Graco D51 User manual

9246A
Husky 515
Husky 716
9065A
Instructions
Air-Operated
Diaphragm Pumps 308981ZBB
EN
For fluid transfer applications. For professional use only. Only models marked with (*) are
approved for use in European explosive atmosphere locations.
100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure
ACETAL*, POLYPROPYLENE, AND PVDF
Husky™ 515
Model No. D 5 1 _ _ _ Acetal NPT Pumps
Model No. D 5 2 _ _ _ Polypropylene Pumps
Model No. D 5 5 _ _ _ PVDF NPT Pumps
Model No. D 5 A _ _ _ Acetal BSPT Pumps
Model No. D 5 B _ _ _ Polypropylene BSPT Pumps
Model No. D 5 E _ _ _ PVDF BSPT Pumps
Model No. D 9 1 _ _ _ Acetal NPT Pumps
Model No. D 9 A _ _ _ Acetal BSPT Pumps
For Additional Models, see Table of Contents
ALUMINUM* AND STAINLESS STEEL*
Husky™ 716
Model No. D 4 D _ _ _ Stainless Steel BSPT Pumps, Remote
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
Model No. D 9 4 _ _ _ Stainless Steel NPT Pumps
Model No. D 9 D _ _ _ Stainless Steel BSPT Pumps
For Additional Models, see Table of Contents
*These models are certified:
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Refer to the Pump Matrix on page 23 to determine
the model number of your pump.
II 2 GD
Ex h IIC 66°C...135°C Gb
Ex h IIIC T135°C Db
ATEX T-code rating is dependent on the temperature
of the fluid being pumped. Fluid temperature is
limited by the materials of the pump interior wetted
parts. See Technical Data for the maximum fluid
operating temperature for your specific pump model.

2 308981
Table of Contents
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Husky 515 and Husky 716 Pump Matrix . . . . . . . 23
Husky 515 and Husky 716 Repair Kits . . . . . . . . . 25
Husky 515 and Husky 716 Common Parts . . . . . 26
Husky 716 Parts Drawing . . . . . . . . . . . . . . . . . . . 30
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Husky 515 Technical Data . . . . . . . . . . . . . . . . . . . 33
Husky 515 Dimensions . . . . . . . . . . . . . . . . . . . . . 34
Husky 716 Technical Data . . . . . . . . . . . . . . . . . . . 35
Reed Switch Technical Data . . . . . . . . . . . . . . . . . 36
Husky 716 Dimensions . . . . . . . . . . . . . . . . . . . . . 37
Husky 515 and 716 Performance Charts . . . . . . . 38
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 40
Symbols
Warning Symbol
Caution Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
CAUTION
This symbol alerts you to the possibility of
damage to or destruction of equipment if you do
not follow the instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
•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 100 psi (0.7 MPa, 7 bar) maximum working pressure at 100 psi (0.7 MPa, 7
bar) maximum incoming air pressure.
•Use fluids and solvents that are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
•Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82°C (180°F) or below -40°C (-40°F).
•Wear hearing protection when operating this equipment.
•Do not lift pressurized equipment.
•Do not kink or overbend hoses or use hoses to pull equipment.
•Comply with all applicable local, state, and national fire, electrical, and safety regulations.
•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.

308981 3
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.
•Do not lift a pump under pressure. If dropped, the fluid section may rupture. Always follow the
•Pressure Relief Procedure on page 10 before lifting the pump.
•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. Read Air Exhaust Ventilation on
page 6.
•Never use an acetal pump to pump acids. Take precautions to avoid acid or acid fumes from con-
tacting the pump housing exterior. Stainless steel parts will be damaged by exposure to acid spills
and fumes.
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 8.
•Never use a polypropylene or PVDF pump with non-conductive flammable fluids as specified by
your local fire protection code. Refer to Grounding on page 8 for additional information. Consult
your fluid supplier to determine the conductivity or resistivity of your fluid.
•If there is any static sparking or you feel an electric shock while using this equipment, stop pump-
ing 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 pumped.
•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. Read Air Exhaust Ventilation on page 6.
•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.
•Keep a fire extinguisher in the work area.
WARNING

4 308981
Installation
General Information
•The 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.
•Always use Genuine Graco Parts and Accessories.
•Use 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 Sequence,
page 32. After the first day of operation, retorque the
fasteners. Although pump use varies, a general guide-
line is to retorque fasteners every two months.
Toxic Fluid Hazard
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.
Mountings
•These pumps can be used in a variety of
installations. Be sure the mounting surface can
support the weight of the pump, hoses, and
accessories, as well as the stress caused during
operation.
•Fig. 2 shows some installation examples. On all
installations, mount the pump using screws and
nuts.
•Prolonged exposure to UV radiation will degrade
natural polypropylene components of the pumps.
To prevent potential injury or equipment damage,
do not expose pump or the plastic components to
direct sunlight for prolonged periods.
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
Read TOXIC FLUID HAZARD on page
3.
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 pump-
ing certain chemicals. Consult engineering guides for
chemical compatibilities and temperature limits, or
contact your Graco distributor.

308981 5
Installation
Air Line
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 accesso-
ries 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 coupler (D) onto
the end of the air hose (C), and screw the mating fit-
ting 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 connectors
(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 sig-
nal, such as Graco’s Cycleflo (P/N 195264) or Cycle-
flo 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
•For all pumps, use flexible fluid hoses.
•If 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.
•At inlet fluid pressures greater than 15 psi (0.1 MPa, 1
bar), diaphragm life will be shortened.
Fluid Outlet Line
1. Use flexible, 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
overtighten.
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 pres-
sure.
3. Install a fluid drain valve (H) near the fluid outlet. Read
the WARNING above.
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 contamination from haz-
ardous fluids.
CAUTION
The pump exhaust air may contain contaminants. Ven-
tilate to a remote area if the contaminants could affect
your fluid supply. Read Air Exhaust Ventilation on
page 6.
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 con-
tamination from hazardous fluids when relieving pres-
sure. Install the valve close to the pump fluid outlet.

6 308981
Installation
Fluid Pressure Relief Valve
Fig. 1
Air Exhaust Ventilation
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.
CAUTION
Some systems may require installation of a pressure
relief valve at the pump outlet to prevent overpressur-
ization 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 exam-
ple, 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, caus-
ing fluid to back up in the outlet line.
1
2
1
2
3
3
9073A
Install valve between fluid inlet and outlet ports.
Connect fluid inlet line here.
Connect fluid outlet line here.
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 flam-
mable 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. 2.
Read TOXIC FLUID HAZARD on
page 3.
Read FIRE AND EXPLOSION
HAZARD on page 3.

308981 7
Installation
Fig. 2
9074A
H
J
A
CDK
LM
N
Y
E
9075A
H
A
CD
K
L
Y
9076A
A
E
K
P
R
S
T
U
V
Y
H
C
D
F
G
B
F
W
X
Z
04054
G
9074A
H
J
A
CDK
LM
N
Y
E
9075A
H
A
CD
K
L
Y
9076A
A
E
K
P
R
S
T
U
V
Y
H
C
D
F
G
B
F
W
X
Z
04054
G
KEY
A Pump
B Bleed-type master air valve (required for pump)
C Electrically conductive air supply line
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
G Pump air regulator
H Fluid drain valve (required)
J Fluid regulator (optional)
K Electrically conductive fluid supply hose
L Fluid suction line
M Underground storage tank
N Wall mounting bracket
Y Ground wire (required; see page 8 for
installation instructions)
ABOVE-GROUND TRANSFER INSTALLATION
55-GALLON BUNG PUMP INSTALLATION
KEY
A Pump
C Electrically conductive air supply line
D Air line quick disconnect
H Fluid drain valve (required)
K Electrically conductive fluid supply
hose
L Fluid suction line
Y Ground wire (required; see page 8 for
installation instructions)
AIR SPRAY INSTALLATION
KEY
A Pump
C Electrically conductive air line to pump
E Gun air line shutoff valve
F Air line filter
G Gun air regulator
H Fluid drain valve (required)
K Electrically conductive fluid supply hose
P Circulating valve
R Electrically conductive air line to gun
S Air spray gun
T Electrically conductive fluid return line
U 5-gallon pail
V Agitator
Y Ground wire (required; see page 8 for
installation instructions)
VENTING EXHAUST AIR
KEY
W Muffler
X Electrically Conductive Air Exhaust
Hose
Z Container for Remote Air Exhaust
All wetted and non-wetted pump parts
must be compatible with the fluid being
pumped.

8 308981
Installation
Grounding
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 flamma-
ble fluid containers during filling.
Ground all of this equipment:
•Pump: 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.
•Air and fluid hoses: Use only flexible, electrically
conductive hoses.
•Air compressor: Follow the manufacturer’s
recommendations.
•Solvent pails used when flushing: Follow the local
code. Use only grounded 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.
•Fluid supply container: Follow the local code.
Fig. 3
WARNING
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before oper-
ating the pump, ground the system as
explained below. Also read the section FIRE
AND EXPLOSION HAZARD on page 3.
The acetal Husky 515 pump contains stainless steel
fibers, which makes the wetted parts conductive.
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, always
ground the entire fluid system by making sure the fluid
system has an electrical path to a true earth ground
(see Fig. 3). Never use a polypropylene or PVDF pump
with non-conductive 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/meter
(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-centi-
meters.
9079A
2
AH
S
T
Z
1
2
1
Y
Y
GROUNDING A PUMP
Hose must be conductive.
Dispense valve nozzle must be in contact with
container.
KEY
A Pump
H Fluid drain valve (required)
S Dispense valve
T Fluid drain line
Y Fluid section grounding via grounding strip or
grounding screw (required for metal and acetal pumps)
Z Container ground wire (required)

308981 9
Installation
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.
1. Relieve the pressure. See Pressure Relief
Procedure on page 11.
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 32.
NOTE: Make sure all manifold o-rings are positioned
correctly before you fasten the manifold. Manifold
o-rings (139) are shown in Fig. 8 and Fig. 9.
NOTE: Pumps with duckbill check valves are shipped
with the inlet manifold on top and the outlet manifold on
the bottom. See page 14 for details.
Fig. 4
f
Fig. 5
1
1
109
9065A
1109
Torque to 80 to 90 in-lb (9 to 10 NSm). See
Torque Sequence, page 32.
outlet
inlet
1
1105
9071A
1105
Torque to 80 to 90 in-lb (9 to 10 NSm). See
Torque Sequence, page 32.
outlet
inlet

10 308981
Install Reed Switch
1. Shut off air to pump and remove valve cover (A).
2. Remove lower carriage and replace with new car-
riage assembly (2), so magnet faces end of valve
chamber.
3. Replace valve cover. Torque to 80 to 100 in-lb
(9.0 to 13.6 N•m).
4. Screw reed switch (1) into one of two holes on under-
side of air motor until it bottoms out.
5. Attach the reed switch cable (1) to the system moni-
toring counts.
NOTE: The following steps will require that the pump
is operated with the targeted fluid, and at the mini-
mum operational speed, so that the reed switch
counting is properly calibrated.
6. Set the inlet air pressure to a minimum of 40 psi (2.76
bar). Observe that the air motor is functioning. If it is
not, increase the pressure until it does begin to oper-
ate.
7. While monitoring the reed switch output at the moni-
toring location, slowly turn the reed switch
counter-clockwise until a consistent pulse output is
observed.
8. Mark a vertical line on the threads of the reed switch
and a corresponding alignment mark on the body of
the air motor.
9. While monitoring the pulse output, slowly turn the
reed switch counter-clockwise until breaks in the
pulses are observed. Make a mark on the air motor
where the line on the threads of the reed switch is
located.
10. Rotate the reed switch clockwise until the line on the
threads is halfway between the two marks on the air
motor.
11. Tighten the lock nut on the reed switch against the air
motor. Do not overtighten.
A
2
1
5
4
Cable connector
Pins 1-3 unused

308981 11
Operation
Pressure Relief Procedure
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,
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
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 appropriate
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 thor-
oughly clean the pump and hoses. Close the air regula-
tor. 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).
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 pres-
sure as described in Pressure Relief Proce-
dure on page 11.
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
•Are instructed to relieve pressure
•Stop pumping
•Check, clean, or service any system equipment
•Install or clean fluid nozzles
1.
2.
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.
5. Place the suction tube (if used) in the fluid to be
pumped.
Read TOXIC FLUID HAZARD
on page 3.
If lifting the pump, follow the Pressure
Relief Procedure above.
Be sure the pump is properly
grounded. Read FIRE AND
EXPLOSION HAZARD on
page 3.
WARNING
The pump may cycle once before the external signal is
applied. Injury is possible. If pump cycles, wait until
end before proceeding.

12 308981
Maintenance
Lubrication
The air valve is lubricated at the factory to operate with-
out additional lubrication. If you want to provide addi-
tional 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.
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 11.
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 32.
Preventive Maintenance Schedule
Establish a preventive maintenance schedule, based on
the pump’s service history. This is especially important
for prevention of spills or leakage due to diaphragm fail-
ure.
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.

308981 13
Troubleshooting
Read Pressure Relief Procedure on page 11, and relieve the pressure before you check or service the
equipment. Check all possible problems and causes before disassembling the pump.
PROBLEM CAUSE SOLUTION
Pump will not cycle, or cycles once and
stops.
Air valve is stuck or dirty. Use filtered air.
Pump cycles at stall or fails to hold
pressure at stall.
Leaky check valves or o-rings. Replace.
Worn check balls or duckbill valves or
guides.
Replace.
Check ball wedged in guide. Repair or replace.
Worn diaphragm shaft seals. Replace.
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking check valve balls. Clean or replace.
Diaphragm ruptured. Replace.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace.
Loose manifolds or damaged manifold
o-rings.
Tighten manifold bolts or nuts; replace
o-rings.
Loose fluid side diaphragm plates. Tighten.
Fluid in exhaust air. Diaphragm ruptured. Replace.
Loose fluid side diaphragm plates. Tighten.
Worn diaphragm shaft seals. Replace.
Pump exhausts air from clamps (metal
pumps).
Loose clamps. Tighten clamp nuts.
Air valve o-ring is damaged. Inspect; replace.
Pump leaks fluid from check valves. Worn or damaged check valve o-rings. Inspect; replace.
Reed switch electrical signal output
erratic or inconsistent
Switch moved Re-install reed switch. See page 10.
Running speed of pump less than reed
switch calibration speed.
Reset reed switch calibration with pump
running at or below minimum operation
speed. See page 10.
Slow changeover or pump inlet pressure
too low.
Increase pump inlet pressure to a
minimum of 40 psi.

14 308981
Service
Air Valve (Husky 515 and Husky 716 pumps without reed switch)
NOTE: Air Valve Repair Kit 241657 is available. Parts included in the kit are marked with a dagger (†) in Fig. 6 and in
the Parts Drawings and Lists. A tube of general purpose grease 111920 is supplied in the kit. Service the air valve as
follows. See Fig. 6.
Relieve the pressure. See Pressure Relief
Procedure on page 11.
1. Remove the cover (10) and the o-ring (4).
2. Remove the carriage plungers (7), carriages (8), car-
riage pins (9), and valve plate (14) from the center
housing (11).
3. 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.
4. Grease the lapped surface of the valve plate (14), and
install the valve plate with the lapped surface facing
up.
5. 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 carriage
plunger bores. See the following important installa-
tion notes:
NOTES:
•When 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.
•When 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
housing (11).
6. Grease the carriage pins (9), and slide the carriage
pins into the carriage pin bores.
7. Install the carriages (8). Make sure the carriages
engage the clip ends of the carriage plungers (7) and
carriage pins (9).
8. Grease the o-ring (4), and seat it in the groove around
the cover opening of the center housing (11).
9. 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).
Fig. 6
1
2
9
14
2
8
7
9
8
2
7
4
10
1
3
3
4
44
2
11
2
2
5
55
6
9069A
4 6
4 6
NOTE: Center housing (11) is shown
separated from the air covers, but it is
not necessary to remove the air covers
for this service. Leave the center housing
and air covers assembled for this ser-
vice.
† Included in Air Valve Repair Kit 241657
Torque to 80 to 100 in-lb (9.0 to 13.6 N-m).
Apply grease.
Apply grease to lapped face.
Apply grease to bores of center housing (11) before
installing.
Seal lips face clip end (the smaller end) of carriage plunger (7).
Install with the clip ends (the smaller ends) facing toward
center of center housing (11).

308981 15
Air Valve (Husky 515 and Husky 716 pumps with reed switch)
NOTE: Air Valve Repair Kit 25C469 is available. Parts included in the kit are marked with a dagger (†) in Fig. 7 and
in the Parts Drawings and Lists. A tube of general purpose grease 111920 is supplied in the kit. Service the air valve
as follows. See Fig. 7.
Relieve the pressure. See Pressure Relief
Procedure on page 11.
1. Remove the cover (10) and the o-ring (4).
2. Remove the carriage plungers (7), carriages (8, 8a),
carriage pins (9), and valve plate (14) from the center
housing (11).
3. Clean all the parts, and inspect them for wear or
damage.
NOTE: If you are installing the new Air Valve Repair Kit
25C469, use all the parts in the kit.
4. Grease the lapped surface of the valve plate (14), and
install the valve plate with the lapped surface facing
up.
5. 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 carriage
plunger bores. See the following important installa-
tion notes:
NOTES:
•When 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.
•When 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
housing (11).
6. Grease the carriage pins (9), and slide the carriage
pins into the carriage pin bores.
7. Install the carriages (8, 8a). Make sure the carriages
engage the clip ends of the carriage plungers (7) and
carriage pins (9).
8. Grease the o-ring (4), and seat it in the groove around
the cover opening of the center housing (11).
9. 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).
Fig. 7
6
5
4
3
2
1
NOTE: Center housing (11) is shown
separated from the air covers, but it is
not necessary to remove the air covers
for this service. Leave the center housing
and air covers assembled for this ser-
vice.
Apply grease to lapped face.
Apply grease to bores of center housing (11) before
installing.
Seal lips face clip end (the smaller end) of carriage
plunger (7).
Install with the clip ends (the smaller ends) facing toward
center of center housing (11).
† Included in Air Valve Repair Kit 25C469
Torque to 80 to 100 in-lb (9.0 to 13.6 N-m).
Apply grease.
11
†7
†8
†2
10
4
9†
8a†
9†
18
2†
7†
14†
6
5
5
4
4
4
3
6
4
1
2
2
2

16 308981
Service
Air Section (Husky 515 and 716)
NOTE: Air Section Repair Kit 25U241 is available. Parts included with the kit are marked with an asterisk (*) in Fig. 10 and Fig.
11. General purpose grease 111920 is supplied in the kit. Service the air section as follows. See Fig. 10 and Fig. 11.
Disassembly
Relieve the pressure. See Pressure Relief
Procedure on page 11.
1. Remove the manifolds (102) and fluid covers (101).
NOTE: Make sure all the check valve parts stay in
place. See Fig. 9.
2. Remove the grounding strip from the vee clamps
(109), and remove the vee clamps.
3. 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 diaphragm and the air
side plate (6). Pull the other 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 (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.
5. 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.
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 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) thread locker to the
threads of the screws (140). Install on one and of the
diaphragm shaft (15) the following parts (see proper
order in Fig. 11): air-side diaphragm plate (6), backup
diaphragm (402, used only on models with PTFE dia-
phragms), 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).
NOTE: When you install the vee clamps in step 9, orient
the center housing (11) so the air inlet is approximately
45° above horizontal and the muffler (3) is
approximately 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 32.
11. Make sure all the check valve parts are in place. See
Fig. 9.
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 32.

308981 17
Service
Ball or Duckbill Check Valves
NOTE: Fluid Section Repair Kit D05XXX is available.
See page 27 to order the correct kit for your pump.
Adhesive 113500 is supplied in the kit.
Relieve the pressure. See Pressure Relief
Procedure on page 11.
1. Remove the top and bottom manifolds (102, 103).
2. Remove all parts shown with a dagger (†) in Fig. 8
and Fig. 9.
3. Clean all parts, and replace worn or damaged parts.
4. 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 32.
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.
202
201
139
9080A

18 308981
Service
Fig. 8
Fig. 9
103
202
139
202
201
301
139
201
301
202
201
139
109
109
1
1
1
202
201
139
9067A
102
139
139
Torque to 80 to 90 in-lb (9 to
10 N-m). See Torque
Sequence, page 32.
Husky 515
139
201
202
139
201
101
202
139
139
201
202
139
301
301
105
105
106
106
107
102
102
1
1
1
9081A
139
201
202
Torque to 80 to 90 in-lb (9 to
10 N-m). See Torque
Sequence, page 32.
Husky 716

308981 19
Service
Diaphragms (Husky 515)
NOTE: Fluid Section Repair Kit D05XXX is available. See page 23 to order the correct kit for your pump. Service the
diaphragms as follows. See Fig. 10.
Disassembly
Relieve the pressure. See Pressure Relief
Procedure on page 11.
1. Remove manifolds (102,103) and fluid covers (101).
NOTE: Make sure all the check valve parts stay in
place. See Fig. 8.
2. 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: 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 diaphragm is sep-
arated from the air cover. Rotate the separated dia-
phragm counterclockwise until the diaphragm
assembly comes free.
3. 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.
4. Inspect all parts for wear or damage, and replace as
necessary.
Reassembly
1. Apply medium-strength (blue) thread locker to the
threads of the fluid-side diaphragm plate (133).
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), and fluid-side diaphragm plate (133).
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.
2. Repeat step 1 for the other end of the diaphragm
shaft (15). Torque the fluid-side diaphragm plates
(133) to 80–90 in-lb (9–10 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 pat-
tern 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.
3. Make sure all the check valve parts are in place. See
Fig. 8.
4. 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 32.

20 308981
Service
Diaphragms (Husky 515)
Fig. 10
6
12*
416*
109
105 401
102
109
101
15
11
114
106
103
1
2
3
1*
1
2
4
3
4
4
4
109
4*13
3
402 1
26
401
1
3
HD Overmolded Diaphragm
The 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 diaphragm shaft (15).
Apply medium-strength (blue) thread locker to 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
Sequence, page 32.