Instructions

Air???Operated

Diaphragm Pumps

308981ZAD

EN

ALUMINUM AND STAINLESS STEEL*

Huskyt 716

Model No. D 5 3 _ _ _ Aluminum NPT Pumps Model No. D 5 4 _ _ _ Stainless Steel NPT Pumps Model No. D 5 C _ _ _ Aluminum BSPT Pumps Model No. D 5 D _ _ _ Stainless Steel BSPT Pumps For Additional Models, see Table of Contents

Important Safety Instructions

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

Refer to the Pump Matrix on page 22 to determine the model number of your pump.

9246A

Husky 716

Table of Contents

Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Husky 515 and Husky 716 Pump Matrix . . . . . . . . . . 22

Husky 515 and 715 Additional Pumps . . . . . . . . . . . . 23

Husky 515 and Husky 716 Repair Kits . . . . . . . . . . . . 22

Parts

Husky 515 and Husky 716 Common Parts . . . . . . 24 Husky 515 Parts Drawing . . . . . . . . . . . . . . . . . . . . 25 Husky 515 Fluid Section Parts List . . . . . . . . . . . . . 26 Husky 716 Parts Drawing . . . . . . . . . . . . . . . . . . . . 27 Husky 716 Fluid Section Parts List . . . . . . . . . . . . . 28

Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Husky 515:

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Husky 716:

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Husky 515 and Husky 716 Performance Charts . . . 34

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 36

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Symbols

Warning Symbol

WARNING

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.

General Information

DThe Typical Installations in Fig. 2 are only guides for selecting and installing system components. Contact your Graco distributor for assistance in planning a system to suit your needs.

DAlways use Genuine Graco Parts and Accessories.

DUse a compatible, liquid thread sealant on all male threads. Tighten all connections firmly to avoid air or fluid leaks.

Tightening Threaded Fasteners Before

First Use

Before using the pump for the first time, check and retorque all external fasteners. See Torque Se- quence, page 29. After the first day of operation, retorque the fasteners. Although pump use varies, a general guideline is to retorque fasteners every two months.

Toxic Fluid Hazard

Read Toxic Fluid Hazard on page 3.

Use fluids and solvents that 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.

CAUTION

Safe Operating Temperatures

Minimum (all pumps): 40_ F (4_ C) Maximum

Acetal: 180_ F (82_ C)

Polypropylene: 150_ F (66_ C)

Aluminum, stainless steel, PVDF: 225_ F (107_ C)

These temperatures are based upon mechanical stress only and may be significantly altered by pumping certain chemicals. Consult engineering guides for chemical com- patibilities and temperature limits, or contact your Graco distributor.

Mountings

DThese pumps can be used in a variety of installa- tions. Be sure the mounting surface can support the weight of the pump, hoses, and accessories, as well as the stress caused during operation.

DFig. 2 shows some installation examples. On all installations, mount the pump using screws and nuts.

Pumping High-Density Fluids

High density fluids may prevent the lighter non-metallic check valve balls from seating properly, which reduces pump performance significantly. Stainless steel balls should be used for such applications.

Split Manifolds

Plastic Split Manifold Kits are available to enable you to pump two fluids simultaneously or to mix two fluids in the pump. To order a Split Manifold Kit, use the Part No. from the list below:

241240 polypropylene; split inlet

241241 acetal; split inlet

241242 PVDF; split inlet

241243 polypropylene; split outlet

241244 acetal; split outlet

241245 PVDF; split outlet

Air Line

WARNING

A bleed-type master air valve (B) is required in your system to relieve air trapped between this valve and the pump. See Fig. 2. 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 contamina- tion from hazardous fluids.

CAUTION

The pump exhaust air may contain contaminants. Ventilate to a remote area if the contaminants could affect your fluid supply. Read Air Exhaust Ventila- tion on page 6.

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 electrically conductive.

a.The fluid pressure can be controlled in either of two ways. To control it on the air side, install an air regulator (G). To control it on the fluid side, install a fluid regulator (J) near the pump fluid outlet (see Fig. 2).

b.Locate one bleed-type master air valve (B) close to the pump and use it to relieve trapped air. Read 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.

2.Install an electrically conductive, flexible air hose

(C) between the accessories and the 1/4 npt(f) pump air inlet. Use a minimum 1/4 in. (6.3 mm) ID air hose. Screw an air line quick disconnect cou- pler (D) onto the end of the air hose (C), and screw the mating fitting into the pump air inlet snugly. Do not connect the coupler (D) to the fitting yet.

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 (16) on underside 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

DIf using a conductive (acetal) pump, use conductive hoses. If using a non-conductive pump, ground the fluid system. Read Grounding on page 8. The fluid inlet port is 1/2 in. or 3/4 in.

DAt inlet fluid pressures greater than 15 psi

(0.1 MPa, 1 bar), diaphragm life will be shortened.

Fluid Outlet Line

WARNING

A fluid drain valve (H) is required in your system to relieve pressure in the hose if it is plugged. See Fig. 2. 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.

1.Use electrically conductive fluid hoses (K). The pump fluid outlet is 1/2 in. or 3/4 in. Screw the fluid fitting into the pump outlet snugly. Do not over- tighten.

2.Install a fluid regulator (J) at the pump fluid outlet to control fluid pressure, if desired (see Fig. 2). See Air Line, step 1a, for another method of controlling pressure.

3.Install a fluid drain valve (H) near the fluid outlet. Read the WARNING above.

Fluid Pressure Relief Valve

CAUTION

Some systems may require installation of a pressure relief valve at the pump outlet to prevent overpres- surization and rupture of the pump or hose.

See Fig. 1.

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.

1Install valve between fluid inlet and outlet ports.

2Connect fluid inlet line here.

3Connect fluid outlet line here.

3

1

2

Air Exhaust Ventilation

Read Toxic Fluid Hazard on page 3.

Read Fire and Explosion

Hazard on page 3.

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 appropriate con- tainer at the end of the air exhaust line to catch the fluid. See Fig. 2 .

The air exhaust port is 3/8 npt(f). Do not restrict the air exhaust port. Excessive exhaust restriction can cause erratic pump operation.

See Venting Exhaust Air in Fig. 2. Exhaust to a remote location as follows:

1.Remove the muffler (W) from the pump air exhaust port.

2.Install an electrically conductive air exhaust hose

(X) and connect the muffler to the other end of the hose. The minimum size for the air exhaust hose is 3/8 in. (10 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.

3.Place a container (Z) at the end of the air exhaust line to catch fluid in case a diaphragm ruptures. See Fig. 2.

ABOVE-GROUND TRANSFER INSTALLATION

J

C D A K

H

E B

F G

KEY

APump

BBleed-type master air valve (required for pump)

CElectrically conductive air supply line

DAir line quick disconnect

EMaster air valve (for accessories)

FAir line filter

GPump air regulator

HFluid drain valve (required)

JFluid regulator (optional)

KElectrically conductive fluid supply hose

LFluid suction line

MUnderground storage tank

NWall mounting bracket

YGround wire (required; see page 8 for installation instructions)

YGround wire (required; see page 8 for installation instructions)

K

H

L

9075A

U

SAir spray gun

TElectrically conductive fluid return line

U 5-gallon pail

V Agitator

Y Ground wire (required; see page 8 for installation instructions)

Grounding

WARNING

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 3.

The acetal Husky 515 pump contains stainless steel fibers, which makes the wetted parts conduc- tive. Attaching the ground wire to the grounding screw (106) grounds the wetted parts. See grounding screw on page 25.

The metal Husky 716 pumps have a grounding strip connecting the vee clamps (109). Attach a ground wire to the grounding strip with the screw, lockwasher, and nut as shown in the Grounding Detail on page 27.

The polypropylene and PVDF Husky 515 pumps are not conductive.

When pumping conductive flammable fluids, al- ways ground the entire fluid system by making sure the fluid system has an electrical path to a

Ground all of this equipment:

DPump: The metal pump has a grounding strip in front of the center housing. The acetal pump has a grounding screw on the top manifold. Connect the non-clamp end of the ground wire to the grounding strip or grounding screw, and connect the clamp end of the ground wire to a true earth ground. To order a ground wire and clamp, order Part No. 222011.

DAir and fluid hoses: Use only electrically conductive hoses.

DAir compressor: Follow the manufacturer???s recom- mendations.

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

DFluid supply container: Follow the local code.

true earth ground (see Fig. 3). Never use a poly- propylene or PVDF pump with non-conductive

KEY

GROUNDING A PUMP

flammable fluids as specified by your local fire protection code.

US Code (NFPA 77 Static Electricity) recommends 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.

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.

NOTE: When pumping conductive flammable fluids with a polypropylene or PVDF pump, always ground the fluid system. See the WARNING above. Fig. 3 shows a recommended method of grounding flam- mable fluid containers during filling.

A Pump

H Fluid drain valve (required)

SDispense valve

TFluid drain line

YFluid section grounding via grounding strip or grounding screw (required for metal and acetal pumps)

ZContainer ground wire (required)

1Hose must be conductive.

2Dispense valve nozzle must be in contact with container.

Y

A

H

Y

T 1

Z

S 2

Changing the Orientation of the Fluid Inlet and Outlet Ports (Husky 515)

You can change the orientation of the fluid inlet and outlet ports by repositioning the manifolds. For Husky 515, see Fig. 4. For Husky 716, see Fig. 5.

2.Remove the four manifold nuts (109) or bolts (105).

3.Turn the manifold to the desired position, reinstall the nuts or bolts, and torque to 80 to 90 in-lb

(9 to 10 NSm). See Torque Sequence, page 29.

NOTE: Make sure all manifold o-rings are posi- tioned correctly before you fasten the manifold. Manifold o-rings (139) are shown in Fig. 7 and Fig. 8.

NOTE: Pumps with duckbill check valves are shipped with the inlet manifold on top and the outlet manifold

1Torque to 80 to 90 in-lb (9 to 10 NSm). See

Torque Sequence, page 29.

109 1

outlet

inlet

1 109

on the bottom. See page 14 for details.

Fig. 4

9065A

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, or splashing fluid, follow this procedure whenever you

DAre instructed to relieve pressure

DStop pumping

DCheck, clean, or service any system equipment

DInstall 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, and have a container ready to catch the drainage.

Flush Pump Before First Use

The pump was tested with water. Prior to first use, flush the pump thoroughly with a compatible solvent.

Reactor feed pumps, part numbers 246484, 246485, and 257447, were tested with lightweight oil, which is left in the fluid passages. 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 Pump.

Starting and Adjusting Pump

2.If lifting the pump, follow the Pres-

sure Relief Procedure above.

Explosion Hazard on page 3.

4.Check all fittings to be sure they are tight. Use a compatible liquid thread sealant on all male

threads. Tighten the fluid inlet and outlet fittings snugly. Do not overtighten the fittings into the pump.

10 308981

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

NOTE: If the inlet fluid 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.

6.Place the end of the fluid hose (K) into an appro- priate container.

7.Close the fluid drain valve (H).

8.With the pump air regulator (G) closed, open all bleed-type master air valves (B, E).

9.If the fluid hose has a dispensing device, hold it open while continuing with the following step. Slowly open the air regulator (G) 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.Fig. 2 and Parts Drawings. Follow preceding steps 1 through 8 of Starting and Adjusting Pump.

2.Open air regulator (G).

WARNING

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 to push type connectors (16).

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

At the end of the work shift, relieve the pressure as described in Pres- sure Relief Procedure at left.

Lubrication

The air valve is lubricated at the factory to operate without additional lubrication. If you want to provide additional lubrication, remove the hose from the pump air inlet and add two drops of machine oil to the air inlet every 500 hours of operation or every month.

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.

Flushing and Storage

Flush the pump 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 you store it for any length of time.

Read Pressure Relief Procedure on page 10.

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 29.

Preventive Maintenance Schedule

Establish a preventive maintenance schedule, based on the pump???s service history. This is especially impor- tant for prevention of spills or leakage due to dia- phragm failure.

1. Relieve the pressure. See Pressure Relief Procedure on page 10.

2.Remove the cover (10) and the o-ring (4).

3.Remove the carriage plungers (7), carriages (8), carriage pins (9), and valve plate (14) from the center housing (11).

4.Clean all the parts, and inspect them for wear or damage.

NOTE: If you are installing the new Air Valve Repair Kit 241657, use all the parts in the kit.

5.Grease the lapped surface of the valve plate (14), and install the valve plate with the lapped surface facing up.

6.Grease the bores of the center housing (11), install the u-cup packings (2) on the carriage plungers (7), and slide the carriage plungers into the car- riage plunger bores. See the following important installation notes:

NOTES:

DWhen you install each u-cup packing (2) on each carriage plunger (7), make sure the lips of the u-cup packing face toward the clip end (the smaller end) of the carriage plunger.

DWhen you slide the carriage plungers (7) into the bores, slide them in with the clip ends (the smaller ends) facing toward the center of the center hous- ing (11).

7.Grease the carriage pins (9), and slide the carriage pins into the carriage pin bores.

8.Install the carriages (8). Make sure the carriages engage the clip ends of the carriage plungers (7) and carriage pins (9).

9.Grease the o-ring (4), and seat it in the groove around the cover opening of the center hous- ing (11).

10.Screw the cover (10) into the center housing, and torque the cover to 80 to 100 in-lb (9.0 to 13.6 N-m).

{ Included in Air Valve Repair Kit 241657

1Torque to 80 to 100 in-lb (9.0 to 13.6 N-m).

2Apply grease.

3Apply grease to lapped face.

4Apply grease to bores of center housing (11) before installing.

5Seal lips face clip end (the smaller end) of carriage plunger (7).

6Install with the clip ends (the smaller ends) facing toward center of center housing (11).

Fig. 6

4 2

11

9{ 2 8{

9{ 2

9069A

Ball or Duckbill Check Valves

NOTE: Fluid Section Repair Kit D05XXX is available. See page 22 to order the correct kit for your pump. Parts included in the kit are marked with a double dagger (}) in Fig. 7 and Fig. 8 and in the Parts Draw- ings and Lists. General purpose grease 111920 and Adhesive 113500 are supplied in the kit.

1. Relieve the pressure. See Pressure Relief Procedure on page 10.

2.Remove the top and bottom manifolds (102, 103).

3.Remove all parts shown with a dagger (}) in Fig. 7 and Fig. 8.

4.Clean all parts, and replace worn or damaged parts.

5.Reassemble the pump.

NOTE: Torque the manifold nuts (109) or bolts (105) to 80 to 90 in-lb (9 to 10 NSm). See Torque Sequence, page 29.

Inlet and Outlet for Pumps with Duckbill Check Valves

Pumps with duckbill check valves are shipped with the inlet manifold on top and the outlet manifold on the bottom. To make the inlet manifold on the bottom and the outlet manifold on the top, rotate each of the four duckbill assemblies vertically 180_ as shown below.

}139

}201

9080A

}202

Husky 515

1 109

103

139}

202}

301}

201}

Husky 716

1105

107

}202

}201

}139

}202

}201

}139

1

139}

139}

202}

301}

201}

139} 102

109 1

Torque to 80 to 90 in-lb (9 to 10 N-m). See

Torque Sequence, page 29.

102

}139

}202

}301

}201

}139

106

101

106

}139

}202

}301

}201

}139

102

202}

201}

139}

202}

201}

139}

Fig. 7

9067A

Disassembly

1. Relieve the pressure. See Pressure Relief Procedure on page 10.

2.Remove manifolds (102 and 103) and fluid cov- ers (101).

NOTE: Make sure all the check valve parts stay in place. See Fig. 7 on page 15.

3.Remove one of the fluid-side diaphragm plates (105) (whichever one comes loose first when you use a wrench on the hex of each), and pull the diaphragm shaft out of the center housing (11).

Overmolded Diaphragms: The air cover bolts may make it difficult to remove the overmolded diaphragms on the 515 pump. Use a flat surface that fits within the bolt pattern to apply pressure on one of the diaphragms to shift the diaphragm shaft to one side. Apply pressure until the other dia- phragm is separated from the air cover. Rotate the separated diaphragm counterclockwise until the diaphragm assembly comes free. Pull the second diaphragm assembly and the diaphragm shaft (15) out of the center housing. (11)

4.Use a wrench on the flats of the diaphragm shaft

(15)to remove the other fluid-side diaphragm plate

(105)from the diaphragm shaft.

Overmolded Diaphragms: Use a wrench on the flats of the diaphragm shaft (15) to remove the second diaphragm.

5.Remove the screws (106), remove the left (114) and right (113) air covers, and remove all old gasket (12) material from the ends of the center housing (11) and the surfaces of the air covers.

6.Remove the diaphragm shaft u-cups (416) and pilot pin o-rings (1).

7.Inspect all parts for wear or damage, and replace as necessary.

Reassembly

1.Insert a diaphragm shaft u-cup (416) and a pilot pin o-ring (1) into the bores of the center housing

NOTE: Make sure the lips of the u-cup face out of the center housing.

2.Line up the holes in the gasket (12) with the holes in the end of the center housing (11), and use six screws (106) to fasten an air cover (113 or 114) to the end of the center housing (11). Torque the screws to 35 to 45 in-lb (4.0 to 5.1 N-m).

3.Position the exhaust cover (13) and o-ring (4) on the center housing (11).

4.Repeat steps 1 and 2 for the other end of the center housing and the remaining air cover.

5.Apply medium-strength (blue) Loctite or equivalent to the threads of the fluid-side diaphragm plates

(105). Install on one end of the diaphragm shaft

(15)the following parts (see proper order in Fig. 9): air-side diaphragm plate (6), backup diaphragm (402, used only on models with PTFE dia- phragms), diaphragm (401), and fluid-side dia- phragm plate (105).

NOTE: The words ???AIR SIDE??? on the diaphragm (401), the backup diaphragm (402, used only on models with PTFE diaphragms) and the flat side of the air-side diaphragm plate (6) must face toward the diaphragm shaft (15).

Overmolded Diaphragms: Assemble the air???side plate (6) onto the diaphragm (401). The words AIR SIDE on the air???side plate must face away from the diaphragm. Apply medium???strength (blue) thread locking adhesive to the threads of the diaphragm assembly. Screw the assembly into the diaphragm shaft (15) hand tight.

6.Put grease on the diaphragm shaft (15), and carefully (do not damage the shaft u-cups) run the diaphragm shaft (15) through the center housing (11) bore.

7.Repeat step 5 for the other end of the diaphragm shaft (15), and torque the fluid-side diaphragm plates (105) to 80 to 90 in-lb (9 to 10 N-m) at 100 rpm maximum.

Overmolded Diaphragms: The air cover bolts may make it difficult to assemble the overmolded diaphragms on the 515 pump. Two people are needed. Use a flat surface that fits within the bolt pattern to apply pressure on the diaphragm that has already been assembled. Apply pressure until the diaphragm shaft sticks out of the other end of the center housing far enough to attach the second diaphragm assembly. Screw the assembly into the shaft (15) hand tight.

8.Install the muffler (3).

9.Make sure all the check valve parts are in place. See Fig. 7 on page 15.

10.Reinstall the fluid covers (101) and manifolds (102 and 103), and torque the fluid cover and manifold nuts (109) to 80 to 90 in-lb (9 to 10 N-m). See

Torque Sequence, page 29.

Service

Diaphragms (Husky 515)

} Included in Fluid Section Repair Kit D05XXX

4

13

3

109 7

Fig. 9

1Install with lips facing out of center housing (11).

2Torque to 35 to 45 in-lb (4.0 to 5.1 N-m).

3Apply grease.

4The words ???AIR SIDE??? on diaphragms (and on backup diaphragms required on PTFE models) must face toward diaphragm shaft (15).

Flat side of air-side diaphragm plate must face toward

5diaphragm shaft (15).

Apply medium-strength (blue) LoctiteR or equivalent

6to threads, and torque to 80 to 90 in-lb (9 to 10 N-m) at

100 rpm maximum.

Torque to 80 to 90 in-lb (9 to 10 N-m). See Torque Se-

7quence, page 29.

Disassembly

1. Relieve the pressure. See Pressure Relief Procedure on page 10.

2.Remove the manifolds (102) and fluid cov- ers (101).

NOTE: Make sure all the check valve parts stay in place. See Fig. 8 on page 15.

3.Remove the grounding strip from the vee clamps (109), and remove the vee clamps.

4.Remove one of the fluid-side diaphragm plates (133) (whichever one comes loose first when you use a wrench on the hex of each), and pull the diaphragm shaft out of the center housing (11).

Overmolded Diaphragms: Grip both diaphragms securely around the outer edge and rotate counter- clockwise. One diaphragm assembly will come free and the other will remain attached to the diaphragm shaft (15). Remove the freed dia- phragm and the air side plate (6). Pull the other diaphragm assembly and the diaphragm shaft (15) out of the center housing (11).

5.Use a wrench on the flats of the diaphragm shaft

(15)to remove the other fluid-side diaphragm plate

(133)from the diaphragm shaft.

Overmolded Diaphragms: Use a wrench on the flats of the diaphragm shaft (15) to remove the second diaphragm from the diaphragm shaft.

6.Remove the screws (141) and air covers (136), and remove all old gasket (12) material from the ends of the center housing (11) and the surfaces of the air covers.

7.Remove the diaphragm shaft u-cups (416) and pilot pin o-rings (1).

8.Inspect all parts for wear or damage, and replace as necessary.

Reassembly

1.Insert a diaphragm shaft u-cup (416) and a pilot pin o-ring (1) into the end of the diaphragm shaft bore of the center housing (11).

NOTE: Make sure the lips of the u-cup face out of the center housing.

2.Line up the holes in the gasket (12) with the holes in the end of the center housing (11), and use six screws (141) to fasten an air cover (136) to the end of the center housing (11). Torque the screws to 35 to 45 in-lb (4.0 to 5.1 N-m).

3.Position the exhaust cover (13) and o-ring (4) on the center housing (11).

4.Repeat steps 1 and 2 for the other end of the center housing and the remaining air cover.

5.Apply medium-strength (blue) Loctite or equivalent to the threads of the screws (140). Install on one end of the diaphragm shaft (15) the following parts (see proper order in Fig. 10): air-side diaphragm plate (6), backup diaphragm (402, used only on models with PTFE diaphragms), diaphragm (401), fluid-side diaphragm plate (133), o-ring (115), and screw (140).

NOTE: The words ???AIR SIDE??? on the diaphragm (401), the backup diaphragm (402, used only on models with PTFE diaphragms), and the flat side of the air-side diaphragm plate (6) must face toward the diaphragm shaft (15).

Overmolded Diaphragms: Assemble the air???side plate (6) onto the diaphragm (401). The words AIR SIDE on the air side plate must face away from the diaphragm. Apply medium???strength (blue) thread locking adhesive to the threads of the diaphragm assembly. Screw the assembly into the diaphragm shaft (15) hand tight.

6.Put grease on the diaphragm shaft (15), and carefully (do not damage the shaft u-cups) run the diaphragm shaft (15) through the center housing

(11)bore.

7.Repeat step 5 for the other end of the diaphragm shaft (15), and torque the diaphragm shaft screws

(140)to 80 to 90 in-lb (9 to 10 N-m) at 100 rpm maximum.

Overmolded Diaphragms: Repeat Step 5 for the other end of the diaphragm shaft (15).

8. Install the muffler (3).

When you install the vee clamps in step 10, orient the center housing (11) so the air inlet is approximately 45_ above horizontal and the muffler (3) is approxi- mately horizontal.

9.Apply thin, even film of grease to inside of vee clamp (109).

10.Position the fluid covers (101), install the vee clamps (109) around the fluid and air covers, install the grounding strip on the vee clamps, and torque the vee clamp nuts to 80 to 90 in-lb (9 to 10 N-m). See Torque Sequence, page 29.

11.Make sure all the check valve parts are in place. See Fig. 8 on page 15.

12.Install the manifolds (102), and torque the manifold bolts (105) to 80 to 90 in-lb (9 to 10 N-m). See

Torque Sequence, page 29.

105

7

102

101

102

105

7

Fig. 10

11

416} 1

4

13

2 141

3

12}

136

3

3Apply grease.

4The words ???AIR SIDE??? on diaphragms (and on backup diaphragms used on PTFE models) must face toward diaphragm shaft (15).

5Flat side of the air-side diaphragm plate must face toward diaphragm shaft (15).

9072A

Model 241564, 515 pump

Same as the D51211 pump, but with an open downward port.

Model 241565, 515 pump

Same as the D52911 pump, but with an open downward port.

Model 248171, 515 pump

Same as the D51277 pump, except with split inlets/outlets.

Model 248172, 515 pump

Same as the D51255 pump, except with split inlets/outlets.

Model 248173, 515 pump

Same as the D52977 pump, except with split inlets/outlets.

Model 248174, 515 pump

Same as the D52955 pump, except with split inlets/outlets.

Model 246484, 515 pump

Same as the D51331 pump, but with an open downward port. Use inlet manifold 241558.

Model 24G745, 515 pump

Same as the D5B981 pump, but with BSPP threads.

Model 246485, 716 pump

Same as the D53331 pump, but with an open downward port. Use inlet manifold 190246.

Model 243305, 716 pump

Same as the D53266 pump, but with an open downward port. Use inlet manifold 190246.

Model 243306, 716 pump

Same as the D53277 pump, but with an open downward port. Use inlet manifold 190246.

Model 243307, 716 pump

Same as the D53211 pump, but with an open downward port. Use inlet manifold 190246.

Model 257447, 716 pump

Same as the D54311 pump, but tested for use with moisture???sensitive materials.

Model 24B674, 716 pump

Same as the D54311 pump

Pumps with Overmolded Diaphragms

Model 24N093, 515 pump

Same as the D5291_ pump, but with overmolded diaphragm parts shown in table.

Model 24N094, 515 pump

Same as the D5B91_ pump, but with overmolded diaphragm parts shown in table.

Model 24N095, 515 pump

Same as the D55A1_ pump, but with overmolded diaphragm parts shown in table.

Model 24N096, 515 pump

Same as the D5121_ pump, but with overmolded diaphragm parts shown in table.

Model 24N097, 515 pump

Same as the D5133_ pump, but with overmolded diaphragm parts shown in table.

Model 24N098, 515 pump

Same as the D5A21_ pump, but with overmolded diaphragm parts shown in table.

Model 24N257, 716 pump

Same as the D5321_ pump, but with overmolded diaphragm parts shown in table.

Model 24N258, 716 pump

Same as the D5331_ pump, but with overmolded diaphragm parts shown in table.

Model 24N259, 716 pump

Same as the D5333_ pump, but with overmolded diaphragm parts shown in table.

Model 24N260, 716 pump

Same as the D5421_ pump, but with overmolded diaphragm parts shown in table.

Model 24N261, 716 pump

Same as the D5431_ pump, but with overmolded diaphragm parts shown in table.

Model 24N262, 716 pump

Same as the D5433_ pump, but with overmolded diaphragm parts shown in table.

Air Motor Parts List (Matrix Column 2)

Guide Parts List (Matrix Column 4)

Ball Parts List (Matrix Column 5)

Diaphragm Parts List (Matrix Column 6)

{ Included in Air Valve Repair Kit 241657

} Included in Fluid Section Repair Kit D05XXX

* These parts are unique to the remote operated air motor.

111

109

103

139}

106

grounding screw (acetal pump only)

114

{ Included in Air Valve Repair Kit 241657

} Included in Fluid Section Repair Kit D05XXX

* These parts are unique to the remote oper- ated air motor.

}12

}202

}201

}139

101

115

402}

105 401}

139} 109

10

}202

}201

}139

202}

301}

201}

139}

4

101

104

102

{9

L16 117

}1

L17

109

15

}416

116

11

113

4

13

3

{ Included in Air Valve Repair Kit 241657

} Included in Fluid Section Repair Kit D05XXX

* These parts are unique to the remote operated air motor.

4

105

107

112

}139

}202

}301

}201

}139

106

101

117

106

102

103

202}

201}

139}

109

136

}401

133

{14

{9

4

13

3

}139

}202

}301

}201

}139

102

202}

201}

139}

140

}115

Grounding Detail

123

122

112

121

110

9070A

Husky 515

1.Left/Right Fluid Covers

Torque bolts to 80???90 in???lb (9???10 NSm)

SIDE VIEW

2.Inlet Manifold

Torque bolts to 80???90 in???lb (9???10 NSm)

BOTTOM VIEW

3.Outlet Manifold

Torque bolts to 80???90 in???lb (9???10 NSm)

TOP VIEW

Husky 716

1.Left/Right Fluid Covers

Torque bolts to 80???90 in???lb (9???10 NSm)

FRONT VIEW

2.Inlet Manifold

Torque bolts to 80???90 in???lb (9???10 NSm)

5

3

BOTTOM VIEW

3.Outlet Manifold

Torque Bolts to 80???90 in???lb (9???10 NSm)

9

7

TOP VIEW

1/4 npt(f) Air Inlet

* Pumps with duckbill check valves are shipped with the inlet manifold on top and the outlet manifold on the bottom. To make the inlet manifold on the bottom and the outlet manifold on the top, rotate each of the four duckbill assemblies vertically 180_ as shown below.

7.75 in.

(196.9 mm)

139

201

202

SIDE VIEW

3.13 in.

(79.5 mm)

3/4 npt(f) or bspt(f)

Fluid Outlet *

3/4 npt (f) or bspt(f) Fluid Inlet *

4.30 in.

(109.2 mm)

6.25 in.

(158.8 mm)

10.63 in.

(270.0 mm)

9.94 in.

(252.5

mm)

8.56 in.

(217.4

mm)

1.38 in.

(35.1 mm)

PUMP MOUNTING HOLE PATTERN

Four 0.30 in.

(7.6 mm)

Diameter Slots

4.30 in.

(109.2 mm)

6.12 in.

(155.4 mm)

9077A

* Pumps with duckbill check valves are shipped with the inlet manifold on top and the outlet manifold on the bottom. To make the inlet manifold on the bottom and the outlet manifold on the top, rotate each of the four duckbill assemblies vertically 180_ as shown below.

139

201

202

SIDE VIEW

1/4 npt(f)

Air Inlet

7.37 in.

(187.2 mm)

6.62 in.

(168.1 mm)

3/4 npt(f) or bspt(f) Fluid Inlets *

Note: Bottom port open on 243305,

243306, 243307, and 246485 only.

3/4 npt(f), bspt(f), or bspp(f) Fluid Outlet *

10.43 in.

(264.9

mm)

9.18 in.

(233.2

mm)

7.80 in.

(198.1

mm)

1.38 in.

(35.1 mm)

3/4 npt(f), bspt(f), or bspp(f) Fluid Outlet *

4.29 in.

(109.0 mm)

6.04 in.

(153.4 mm)

PUMP MOUNTING HOLE PATTERN

Four 0.28 in. (7.1 mm) Diameter Slots

4.29 in.

(109.0 mm)

6.62 in.

(168.1 mm)

3/4 npt(f) or bspt(f) Fluid Inlets *

9078A