308981 19
Service
Diaphragms (Husky 515)
NOTE: Fluid Section Repair Kit D05XXX is available. See page 25 to order the correct kit for your pump. Parts
included in the kit are marked with a double dagger (‡) in Fig. 10 and in the Parts Drawings and Lists. General pur-
pose grease 111920 and Adhesive 113500 are supplied in the kit. Service the diaphragms as follows. See Fig. 10.
Disassembly
Relieve the pressure. See Pressure Relief
Procedure on page 11.
1. Remove manifolds (102 and 103) and fluid cov-
ers (101).
NOTE: Make sure all the check valve parts stay in
place. See Fig. 8.
2. Remove one of the fluid-side diaphragm plates
(105) (whichever one comes loose first when you
use a wrench on the hex of each), and pull the
diaphragm shaft out of the center housing (11).
Overmolded Diaphragms: The air cover bolts may
make it difficult to remove the overmolded diaphragms
on the 515 pump. Use a flat surface that fits within the
bolt pattern to apply pressure on one of the diaphragms
to shift the diaphragm shaft to one side. Apply pressure
until the other diaphragm is separated from the air
cover. Rotate the separated diaphragm counterclock-
wise until the diaphragm assembly comes free. Pull the
second diaphragm assembly and the diaphragm shaft
(15) out of the center housing. (11)
3. Use a wrench on the flats of the diaphragm shaft
(15) to remove the other fluid-side diaphragm
plate (105) from the diaphragm shaft.
Overmolded Diaphragms: Use a wrench on the flats of
the diaphragm shaft (15) to remove the second dia-
phragm.
4. Remove the screws (106), remove the left (114)
and right (113) air covers, and remove all old
gasket (12) material from the ends of the center
housing (11) and the surfaces of the air covers.
5. Remove the diaphragm shaft u-cups (416) and
pilot pin o-rings (1).
6. Inspect all parts for wear or damage, and replace
as necessary.
Reassembly
1. Insert a diaphragm shaft u-cup (416) and a pilot
pin o-ring (1) into the bores of the center hous-
ing (11).
NOTE: Make sure the lips of the u-cup face out of the
center housing.
2. Line up the holes in the gasket (12) with the
holes in the end of the center housing (11), and
use six screws (106) to fasten an air cover (113
or 114) to the end of the center housing (11).
Torque the screws to 35 to 45 in-lb (4.0 to 5.1
N-m).
3. Position the exhaust cover (13) and o-ring (4) on
the center housing (11).
4. Repeat steps 1 and 2 for the other end of the
center housing and the remaining air cover.
5. Apply medium-strength (blue) thread locker to
the threads of the fluid-side diaphragm plate
(105). Install on one end of the diaphragm shaft
(15) the following parts (see proper order in
Fig.
10): air-side diaphragm plate (6), backup dia-
phragm (402, used only on models with PTFE
diaphragms), diaphragm (401), and fluid-side
diaphragm plate (105).
NOTE: The words “AIR SIDE” on the diaphragm (401),
the backup diaphragm (402, used only on models with
PTFE diaphragms) and the flat side of the air-side dia-
phragm plate (6) must face toward the diaphragm shaft
(15).
Overmolded Diaphragms: Assemble the air-side plate
(6) onto the diaphragm (401). The words AIR SIDE on
the air-side plate must face away from the diaphragm.
Apply medium-strength (blue) thread locking adhesive
to the threads of the diaphragm assembly. Screw the
assembly into the diaphragm shaft (15) hand tight.
6. Put grease on the diaphragm shaft (15), and
carefully (do not damage the shaft u-cups) run
the diaphragm shaft (15) through the center
housing (11) bore.
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