIZED EQUIPMENT HAZARD The equipment stays pressurized until pressure is manually relieved. T o 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, [...]

308441 1 1 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 conta[...]

12 308441 T roubleshooting W ARNING T o reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 10.  Relieve the pressure before checking or servicing the equipment.  Check all possible problems and causes before disassembling the pump. PROBLEM CAUSE SOLUTION Pump [...]

308441 13 T roubleshooting PROBLEM CAUSE SOLUTION Fluid in exhaust air . Diaphragm ruptured. Replace. See pages 17–19. Loose diaphragm shaft bolt (107). T ighten 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), [...]

14 308441 Service Repairing the Air V alve T ools Required  T orque wrench  T orx (T20) screwdriver or 7 mm (9/32 in.) socket wrench  Needle-nose pliers  O-ring pick  Lithium base grease NOTE: Air V alve Repair Kits 236273 (aluminum center housing models) and 255061 (sst center housing models) are available. Refer to page 23. Parts i[...]

308441 15 Service 03270 Fig. 8 17  16 11 10  12 15 1 2 Insert narrow end first. Grease. 3 Install with lips facing narrow end of piston (1 1) . 4 Insert wide end first. 1 2 3 4 2 03271 1 2 8  9  3 Rounded side must face down (aluminum center housing mod- els only). T ighten screws until they bottom out on the housing. Fig. 9 1 [...]

16 308441 Service Ball Check V alve Repair T ools Required  T orque 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[...]

308441 17 Service Diaphragm Repair T ools Required  T orque 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 k[...]

18 308441 Service 4. Loosen but do not remove the diaphragm shaft bolts (107), using a 15 mm socket wrench (1 in. on stainless steel models) on both bolts. NOTE: This step does not apply to pumps with overmolded diaphragms. 5. Unscrew one bolt from the diaphragm shaft (24) and remove the o-ring (108), fluid side diaphragm plate (105), PTFE diaphrag[...]

308441 19 Service 03275A 03274A Fig. 12 1 3 4 2 24 104 403* 401* 108* 107 24 24 104 401* 403* 107 105 19 402* Cutaway V iew , with Diaphragms in Place Cutaway V iew , with Diaphragms Removed 1 Lips face out of housing (1). Rounded side faces diaphragm (401). Air Side must face center housing (1). 1 Grease. Apply medium-strength (blue) Loctite  o[...]

20 308441 Service Bearing and Air Gasket Removal T ools Required  T orque wrench  10 mm socket wrench  Bearing puller  O-ring pick  Press, or block and mallet Disassembly NOTE: Do not remove undamaged bearings. W ARNING T o reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure R[...]

308441 21 Service 03277 Fig. 13 1 3 2 25 23 22 1 19 15 12 16 H M Insert b earings tapered end first. Press-fit bearings flush with surface of center housing (1). Apply medium-strength (blue) Loctite  or equivalent. T orque to 130–150 in-lb (15–17 N  m). Detail of Air V alve Bearings 1 1 1 2 2 2 3 03278B 4 Muf fle r not included on Model N[...]

22 308441 Pump Matrix Husky 1590 Aluminum and Stainless Steel Pumps, Series A Y our Model No. is marked on the pump’s serial plate. T o 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 rem[...]

308441 23 Repair Kit Matrix For Husky 1590 Aluminum and Stainless Steel Pumps, Series A Repair Kits may be ordered separately . T o 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 24). Parts included in the Air V alve Repair Kit are marked with a s[...]

24 308441 Parts Drawing 1 Not used on some models. Aluminum Model Shown 2 Used on PTFE models only . * These parts are included in the Pump Repair Kit, which may be purchased separately . Refer to the Repair Kit Matrix on page 23 to determine the correct kit for your pump.  These parts are included in Air Valve Repair Kit 236273 (aluminum center[...]

308441 25 Parts Air Motor Parts List (Matrix Column 2) Digit Ref. No. Part N o. Description Qty B 1 188838 HOUSING, center; aluminum 1 2 188854 COVER, air valve; aluminum 1 3 1 16344 SCREW , mach, hex flange hd; M5 x 0.8; 12 mm (0.47 in.) 9 4  188618 GASKET , cover; foam 1 5 188855 CARRIAGE; aluminum 1 6  108730 O-RING; nitrile 1 7 ?[...]

26 308441 Parts Fluid Section Parts List (Matrix Column 3) Digit Ref. No. Part N o. Description Qty 3 101 15A615 COVER, fluid; aluminum 2 102 189402 MANIFOLD, inlet; aluminum 1 103 15A616 MANIFOLD, outlet; aluminum 1 104 15K448 PLA TE, air side; aluminum 2 105 189843 PLA TE, fluid side; carbon steel 2 106 1 15644 SCREW ; M10 x 1.25; 35 mm (1.38 in.[...]

308441 27 Parts Seat Parts List (Matrix Column 4) Digit Ref. No. Part N o. Description Qty 3 201* 189318 SEA T ; 316 stainless steel 4 202* 1 12418 O-RING; PTFE 4 4 201* 189319 SEA T ; 17-4 stainless steel 4 202* 1 12418 O-RING; PTFE 4 5 201* 189322 SEA T ; TPE 4 202 None Not Used 0 6 201* 189320 SEA T ; Santoprene 4 202* 1 12418 O-RING; PTFE 4 7 2[...]

28 308441 T orque Sequence Always follow torque sequence when instructed to torque fasteners. 1. Left/Right Fluid Covers T orque bolts to 190–220 in–lb (22–25 N  m). SIDE VIEW 42 7 9 5 3 6 10 8 1 2. Inlet Manifold T orque bolts to 120–150 in–lb (14–17 N  m). BOTT OM VIEW 13 12 11 14 3. Outlet Manifold T orque bolts to 120–150 in[...]

308441 29 Dimensions 5.23 in. (132.5 mm) 6.0 in. (152.5 mm) PUMP MOUNTING HOLE P A TTERN SIDE VIEW 1.5 npt(f) Outlet Port 6.0 in. (152.5 mm) 6.0 in. (152.5 mm) .45 in. (1 1.5 mm) 10.46 in. (265.5 mm) 45 ° 7438B 1.5 npt(f) Inlet Port 152.5 mm 38 mm FRONT VIEW 1/2 npt(f) Air Inlet 3/4 npt(f) Air Exhaust C B 268 mm 379.5 mm 197 mm A A B C 16.81 in. ([...]

30 308441 T echnical Data Maximum fluid working pressure 120 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (0.8 MPa, 8 bar) Air pressure operating range 20–120 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

308441 31 Performance Chart 0 20 40 60 80 100 120 0 15 30 45 60 75 90 105 120 TEST CONDITIONS Pump tested in water with PTFE diaphragm and inlet submerged. (1 14) (170) (0.28, 2.8) (0.14, 1.4) (0.42, 4.2) KEY FLUID PRESSURE AND FLOW SCFM AIR CONSUMPTION Example of Finding Pump Air Consumption and Air Pressure at a Specific Fluid Delivery and Discha[...]

32 308441 Graco W arranties Graco Standard Husky Pump W arranty Graco w arrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a per[...]