Graco Husky 15120 Use and care manual

Repair/Parts
Husky™ 15120 Air-Operated
Diaphragm Pump3A2889A
EN
Polypropylene or PVDF pumps for fluid transfer applications, including high viscosity materials. For
professional use only.
Not for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Maximum Working Pressure: 125 psi
(0.86 MPa, 8.6 bar)
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Warnings ........................................................... 3
Ordering Information........................................... 6
Related Manuals ................................................ 6
Configuration Number Matrix............................... 7
Troubleshooting.................................................. 8
Notes................................................................. 10
Repair................................................................ 11
Pressure Relief Procedure............................ 11
Replace Complete Air Valve ......................... 11
Replace Seals or Rebuild Air Valve............... 12
Check Valve Repair ..................................... 14
Diaphragm and Center Section Repair ........... 15
Torque Instructions ............................................. 19
Parts.................................................................. 20
Accessories........................................................ 31
Technical Data ...................................................32
Graco Standard Husky Pump Warranty................ 34
23A2889A

Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer backtothese
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
•Grounda
ll equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
• Route exhaust away from all ignition sources. If diaphragm ruptures, fluid may be exhausted
with air.
Static charge may build up on plastic parts during cleaning and could discharge and ignite
flammable vapors. To help prevent fire and explosion:
• Clean plastic parts only in well ventilated area.
• Do not clean with a dry cloth.
• Do not operate electrostatic guns in equipment work area.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin
and cause serious injury.
• Follow the Pressure Relief Procedure when you stop spraying/dispensing and before
cleaning, checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
•Ch
eck hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
3A2889A 3

Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
•Turnoffal
l equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
•Makesure
all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure
due to the thermal expansion. Over-pressurization can result in equipment rupture and serious
injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
•Use
only compatible water-based solvents to clean plastic structural or pressure-containing
parts.
•SeeTechnical Data in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.
43A2889A

Warnings
WARNING
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into
the air.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:
•Protect
ive eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
3A2889A 5

Ordering Information
Ordering Information
To Find Your Nearest Distributor
1. Visit www.graco.com.
2. Click on Where to Buy and use the Distributor
Locator.
To Specify the Configuration of a New
Pump
Please call your distributor.
OR
Use the Online Husky Selector Tool on the Process
Equipmentpage at www.graco.com.
To Order Replacement Parts
Please call your distributor.
Distributor Note
1. To find part numbers for new pumps or kits, use
the Online Husky Selector Tool.
2. To find part numbers for replacement parts:
a. Use the 20–digit number from the ID
plate on the pump. If you only have
the Graco 6–digit part number, use the
Online Husky Selector Tool to find the
corresponding 20–digit number.
b. Use the Configuration Number Matrix on the
next page to understand which parts are
described by each digit.
c. Refer to the main Parts illustration and to the
Parts/Kits Quick Reference. Follow the page
references on these two pages for further
ordering information, as needed.
3. Please call Graco Customer Service to order.
Related Manuals
Manual
Number
Title
3A2888 Husky 15120 Air-Operated Diaphragm
Pump, Operation
63A2889A

Configuration Number Matrix
Configuration Number Matrix
Check the identification plate (ID) for the Configuration Number of your pump. Use the following matrix to
define the components of your pump.
CONFIGURATION NO.PART NO. SERIAL NO.
SERIESDATE CODE MAX WPR PSI-bar
Graco Inc., P.O. Box 1441
Mpls, MN 55440 USA
MADE IN
Sample Configuration Number: 15120P-P01AP1PPPTFKPT
15120P P01A P1 PP PT FK PT
Pump Model Center
Section and
Air Valve
Fluid Covers
and Manifolds
Seats Balls Diaphragms Manifold and Seat Seals
Pump Center Section and Air
Valve Material
For Use With Fluid Covers and Manifolds
15120P
Polypropylene
P01A Polypropylene Standard
Diaphragms
P1 Polypropylene, Center Flange,
ANSI/DIN
15120F
PVDF
P01G Polypropylene Overmolded
Diaphragms
P2 Polypropylene, End Flange,
ANSI/DIN
F2 PVDF, End Flange, ANSI/DIN
Seat Material Ball Material Diaphragm Material Manifold and Seat
Seal Material
PP Polypropylene FK FKM FK FKM PT PTFE
PV PVDF PT PTFE PO PTFE/EPDM Overmolded
SP Santoprene SP Santoprene PT PTFE/Santoprene 2–Piece
SS Stainless
Steel
SP Santoprene
3A2889A 7

Troubleshooting
Troubleshooting
Problem Cause Solution
Pump is running too fast, causing
cavitation before prime.
Reduce air inlet pressure.
Check valve ball severely worn or
wedged in seat or manifold.
Replace ballandseat.
Seat severely worn. Replace ball and seat.
Outlet or inlet clogged. Unclog.
Inlet or outlet valve closed. Open.
Inlet fittings or manifolds loose. Tighten.
Pump cycles but will not prime.
Manifold o-rings damaged. Replace o-rings.
Pump cycles at stall or fails to hold
pressure at stall.
Worn check valve balls, seats, or
o-rings.
Replace.
Air valve is stuck or dirty. Disassemble and clean air valve.
Use filtered air.
Check valve ball severely worn and
wedged in seat or manifold.
Replace ball and seat.
Pilot valve worn, damaged, or
plugged.
Replace pilot valve.
Air valve gasket damaged. Replace gasket.
Pump will not cycle, or cycles once
and stops.
Dispensing valve clogged. Relieve pressure and clear valve.
Clogged suction line. Inspect; clear.
Sticky or leaking check valve balls. Clean or replace..
Diaphragm (or backup) ruptured. Replace.
Restricted exhaust. Remove restriction.
Pilot valves damaged or worn. Replace pilot valves.
Air valve damaged. Replace air valve.
Air valve gasket damaged. Replace air valve gasket.
Air supply erratic. Repair air supply.
Pump operates erratically.
Exhaust muffler icing. Use drier air supply.
83A2889A

Troubleshooting
Problem Cause Solution
Suction line is loose. Tighten.
Diaphragm (or backup) ruptured. Replace.
Loose manifolds, damaged seats or
o-rings.
Tighten manifold bolts or replace
seats or o-rings.
Pump cavitation. Reduce pump speed or suction lift.
Air bubbles in fluid.
Loose diaphragm shaft bolt. Tighten.
Diaphragm (or backup) ruptured. Replace. Exhaust air contains fluid being
pumped. Loose diaphragm shaft bolt. Tighten or replace.
Moisture in exhaust air. High inlet air humidity. Use drier air supply.
Worn air valve cup or plate. Replace cup and plate.
Damaged air valve gasket. Replace gasket.
Damaged pilot valve. Replace pilot valves.
Pump exhausts excessive air at
stall.
Worn shaft seals or bearings. Replace shaft seals or bearings.
Air valve or fluid cover screws loose. Tighten.
Diaphragm damaged. Replace diaphragm.
Pump leaks air externally.
Air valve gasket damaged. Replace gasket.
Loose manifold screws or fluid cover
screws.
Tighten manifold screws or fluid
coverscrews.
Pump leaks fluid externally from
joints.
Manifold o-rings worn out. Replace o-rings.
3A2889A 9

Notes
Notes
10 3A2889A

Repair
Repair
Pressure Relief Procedure
Follow the Pressure Relief Procedure
whenever you see this symbol.
This equipment stays pressurized until pressure
is relieved manually. To help prevent serious
injury from pressurized fluid, such as splashing
in the eyes or on skin, follow the Pressure Relief
Procedure when you stop pumping and before you
clean, check, or service the equipment.
1. Shut off the air supply to the pump.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve fluid
pressure. Have a container ready to catch the
drainage.
Replace Complete Air Valve
Follow these instructions to install Air Valve
Replacement Kit 24B773.
1. Stop the pump. Follow the
Pressure Relief Procedure, page 11.
2. Disconnect the air line to the motor.
3. Remove nuts (104). Remove the air valve (102)
and gasket (105).
4. Align the new air valve gasket (105*) on the
center housing, then attach the new air valve.
Follow the Torque Instructions, page 19.
5. Reconnect the air line to the motor.
3A2889A 11

Repair
Replace Seals or Rebuild Air Valve
Follow these instructions to service the air valve with
one of the available repair kits. Air Valve Seal Kit
parts are marked with a †. Air Valve Repair Kit parts
are marked with a ♦. Air Valve End Cap Kit parts
aremarkedwitha‡.
Disassemble the Air Valve
1. Perform steps 1-3 under
Replace Complete Air Valve, page 11.
2. Use a T10 Torx screwdriver to remove two
screws (209). Remove the valve plate (205), cup
assembly (212-214), spring (211), and detent
assembly (203).
3. Pull the cup (213) off of the base (212). Remove
the o-ring (214) from the cup.
4. Remove the retaining ring (210) from each end
of the air valve. Use the piston (202) to push
the end cap (207) out of one end. Remove the
u-cup seal (208) from the piston. Pull the piston
out of the end and remove the other u-cup seal
(208). Remove the other end cap (207) and the
end cap o-rings (206).
5. Remove the detent cam (204) from the air valve
housing (201).
Reassemble the Air Valve
NOTE: Apply lithium-based grease when instructed
to grease. Order Graco PN 111920.
1. Use all parts in the repair kits. Clean other parts
and inspect for damage. Replace as needed.
2. Grease the detent cam (204♦) and install into
housing (201).
3. Grease the u-cups (208♦†) and install on the
piston with lips facing toward the center of the
piston.
Lips face
down.
Lips face
up.
4. Grease both ends of the piston (202♦) and the
housing bore. Install the piston in the housing
(201), with the flat side toward the cup (213♦).
Be careful not to tear u-cups (208♦†) when
sliding piston into housing.
5. Grease new o-rings (206♦†‡) and install on the
end caps (207‡). Install the end caps into the
housing.
6. Install a retaining ring (210‡) on each end to hold
end caps in place.
123A2889A

Repair
7. Grease and install the detent assembly (203♦)
into the piston. Install the o-ring (214♦) on the
cup (213♦). Apply a light film of grease to the
outsidesurfaceoftheo-ringandtheinside
mating surface of the base (212♦).
Orient the end of the base that has a magnet
toward the end of the cup that has the larger
cutout. Engage the opposite end of the parts.
Leave the end with the magnet free. Tilt the base
toward the cup and fully engage the parts, using
care so that the o-ring remains in place. Install
the spring (211♦) onto the protrusion on the cup.
Align the magnet in the base with the air inlet and
install the cup assembly.
8. Grease the cup side and install the valve plate
(205♦). Align the small hole in the plate with the
air inlet. Tighten the screws (209♦†) to hold it in
place.
Apply lithium-
based grease.
U-cup lips must
face piston.
Apply lithium-
based grease to
contact surface.
Air inlet.
3A2889A 13

Repair
Check Valve Repair
NOTE: Kits are available for new check valve balls
and seats in a range of materials. See page 27
to order kits in the material(s) desired. O-ring and
fastener kits also are available.
NOTE: To ensure proper seating of the check balls,
always replace the seats when replacing the balls.
Also, replace the o-rings every time the manifold is
removed.
Disassemble the Check Valve
1. Follow the Pressure Relief Procedure, page 11.
Disconnect all hoses.
2. Remove the pump from its mounting.
3. NOTE: Use hand tools until thread-locking
adhesive patch releases. Use a 17 mm (11/16 in)
socket wrench to remove the manifold fasteners
(5), then remove the manifold (3).
4. Remove the o-rings (9), seats (7), and balls (8).
5. Turn thepumpoverandremovetheinlet
manifold (4).
6. Remove the o-rings (9), seats (7), and balls (8).
Reassemble the Check Valve
1. Clean all parts and inspect for wear or damage.
Replace parts as needed.
2. Reassemble in the reverse order, following all
notes in the illustration. Put the inlet manifold on
first. Be sure the ball checks (7-9) and manifolds
(3, 4) are assembled exactly as shown. The ball
must seat on the chamfered side of the seat.
The arrows (A) on the fluid covers (2) must point
toward the outlet manifold (3).
Figure 1 Check valve assembly
Torqueto190to200in-lb(21to25
N·m). Follow torque sequence. See
Torque Instructions, page 19.
Arrow (A) must point toward outlet
manifold
The chamfered side of the seat must face
the ball.
143A2889A

Repair
Diaphragm and Center Section Repair
NOTE: Diaphragm kits are available in a range of
materials and styles. See pages 28 – 29. A Center
Rebuild Kit also is available. See page 23. Parts
included in the Center Rebuild Kit are marked with an
*. For best results, use all kit parts.
Disassemble the Diaphragm and Center
Section
1. Follow the Pressure Relief Procedure, page 11.
2. Remove the manifolds and disassemble
the ball check valves as explained in
Check Valve Repair, page 14.
NOTE: You may wish to remove the inner fluid
cover bolts (5) as you remove each manifold, for
convenience.
3. Overmolded Diaphragms (PO models)
a. Orient the pump so one of the fluid covers
(2) faces up. Use a 17 mm socket wrench to
remove the fluid cover bolts (5, 6), then pull
the fluid cover up off the pump.
b. The exposed diaphragm (12) will screw off by
hand. The shaft will either release and come
off with this diaphragm, or remain attached to
the other diaphragm. If the diaphragm shaft
bolt (14) remains attached to the shaft (108),
remove it. Remove the air side diaphragm
plate (11) and washer (17).
c. Turn the pump over and remove the other
fluid cover. Remove the diaphragm (and the
shaft, if necessary).
d. If the shaft is still attached to either
diaphragm, grasp the diaphragm firmly and
useawrenchontheflatsoftheshaftto
remove. Also remove the air side diaphragm
plate (11) and washer (17). Continue with
Step 5.
4. All Other Diaphragms
a. Orient the pump so one of the fluid covers
facesup. Usea17mmsocketwrenchto
remove the fluid cover screws (5, 6), then pull
thefluidcover(2)upoffthepump. Turnthe
pump over and remove the other fluid cover.
b. Hold the hex of one fluid side diaphragm
plate (15) with a 1–1/2 socket or box end
wrench. Use another wrench (same size)
on the hex of the other plate to remove.
Then remove all parts of each diaphragm
assembly.
5. Inspect the diaphragm shaft (108) for wear or
scratches. If it is damaged, inspect the bearings
(107) in place. If they are damaged, use a
bearing puller to remove them.
NOTE: Do not remove undamaged bearings.
6. Useano-ringpicktoremovetheu-cuppackings
(106) from the center housing. Bearings (107)
canremaininplace.
7. If necessary, use a socket wrench to remove the
pilot valves (111).
8. Remove the pilot valve cartridges only if
necessary due to a known or suspected problem.
After removing pilot valves, use a hex to remove
the cartridges (109), then remove cartridge
o-rings (110). If stripped, use two screwdrivers to
screw out the cartridge.
NOTE: Do not remove undamaged pilot valve
cartridges.
3A2889A 15

Repair
Reassemble the Diaphragm and Center Section
Follow all notes in the illustration. These notes
contain important information.
NOTE: Apply lithium-based grease whenever
instructed to grease.
1. Clean all parts and inspect for wear or damage.
Replace parts as needed.
2. If removed, grease and install the new pilot valve
cartridges (109), cartridge o-rings (110), and
retaining rings (113).
NOTE: Cartridges (109)
must be installed before
pilot valves (111).
3. Grease and install the pilot valves (111). Torque
to 20-25 in.-lb (2-3 N•m), at 110 rpm. Do not
over-torque.
4. Grease and install the diaphragm shaft u-cup
packings (106) so the lips face out of the housing.
5. If removed, insert the new bearings (107) into
the center housing. Use a press or a block and
rubber mallet to press-fit the bearing so it is flat
with the surface of the center housing.
6. Overmolded Diaphragms (PO)
a. Clamp theshaftflatsinavise.
b. If diaphragm setscrew comes loose or is
replaced, apply permanent (red) thread
locker to diaphragm side threads. Screw into
diaphragm until tight.
c. Assemble the air side plate (11) and washer
(17) onto the diaphragm. The rounded side
of the plate must face the diaphragm.
d. Apply primer and medium-strength (blue)
thread locker to the threads of the diaphragm
assembly. Screw the assembly into the shaft
as tight as possible by hand.
e. Grease the shaft u-cups (106*) and the
length and ends of the diaphragm shaft
(108*). Slide the shaft into the housing.
f. Reattach one fluid cover (3). Arrow (A)
must point toward the air valve. See
Torque Instructions, page 19.
g. Repeat Steps b-d for the other diaphragm
assembly and install on the exposed end of
the shaft.
h. Tighten by hand as much as possible. Go
to Step 8.
7. All Other Diaphragms
a. Assemble the diaphragm (12), the backup
diaphragm (13, if present), the air side
diaphragm plate (11), and the washer (17)
on the fluid side plate (10) exactly as shown.
b. Apply primer and medium-strength (blue)
thread locker to the threads of the screw on
thefluids
ide plate. Screw the assembly into
the shaft hand-tight.
c. Grease the shaft u-cups (106*) and the
length and ends of the diaphragm shaft
(108*). Slide the shaft into the housing.
d. Repeat for the other diaphragm assembly
and install on the exposed end of the shaft.
e. Hold one of the plates with a wrench,
and torque the other plate to 65–70 ft-lb
(88–95 N•m) at 100 rpm maximum. Do not
over-torque.
f. Reattach one fluid cover (3). Arrow (A)
must point toward the air valve. See
Torque Instructions, page 19.
16 3A2889A

Repair
SP and FK Models PO Models
PT Models Rounded side faces diaphragm
Apply lithium based grease.
Apply primer and medium-strength (blue) thread
locker. Torque to 65-70 ft-lb (88–95 N•m).
AIR SIDE markings on diaphragm must face
center housing.
If screw comes loose or is replaced, apply
permanent (red) thread locker to diaphragm side
threads. Apply primer and medium-strength (blue)
thread locker to shaft side threads.
Lips must face out of housing.
Cartridges (109) must be installed before pilot
valves (111).
Torque to 20-25 in.-lb (2-3 N•m).
3A2889A 17

Repair
8. To ensure proper seating and extend diaphragm
life, apply air pressure to the pump prior to
attaching the second fluid cover.
a. Place the supplied tool (302) where the air
valve gasket (105) normally goes. Arrows
(A) must face toward the fluid cover that is
already attached.
Figure 2 Fluid cover tool
b. Reattach the air valve.
c. Supply a minimum of 20 psi (0.14 MPa, 1.4
bar) air pressure to the air valve. Shop air
may be used. The diaphragm will shift so the
second fluid cover will seat properly. Keep
air pressure on until the second fluid cover
is attached.
d. Attach the second fluid cover (3). See
Torque Instructions, page 19.
e. Removetheairvalveandthetool(302),
replace the gasket (105), and reattach the air
valve. See Torque Instructions, page 19.
NOTE: If you are replacing the diaphragms
but not the air valve, you must remove the air
valve and gasket, put the tool in place of the
gasket, andputtheairvalvebackontoget
the air pressure needed for proper installation
of the second fluid cover. Remember to
remove the tool and replace the gasket when
finished.
f. Reassemble the ball check valves
and manifolds as explained in
Check Valve Repair, page 14.
18 3A2889A

Torque Instructions
Torque Instructions
If fluid cover or manifold fasteners have been
loosened, it is important to torque them using the
following procedure to improve sealing.
NOTE: Fluid cover and manifold fasteners have a
thread-locking adhesive patch applied to the threads.
If this patch is excessively worn, the fasteners may
loosen during operation. Replace screws with new
ones or apply medium-strength (blue) Loctite or
equivalent to the threads.
NOTE: Always completely torque fluid covers before
torquing manifolds.
1. Start all fluid cover screws a few turns. Then, turn
down each screw just until head contacts cover.
2. Turn each screw by 1/2 turn or less working in a
crisscross pattern to specified torque.
3. Repeat for manifolds.
Fluid cover and manifold fasteners: 190to220
in-lb (21 to 25 Nm)
4. Retorque the air valve fasteners in a crisscross
pattern to the specified torque.
Air valve fasteners: 45to55in-lb(5to6Nm)
5. Retorque the pilot valves to the specified torque.
Do not overtorque.
Pilot valves: 20to25in-lb(2to3Nm)
Fluid Cover Screws
Inlet and Outlet Manifold Screws
Air Valve Screws and Pilot Valves
3A2889A 19

Parts
Parts
20 3A2889A