Graco Husky 1590 DB3 Series User manual

Installation – Parts List
308441ZAH
EN
1.5-inch AODD pump for fluid transfer applications.
For professional use only.
See Models on page 2 for a list of pump models and descriptions.
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
03263B
Model No. DB3777 shown
II 2 GD c IIC T4
ALUMINUM AND STAINLESS STEEL
Husky1590 Air-Operated
Diaphragm Pumps

2 308441ZAH
Table of Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Repairing the Air Valve . . . . . . . . . . . . . . . . . . . 15
Ball Check Valve Repair . . . . . . . . . . . . . . . . . . 17
Diaphragm Repair . . . . . . . . . . . . . . . . . . . . . . . 18
Bearing and Air Gasket Removal . . . . . . . . . . . 21
Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Repair Kit Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Torque Instructions . . . . . . . . . . . . . . . . . . . . . . . . 29
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Performance Chart . . . . . . . . . . . . . . . . . . . . . . . . . 34
Graco Standard Husky Pump Warranty . . . . . . . . 36
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 36
Models
*Refer to the Pump Matrix on page 23 to determine the Model No. of your pump.
NOTE: Plus Models include stainless steel center sections.
Model No. Description
*DB3______ Aluminum Pumps
*DC3______ Aluminum Pumps, Remote
*DB4______ Stainless Steel Pumps
*DC4______ Stainless Steel Pumps, Remote
*DBC______ Aluminum BSPT Pumps
*DCC______ Aluminum BSPT Pumps, Remote
*DBD______ Stainless Steel BSPT Pumps
*DCD______ Stainless Steel BSPT Pumps, Remote
*DT4______ Stainless Steel Plus Pumps
*DU4______ Stainless Steel Plus Pumps, Remote
*DTD______ Stainless Steel BSPT Plus Pumps
*DUD______ Stainless Steel BSPT Plus Pumps, Remote
*DTP______ Stainless Steel Pumps with Flanged Manifold Ports (Vertical Outlet)
*DTR______ Stainless Steel Pumps with Flanged Manifold Ports (Horizontal Outlet)
253485 Aluminum Pump
232502 Private-Label Aluminum Pump
24B780 Stainless Steel Plus Pump with overmolded diaphragms
24B781 Stainless Steel Pump with overmolded diaphragms
24G411 Aluminum BSPT Pump with overmolded diaphragms
24J358 Aluminum Pump with overmolded diaphragms
24J359 Aluminum Pump with overmolded diaphragms
25A017 Aluminum Pump with overmolded diaphragms, SST balls

308441ZAH 3
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 120 psi (0.8 MPa, 8 bar) maximum working pressure at 120 psi (0.8 MPa, 8 bar)
maximum incoming air pressure.
•Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical
Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
•Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use could result in a chemical
reaction, with the possibility of explosion.
•Do not use hoses to pull equipment.
•Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco
hoses to temperatures above 82C (180F) or below -40C (-40F).
•Do not lift pressurized equipment.
•Comply with all applicable local, state, and national fire, electrical, and safety regulations.

4 308441ZAH
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
•Know the specific hazards of the fluid you are using.
•Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state
and national guidelines.
•Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
•Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas. If the
diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 10.
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 Installation on page 6.
•If there is any static sparking or you feel an electric shock while using this equipment, stop pumping
immediately. Do not use the equipment until you identify and correct the problem.
•Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being
sprayed.
•Pipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm fails, the
fluid is exhausted along with the air. See Air Exhaust Ventilation on page 10.
•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.
WARNING

308441ZAH 5
Installation
General Information
•The typical installation shown in FIG. 1 is only a guide
for selecting and installing system components.
Contact your Graco distributor for assistance in
planning a system to suit your needs.
•Always use Genuine Graco Parts and Accessories.
Refer to Product Data Sheet 305646.
•Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 25-26.
•Lift the pump by grasping the outlet manifold (1)
securely. See FIG. 3 on page 9.
Tightening Screws Before First Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque
Instructions, 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.
Tips to Reduce Cavitation
Cavitation in a diaphragm pump is the formation and
collapse of bubbles in the pumped liquid. Frequent or
excessive cavitation can cause serious damage,
including pitting and early wear of fluid chambers, balls,
and seats. It may result in reduced efficiency of the
pump. Cavitation damage and reduced efficiency both
result in increased operating costs.
Cavitation depends on the vapor pressure of the pumped
liquid, the system suction pressure, and the velocity
pressure. It can be reduced by changing any of these
factors.
1. Reduce vapor pressure: Decrease the temperature
of the pumped liquid.
2. Increase suction pressure:
a. Lower the installed position of the pump relative
to the liquid level in the supply.
b. Reduce the friction length of the suction piping.
Remember that fittings add friction length to the
piping. Reduce the number of fittings to reduce
the friction length.
c. Increase the size of the suction piping.
NOTE: Be sure the inlet fluid pressure does not
exceed 25 % of the outlet working pressure.
3. Reduce liquid velocity: Slow the cyclic rate of the
pump.
Pumped liquid viscosity is also very important but nor-
mally is controlled by factors that are process dependent
and cannot be changed to reduce cavitation. Viscous liq-
uids are more difficult to pump and more prone to cavita-
tion.
Graco recommends taking all the above factors into
account in system design. To maintain pump efficiency,
supply only enough air pressure to the pump to achieve
the required flow.
Graco distributors can supply site specific suggestions to
improve pump performance and reduce operating costs.
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
equipment. Ground all of this equipment:
WARNING
Hazardous fluid or toxic fumes can cause
serious injury or death if splashed in the
eyes or on the skin, inhaled, or swallowed.
1. Read TOXIC FLUID HAZARD on page 4.
2. Use fluids and solvents which are compatible with
the equipment wetted parts. Refer to the
Technical Data section of all equipment
manuals. Read the fluid and solvent
manufacturer’s warnings.
WARNING
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before
operating the pump, ground the system as
explained below. Also, read the section
FIRE AND EXPLOSION HAZARD, on
page 4.

6 308441ZAH
Installation
•Pump: Connect a ground wire and clamp as shown in
FIG. 1. Loosen the grounding screw (W). Insert one
end of a 12 ga (1.5 mm2) minimum ground wire (Y)
behind the grounding screw and tighten the screw
securely. Connect the clamp end of the ground wire
to a true earth ground. Order Part No. 222011
Ground Wire and Clamp.
FIG. 1 ___________________________
•Air and fluid hoses: Use only grounded hoses with a
maximum of 500 ft (150 m) combined hose length to
ensure grounding continuity.
•Air compressor: Follow the manufacturer’s
recommendations.
•All solvent pails used when flushing: Follow the local
code. Use only metal pails, which are conductive. Do
not place the pail on a non-conductive surface, such
as paper or cardboard, which interrupts the
grounding continuity.
•Fluid supply container: Follow the local code.
Mountings
1. Be sure the mounting surface can support the weight
of the pump, hoses, and accessories, as well as the
stress caused during operation.
2. For all mountings, be sure the pump is bolted directly
to the mounting surface.
3. For ease of operation and service, mount the pump
so the air valve cover (2), air inlet, and fluid inlet and
outlet ports are easily accessible.
4. Rubber Foot Mounting Kit 236452 is available to
reduce noise and vibration during operation.
Air Line
1. Install the air line accessories as shown in FIG. 2.
Mount these accessories on the wall or on a bracket.
Be sure the air line supplying the accessories is
grounded.
a. Install an air regulator (C) and gauge to control
the fluid pressure. The fluid outlet pressure will
be the same as the setting of the air regulator.
b. Locate one bleed-type master air valve (B) close
to the pump and use it to relieve trapped air. See
the WARNING above. Locate the other master
air valve (E) upstream from all air line
accessories and use it to isolate them during
cleaning and repair.
c. The air line filter (F) removes harmful dirt and
moisture from the compressed air supply.
2. Install a grounded, flexible air hose (A) between the
accessories and the 1/2 npt(f) pump air inlet (N). See
FIG. 3. Use a minimum 1/2 in. (13 mm) ID air hose.
Screw an air line quick disconnect coupler (D) onto
the end of the air hose (A), and screw the mating
fitting into the pump air inlet snugly. Do not connect
the coupler (D) to the fitting until you are ready to
operate the pump.
CAUTION
The pump exhaust air may contain contaminants.
Ventilate to a remote area if the contaminants could
affect your fluid supply. See Air Exhaust Ventilation
on page 10.
Y
W
02646B
WARNING
A bleed-type master air valve (B) is required in your
system to relieve air trapped between this valve and
the pump. Trapped air can cause the pump to cycle
unexpectedly, which could result in serious injury,
including splashing in the eyes or on the skin, injury
from moving parts, or contamination from hazardous
fluids. See FIG. 2.

308441ZAH 7
Installation
Installation of Remote Pilot Air Lines
1. Refer to Parts Drawing. Connect air line to pump as
in preceding steps.
2. Connect 1/4 in. O.D. tubing to push type connectors
(14) on air motor of pump.
NOTE: by replacing the push type connectors, other
sizes or types of fittings may be used. The new fittings
will require 1/8 in. npt threads.
3. Connect remaining ends of tubes to external air
signal, such as Graco’s Cycleflo (P/N 195264) or
Cycleflo II (P/N195265) controllers.
NOTE: the air pressure at the connectors must be at
least 30% of the air pressure to the air motor for the
pump to operate.
Fluid Suction Line
1. Use grounded fluid hoses (G). The pump fluid inlet
(R) is 1-1/2 in. npt(f). Screw the fluid fitting into the
pump inlet securely.
2. If the fluid inlet pressure to the pump is more than
25% of the outlet working pressure, the ball check
valves will not close fast enough, resulting in
inefficient pump operation.
3. At inlet fluid pressures greater than 15 psi (0.1 MPa,
1 bar), diaphragm life will be shortened.
4. See the Technical Data on page 33 for maximum
suction lift (wet and dry).
Fluid Outlet Line
1. Use grounded fluid hoses (L). The pump fluid
outlet (S) is 1-1/2 in. npt(f). Screw the fluid fitting into
the pump outlet securely.
2. Install a fluid drain valve (J) near the fluid outlet.
See the WARNING above.
3. Install a shutoff valve (K) in the fluid outlet line.
WARNING
A fluid drain valve (J) is required to relieve pressure in
the hose if it is plugged. The drain valve reduces the
risk of serious injury, including splashing in the eyes
or on the skin, or contamination from hazardous fluids
when relieving pressure. Install the valve close to the
pump fluid outlet. See FIG. 2.

8 308441ZAH
FIG. 2 ____________________________________________________________
Y
J
FEB C
A
DKL
G
H
R
S
03265B
Muffler not included
on Model No. 253485
TYPICAL FLOOR-MOUNT INSTALLATION
KEY
A Air supply hose
B Bleed-type master air valve (required for
pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
G Fluid suction hose
H Fluid supply
J Fluid drain valve (required)
K Fluid shutoff valve
L Fluid hose
R Fluid inlet port
S Fluid outlet port
Y Ground wire (required; see page 5 for
installation instructions)

308441ZAH 9
Installation
Changing the Orientation of the Fluid Inlet
and Outlet Ports
NOTE: Remove and rotate the center manifold(s) to
change the orientation of inlet or outlet port(s). Follow the
Torque Instructions, page 29.
KEY
Apply medium-strength (blue) thread locker to the threads. See
Torque Instructions, page 29.
Apply medium-strength (blue) thread locker to the threads. See
Torque Instructions, page 29.
FIG. 3 __________________________
Fluid Pressure Relief Valve
KEY
R 1.5 in. npt(f) fluid inlet port
S 1.5 in. npt(f) fluid outlet port
V Pressure relief valve (Order Part No. 112119 for stainless
steel pumps)
Install valve between fluid inlet and outlet ports.
Connect fluid inlet line here.
Connect fluid outlet line here.
Muffler not included on Model No. 253485
FIG. 4 ___________________________
1
2
N
P
2
1
106
106
102
103
101
112 2
03263B
Aluminum Model Shown
N 1/2 in. npt(f) air inlet port
P Muffler. (Not included on
Model No. 253485)
101 Covers
102 Fluid inlet manifold
103 Fluid outlet manifold
106 Manifold and cover
screws
112 Bottom cover screws
CAUTION
Some systems may require installation of a
pressure relief valve at the pump outlet to prevent
overpressurization and rupture of the pump orhose.
See FIG. 4.
Thermal expansion of fluid in the outlet line can
cause overpressurization. This can occur when
using long fluid lines exposed to sunlight or ambient
heat, or when pumping from a cool to a warm area
(for example, from an underground tank).
Overpressurization can also occur if the Husky
pump is being used to feed fluid to a piston pump,
and the intake valve of the piston pump does not
close, causing fluid to back up in the outlet line.
1
2
3
4
R
S
1
2
V
03461B
3
4

10 308441ZAH
Installation
Air Exhaust Ventilation The air exhaust port is 3/4 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
erratic pump operation.
If the muffler (P) is installed directly to the air exhaust
port, apply PTFE thread tape or anti-seize thread
lubricant to the muffler threads before assembly.
To provide a remote exhaust:
1. Remove the muffler (P) from the pump air exhaust
port.
2. Install a grounded air exhaust hose (T) and connect
the muffler (P) to the other end of the hose. The
minimum size for the air exhaust hose is 3/4 in.
(19 mm) ID. If a hose longer than 15 ft (4.57 m) is
required, use a larger diameter hose. Avoid sharp
bends or kinks in the hose. See FIG. 4.
3. Place a container (U) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures.
VENTING EXHAUST AIR
FIG. 5 ____________________________________________________________
WARNING
FIRE AND EXPLOSION HAZARD
Be sure to read and follow the warnings
and precautions regarding TOXIC FLUID
HAZARD, and FIRE AND EXPLOSION
HAZARD on page 4, before operating this
pump.
Be sure the system is properly ventilatedfor your type
of installation. You must vent the exhaust to a safe
place, away from people, animals, food handling
areas, and all sources of ignition when pumping
flammable or hazardous fluids.
Diaphragm failure will cause the fluid being pumped
to exhaust with the air. Place an appropriate
container at the end of the air exhaust line to catch
the fluid. See FIG. 5.
03267A
FBEC
A
D
P
T
U
KEY
A Air supply line
B Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
P Muffler (not included on Model
No. 253485)
T Grounded air exhaust hose
U Container for remote air exhaust