Graco Water Pump 308441ZAD User Manual

Instructions – Parts List  
ALUMINUM AND STAINLESS STEEL  
Huskyt 1590 Air-Operated  
308441ZAD  
ENG  
Diaphragm Pumps  
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  
Patent No.  
CN ZL94102643.4  
FR 9408894  
JA 3517270  
US 5,386,452  
Important Safety Instructions  
Read all warnings and instructions in this manual.  
Save these instructions.  
Model No. DB3777 shown  
03263B  
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Symbols  
Warning Symbol  
Caution Symbol  
WARNING  
CAUTION  
This symbol alerts you to the possibility of serious  
injury or death if you do not follow the instructions.  
This symbol alerts you to the possibility of damage to  
or destruction of equipment if you do not follow the  
instructions.  
WARNING  
EQUIPMENT MISUSE HAZARD  
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.  
D This equipment is for professional use only.  
INSTRUCTIONS  
D Read all instruction manuals, tags, and labels before operating the equipment.  
D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.  
D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.  
D Check equipment daily. Repair or replace worn or damaged parts immediately.  
D 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.  
D 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.  
D 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.  
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D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-  
pose Graco hoses to temperatures above 82_ C (180_ F) or below –40_ C (–40_ F).  
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308441  
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WARNING  
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.  
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state and national guidelines.  
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and solvent manufacturer.  
D 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 9.  
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.  
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D 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.  
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being sprayed.  
D 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 9.  
D Keep the work area free of debris, including solvent, rags, and gasoline.  
D Electrically disconnect all equipment in the work area.  
D Extinguish all open flames or pilot lights in the work area.  
D Do not smoke in the work area.  
D Do not turn on or off any light switch in the work area while operating or if fumes are present.  
D Do not operate a gasoline engine in the work area.  
4
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Installation  
General Information  
Grounding  
D The typical installation shown in Fig. 2 is only a  
guide for selecting and installing system compo-  
nents. Contact your Graco distributor for assistance  
in planning a system to suit your needs.  
WARNING  
FIRE AND EXPLOSION HAZARD  
This pump must be grounded. Before  
operating the pump, ground the system  
as explained below. Also, read the sec-  
tion FIRE AND EXPLOSION HAZARD,  
on page 4.  
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Refer to Product Data Sheet 305646.  
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. Ground all of this equipment:  
D Reference numbers and letters in parentheses refer  
to the callouts in the figures and the parts lists on  
pages 25–24.  
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(
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D 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 mm@) 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.  
securely. See Fig. 3 on page 8.  
WARNING  
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.  
Y
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 manu-  
als. Read the fluid and solvent manufacturer’s  
warnings.  
W
02646B  
Fig. 1  
Tightening Screws Before First Use  
D Air and fluid hoses: Use only grounded hoses with  
a maximum of 500 ft (150 m) combined hose  
length to ensure grounding continuity.  
Before using the pump for the first time, check and  
retorque all external fasteners. See Torque Se-  
quence, page 28. After the first day of operation,  
retorque the fasteners. Although pump use varies, a  
general guideline is to retorque fasteners every two  
months.  
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mendations.  
D All solvent pails used when flushing: Follow the  
local code. Use only metal pails, which are conduc-  
tive. Do not place the pail on a non-conductive  
surface, such as paper or cardboard, which inter-  
rupts the grounding continuity.  
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308441  
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Installation  
c. The air line filter (F) removes harmful dirt and  
Mountings  
moisture from the compressed air supply.  
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 9.  
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 cou-  
pler (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.  
1. Be sure the mounting surface can support the  
weight of the pump, hoses, and accessories, as  
well as the stress caused during operation.  
Installation of Remote Pilot Air Lines  
2. For all mountings, be sure the pump is bolted  
directly to the mounting surface.  
1. Refer to Parts Drawings. Connect air line to pump  
as in preceding steps.  
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.  
2. Connect 1/4 in. O.D. tubing to push type connec-  
tors (14) on air motor of pump.  
4. Rubber Foot Mounting Kit 236452 is available to  
reduce noise and vibration during operation.  
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.  
Air Line  
3. Connect remaining ends of tubes to external air  
signal, such as Graco’s Cycleflo (P/N 195264) or  
Cycleflo II (P/N195265) controllers.  
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.  
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.  
1. Install the air line accessories as shown in Fig. 2.  
Mount these accessories on the wall or on a  
bracket. Be sure the air line supplying the acces-  
sories is grounded.  
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.  
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.  
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 30 for maximum  
suction lift (wet and dry).  
6
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Installation  
1. Use grounded fluid hoses (L). The pump fluid  
Fluid Outlet Line  
outlet (S) is 1–1/2 in. npt(f). Screw the fluid fitting  
into the pump outlet securely.  
WARNING  
A fluid drain valve (J) is required to relieve pres-  
sure in the hose if it is plugged. The drain valve  
reduces the risk of serious injury, including splash-  
ing 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.  
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.  
TYPICAL FLOOR-MOUNT INSTALLATION  
KEY  
A
B
Air supply hose  
B
E
C F  
Bleed-type master air valve  
(required for pump)  
Air regulator  
Air line quick disconnect  
Master air valve (for accessories)  
Air line filter  
Fluid suction hose  
Fluid supply  
Fluid drain valve (required)  
Fluid shutoff valve  
Fluid hose  
C
D
E
F
G
H
J
A
K
L
S
D
K
L
R
S
Y
1.5 npt(f) fluid inlet port  
1.5 npt(f) fluid outlet port  
Ground wire (required; see page 5  
for installation instructions)  
Y
H
J
R
G
Muffler not included  
on Model No. 253485  
03265B  
Fig. 2  
308441  
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Installation  
Changing the Orientation of the Fluid Inlet  
Fluid Pressure Relief Valve  
and Outlet Ports  
The pump is shipped with the fluid inlet (R) and outlet  
(S) ports facing the same direction. See Fig. 3. To  
change the orientation of the inlet and/or outlet port:  
CAUTION  
Some systems may require installation of a pres-  
sure relief valve at the pump outlet to prevent  
overpressurization and rupture of the pump or  
hose. See Fig. 4.  
1. Remove the screws (106) holding the inlet (102)  
and/or outlet (103) manifold to the covers (101).  
Thermal expansion of fluid in the outlet line can  
cause overpressurization. This can occur when  
using long fluid lines exposed to sunlight or ambi-  
ent heat, or when pumping from a cool to a warm  
area (for example, from an underground tank).  
2. Reverse the manifold and reattach. Install the  
screws, and torque according to the torque notes  
in Fig. 3.  
KEY  
N
P
1/2 npt(f) air inlet port  
Muffler. Air exhaust port  
is 3/4 npt(f) . (Not included  
on Model No. 253485)  
1.5 npt(f) fluid  
101Covers  
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.  
102Fluid inlet manifold  
103Fluid outlet manifold  
106Manifold and cover screws  
112 Bottom cover screws  
R
S
inlet port  
1.5 npt(f) fluid  
outlet port  
Apply medium-strength (blue) LoctiteR or equivalent to the  
threads. Torque to 120–150 in-lb (14–17 NS m). See Torque  
Sequence, page 28.  
KEY  
1
2
R
S
V
1.5 npt(f) fluid inlet port  
1.5 npt(f) fluid outlet port  
Pressure relief valve (Order Part No. 112119 for stainless steel  
pumps)  
Apply medium-strength (blue) LoctiteR or equivalent to the  
threads. Torque to 190–220 in-lb (22–25 NS m). See Torque  
Sequence, page 28.  
1
2
Install valve between fluid inlet and outlet ports.  
Connect fluid inlet line here.  
103  
3
Connect fluid outlet line here.  
1
106  
4
Muffler not included on Model No. 253485  
3
S
S
N
106 2  
V
1
101  
2
112  
2
P
R
102  
4
R
03263B  
Aluminum Model Shown  
03461B  
Fig. 4  
Fig. 3  
8
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Installation  
The air exhaust port is 3/4 npt(f). Do not restrict the air  
Air Exhaust Ventilation  
exhaust port. Excessive exhaust restriction can cause  
erratic pump operation.  
WARNING  
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.  
FIRE AND EXPLOSION HAZARD  
Be sure to read and follow the warnings  
and precautions regarding TOXIC  
FLUID HAZARD, and FIRE OR EXPLO-  
SION HAZARD on page 4, before op-  
erating this pump.  
To provide a remote exhaust:  
1. Remove the muffler (P) from the pump air exhaust  
port.  
Be sure the system is properly ventilated for your  
type of installation. You must vent the exhaust to a  
safe place, away from people, animals, food handl-  
ing areas, and all sources of ignition when pumping  
flammable or hazardous fluids.  
2. Install a grounded air exhaust hose (T) and con-  
nect 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. 5.  
Diaphragm failure will cause the fluid being  
pumped to exhaust with the air. Place an appropri-  
ate container at the end of the air exhaust line to  
catch the fluid. See Fig. 5.  
3. Place a container (U) at the end of the air exhaust  
line to catch fluid in case a diaphragm ruptures.  
VENTING EXHAUST AIR  
KEY  
A
B
Air supply line  
Bleed-type master air valve  
(required for pump)  
C
D
E
F
Air regulator  
Air line quick disconnect  
Master air valve (for accessories)  
Air line filter  
Muffler (not included on  
Model No. 253485)  
E
F
C
B
A
P
T
U
Grounded air exhaust hose  
Container for remote air exhaust  
D
T
U
P
03267A  
Fig. 5  
308441  
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Operation  
NOTE: If the fluid inlet pressure to the pump is more  
Pressure Relief Procedure  
than 25% of the outlet working pressure, the ball check  
valves will not close fast enough, resulting in inefficient  
pump operation.  
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 from  
the gun or splashing fluid, follow this procedure  
whenever you:  
4. Place the end of the fluid hose (L) into an appropri-  
ate container.  
5. Close the fluid drain valve (J). See Fig. 2.  
6. Close the pump air regulator (C). Open all bleed-  
type master air valves (B, E).  
D Are instructed to relieve pressure,  
D Stop pumping,  
D Check, clean or service any system equipment,  
D Install or clean fluid nozzles.  
7. If the fluid hose has a dispensing device, hold it  
open while continuing with the following step.  
8. Slowly open the air regulator (C) 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.  
1. Shut off the air to the pump.  
2. Open the dispensing valve, if used.  
If you are flushing, run the pump long enough to  
thoroughly clean the pump and hoses. Close the  
air regulator. Remove the suction tube from the  
solvent and place it in the fluid to be pumped.  
3. Open the fluid drain valve to relieve all fluid pres-  
sure, having a container ready to catch the drain-  
age.  
Operation of Remote Piloted Pumps  
Flush the Pump Before First Use  
1. Follow preceding steps 1 through 7 of Starting  
and Adjusting Pump.  
The pump was tested with lightweight oil, which is left  
in the fluid passages to protect parts. To avoid contam-  
inating your fluid with oil, flush the pump with a com-  
patible solvent before using the equipment. Follow the  
steps under Starting and Adjusting the Pump.  
2. Open air regulator (C).  
WARNING  
The pump may cycle once before the external sig-  
nal is applied. Injury is possible. If pump cycles,  
wait until end before proceeding.  
Starting and Adjusting the Pump  
WARNING  
TOXIC FLUID HAZARD  
To reduce the risk of serious injury,  
splashing in the eyes or on the skin, and  
3. Pump will operate when air pressure is alternately  
applied and relieved to push type connectors (14).  
toxic fluid spills, never move or lift a  
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 under pressure. If dropped, the fluid section  
may rupture. Always follow the Pressure Relief  
Procedure above before lifting the pump.  
1. Be sure the pump is properly grounded. Refer to  
Pump Shutdown  
Grounding on page 5.  
WARNING  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure at left.  
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 securely.  
3. Place the suction tube (if used) in the fluid to be  
pumped.  
At the end of the work shift, relieve the pressure.  
10  
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Maintenance  
Lubrication  
Flushing and Storage  
The air valve is designed to operate unlubricated,  
however if 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.  
WARNING  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 10.  
CAUTION  
Do not over-lubricate the pump. Oil is exhausted  
through the muffler, which could contaminate your  
fluid supply or other equipment. Excessive lubrica-  
tion can also cause the pump to malfunction.  
Flush the pump often enough 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  
storing it for any length of time.  
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 28.  
308441  
11  
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Troubleshooting  
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WARNING  
the equipment.  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 10.  
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disassembling the pump.  
PROBLEM  
CAUSE  
SOLUTION  
Pump cycles at stall or fails to hold  
pressure at stall.  
Worn check valve balls (301), seats Replace. See page 16.  
(201) or o-rings (202).  
Pump will not cycle, or cycles once Air valve is stuck or dirty.  
and stops.  
Disassemble and clean air valve.  
See pages 14–15. Use filtered air.  
Check valve ball (301) severely  
worn and wedged in seat (201) or  
manifold (102 or 103).  
Replace ball and seat. See page  
16.  
Check valve ball (301) is wedged  
Install Pressure Relief Valve  
into seat (201), due to overpressur- (see page 8).  
ization.  
Dispensing valve clogged.  
Clogged suction line.  
Sticky or leaking balls (301).  
Diaphragm ruptured.  
Restricted exhaust.  
Suction line is loose.  
Diaphragm ruptured.  
Relieve pressure and clear valve.  
Inspect; clear.  
Pump operates erratically.  
Air bubbles in fluid.  
Clean or replace. See page 16.  
Replace. See pages 17–19.  
Remove restriction.  
Tighten.  
Replace. See pages 17–19.  
Loose inlet manifold (102), dam-  
aged seal between manifold and  
Tighten manifold bolts (106) or re-  
place seats (201) or o-rings (202).  
seat (201), damaged o-rings (202). See page 16.  
Loose diaphragm shaft bolt (107).  
Tighten or replace. See pages  
17–19.  
Damaged o-ring (108).  
Replace. See pages 17–19.  
12  
308441  
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Troubleshooting  
PROBLEM  
CAUSE  
SOLUTION  
Fluid in exhaust air.  
Diaphragm ruptured.  
Loose diaphragm shaft bolt (107).  
Replace. See pages 17–19.  
Tighten or replace. See pages  
17–19.  
Damaged o-ring (108).  
Replace. See pages 17–19.  
Pump exhausts excessive air at  
stall.  
Worn air valve block (7), o-ring (6), Repair or replace. See pages  
plate (8), pilot block (18), u-cups  
(10), or pilot pin o-rings (17).  
14–15.  
Worn shaft seals (402).  
Replace. See pages 17–19.  
Pump leaks air externally.  
Air valve cover (2) or air valve cover Tighten screws. See page 15.  
screws (3) are loose.  
Air valve gasket (4) or air cover  
gasket (22) is damaged.  
Inspect; replace. See pages 14–15,  
20–21.  
Air cover screws (25) are loose.  
Tighten screws. See pages 20–21.  
Pump leaks fluid externally from ball Loose manifolds (102, 103), dam-  
check valves. aged seal between manifold and  
Tighten manifold bolts (106) or re-  
place seats (201) or o-rings (202).  
seat (201), damaged o-rings (202). See page 16.  
308441  
13  
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Service  
Repairing the Air Valve  
Tools Required  
2
3
2
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wrench  
D Needle-nose pliers  
D O-ring pick  
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NOTE: Air Valve Repair Kits 236273 (aluminum center  
housing models) and 255061 (sst center housing  
models) are available. Refer to page 23. Parts included  
in the kit are marked with a symbol, for example (4  
{
H
)
.
Use all the parts in the kit for the best results.  
Disassembly  
1
WARNING  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 10.  
Muffler not included on  
Model No. 253485  
1
2
Torque to 50–60 in-lb  
(5.6–6.8 NSm).  
1. Relieve the pressure.  
03268B  
Fig. 6  
2. With a Torx (T20) screwdriver or 7 mm (9/32 in.)  
socket wrench, remove the six screws (3), air  
valve cover (2), and gasket (4). See Fig. 6.  
1
2
5
See Detail at right.  
Grease.  
3. Move the valve carriage (5) to the center position  
and pull it out of the cavity. Remove the valve  
{
{
H 6  
H 7  
2
3
3
Grease lower face.  
block (7  
{
H
)
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.
Using a needle-nose pliers, pull the pilot block (18)  
straight up and out of the cavity. See Fig. 7.  
4. Pull the two actuator pistons (11) out of the bear-  
ings (12). Remove the u-cup packings (10) from  
the pistons. Pull the pilot pins (16) out of the  
bearings (15). Remove the o-rings (17) from the  
pilot pins. See Fig. 8.  
18{  
H
3
5 1  
5. Inspect the valve plate (8H ) in place. If damaged,  
use a Torx (T20) screwdriver or 7 mm (9/32 in.)  
socket wrench to remove the three screws (3).  
Remove the valve plate (8H ) and, on aluminum  
center housing models only, remove the seal (9).  
See Fig. 9.  
11  
6. Inspect the bearings (12, 15) in place. See Fig. 8.  
The bearings are tapered and, if damaged, must  
be removed from the outside. This requires disas-  
sembly of the fluid section. See page 20.  
7. Clean all parts and inspect for wear or damage.  
Replace as needed. Reassemble as explained on  
page 15.  
03269  
Fig. 7  
14  
308441  
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Service  
Reassembly  
1
2
3
Insert narrow end first.  
1. If you removed the bearings (12, 15), install new  
ones as explained on page 20. Reassemble the  
fluid section.  
Grease.  
Install with lips facing  
narrow end of piston (11).  
4
Insert wide end first.  
2. On aluminum center housing models, install the  
valve plate seal (9 H ) into the groove at the bot-  
{
tom of the valve cavity. The rounded side of the  
seal must face down into the groove. See Fig. 9.  
2
3
10{  
H
3. Install the valve plate (8H ) in the cavity. On alumi-  
num center housing models, the plate is reversible,  
so either side can face up. Install the three screws  
(3), using a Torx (T20) screwdriver or 7 mm (9/32  
in.) socket wrench. Tighten until the screws bottom  
out on the housing. See Fig. 9.  
4
11  
12  
4. Install an o-ring (17 H ) on each pilot pin (16).  
{
Grease the pins and o-rings. Insert the pins into  
the bearings (15), narrow end first. See Fig. 8.  
5. Install a u-cup packing (10 H ) on each actuator  
{
piston (11), so the lips of the packings face the  
narrow end of the pistons. See Fig. 8.  
1
17{  
H
15 16  
2
03270  
Fig. 8  
6. Lubricate the u-cup packings (10 H ) and actuator  
{
1
2
Rounded side must face down  
(aluminum center housing mod-  
3
2
pistons (11). Insert the actuator pistons in the  
bearings (12), wide end first. Leave the narrow  
end of the pistons exposed. See Fig. 8.  
els only).  
Tighten screws until  
8H  
they bottom out on the  
housing.  
7. Grease the lower face of the pilot block (18 H ) and  
{
install so its tabs snap into the grooves on the  
ends of the pilot pins (16). See Fig. 7.  
9{  
H
1
8. Grease the o-ring (6 H ) and install it in the valve  
{
block (7). Push the block onto the valve carriage  
(5). Grease the lower face of the valve block. See  
Fig. 7.  
9. Install the valve carriage (5) so its tabs slip into the  
grooves on the narrow end of the actuator pistons  
(11). See Fig. 7.  
10. Align the valve gasket (4 H ) and cover (2) with the  
{
six holes in the center housing (1). Secure with six  
screws (3), using a Torx (T20) screwdriver or 7  
mm (9/32 in.) socket wrench. Torque to 50–60 in-lb  
(5.6–6.8 NSm). See Fig. 6.  
03271  
Fig. 9  
308441  
15  
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Service  
Apply medium-strength (blue) LoctiteR or equivalent to the  
Ball Check Valve Repair  
1
threads. Torque to 120–150 in-lb (14–17 NS m). See Torque  
Sequence, page 28.  
Tools Required  
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Arrow (A) must point toward  
outlet manifold (103).  
2
D 13 mm socket wrench  
D O-ring pick  
3
4
Not used on some models.  
Beveled seating surface  
must face ball (301).  
Disassembly  
NOTE: A Fluid Section Repair Kit is available. Refer to  
page 23 to order the correct kit for your pump. Parts  
included in the kit are marked with an asterisk, for  
example (201*). Use all the parts in the kit for the best  
results.  
1
106  
103  
NOTE: To ensure proper seating of the balls (301),  
always replace the seats (201) when replacing the  
balls. Also, on some models, replace the o-rings (202).  
301*  
WARNING  
201* 4  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 10.  
202*  
101  
3
A
2
1. Relieve the pressure. Disconnect all hoses.  
2. Remove the pump from its mounting.  
3. Using a 13 mm socket wrench, remove the four  
bolts (106) holding the outlet manifold (103) to the  
fluid covers (101). See Fig. 10.  
3
4. Remove the o-rings (202, not used on some  
models), seats (201), and balls (301) from the  
manifold.  
301*  
201*  
202*  
4
5. Turn the pump over and remove the inlet manifold  
(102). Remove the o-rings (202, not used on some  
models), seats (201), and balls (301) from the fluid  
covers (101).  
3
Reassembly  
102  
1. Clean all parts and inspect for wear or damage.  
Replace parts as needed.  
2. Reassemble in the reverse order, following all  
notes in Fig. 10. Be sure the ball checks are  
assembled exactly as shown. The arrows (A) on  
the fluid covers (101) must point toward the outlet  
manifold (103).  
106 1  
03272B  
Fig. 10  
16  
308441  
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Service  
Diaphragm Repair  
WARNING  
Tools Required  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 10.  
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1 in. socket wrench (stainless steel models)  
1. Relieve the pressure.  
D 19 mm open–end wrench  
D O-ring pick  
2. Remove the manifolds and disassemble the ball  
check valves as explained on page 16.  
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Disassembly  
3. Using a 13 mm socket wrench, remove the screws  
(106 and 112) holding the fluid covers (101) to the  
air covers (23). Pull the fluid covers (101) off the  
pump. See Fig. 11.  
NOTE: A Fluid Section Repair Kit is available. Refer to  
page 23 to order the correct kit for your pump. Parts  
included in the kit are marked with an asterisk, for  
example (401*). Use all the parts in the kit for the best  
results.  
Apply medium-strength (blue) LoctiteR or equivalent to  
1
the threads. Torque to 190–220 in-lb (22–25 NS m).  
See Torque Sequence, page 28.  
2
3
Arrow (A) must point toward air valve (B).  
Muffler not included on Model No. 253485.  
B
23  
101  
2
A
1
106  
3
1
112  
03273C  
Fig. 11  
308441  
17  
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Service  
4. Loosen but do not remove the diaphragm shaft  
a. Install the o-ring (108*) on the shaft bolt (107).  
bolts (107), using a 15 mm socket wrench (1 in. on  
stainless steel models) on both bolts. NOTE: This  
step does not apply to pumps with overmolded  
diaphragms.  
b. Install the fluid side diaphragm plate (105) on  
the bolt so the rounded side faces in, toward  
the diaphragm (401).  
c. On PTFE models only, install the PTFE dia-  
phragm (403*). Make certain the side marked  
AIR SIDE faces the center housing (1).  
5. Unscrew one bolt from the diaphragm shaft (24)  
and remove the o-ring (108), fluid side diaphragm  
plate (105), PTFE diaphragm (403, used on PTFE  
models only), diaphragm (401), and air side dia-  
phragm plate (104). See Fig. 12.  
d. Install the diaphragm (401*) on the bolt. Make  
certain the side marked AIR SIDE faces the  
center housing (1).  
For overmolded diaphragms: Grip both dia-  
phragms securely around the outer edge and  
rotate counterclockwise. One diaphragm assembly  
will come free and the other will remain attached to  
the shaft. Remove the freed diaphragm and air  
side plate.  
e. Install the air side diaphragm plate (104) so  
the recessed side faces the diaphragm (401).  
f. Apply medium-strength (blue) LoctiteR or  
equivalent to the bolt (107) threads. Screw the  
bolt (107) into the shaft (24) hand tight.  
6. Pull the other diaphragm assembly and the dia-  
phragm shaft (24) out of the center housing (1).  
Hold the shaft flats with a 19 mm open–end  
g. For overmolded diaphragms: Assemble the air  
side plate (104) onto the diaphragm (403). The  
wide, radiused side of the plate must face the  
diaphragm. Apply medium–strength (blue)  
Loctite or equivalent to the threads of the  
diaphragm assembly. Screw the assembly into  
the shaft (24) hand tight.  
wrench, and remove the bolt (107) from the shaft.  
Disassemble the remaining diaphragm assembly.  
For overmolded diaphragms: Pull the other dia-  
phragm assembly and the diaphragm shaft (24)  
out of the center housing (1). Hold the shaft flats  
with a 19 mm open–end wrench and remove the  
diaphragm and air side plate from the shaft.  
3. Grease the length and ends of the diaphragm shaft  
(24), and slide it through the housing (1).  
4. Assemble the other diaphragm assembly to the  
shaft as explained in step 2.  
7. Inspect the diaphragm shaft (24) for wear or  
scratches. If it is damaged, inspect the bearings  
(19) in place. If the bearings are damaged, refer to  
page 20.  
5. Hold one shaft bolt (107) with a wrench and torque  
the other bolt to 20–25 ft-lb (27–34 NSm) at 100  
rpm maximum. NOTE: This step does not apply to  
pumps with overmolded diaphragms.  
8. Reach into the center housing (1) with an o-ring  
pick and hook the u-cup packings (402), then pull  
them out of the housing. This can be done with the  
bearings (19) in place.  
6. Align the fluid covers (101) and the center housing  
(1) so the arrows (A) on the covers face the same  
direction as the air valve (B). Apply medium-  
strength (blue) LoctiteR or equivalent to the  
threads of screws (106) and (112), and secure the  
covers with the screws handtight. Install the  
longer screws (112) in the bottom holes of the  
covers. See Fig. 11. Using a 13 mm socket  
wrench, torque the screws oppositely and evenly  
to 190–220 in-lb (22–25 NSm). See Torque Se-  
quence, page 28.  
9. Clean all parts and inspect for wear or damage.  
Replace parts as needed.  
Reassembly  
1. Install the shaft u-cup packings (402*) so the lips  
face out of the housing (1). Lubricate the pack-  
ings. See Fig. 12.  
2. Install the diaphragm assembly on one end of the  
shaft (24) as follows. For pumps with overmolded  
diaphragms, go directly to step g.  
7. Reassemble the ball check valves and manifolds  
as explained on page 16.  
18  
308441  
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Service  
19  
402*  
1
105  
2
5
107  
403*  
3
6
1
1
24  
104  
401*  
4
7
3
03274A  
03275A  
Cutaway View, with Diaphragms in Place  
Cutaway View, with Diaphragms Removed  
24 4  
7
104  
401* 3  
3
5
403*  
105  
2
1
24  
4
108*  
107  
6
1
2
Lips face out of housing (1).  
Rounded side faces diaphragm (401).  
Air Side must face center housing (1).  
Grease.  
3
4
5
6
Used on pumps with PTFE diaphragms only.  
Apply medium-strength (blue) LoctiteR or equiva-  
lent. Torque to 20 to 25 ft-lb (27 to 34 N-m) at 100  
rpm maximum.  
7
8
8
Recessed side faces diaphragm (401).  
Muffler not included on Model No. 253485.  
03276C  
Fig. 12  
308441  
19  
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Service  
7. Use a bearing puller to remove the diaphragm  
Bearing and Air Gasket Removal  
shaft bearings (19), air valve bearings (12) or pilot  
pin bearings (15). Do not remove undamaged  
bearings.  
Tools Required  
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8. If you removed the diaphragm shaft bearings (19),  
reach into the center housing (1) with an  
o-ring pick and hook the u-cup packings (402),  
then pull them out of the housing. Inspect the  
packings. See Fig. 12.  
D 10 mm socket wrench  
D Bearing puller  
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Reassembly  
1. If removed, install the shaft u-cup packings (402*)  
Disassembly  
NOTE: Do not remove undamaged bearings.  
so the lips face out of the housing (1).  
2. The bearings (12, 15, and 19) are tapered and can  
only be installed one way. Insert the bearings into  
the center housing (1), tapered end first. Using a  
press or a block and rubber mallet, press-fit the  
bearing so it is flush with the surface of the center  
housing.  
WARNING  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 10.  
3. Reassemble the air valve as explained on page  
15.  
1. Relieve the pressure.  
4. Align the new air cover gasket (22) so the pilot pin  
(16) protruding from the center housing (1) fits  
through the proper hole (H) in the gasket.  
2. Remove the manifolds and disassemble the ball  
check valves as explained on page 16.  
3. Remove the fluid covers and diaphragm assem-  
blies as explained on page 17.  
5. Align the air cover (23) so the pilot pin (16) fits in  
the middle hole (M) of the three small holes near  
the center of the cover. Apply medium-strength  
(blue) LoctiteR or equivalent to the threads of  
screws (25), and install the screws handtight. See  
Fig. 13. Using a 10 mm socket wrench, torque the  
screws oppositely and evenly to 130–150 in-lb  
(15–17 NSm).  
NOTE: If you are removing only the diaphragm shaft  
bearing (19), skip step 4.  
4. Disassemble the air valve as explained on page  
14.  
5. Using a 10 mm socket wrench, remove the screws  
(25) holding the air covers (23) to the center  
housing (1). See Fig. 13.  
6. Install the diaphragm assemblies and fluid covers  
as explained on page 17.  
6. Remove the air cover gaskets (22). Always replace  
the gaskets with new ones.  
7. Reassemble the ball check valves and manifolds  
as explained on page 16.  
20  
308441  
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Service  
12  
1
2
3
Insert bearings tapered end first.  
2
1
Press-fit bearings flush with surface of center housing (1).  
Apply medium-strength (blue) LoctiteR or equivalent. Torque  
to 130–150 in-lb (15–17 NSm).  
4
Muffler not included on Model No. 253485.  
03277  
1
2
1
15  
16  
Detail of Air Valve Bearings  
2
19  
1
M
23  
H
22  
25  
3
4
03278B  
Fig. 13  
308441  
21  
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Pump Matrix  
Husky 1590 Aluminum and Stainless Steel Pumps, Series A  
Your Model No. is marked on the pump’s serial plate. To determine the Model No. of your pump from the following  
matrix, select the six digits which 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 an aluminum air motor, aluminum fluid section, polypropylene seats, PTFE balls, and PTFE diaphragms  
is Model No. D B 3 9 1 1. To order replacement parts, refer to the part lists on pages 25–24. The digits in the  
matrix do not correspond to the ref. nos. in the parts drawing and lists.  
Diaphragm  
Pump  
Air Motor  
aluminum  
aluminum  
Fluid Section  
aluminum  
Seats  
Balls  
Diaphragms  
TPE  
232502*  
TPE  
acetal  
253485*  
aluminum  
Buna–N  
1 (not used)  
Buna–N  
1 (PTFE)  
Buna–N  
1 (PTFE)  
D (for all pumps)  
B aluminum  
(standard)  
1 (not used)  
24B780*  
C aluminum  
(remote)  
2 (not used)  
2 (not used)  
2 (acetal)  
2 (not used)  
24B781*  
24G411*  
T sst (standard) 3 (aluminum)  
3 (316 sst)  
3 (not used)  
4 (440C sst)  
5 (TPE)  
3 (not used)  
4 (not used)  
5 (TPE)  
U sst (remote)  
4 (sst)  
4 (17–4 PH sst)  
5 (TPE)  
5 (not used)  
C (aluminum  
BSPT)  
6 (Santoprener )  
6 (Santoprener )  
6 (Santoprener )  
D (sst BSPT)  
7 (Buna–N)  
7 (Buna–N)  
7 Buna–N)  
8 (Fluoroelastomer) 8 (Fluoroelastomer) 8 (Fluoroelastomer)  
9 (polypropylene)  
A (PVDF)  
9 (not used)  
A (not used)  
G (Geolastr )  
9 (not used)  
A (not used)  
G (Geolastr )  
G (Geolastr )  
246451 Stainless Steel Air Motor Conversion Kit  
* 24B781 Stainless Steel Pump  
This pump is the same as Model DB4311 except for  
the serial plate and parts listed in the chart below.  
Use kit 246451 and refer to manual 309643 (included  
with kit) to convert from aluminum air motor to  
stainless steel air motor.  
* 24G411 Aluminum Pump  
This pump is the same as Model DBC311 except for  
the serial plate and parts listed in the chart below.  
* 232502, Aluminum 1590 Pump, Series D  
Model No. 232502 is a private-label aluminum 1590  
pump. This pump is the same as Model No. DB3525  
except for the label and:  
* 24J358 Aluminum Pump  
This pump is the same as Model DB3311 except for  
the serial plate and parts listed in the chart below.  
Ref. Nos. 10 and 402 are 115666 Packing, U–cup,  
Fluoroelastomer  
* 24J359 Aluminum Pump  
This pump is the same as Model DB3321 except for  
the serial plate and parts listed in the chart below.  
Ref. No. 17 is 168518 O–ring, Fluoroelastomer  
Use 243492 as the Air Valve Repair Kit  
Ref. 106 is 112416 SCREW, SST; M10 x 1.5, 30 mm  
Ref. 112 is 112417 SCREW, SST; M10 x 1.5; 90 mm  
Ref.  
No.  
104  
105  
107  
108  
401  
Part No. Description  
Qty  
2
* 253485, Aluminum 1590 Pump, Series A  
Model No. 253485 is an aluminum 1590 pump. This  
pump is the same as Model No. DB3777 except for the  
label and that 253485 does not include Ref. No. 111  
Muffler.  
15H810  
–––  
PLATE, air side; alum.  
not used  
not used  
not used  
0
–––  
0
–––  
0
* 24B780 Stainless Steel Plus Pump  
This pump is the same as Model DT4311 except for  
the serial plate and parts listed in the chart below.  
15G745 DIAPHRAGM, HD, overmolded;  
PTFE/EPDM  
2
22  
308441  
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Repair Kit Matrix  
For Husky 1590 Aluminum and Stainless Steel Pumps, Series A  
Repair Kits may be ordered separately. To repair the air valve, order Part No. 236273 for aluminum center housing  
models or Part No. 255061 for stainless steel center housing models (see page 24). Parts included in the Air Valve  
Repair Kit are marked with a symbol in the parts list, for example (3).  
To repair your pump, select the six digits which describe your pump from the following matrix, working from left to  
right. The first digit is always D, the second digit is always 0 (zero), and the third is always B. The remaining three  
digits define the materials of construction. Parts included in the kit are marked with an asterisk in the parts list, for  
example (201*). For example, if your pump has polypropylene seats, PTFE balls, and PTFE diaphragms, order  
Repair Kit D 0 B 9 1 1. If you only need to repair certain parts (for example, the diaphragms), use the 0 (null)  
digits for the seats and balls, and order Repair Kit D 0 B 0 0 1. The digits in the matrix do not correspond to the  
ref. nos. in the parts drawing and lists on pages 24–25.  
Diaphragm  
Pump  
Null  
Shaft O-ring  
Seats  
Balls  
Diaphragms  
0 (null)  
D (for all pumps) 0 (for all pumps) B (PTFE)  
0 (null)  
0 (null)  
1 (not used)  
2 (not used)  
3 (316 sst)  
4 (17–4 PH sst)  
5 (TPE)  
1 (PTFE)  
1 (PTFE)  
2 (acetal)  
3 (not used)  
4 (440C sst)  
5 (TPE)  
2 (not used)  
3 (not used)  
4 (not used)  
5 (TPE)  
6 (Santoprener )  
7 (Buna–N)  
6 (Santoprener )  
7 (Buna–N)  
6 (Santoprener )  
7 (Buna–N)  
8 (Fluoroelastomer) 8 (Fluoroelastomer) 8 (Fluoroelastomer)  
9 (polypropylene)  
A (PVDF)  
9 (not used)  
A (not used)  
G (Geolastr )  
9 (not used)  
A (not used)  
G (Geolastr )  
G (Geolastr )  
Part No. 253627: Husky 1590 HD Overmolded PTFE/EPDM Diaphragm Repair Kit.  
Part No. 289225: Husky 1590 HD Overmolded PTFE/EPDM Diaphragm Repair Kit,  
with new air side diaphragm plates.  
Part No. 24F398: Husky 1590 PTFE/Santoprene Backer Diaphragm Repair Kit,  
for metal pumps.  
308441  
23  
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Parts Drawing  
2
3
5
J
{
4
11  
J
{
1
0
6{  
J
J
{
1
7
7{J  
16  
8
J
J
{
1
8
3
1
9{  
16  
17  
{
J
12  
14 }  
110Y  
10{J  
11  
22  
106  
23  
20  
103  
15  
25  
111  
1
301*  
201*  
1
402* 19  
202* 1  
106  
13 }  
24  
Aluminum Model Shown  
104  
1
2
Not used on some models.  
Used on PTFE models only.  
101  
401*  
108*  
Used on stainless steel models only.  
3
1
403*  
105  
107  
113  
}
These parts are unique to remote piloted air motor, DC––––, DT––––  
3
112  
*
These parts are included in the Pump Repair Kit,  
which may be purchased separately.  
Refer to the Repair Kit Matrix on page 23 to  
determine the correct kit for your pump.  
*301  
*201  
202*  
1
{
These parts are included in Air Valve Repair Kit 236273 (aluminum  
center housing models), which may be purchased separately.  
J
T
h
e
s
e
p
a
r
t
s
a
r
e
i
n
c
l
u
d
e
d
i
n
A
i
r
V
a
l
v
e
R
e
p
a
i
r
K
i
t
2
5
5
0
6
1
(
s
t
a
i
n
l
e
s
s
102  
steel center housing models), which may be purchased separately.  
Y
R
e
p
l
a
c
e
m
e
n
t
D
a
n
g
e
r
a
n
d
W
a
r
n
i
n
g
l
a
b
e
l
s
,
106  
tags and cards are available at no cost.  
03279C  
24  
308441  
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Parts  
Air Motor Parts List (Matrix Column 2)  
Ref.  
Digit No.  
Ref.  
Digit No.  
Part No. Description  
Qty  
Part No. Description  
Same as B with the following exceptions  
Qty  
B
1
2
3
188838  
188854  
116344  
HOUSING, center;  
aluminum  
1
C
1
195921  
HOUSING, center;  
remote, aluminum  
1
2
COVER, air valve;  
aluminum  
1
9
23  
195918  
COVER, air; remote  
SCREW, mach, hex  
flange hd; M5 x 0.8;  
12 mm (0.47 in.)  
T
Same as B with the following exceptions  
1
15K009  
15K696  
15H178  
HOUSING, center;  
stainless steel  
1
1
1
4
5
6
7
8
9
{
H
188618  
188855  
108730  
188616  
188615  
188617  
112181  
188612  
188613  
104765  
115671  
GASKET, cover; foam  
CARRIAGE; aluminum  
O-RING; nitrile  
1
1
1
1
1
1
2
2
2
2
2
2
COVER, air valve;  
stainless steel  
{
{
H
H
PLATE, air valve;  
stainless steel  
8
9
H
BLOCK, air valve; acetal  
PLATE, air valve; sst  
SEAL, valve plate; buna-N  
PACKING, u-cup; nitrile  
PISTON, actuator; acetal  
BEARING, piston; acetal  
PLUG, pipe; headless  
2
{
H
23  
15A739  
COVER, air; stainless  
steel  
10  
11  
12  
{
H
25  
112178  
SCREW; M8 x 1.25;  
25 mm (1 in.), stainless  
steel  
12  
U
Same as B with the following exceptions  
13}  
14}  
FITTING, connector;  
male  
1
15K011  
15K696  
15H178  
HOUSING, center;  
remote, stainless steel  
1
1
1
15  
16  
188611  
188610  
157628  
188614  
188609  
116343  
188603  
189400  
189245  
115643  
BEARING, pin; acetal  
PIN, pilot; stainless steel  
O-RING; buna-N  
2
2
COVER, air valve;  
stainless steel  
2
PLATE, air valve;  
stainless steel  
8
9
H
17  
18  
19  
20  
22  
23  
24  
25  
{
{
H
H
2
BLOCK, pilot; acetal  
BEARING, shaft; acetal  
SCREW, grounding  
1
2
2
23  
15B795  
COVER, air; remote,  
stainless steel  
1
25  
112178  
SCREW; M8 x 1.25;  
25 mm (1 in.), stainless  
steel  
12  
GASKET, air cover; foam  
COVER, air; aluminum  
SHAFT, diaphragm; sst  
2
2
1
SCREW; M8 x 1.25;  
12  
25 mm (1 in.), aluminum  
308441  
25  
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Parts  
Fluid Section Parts List (Matrix Column 3)  
Ref.  
Ref.  
Digit No.  
Part No. Description  
Qty  
2
Digit No.  
Part No. Description  
Qty  
2
C
101  
102  
15A615  
192078  
COVER, fluid; aluminum  
3
101  
102  
15A615  
189402  
COVER, fluid; aluminum  
MANIFOLD, inlet;  
aluminum; BSPT  
1
MANIFOLD, inlet;  
aluminum  
1
103  
104  
105  
106  
107  
108*  
15A658  
15K448  
189843  
115644  
189410  
MANIFOLD, outlet;  
aluminum; BSPT  
1
103  
104  
105  
106  
107  
108*  
15A616  
15K448  
189843  
115644  
189410  
MANIFOLD, outlet;  
aluminum  
1
PLATE, air side;  
aluminum  
2
PLATE, air side;  
aluminum  
2
PLATE, fluid side;  
carbon steel  
2
PLATE, fluid side;  
carbon steel  
2
SCREW; M10 x 1.25;  
35 mm (1.38 in.)  
24  
2
SCREW; M10 x 1.25;  
35 mm (1.38 in.)  
24  
2
BOLT; M12 x 1.75;  
55 mm (2.17 in.); 316 sst  
BOLT; M12 x 1.75;  
55 mm (2.17 in.); 316 sst  
104319  
188970  
102656  
115645  
O-RING; PTFE  
LABEL, warning  
MUFFLER  
2
1
1
4
104319  
188970  
102656  
O-RING; PTFE  
LABEL, warning  
2
1
1
110  
111  
112  
Y
110  
111  
Y
MUFFLER (not used on  
Model No. 253485)  
SCREW; M10 x 1.50;  
90 mm (3.54 in.)  
112  
115645  
SCREW; M10 x 1.50;  
90 mm (3.54 in.)  
4
D
101  
102  
194169  
195574  
COVER, fluid; sst  
2
1
4
101  
102  
103  
104  
194169  
194170  
194221  
15K448  
COVER, fluid; sst  
2
1
1
2
MANIFOLD, inlet; sst;  
BSPT  
MANIFOLD, inlet; sst  
MANIFOLD, outlet; sst  
103  
104  
195575  
15K448  
MANIFOLD, outlet; sst;  
BSPT  
1
2
PLATE, air side;  
aluminum  
PLATE, air side;  
aluminum  
105  
106  
189309  
112416  
PLATE, fluid side; sst  
2
105  
106  
189309  
112416  
PLATE, fluid side; sst  
2
SCREW; M10 x 1.25;  
30 mm (1.18 in.); sst  
24  
SCREW; M10 x 1.25;  
30 mm (1.18 in.); sst  
24  
107  
189410  
BOLT; M12 x 1.75;  
55 mm (2.17 in.); 316 sst  
2
107  
189410  
BOLT; M12 x 1.75;  
55 mm (2.17 in.); 316 sst  
2
108*  
104319  
188621  
102656  
112417  
O-RING; PTFE  
LABEL, warning  
MUFFLER  
2
1
1
4
108*  
104319  
188621  
102656  
112417  
O-RING; PTFE  
LABEL, warning  
MUFFLER  
2
1
1
4
110  
111  
112  
Y
110  
111  
112  
Y
SCREW; M10 x 1.50;  
90 mm (3.54 in.); sst  
SCREW; M10 x 1.50;  
90 mm (3.54 in.); sst  
113  
114862  
NUT, hex, M10, fhn  
8
26  
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Parts  
Seat Parts List (Matrix Column 4)  
Ball Parts List (Matrix Column 5)  
Ref.  
Ref.  
Digit No.  
Part No. Description  
Qty  
4
Digit No.  
Part No. Description  
Qty  
1
2
4
301*  
301*  
301*  
112419  
112423  
112420  
BALL; PTFE  
BALL; acetal  
3
4
201*  
189318  
SEAT; 316 stainless  
steel  
4
4
202*  
201*  
112418  
189319  
O-RING; PTFE  
4
4
BALL; 440C stainless  
steel  
4
SEAT; 17-4 stainless  
steel  
5
6
7
8
G
301*  
301*  
301*  
301*  
301*  
112831  
112421  
15B490  
15B489  
114752  
BALL; TPE  
4
4
4
4
4
202*  
201*  
202  
112418  
189322  
None  
O-RING; PTFE  
SEAT; TPE  
4
4
0
4
4
4
0
4
0
4
4
4
4
4
4
BALL; Santoprene  
BALL; Buna–N  
5
6
7
8
9
A
G
Not Used  
BALL; Fluoroelastomer  
201*  
202*  
201*  
202  
189320  
112418  
15B266  
None  
SEAT; Santoprene  
O-RING; PTFE  
SEAT; Buna–N  
Not used  
BALL; Geolast  
R
Diaphragm Parts List (Matrix Column 6)  
Ref.  
Digit No.  
Part No. Description  
Qty  
1
401*  
Not sold  
DIAPHRAGM, backup;  
2
201*  
202  
15B264  
None  
SEAT; Fluoroelastomer  
Not used  
separately polychloroprene (CR)  
402*  
403*  
401*  
402*  
401*  
112181  
15K312  
189425  
112181  
189426  
PACKING, u-cup; nitrile  
DIAPHRAGM; PTFE  
DIAPHRAGM; TPE  
2
2
2
2
2
201*  
202*  
201*  
202*  
201*  
202*  
193417  
112418  
189732  
112418  
194213  
112418  
SEAT; polypropylene  
O-RING; PTFE  
SEAT; PVDF  
5
6
PACKING, u-cup; nitrile  
O-RING; PTFE  
DIAPHRAGM; Santo-  
prene  
SEAT; Geolast  
R
402*  
401*  
402*  
401*  
112181  
15B312  
112181  
15B501  
PACKING, u-cup; nitrile  
DIAPHRAGM; Buna–N  
PACKING, u-cup; nitrile  
2
2
2
2
O-RING; PTFE  
7
8
DIAPHRAGM;  
Fluoroelastomer  
402*  
401*  
112181  
194214  
PACKING, u-cup; nitrile  
2
2
G
DIAPHRAGM;  
GeolastR  
402*  
112181  
PACKING, u-cup; nitrile  
2
* These parts are included in the pump repair kit, purchased  
separately. See Repair Kit Matrix on page 23 to determine  
the correct kit for your pump.  
308441  
27  
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Torque Sequence  
Always follow torque sequence when instructed to torque fasteners.  
1. Left/Right Fluid Covers  
3. Outlet Manifold  
Torque bolts to 190–220 in–lb (22–25 NSm).  
Torque bolts to 120–150 in–lb (14–17 NSm).  
18  
15  
1
3
8
5
16  
17  
9
10  
TOP VIEW  
7
6
4
2
SIDE VIEW  
2. Inlet Manifold  
Torque bolts to 120–150 in–lb (14–17 NSm).  
14  
11  
12  
13  
BOTTOM VIEW  
28  
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Dimensions  
FRONT VIEW  
PUMP MOUNTING HOLE PATTERN  
197 mm  
6.0 in.  
(152.5 mm)  
1/2 npt(f)  
Air Inlet  
3/4 npt(f)  
Air Exhaust  
6.0 in.  
(152.5 mm)  
B
C
A
268 mm  
38 mm  
1
152.5 mm  
379.5 mm  
Muffler not included on Model No. 253485.  
1
SST Pumps  
Alum. Pumps  
16.81 in. (427 mm)  
18.31 in. (465 mm)  
19.56 in. (497 mm)  
Dim.  
A
16.25 in. (412.5 mm)  
17.75 in. (451 mm)  
19.0 in. (482.5 mm)  
B
C
SIDE VIEW  
5.23 in.  
(132.5 mm)  
1.5 npt(f) Outlet Port  
45°  
1.5 npt(f) Inlet Port  
6.0 in.  
(152.5 mm)  
1
.45 in.  
(11.5 mm)  
10.46 in.  
(265.5 mm)  
7438B  
308441  
29  
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Technical Data  
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 psi  
(0.8 MPa, 8 bar)  
Air pressure operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–120 psi  
(0.14 –0.8 MPa, 1.4–8 bar)  
Maximum air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 scfm  
Air consumption at 70 psi/60 gpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 scfm (see chart)  
Maximum free-flow delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 gpm (378.5 l/min)  
Maximum pump speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 cpm  
Gallons (Liters) per cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 (1.9)  
Maximum suction lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ft (5.48 m) wet or dry  
Maximum size pumpable solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/16 in. (4.8 mm)  
* Maximum noise level at 100 psi, full flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 dBa  
* Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 dBa  
* Noise level at 70 psi, 50 cycles/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 dBa  
Maximum operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150_ F (65.5_ C);  
200_ F (93.3_ C) for models with PTFE diaphragms  
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 npt(f)  
Fluid inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 npt(f)  
Fluid outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 npt(f)  
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vary by Model. See pages 22–24.  
Non-wetted external parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aluminum, 302, 316 stainless steel, polyester (labels)  
Weight  
Aluminum pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.5 lb (15.2 kg)  
Stainless steel pumps with aluminum center section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 lb (32.7 kg)  
Stainless steel pumps with stainless steel center section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 lb (40 kg)  
Geolast  
R
is a registered trademarks of the ExxonMobil Chemical Co.  
SantopreneR is a registered trademarks of the Monsanto Co.  
Loctiter is a registered trademark of the Loctite Corporation.  
*
Noise levels measured with the pump mounted on the floor, using Rubber Foot Kit 236452. Sound power  
measured per ISO Standard 9216.  
30  
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Performance Chart  
Example of Finding Pump Air Consumption and Air Pressure at a Specific Fluid Delivery and Discharge Head:  
To supply 60 gpm (227 liters) fluid flow (horizontal scale) at 40 psi (0.28 MPa, 2.8 bar) discharge head pressure (vertical scale) re-  
quires approximately 50 scfm (1.40 m#/min) air consumption at 70 psi (0.49 MPa, 4.9 bar) inlet air pressure.  
feet  
(meters)  
psi  
(MPa, bar)  
280  
120  
(0.8, 8)  
A
(85.3)  
INLET AIR PRESSURES  
A
B
C
D
120 psi air (0.8, 8 bar)  
100 psi air (0.7, 7 bar)  
70 psi air (0.49, 4.9 bar)  
40 psi air (0.28, 2.8 bar)  
240  
100  
(0.7, 7.0)  
E
(73.2)  
B
200  
(61.0)  
80  
(0.56, 5.6)  
AIR CONSUMPTION  
F
160  
E
F
20 scfm (0.56 m#/min)  
40 scfm (1.12 m#/min)  
60 scfm (1.68 m#/min)  
80 scfm (2.24 m#/min)  
C
D
(48.8)  
60  
(0.42, 4.2)  
G
H
120  
(36.6)  
G
40  
(0.28, 2.8)  
80  
(24.4)  
20  
40  
(0.14, 1.4)  
(12.2)  
H
0
0
15  
(57)  
30  
45  
(170)  
60  
75  
90  
105  
120  
0
(114)  
(227)  
(284)  
(341)  
(397)  
(454)  
FLUID FLOW GPM (lpm)  
TEST CONDITIONS  
Pump tested in water with PTFE diaphragm and inlet  
submerged.  
KEY  
FLUID PRESSURE AND FLOW  
SCFM AIR CONSUMPTION  
308441  
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Graco Warranties  
Graco Standard Husky Pump Warranty  
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the  
date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco,  
Graco will, for a period of five years from the date of sale, repair or replace any part of the equipment determined by Graco to be  
defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written  
recommendations.  
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by  
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-  
stitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of  
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,  
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.  
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for  
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The  
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect  
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and  
transportation.  
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT  
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.  
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other  
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any  
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within six years of the date  
of sale.  
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection  
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured  
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide  
purchaser with reasonable assistance in making any claim for breach of these warranties.  
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment  
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,  
breach of warranty, the negligence of Graco, or otherwise.  
FOR GRACO CANADA CUSTOMERS  
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings  
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-  
sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires  
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.  
Extended Product Warranty  
Graco warrants all Husky 205, 307, 515, 716, 1040, 1590, 2150, and 3275 air valve center sections to be free from defects in material  
and workmanship for a period of fifteen years from date installed in service by the original purchaser. Normal wear of items such as  
packings or seals are not considered to be defects in material and workmanship.  
Five years  
Six to Fifteen years  
Graco will provide parts and labor.  
Graco will replace defective parts only.  
Graco Information  
TO PLACE AN ORDER, contact your Graco distributor or call to identify the distributor closest to you:  
Phone: 612–623–6921 or Toll Free: 1–800–328–0211 Fax: 612–378–3505  
All written and visual data contained in this document reflects the latest product information available at the time of publication.  
Graco reserves the right to make changes at any time without notice.  
Original instructions. This manual contains English. MM 308441  
Graco Headquarters: Minneapolis  
International Offices: Belgium, China, Japan, Korea  
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441  
Copyright 1995, Graco Inc. is registered to ISO 9001  
Revised 02/2011  
32  
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