Graco Husky 205 D120 Series User manual

Instructions – Parts List
Husky™205 Air-Operated
Diaphragm Pumps 308652ZAS
EN
100 psi (0.7 MPa, 7 bar) Maximum Incoming Air Pressure
100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure
ti10660a
Part No. D120XX
Polypropylene Pump with Air-Operated Motor
Part No. D110XX* and DM10XX*
Acetal Pump with Air-Operated Motor
Part No. D150XX and DM50XX
PVDF Pump with Air-Operated Motor
Part No. D220XX
Polypropylene Pump with Solenoid Ports
Part No. D210XX*
Acetal Pump with Solenoid Ports
Part No. D250XX
PVDF Pump with Solenoid Ports
These models are certified:
Important Safety Instructions.
Read all warnings and instructions in this manual.
Save these instructions.
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 308652ZAS
Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Parts Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Service Kit Matrix . . . . . . . . . . . . . . . . . . . . . . . . . 15
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . 19
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Dimensions and Mounting Hole Layout . . . . . . . 21
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . 22
Graco Standard Husky Pump Warranty . . . . . . . 24
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 24
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.

308652ZAS 3
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Any misuse of the equipment or accessories, such as overpressurizing, modifying parts, using
incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and
result in splashing in the eyes or on the skin, other serious injury, or fire, explosion or property
damage.
•This equipment is for professional use only. Observe all warnings. Read and understand all
instruction manuals, warning labels, and tags before you operate this equipment. If you are not
sure, or if you have questions about installation or operation, call your Graco distributor.
•Never alter or modify any part of this equipment; doing so could cause it to malfunction. Use only
genuine Graco part numbers and accessories.
•Check all equipment regularly and repair or replace worn or damaged parts immediately.
•Never exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the Technical Data on page 21.
•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.
•Be sure that all fluids and solvents used are chemically compatible with the wetted parts shown in
the Technical Data on page 21. Always read the manufacturer’s literature before you use fluid or
solvent in the pump.
•Never move or lift a pump under pressure. If dropped, the fluid section may rupture. Always follow
the Pressure Relief Procedure on page 9 before you move or lift the pump.
•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 5 for additional information. Consult
your fluid supplier to determine the conductivity or resistivity of your fluid.
•Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being pumped.

4 308652ZAS
United States Government safety standards have been adopted under the Occupational Safety and Health Act.
You should consult these standards—particularly the General Standards, Part 1910, and the Construction Standards,
Part 1926.
WARNING
HAZARDOUS FLUIDS
Improper handling of hazardous fluids or inhaling toxic vapors can cause extremely serious injury or
death from splashing in the eyes, ingestion, or bodily contamination. Observe all the following
precautions when you handle hazardous or potentially hazardous fluids.
•Know what fluid you are pumping and its specific hazards. Take precautions to avoid a toxic fluid
spill.
•Always wear appropriate clothing and equipment, such as eye protection and breathing
apparatus, to protect yourself.
•Store hazardous fluid in an appropriate, approved container. Dispose of it according to all Local,
State, and Federal guidelines for hazardous fluids.
•Secure the fluid outlet hose tightly into the receiving container to prevent it from coming loose and
improperly draining the fluid.
•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 6.
FIRE AND EXPLOSION HAZARD
Static electricity is created by the flow of fluid through the pump and hose. If the equipment is not
properly grounded, sparking may occur. Sparks can ignite fumes from solvents and the fluid being
pumped, dust particles, and other flammable substances, whether you are pumping indoors or
outdoors, and can cause a fire or explosion and serious injury and property damage.
•To reduce the risk of static sparking, ground the pump and all other equipment used or located in
the work area. Check your local electrical code for detailed grounding instructions for your area
and type of equipment. See Grounding on page 5.
•If you experience any static sparking or even a slight shock while using this equipment, stop
pumping immediately. Check the entire system for proper grounding. Do not use the system
again until you have identified and corrected the problem.
•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 6.
•Do not smoke in the work area. Do not operate the equipment near a source of ignition or an open
flame, such as a pilot light.

308652ZAS 5
Installation
Tightening Threaded Fasteners Before First
Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque Sequence,
page 20. After the first day of operation, retorque the
fasteners. Although pump use varies, a general guideline
is to retorque fasteners every two months.
Use a compatible thread sealant on all male threads.
Tighten all connections firmly to avoid air or fluid leaks.
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.
Acetal Pump Grounding Instructions
For polypropylene and PVDF pumps, see the warning
above.
Ground all of this equipment.
Pump: Connect a ground wire (A) and clamp, Part No.
222011. See FIG. 1. The pump grounding locations are
on the manifold between the inlet and outlet ports. Use
the nut (B) and bolt (C) that are provided with the pump,
and install as follows:
1. Place the nut in the nut catcher on the underside of
the manifold.
2. Insert the bolt through the loop end of the ground
wire.
3. Insert the bolt through the hole on the pump manifold
and tighten it into the nut that you positioned in
step 1.
4. Connect the clamp end of the ground wire to a true
earth ground.
•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 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.
CAUTION
To avoid pump damage, do not overtighten the
fittings to the pump.
WARNING
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before
you operate the pump, ground the
system as explained below. Also read
the section FIRE AND EXPLOSION
HAZARD on page 4.
The acetal pump contains stainless steel fibers which
make the wetted parts conductive. Attaching the
ground wire to one of the grounding locations
grounds the wetted parts.
The polypropylene and PVDF pumps are not
conductive. When you pump conductive flammable
fluids, always ground the entire fluid system by
making sure the fluid has an electrical path to a true
earth ground. See FIG. 1. Never use a polypropylene
or PVDF pump with non-conductive flammable fluids
as specified by your local fire protection code.
Consult your fluid supplier to determine the
conductivity or resistivity of your fluid.
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-centimeters.
FIG. 1
06179A
A
C
B
grounding hole

6 308652ZAS
Installation
Air Exhaust Ventilation
Mountings
•Mounting Bracket: The pump is shipped with a 90
degree mounting bracket (60). Mount the pump to the
bracket using the four screws (61) provided. Secure
the opposite portion of the mounting bracket to a
horizontal surface. The mounting bracket must be
used for proper pump performance.
•Be sure the mounting can support the weight of the
pump, hoses, and accessories, as well as the stress
caused during operation.
•For all mountings, be sure the pump is secured with
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.
WARNING
TOXIC FLUID HAZARD
Read the HAZARDOUS FLUIDS and
FIRE AND EXPLOSION HAZARD
sections on page 4 before you operate
this pump.
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 or food handling
areas when pumping flammable or
hazardous fluids.
If the diaphragm ruptures, the fluid being pumped is
exhausted with the air. Place a container at the end of
the air exhaust line to catch fluid in case the
diaphragm ruptures, and disconnect the pump.
CAUTION
The pump exhaust air may contain contaminants. If
needed, ventilate to a remote area to reduce possible
fluid contamination. See Air Exhaust Ventilation on
page 6.
FIG. 2
WARNING
To reduce the risk of serious injury, splashing in the
eyes or on the skin, and toxic fluid spills, never move
or lift a pump under pressure. If dropped, the fluid
section may rupture. Always follow the Pressure
Relief Procedure on page 9 before you move or lift
the pump.
ti10662a

308652ZAS 7
Installation
Air Lines
1. Mount the air line accessories on the wall or on a
bracket. Be sure the air line supplying the
accessories is grounded.
a. The pump speed can be controlled in one of two
ways: To control it on the air side, install an air
regulator. To control it on the fluid side, install a
fluid valve near the outlet.
b. Install a bleed-type master air valve downstream
from the air regulator, and use it to relieve
trapped air. See the Bleed-Type Master Air
Valve and Fluid Drain Valve warning above.
Locate another bleed-type master air valve
upstream from all air line accessories, and use it
to isolate the accessories during cleaning and
repair.
c. The air line filter removes harmful dirt and
moisture from the compressed air supply.
2. Install a flexible air hose between the accessories
and the pump air inlet. Screw the air line fitting into
the air inlet.
3. Do not restrict the exhaust port. Excessive exhaust
restriction can cause erratic pump operation.
Fluid Lines
Use flexible fluid hoses for fluid-in and fluid-out lines. On
each end of the fluid manifold are a fluid IN port and a
fluid OUT port. FIG. 3. NOTE: Make sure the fluid OUT
port on the fluid manifold is mounted up. This will
assure proper pump priming. Fluid-in and fluid-out lines
can be connected on the same end, or opposite ends of
the manifold. Plug ports that are not used (plugs
provided).
Typical Installation
The installations shown in FIG. 4 are only a guide to help
select and install a pump; they are not actual system
designs.
Typical installation includes (not supplied by Graco):
•For solenoid operation: a four-way, 5-port, 3-position
solenoid valve with 1/4-in. ports, or two 3-position
3-way valves. Mac series 44 (4-way), or series 35
(3-way). Either way, air pressure should be released
if not cycling.
•PLC or timer. Consult your local industrial controls
distributor.
WARNING
Bleed-Type Master Air Valve and Fluid Drain
Valve
A bleed-type master air valve and a fluid drain valve
are required on your system.
The bleed-type master air valve relieves air trapped
between itself and the pump. Trapped air can cause
the pump to cycle unexpectedly, which could result in
serious bodily injury, including splashing in the eyes,
injury from moving parts, or contamination from
hazardous fluids.
The fluid drain valve reduces the risk of serious bodily
injury, including splashing in the eyes or on the skin,
or contamination from hazardous fluids. Install the
fluid drain valve close to the pump’s fluid outlet to
relieve pressure in the hose if the hose becomes
plugged.
FIG. 3
CAUTION
For solenoid operation, the pump must exhaust
through the solenoid. Failure to exhaust through
solenoid could cause the diaphragms to fail.
06179A
ti10661a

8 308652ZAS
Installation
FIG. 4.
C
J
L
N
T
Y
A
U
EH
B
G
F
C
J
N
A
L
L
C
Y
ti10663a
KEY
A Husky 205 pump
B Bleed-type master air valve (required for
pump)
C Air line(s)
E Master air valve (for accessories)
F Air line filter
G Muffler
H Pump air regulator
J Fluid drain valve (required on fluid outlet
side of pump)
L Flexible fluid suction line
N Flexible fluid supply hose
T Bung adapter
U 4-way solenoid
Y Ground wire (required)
See page 4 for installation instructions.
Internal Air Valve View
(shown upright for clarity)
Remote Solenoid View
Remote Solenoid Operated
Internal Air Valve Operated
Air line to
Port A Air line to
Port B
Air line to inlet

308652ZAS 9
Operation
Pressure Relief Procedure
1. Shut off air and reserve air to the pump.
2. Open the dispensing valve if the system has one.
3. Open the fluid drain valve to relieve all system
pressure, and have a container ready to catch the
drainage.
Flushing the Pump Before First Use
The pump was tested in water. If water could
contaminate the fluid you are pumping, flush it thoroughly
with a compatible solvent. Follow the procedure in
Starting and Adjusting the Pump.
Starting and Adjusting the Pump
1. Be sure the pump is properly grounded. Read and
follow the instructions in Grounding on page 5.
2. Check all fittings to be sure they are tight. Be sure to
use a compatible liquid thread sealant on all male
threads. Tighten the fluid inlet and outlet fittings and
plugs securely. Retorque all fasteners before
start-up. See Torque Sequence, page 20.
3. Place the suction tube (if used) in the fluid to be
pumped.
4. Place the end of the outlet hose into an appropriate
container.
5. Close the fluid drain valve.
6. With the air regulator closed, open all bleed-type
master air valves.
7. If the outlet hose has a dispensing device, hold it
open while continuing with step 8.
8. Slowly open the air regulator until the pump starts to
cycle. Allow the pump to cycle until all air is pushed
out of the lines and the pump is primed.
NOTE: To prime a remote solenoid-operated air
valve, operate the pump at a minimum 60 cpm rate
until the pump is fully primed.
Pump Shutdown
At the end of the work shift, and before you check, adjust,
clean, or repair the system, relieve air and fluid
pressure.
WARNING
To reduce the risk of serious injury, including
splashing fluid in the eyes or on the skin, follow this
procedure whenever you are instructed to relieve
pressure, when you shut off the pump, and before
you check, adjust, clean, move, or repair any system
equipment.
WARNING
To reduce the risk of serious injury, splashing in the
eyes or on the skin, and toxic fluid spills, never move
or lift a pump under pressure. If the pump is dropped,
the fluid section could rupture. Always follow the
Pressure Relief Procedure above before you move
or lift the pump.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.

10 308652ZAS
Maintenance
Lubrication
The air valve is lubricated at the factory and designed to
operate without additional lubrication.
If added lubrication is desired, every 500 hours of
operation (or monthly), remove the hose from the pump
air inlet and add two drops of machine oil to the air inlet.
Tightening Threaded Connections
Before each use, check all hoses for wear or damage,
and replace as necessary. Be sure all threaded
connections are tight and free of leaks.
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 20.
Flushing and Storage
Flush the pump to prevent the fluid from drying or
freezing in the pump and damaging it. Always flush the
pump and relieve the pressure before storing for any
length of time. Use a compatible solvent.
If you are flushing, run the pump long enough to
thoroughly clean the pump and hoses, close the air
regulator, and remove the suction hose from the solvent
and place it in the fluid to be pumped.
If you are shutting down the pump, remove the suction
hose from the fluid container, run the pump until the fluid
is forced out of the system, and shut off the air supply
immediately.
CAUTION
Do not over-lubricate the pump. Excess oil is
exhausted through the muffler, which could
contaminate your fluid supply or other equipment.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.

308652ZAS 11
Troubleshooting
Relieve the pressure before you check or service the
equipment.
Check all possible problems and causes before you
disassemble the pump.
Internal Air Valve-Operated and Remote Solenoid-Operated Pumps
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
PROBLEM CAUSE SOLUTION
The pump cycles at stall, or it fails to
hold pressure at stall. The check valves (20) or o-rings (21) are leaking. Replace the check valves and/or o-rings. See page 15.
The check valves (20) are worn. Replace the check valves.
See page 15.
Debris is stuck between the a check
valve (20) and the seat. Clean the check valve/seat area. See page 15.
The pump operates erratically. The suction line is clogged. Inspect and clear the line.
The check valves (20) are sticking or
leaking. Replace the check valves, or clean and check the valve/seat area.
See page 15.
A diaphragm (30) is ruptured. Replace the ruptured diaphragm.
See page 14.
There are air bubbles in the fluid. The suction line is loose. Tighten the suction line.
A diaphragm (30) is ruptured. Replace the ruptured diaphragm.
See page 14.
The manifold (52) is loose, or the
o-rings (21) are damaged. Tighten the manifold screws (58). Replace the o-rings (21). See
page 15.
The fluid covers (51) are loose. Tighten the fluid cover screws (58).
See page 14.
There is fluid in the exhaust air. A diaphragm (30) is ruptured. Replace the ruptured diaphragm.
See page 14.
A diaphragm plate (50) is loose. Tighten the diaphragm plate.
See page 14.
The pump exhausts air near the fluid
covers. The fluid covers (51) are loose, or the o-rings (57) are damaged. Tighten the fluid cover screws (58), or replace the o-rings. See page 14.
The pump exhausts air near the air
valve. The air valve cover screws (14) are loose. Tighten the screws. See page 13.
The top (5) and/or side (6) air valve
o-rings are damaged. Replace these o-rings. See the Parts Drawing on page 19.
The pump leaks fluid from the check
valves. The o-rings (21) are leaking, or the screws (58) are loose. Replace these o-rings, and tighten the screws. See page 15.

12 308652ZAS
Troubleshooting
Internal Air Valve-Operated Pumps Only
Remote Solenoid-Operated Pumps Only
PROBLEM CAUSE SOLUTION
The pump will not cycle, or it cycles
once and stops. The air valve is stuck or dirty. Disassemble and clean or repair the air valve. See page 13.
Use filtered air.
Not enough air pressure supplied. Increase air pressure supply. Do not
exceed maximum input pressure.
PROBLEM CAUSE SOLUTION
The pump will not prime or loses
prime. The cycle rate is too low. Increase cycle rate to 60 cpm.
The check valves (20) are not
sealing. Inspect the check valves, and replace them if worn or damaged.
See page 15.
Fluid manifold not mounted with
OUT port up. Re-mount fluid manifold so OUT port is up.
The pump leaks air or does not
operate. Air is supplied to Port A and Port B at the same time. Replace both diaphragms (30). See page 14.
Check your installation. See page 8.
Solenoid exhaust is plugged. Ensure that exhaust (G on page 8)
is free of obstructions.

308652ZAS 13
Service
Service Kits
Service Kits may be ordered separately.
To repair the air valve, order Part No. 238853. Parts
included in the Air Valve Service Kit are marked with an
asterisk in the Parts Drawing on page 19, for example
(3*).
For fluid section repair section parts, see the Service Kit
Matrix on page 16. Parts included in the Fluid Section
Service Kit are marked with a dagger in the Parts
Drawing on page 19, for example (4).
Servicing the Air Valve
Service the air valve as follows. See FIG. 5.
1. Relieve the fluid pressure, and disconnect air line
from the pump.
2. Remove the four screws (14) that hold the valve
cover (7) on the center housing (1).
3. Remove the valve block (4) and valve carriage (2),
and replace the u-cups (3). Replace the valve
carriage and valve block. When you replace the valve
carriage, position it all the way to one side or the
other.
NOTE: The valve block shown in FIG. 5 is for pumps
with an air-operated air motor. If your pump has a
solenoid-operated air motor, this step does not
pertain. Items 2, 3, 4, 16, and 17 are not required.
4. Clean any parts that are dirty.
5. To reinstall the valve cover (7), spread cover apart
enough not to damage the square ring packings (6)
and slide cover (7) into the center section.
6. Install the screws (14), and torque to 45 to 47 in-lb
(5.0 to 5.3 Nm). See Torque Sequence on page 20.
7. Reconnect the pump.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
FIG. 5.
7
ti10664b
14
2
4
13
3
1
1
17 16
6
6
Lips of u-cups (3) must face toward each
other (toward center of valve carriage (2)).
1

14 308652ZAS
Service
Replacing Diaphragms
Replace the diaphragms as follows. See FIG. 6 and FIG. 7.
1. Relieve the pressure, and disconnect the air line
from the pump.
2. Remove the eight screws (58) that fasten the two
fluid covers (51) to manifold (52), and remove the
fluid cover/center housing assembly from the
manifold.
3. Remove the six screws (58) that fasten each fluid
cover (51) to the center housing (1), and pull the fluid
covers off of the center housing.
4. Remove the diaphragm plates (50) from the shaft
(10), and remove the diaphragms (30), and air-side
diaphragm plates (11).
5. Remove the diaphragm pins (8), remove and replace
the o-rings (9), and reinstall the diaphragm pins in the
center housing (1).
6. Grease the length of the shaft (10), and slide it
through the center housing (1).
NOTE: Use lithium-base grease, part no. 111920
(Lubriplate 630AA or equivalent).
7. Install the new diaphragms (30) with the concave
side toward the center housing (1).
8. Screw the diaphragm plates (50) onto the shaft (10),
and torque to 28-33 in-lb (3.2-3.7 Nm).
9. Reinstall the fluid covers (51) on the center housing
(1), install the screws (58) that fasten the fluid covers
to the center housing, and torque to 42-47 in-lb
(4.7-5.3 Nm). See Torque Sequence on page 20.
10. Reinstall the fluid covers/center housing assembly on
the manifold (52), install the screws (58) that fasten
the fluid covers/center housing assembly to the
manifold, and torque to 42-47 in-lb (4.7-5.3 Nm).
See Torque Sequence on page 20.
11. Reconnect the pump.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
FIG. 6.
50
30
57
8
06180e
58
58
51
1
10
11
9
12
Service kits include two types of o-rings (57): thin cross section and thick
cross section o-rings. Use thin cross section o-rings on Acetal and PVDF
pump series A to E and Polypropylene pump series A to H. Use thick
cross section o-rings on Acetal and PVDF pump series F and later and
Polypropylene pump series J and later. Discard unused o-rings.

308652ZAS 15
Service
Replacing Check Valves
Replace each pair of check valves as follows. See FIG. 7.
1. Relieve the pressure, and disconnect the air line
from the pump.
2. Remove the eight screws (58) that hold the fluid
cover/center housing assembly on the manifold (52),
and lift the manifold covers/center housing assembly
off of the manifold (52).
3. Remove and replace the check valves (20), being
careful to orient each check valve exactly like the
one it is replacing. Make sure the check valve/seat
area is clean.
4. Remove and replace the sealing o-rings (21).
Once compressed, o-rings may not be reused.
Make sure the check valve/seat area is clean prior to
fully seating o-rings into fluid cover grooves.
5. Reinstall the fluid covers/center housing assembly on
the manifold (52), install the screws (58) that fasten
the fluid covers/center housing assembly to the
manifold, and torque to 42-47 in-lb (4.5-5.0 Nm).
See Torque Sequence on page 20.
6. Reconnect the pump.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
FIG. 7. ti10665a
1
52
21
20
51
58
58

16 308652ZAS
Parts Matrix
Husky 205 Polypropylene, Acetal*, and PVDF Pumps
The Model Number of your pump is marked on the pump’s serial plate. To determine the Model Number of your pump
from the following matrix, select the six digits that describe your pump, working from left to right. The first digit is always
D, designating Husky diaphragm pumps. The remaining five digits define the materials of construction. For example,
a pump with a Husky 205 polypropylene air motor, polypropylene fluid section, polypropylene check valves, and PTFE
diaphragms is Model D 1 2 0 9 1.To order replacement parts, refer to the Part Lists on pages 17 and 19. The digits
in the matrix do not correspond to the reference numbers in text, Parts Drawings, or Parts Lists.
*Note: Model 24E366 uses the same parts as D11021.
The pump is packaged and sold as PN 24J001.
Service Kit Matrix
Air Valve and Fluid Section Service Kits for Husky 205 Pumps
To determine the Model Number of your service kit from the following matrix, select the six digits that describe your
pump, working from left to right. The first digit is always D, designating Husky diaphragm pumps. The second digit is
always 0 (zero), and the third digit is always 1 (one). The remaining five digits define the materials of construction. For
example, if your pump has polypropylene checks and PTFE diaphragms, order Repair Kit D 0 1 0 9 1. If you only
need to repair certain parts (for example, the diaphragms), use the 0 (null) digit for the balls, and order Repair Kit
D 0 1 0 0 1. To order replacement parts, refer to the Part Lists on pages 17 and 19. The digits in the matrix do not
correspond to the reference numbers in text, Parts Drawings, or Parts Lists.
Diaphragm Pump Air Motor Fluid Section Seats and Guides Checks Diaphragms
D (for all pumps) 1 (Husky 205;
polypropylene,
standard)
2 (Husky 205;
polypropylene, for
solenoid operation)
M (Husky 205;
polypropylene,
standard with
fluoroelastomer
o-rings on actuator
pin)
1 (acetal)*
2 (polypropylene)
3 (not used)
4 (not used)
5 (PVDF)
0 (no seats/guides) 2 (acetal)
A (PVDF)
9 (polypropylene)
1 (PTFE)
6 (Santoprene)
II 2 GD
Ex h IIC 66°C...135°C Gb
Ex h IIIC T135°C Db
Diaphragm Pump Air Motor O-rings Seats Checks Diaphragms
D (for all pumps
except DMXXXX) 0 (for all pumps except DMXXXX) 1 (for all pumps except DMXXXX) 0 (for all pumps except DMXXXX) 0 (null)
A (PVDF)
2 (acetal)
9 (polypropylene)
0 (null)
1 (PTFE)
6 (Santoprene)

308652ZAS 17
Parts
Air Motor Section (matrix column 2)
Digit Ref. No. Part No. Description Qty.
1 1 240898 HOUSING, center, assembly
(includes 12 and 57) 1
2 191157 CARRIAGE, valve 1
3 113869 SEAL, u-cup 2
4 194533 VALVE BLOCK (for pump
with air-operated air motor) 1
5 191160 GASKET, molded 1
6 115056 O-RING, packing 2
8 191021 PIN, actuator 2
9 113565 O-RING, packing 2
103557 O-RING, packing (DMXXXX
pumps only) 2
10 193778 SHAFT, diaphragm 1
11 193775 PLATE, diaphragm, air side 2
12 114710 O-RING, diaphragm shaft 2
14 113341 SCREW, torx 4
15 114174 MUFFLER, porous plastic 1
16 194386 SEAL, valve plate 1
17 194384 PLATE, valve 1
2 1 240899 HOUSING, center, assembly
(includes 12 and 57) 1
10 193778 SHAFT, diaphragm 1
11 193775 PLATE, diaphragm, air side 1
12 114710 O-RING, diaphragm shaft 2
14 113341 SCREW, torx 4
15 114174 MUFFLER, porous plastic 1

18 308652ZAS
Fluid Section (matrix column 3)
* Alternate mounting bracket 17C883 (Ref. 60) is
available. See Parts illustration.
Check Valve (matrix column 5)
NOTE: All check valves contain a hastelloy spring.
Diaphragm (matrix column 6)
Digit Ref. No. Part No. Description Qty.
1 7 191140 COVER, valve 1
49 290229 LABEL, warning 1
50 191553 PLATE, diaphragm; acetal 2
51 276474 COVER, fluid; acetal 2
52 15T287 MANIFOLD; acetal 1
53 113576 PLUG, port; acetal 2
54 100264 SCREW, grounding 2
55 100179 NUT, hex , grounding 2
57 O-RING, packing 2
113570 thin cross section (for Acetal
and PVDF pumps series A to
E, and Polypropylene pumps
series A to H)
104445 thick cross section (for Acetal
and PVDF pumps series F
and later, and Polypropylene
pumps series J and later)
58 113341 SCREW, torx 20
59 111137 O-RING, exhaust 1
60* 194986 BRACKET, mounting 1
61 111630 SCREW, machine, pn hd 4
2 7 191140 COVER, valve 1
49 290229 LABEL, warning 1
50 191141 PLATE, diaphragm;
polypropylene 2
51 COVER, fluid; polypropylene 2
276473 Pump series A to E
278943 Pump series F, G, H
52 MANIFOLD; polypropylene 1
15T286 Pump series E, G
276470 Pump series C, D, F, H
53 113577 PLUG, port; polypropylene 2
57 O-RING, packing 2
113570 thin cross section (for Acetal
and PVDF pumps series A to
E, and Polypropylene pumps
series A to H)
104445 thick cross section (for Acetal
and PVDF pumps series F
and later, and Polypropylene
pumps series J and later)
58 113341 SCREW, torx 20
59 O-RING, exhaust 1
111137 Pump series E, G
115055 Pump series C, D, F, H
60* 194986 BRACKET, mounting 1
61 111630 SCREW, machine, pn hd 4
5 7 191140 COVER, valve 1
49 290229 LABEL, warning 1
50 191554 PLATE, diaphragm; PVDF 2
51 276475 COVER, fluid; PVDF 2
52 15T288 MANIFOLD; PVDF 1
53 113447 PLUG, port; PVDF 2
57 O-RING, packing 2
113570 thin cross section (for Acetal
and PVDF pumps series A to
E, and Polypropylene pumps
series A to H)
104445 thick cross section (for Acetal
and PVDF pumps series F
and later, and Polypropylene
pumps series J and later)
58 113341 SCREW, torx 20
59 111137 O-RING, exhaust 1
60* 194986 BRACKET, mounting 1
61 111630 SCREW, machine, pn hd 4
Digit Ref. Part No. Description Qty.
2 20† 241134 VALVE, check; acetal 4
21 113566 O-RING, packing 4
9 20† 240896 VALVE, check;
polypropylene 4
21 O-RING, packing 4
113566 Pump series A to E
578001 Pump series F, G, H
A 20† 240897 VALVE, check; PVDF 4
21 113566 O-RING, packing 4
Digit Ref. Part No. Description Qty.
130†191402 DIAPHRAGM; PTFE
(for all Husky 205 pumps) 2
630†196385 DIAPHRAGM;
Santoprene
2

308652ZAS 19
Parts
4
8
21
20†
*2
1
8
9
50
11
12
7
10
50
51
5152
54
55
30†
30
57
58
1
15
58
539
*3
* 6
*4
5 *
6*
5
ti10666c
11
14
3
59
*17 *16
60
61
7
7
6
*3
4
6
61
60
57†
Used on acetal models only.
Torque to 45-47 in-lb (5.0-5.3 Nm). See Torque Sequence on page 20
Lips of u-cups (3) must face toward each other, toward center of valve carriage (2).
Torque to 20 in-lb (2.2 Nm).
Torque to 42-47 in-lb (4.7-5.3 Nm). See Torque Sequence on page 20.
Torque to 28-33 in-lb (3.2-3.7 Nm). See Torque Sequence on page 20.
Ensure properly seated in groove.
Not assembled. These plugs are supplied to plug the two ports in the manifold that are not used.
These parts cannot be ordered separately. They come preassembled and are included as part of the Air Valve Service Kit 238853.
* These parts are included in Air Valve Service Kit 238853, which may be purchased separately.
† These parts are included in Fluid Section Service Kit. D010xx, which may be purchased separately.
‡ These parts are included in pump with integral air valve only.
Service kits include two types of o-rings (57): thin cross section and thick cross section o-rings. Use thin cross section o-rings on
Acetal and PVDF pump series A to E and Polypropylene pump series A to H. Use thick cross section o-rings on Acetal and PVDF
pump series F and later and Polypropylene pump series J and later. Discard unused o-rings.
1
3
4
5
6
7
8
9

20 308652ZAS
Torque Sequence
For proper installation, always follow torque sequence
whenever you are instructed to torque screws.
12
3
4
9
6
7
5
10
8
11, 19
12, 20
13
14
15
16 17
18
1. Valve Cover
Torque bolts to 45-47 in-lb (5.0-5.3 Nm) 2. Left/Right Fluid Cover
Torque bolts to 42-47 in-lb (4.7-5.3 Nm)
3. Manifold to Center Section
Torque bolts to 42-47 in-lb (4.7-5.3 Nm)
Back View Front View