Instructions – Parts List ACETAL, POLYPROPYLENE, AND PVDF Huskyt1040 Air-Operated Diaphragm Pumps 308443Z Acetal Model Shown 120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure 120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure *Model No. D71 *Model No. D81 *Model No. D72 *Model No. D82 *Model No. D75 *Model No. D85 *Model No. DR2 *Model No. DS2 *Model No. DR5 *Model No.
Table of Contents Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Service Repairing the Air Valve . . . . . . . . . . . . . . . . . . . . . .
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. Know the specific hazards of the fluid you are using. Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines. Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.
Installation General Information The Typical Installation shown in Fig. 2 is only a guide for selecting and installing system components. Contact your Graco distributor for assistance in planning a system to suit your needs. Always use Genuine Graco Parts and Accessories. Reference numbers and letters in parentheses refer to the callouts in the figures and the parts lists on pages 26 to 27.
Installation Grounding WARNING FIRE AND EXPLOSION HAZARD This pump must be grounded. Before operating the pump, ground the system as explained below. Also read the section FIRE AND EXPLOSION HAZARD on page 3. The acetal pump contains stainless steel fibers which make the wetted parts conductive. Attaching the ground wire to the grounding screw will ground the air motor and the wetted parts. The polypropylene and PVDF pumps are not conductive.
Installation Air Line b. Locate one bleed-type master air valve (B) close to the pump and use it to relieve trapped air. See the WARNING at left. Locate the other master air valve (E) upstream from all air line accessories and use it to isolate them during cleaning and repair. WARNING A bleed-type master air valve (B) is required in your system to relieve air trapped between this valve and the pump.
Installation Mountings Fluid Suction Line CAUTION The pump exhaust air may contain contaminants. Ventilate to a remote area if the contaminants could affect your fluid supply. See Air Exhaust Ventilation on page 10. If using a conductive (Acetal) pump, use conductive hoses (G). If using a non-conductive (polypropylene or PVDF) pump, ground the fluid system. See Grounding on page 5. The pump fluid inlet (R) is a 1” raised face flange. See Flange Connections on page 8. 1.
Installation Flange Connections The fluid inlet and outlet ports are 1” raised face flanges. Connect 1” flanged plastic pipe to the pump as follows. You will need: 1. Place a lockwasher and a flat washer on each bolt. Refer to Fig. 3. Torque wrench 2. Align the holes in the gasket and the pipe flange with the holes in the pump flange. Adjustable wrench One 4.25” diameter, 1/8” thick PTFE gasket, with four 0.62 diameter holes and a 1.15” diameter center 3. Lubricate the threads of the four bolts.
Installation Changing the Orientation of the Fluid Inlet and Outlet Ports The pump is shipped with the fluid inlet (R) and outlet (S) ports facing the same direction. See Fig. 4. To change the orientation of the inlet and/or outlet port: 1. Remove the screws (106 or 112) holding the inlet (102) and/or outlet (103) manifold to the covers (101). 2. Reverse the manifold and reattach. Install the screws (106 or 112). Torque the manifold screws to 80 to 90 in-lb (9 to 10 N-m). See Fig. 4.
Installation Air Exhaust Ventilation The air exhaust port is 3/4 npt(f). Do not restrict the air exhaust port. Excessive exhaust restriction can cause erratic pump operation. WARNING FIRE AND EXPLOSION HAZARD Be sure to read FIRE OR EXPLOSION HAZARD and TOXIC FLUID HAZARD on page 3, before operating 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.
Operation Pressure Relief Procedure 1. Be sure the pump is properly grounded. Refer to Grounding on page 5. 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 Are instructed to relieve pressure Stop pumping Check, clean, or service any system equipment Install or clean fluid nozzles 1.
Operation Operation of Remote Piloted Pumps 1. Follow preceding steps 1 through 7 of Starting and Adjusting Pump. 2. Open air regulator (C). 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 Shutdown WARNING The pump may cycle once before the external signal is applied.
Maintenance Lubrication Tightening Threaded Connections 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. CAUTION 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.
Troubleshooting WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11. 1. Relieve the pressure before checking or servicing the equipment. 2. Check all possible problems and causes before disassembling the pump. PROBLEM CAUSE SOLUTION Pump cycles at stall or fails to hold pressure at stall. Worn check valve balls (301), seats (201) or o-rings (202). Replace. See page 18.
Troubleshooting PROBLEM CAUSE SOLUTION Fluid in exhaust air. Diaphragm ruptured. Replace. See pages 19 to 21. Loose fluid side plate (105). Tighten or replace (pages 19 to 21). Worn air valve block (7), o-ring (6), plate (8), pilot block (18), u-cups (10), or pilot pin o-rings (17). Repair or replace. See pages 16 to 17. Worn shaft seals (402). Replace. See pages 19 to 21. Pump exhausts excessive air at stall. Pump leaks air externally. Air valve cover (2) or air valve cover Tighten screws.
Service Repairing the Air Valve Tools Required 7. Clean all parts and inspect for wear or damage. Replace as needed. Reassemble as explained on page 17. Torque wrench Torx (T20) screwdriver or 7 mm (9/32”) socket wrench 3 2 2 Needle-nose pliers 4 O-ring pick Lithium base grease NOTE: Air Valve Repair Kits 236273 (aluminum center housing models) and 255061 (sst center housing models) are available. Refer to page 26. Parts included in the kit are marked with a symbol, for example (4 ).
Service Reassembly 1 Insert narrow end first. 2 Grease. 3 Install with lips facing narrow end of piston (11). 4 Insert wide end first. 1. If you removed the bearings (12, 15), install new ones as explained on page 22. Reassemble the fluid section. 10 11 2 2. On aluminum center housing models, install the valve plate seal (9 ) into the groove at the bottom of the valve cavity. The rounded side of the seal must face down into the groove. See Fig. 10. 3 4 3.
Service Ball Check Valve Repair Reassembly Tools Required 1. Clean all parts and inspect for wear or damage. Replace parts as needed. Torque wrench 10 mm socket wrench O-ring pick Disassembly NOTE: A Fluid Section Repair Kit is available. Refer to page 25 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. 2. Reassemble in the reverse order, following all notes in Fig. 11.
Service Disassembly NOTE: A Fluid Section Repair Kit is available. Refer to page 25 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. Diaphragm Repair Tools Required Torque wrench WARNING 10 mm socket wrench To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11. 19 mm open–end wrench 1.
Service 4. Unscrew one outer plate (105) from the diaphragm shaft (24). Remove one diaphragm (401), and the inner plate (104). See Fig. 13. NOTE: PTFE models include a PTFE diaphragm (403) in addition to the backup diaphragm (401). 5. Pull the other diaphragm 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 outer plate (105) from the shaft. Disassemble the remaining diaphragm assembly. 6.
Service 19 5 1 24 104 4 2 402* 1 105 403* 401* 3 3 6 1 04236 02637 Cutaway View, with Diaphragms in Place Cutaway View, with Diaphragms Removed 24 4 104 2 401* 3 403* 3 6 1 105 24 5 4 1 Lips face out of housing (1). 2 Rounded side faces diaphragm (401). 3 Air Side must face center housing (1). 4 Grease. 5 Apply medium-strength (blue) Loctite or equivalent. Torque to 20 to 25 ft-lb (27 to 34 N-m) at 100 rpm maximum. 6 Used on Models with PTFE diaphragms only.
Service Bearing and Air Gasket Removal Tools Required Torque wrench 10 mm socket wrench Bearing puller O-ring pick Press, or block and mallet Disassembly NOTE: Do not remove undamaged bearings. WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11. 1. Relieve the pressure. 2. Remove the manifolds and disassemble the ball check valves as explained on page 18. 3.
Service 12 1 2 1 1 Insert bearings tapered end first. 2 Press-fit bearings flush with surface of center housing (1). 3 Apply medium-strength (blue) Loctite or equivalent. Torque to 130 to 150 in-lb (14 to 17 N m). 15 1 1 2 04158 Detail of Air Valve Bearings 16 H 22 M 23 25 19 1 3 2 02639B Fig.
Pump Matrix Husky 1040 Acetal, Polypropylene, and PVDF 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.
Repair Kit Matrix For Husky 1040 Acetal, Polypropylene, and PVDF Pumps, Series A Repair Kits may be ordered separately. To repair the air valve, order Part No. 236273 for aluminum center housing models and Part 255061 for stainless steel center housing models (see page 26). 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.
Parts 3 2 10 11 4 17 5 16 6 18 7 3 8 9 1 16 17 12 10 11 22 106 110 14} 23 25 15 103 24 *402 1 20 19 401* 104 301* 403* 111 1 201* 105 13} 202* 1 112 113* 101 106 *301 *201 202* 1 102 1 Not used on some models. * These parts are included in the Pump Repair Kit, which may be purchased separately. Refer to the Repair Kit Matrix on page 25 to determine the correct kit for your pump.
Parts Air Motor Parts List (Matrix Column 2) Air Motor Parts List (Matrix Column 2) Ref. Digit No. Part No. Description Qty Ref. Digit No. 7 1 188838 HOUSING, center; aluminum 1 8 2 188854 COVER, air valve; aluminum 1 3 116344 SCREW, mach, hex flange hd; M5 x 0.8; 12 mm (0.47 in.) 9 R Part No.
Parts Fluid Section Parts List (Matrix Column 3) Fluid Section Parts List (Matrix Column 3) Ref. Digit No. Part No. Description Qty Ref. Digit No. Part No. Description Qty 1 101 189377 COVER, fluid; acetal 2 5 101 189378 COVER, fluid; PVDF 2 102 189371 MANIFOLD, inlet; acetal 1 102 189372 MANIFOLD, inlet; PVDF 1 103 189374 MANIFOLD, outlet; acetal 1 103 189375 MANIFOLD, outlet; PVDF 1 104 188607 PLATE, air side; alum. 2 104 188607 PLATE, air side; alum.
Parts Seat Parts List (Matrix Column 4) Diaphragm Parts List (Matrix Column 6) Ref. Digit No. Part No. Description Qty Ref. Digit No.
Torque Sequence Always follow torque sequence when instructed to torque fasteners. 1. Left/Right Fluid Covers Torque bolts to 130–150 in–lb (14–17 N m) 1 13 16 15 14 3 5 8 7 6 4 2 2. Inlet Manifold Torque bolts to 80–90 in–lb (9–10 N m) 30 3.
Dimensional Drawings 13.5 in. (343 mm) 7.57 in. (192 mm) FRONT VIEW 1/2 npt(f) Air Inlet 16.88 in. (4.28.5 mm) 12.25 in. (311 mm) 14.75 in. (374.5 mm) 9.8 in. (249 mm) 2.5 in. (63.5 mm) (ANSI Flange) Fluid Outlet 3/4 npt(f) Air Exhaust (muffler included) .375 in. (9.5 mm) 5.5 in. (139.5 mm) 3.95 in. (100 mm) Port Diameter: 1.15 in. (29 mm) Eight 0.62 in. (16 mm) slots SIDE VIEW PUMP MOUNTING HOLE PATTERN 45 Four 0.5 in. (12.5 mm) diameter holes 5.0 in. (127 mm) (ANSI Flange) Fluid Inlet 5.
Technical Data Maximum fluid working pressure . . . . . . . . . . . . . . . . . 120 psi (0.8 MPa, 8 bar) Air pressure operating range . . . . . . . . . . . . . . . . 20 to 120 psi (0.14 to 0.8 MPa, 1.4 to 8 bar) Maximum air consumption . . . . . . . . . . . . . . . . . . . . . . 60 scfm Air consumption at 70 psi/20 gpm . . . . . 20 scfm (see chart) Maximum free-flow delivery . . . . . . . . . . . . 42 gpm (159 l/min) Maximum pump speed . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Chart Fluid Pressure Curves A at 120 psi (0.7 MPa, 7 bar) air pressure B at 100 psi (0.7 MPa, 7 bar) air pressure C at 70 psi (0.48 MPa, 4.8 bar) air pressure D at 40 psi (0.28 MPa, 2.8 bar) air pressure To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (gpm/lpm) and operating air pressure (psi/MPa/bar): 1. Locate fluid flow rate along bottom of chart. 2. Follow vertical line up to intersection with selected fluid outlet pressure curve. 3.
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.
