GE WJRR4170 Pressure Washer User Manual

GE WJRR4170 Pressure Washer User Manual
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. DS5
Acetal Pumps (
certified)
Acetal Pumps, Remote (
certified)
Polypropylene Pumps
Polypropylene Pumps, Remote
PVDF Pumps
PVDF Pumps, Remote
Polypropylene Plus
Pumps
Polypropylene Plus
Pumps, Remote
PVDF Plus Pumps
PVDF Plus
Pumps, Remote
*NOTE: Refer to the Pump Matrix on page 24 to
determine the Model No. of your pump.
NOTE: Plus Models include stainless steel
center sections.
Patent No.
CN ZL94102643.4
FR 9408894
JA 3517270
US 5,368,452
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
04155B
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1994, Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service
Repairing the Air Valve . . . . . . . . . . . . . . . . . . . . . . 16
Ball Check Valve Repair . . . . . . . . . . . . . . . . . . . . . 18
Diaphragm Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bearing and Air Gasket Removal . . . . . . . . . . . . . 22
Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Repair Kit Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 31
Technical Data and Performance Chart . . . . . . . . . . . 32
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 34
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
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.
INSTRUCTIONS
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 120 psi (0.8 MPa, 8 bar) maximum working pressure at 120 psi
(0.8 MPa, 8 bar) maximum incoming air pressure.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
2
308443
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.
Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas.
If the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on
page 10.
To pump acids, always use a PVDF or a polypropylene pump. Take precautions to avoid acid or
acid fumes from contacting the pump housing exterior. Stainless steel parts will be damaged by
exposure to acid spills and fumes. Never use an acetal pump to pump acids.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
Ground the equipment. Refer to Grounding on page 5.
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.
If there is any static sparking or you feel an electric shock while using this equipment, stop
pumping immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being pumped.
Pipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm
fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 10.
Keep the work area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the work area.
Extinguish all open flames or pilot lights in the work area.
Do not smoke in the work area.
Do not turn on or off any light switch in the work area while operating or if fumes are present.
Do not operate a gasoline engine in the work area.
308443
3
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.
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.
Read TOXIC FLUID HAZARD on page 3.
Use fluids and solvents that 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.
4
308443
Tightening Screws Before First Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque Sequence, page 30. After the first day of operation,
retorque the fasteners. Although pump use varies, a
general guideline is to retorque fasteners every two
months.
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. Attaching the ground wire to the
grounding screw will ground only the air motor.
When pumping conductive flammable fluids, always ground the entire fluid system by making
sure the fluid system has an electrical path to a
true earth ground (see Fig. 2). Never use a polypropylene or PVDF pump with non-conductive
flammable fluids as specified by your local fire
protection code.
Ground all of this equipment:
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.
NOTE: When pumping conductive flammable fluids
with a polypropylene or PVDF pump, always ground
the entire fluid system. See the WARNING left. Fig. 2
shows a recommended method of grounding flammable fluid containers during filling. This is only a
guide; contact your Graco distributor for assistance in
grounding your system.
Y
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.
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.
W
02646B
Fig. 1
Air and fluid hoses: Use only grounded hoses with
a maximum of 500 ft (150 m) combined hose
length to ensure grounding continuity.
Air compressor: Follow the manufacturer’s recommendations.
All solvent pails used when flushing: Follow the
local code. Use only 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.
308443
5
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. 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.
c.
The air line filter (F) removes harmful dirt and
moisture from the compressed air supply.
2. Install a grounded, flexible air hose (A) between
the accessories and the 1/2 npt(f) pump air inlet
(N). See Fig. 2. Use a minimum 3/8” (10 mm) ID
air hose. Screw an air line quick disconnect coupler (D) onto the end of the air hose (A), and screw
the mating fitting into the pump air inlet snugly. Do
not connect the coupler (D) to the fitting until you
are ready to operate the pump.
1. Install the air line accessories as shown in Fig. 2.
Mount these accessories on the wall or on a
bracket. Be sure the air line supplying the accessories is grounded.
a. Install an air regulator (C) and gauge to control
the fluid pressure. The fluid outlet pressure will
be the same as the setting of the air regulator.
KEY
A
B
FLOOR MOUNT TYPICAL INSTALLATION
E
F
C
C
D
E
F
G
H
J
K
L
N
R
S
Y
B
A
D
N
Air supply hose
Bleed-type master air valve
(required for pump)
Air regulator
Air line quick disconnect
Master air valve (for accessories)
Air line filter
Fluid suction line
Fluid supply
Fluid drain valve (required)
Fluid shutoff valve
Fluid line
1/2 npt(f) air inlet port
1” fluid inlet port
1” fluid outlet port
Ground wire (required; see page 5
for installation instructions)
S
K
R
J H
G
L
Y
04170B
Fig. 2
6
308443
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. Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as
well as the stress caused during operation.
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.
2. For all mountings, be sure the pump is bolted
directly to the mounting surface.
At inlet fluid pressures greater than 15 psi
(104 kPa, 1 bar), diaphragm life will be shortened.
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.
See the Technical Data on page 32 for maximum
suction lift (wet and dry).
4. Rubber Foot Mounting Kit 236452 is available to
reduce noise and vibration during operation.
Fluid Outlet Line
Installation of Remote Pilot Air Lines
1. Refer to Parts Drawings. Connect air line to pump
as in preceding steps.
2. Connect 1/4 in. O.D. tubing to push type connectors (14) on air motor of pump.
NOTE: by replacing the push type connectors, other
sizes or types of fittings may be used. The new fittings
will require 1/8 in. npt threads.
3. Connect remaining ends of tubes to external air
signal, such as Graco’s Cycleflo (P/N 195264) or
Cycleflo II (P/N195265) controllers.
NOTE: the air pressure at the connectors must be at
least 30% of the air pressure to the air motor for the
pump to operate.
WARNING
A fluid drain valve (J) is required to relieve pressure in the hose if it is plugged. The drain valve
reduces the risk of serious injury, including splashing in the eyes or on the skin, or contamination
from hazardous fluids when relieving pressure.
Install the valve close to the pump fluid outlet. See
Fig. 2.
1. Use grounded fluid hoses (L). The pump fluid
outlet (S) is a 1” raised face flange. Refer to
Flange Connections on page 8.
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.
308443
7
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. Install the
bolts through the holes and secure with the washers and nuts.
Four 1/2” x 2.5” bolts
4. Hold the nuts with a wrench. Refer to the tightening sequence in Fig. 3 and torque the bolts to
10 to 15 ft-lb (14 to 20 N-m). Do not over-torque.
Four 1/2” spring lockwashers
Eight 1/2” flat washers
Four 1/2” nuts.
BOLT TIGHTENING SEQUENCE
1
F
E
S
3
1
2
4
B
A
04405
E
D
C
R
1
04404B
Fig. 3
8
308443
1
KEY
A Flanged plastic pipe
B PTFE gasket
C Bolt
D Lockwasher
E Flat washer
F Nut
R 1” fluid inlet flange
S 1” fluid outlet flange
Torque to 10 to 15 ft-lb (14-20 N-m).
Do not over-torque.
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. See
Torque Sequence, page 30.
Fluid Pressure Relief Valve
CAUTION
Some systems may require installation of a pressure relief valve at the pump outlet to prevent
overpressurization and rupture of the pump or
hose. See Fig. 5.
Thermal expansion of fluid in the outlet line can
cause overpressurization. This can occur when
using long fluid lines exposed to sunlight or ambient heat, or when pumping from a cool to a warm
area (for example, from an underground tank).
KEY
N
P
1/2 npt(f) air inlet port
Muffler; air exhaust port
is 3/4 npt(f)
1” fluid inlet port
1” fluid outlet port
R
S
1
101
102
103
106
112
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.
Covers
Fluid inlet manifold
Fluid outlet manifold
Manifold screws
Manifold screws
Torque to 80 to 90 in-lb (9 to 10 N-m).
See Torque Sequence, page 30.
KEY
R
S
V
103
106
1
1” fluid inlet port
1” fluid outlet port
Pressure relief valve
Part No. 112119 (stainless steel)
S
N
1
Install valve between fluid inlet and outlet ports.
2
Connect fluid inlet line here.
3
Connect fluid outlet line here.
S
3
101
V
P
1
R
2
102
112
1
R
04228B
Acetal Model Shown
Fig. 4
04155B
Fig. 5
308443
9
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. You must
vent the exhaust to a safe place, away from people, animals, food handling areas, and all sources
of ignition when pumping flammable or hazardous
fluids.
2. Install a grounded air exhaust hose (T) and connect the muffler (P) to the other end of the hose.
The minimum size for the air exhaust hose is 3/4
in. (19 mm) ID. If a hose longer than 15 ft (4.57 m)
is required, use a larger diameter hose. Avoid
sharp bends or kinks in the hose. See Fig. 6.
Diaphragm failure will cause the fluid being
pumped to exhaust with the air. Place an appropriate container at the end of the air exhaust line to
catch the fluid. See Fig. 6.
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
E
F
C
B
A
D
C
D
E
F
P
T
U
Air supply line
Bleed-type master air valve
(required for pump)
Air regulator
Air line quick disconnect
Master air valve (for accessories)
Air line filter
Muffler
Grounded air exhaust hose
Container for remote air exhaust
T
U
P
04168A
Fig. 6
10
308443
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. Shut off the air to the pump.
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.
NOTE: 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.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve all fluid pressure, having a container ready to catch the drainage.
4. Place the end of the fluid hose (L) into an appropriate container.
5. Close the fluid drain valve (J). See Fig. 2.
Flush the Pump Before First Use
The pump was tested in water. If the water could
contaminate the fluid you are pumping, flush the pump
thoroughly with a compatible solvent. Follow the steps
under Starting and Adjusting the Pump.
Starting and Adjusting the Pump
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. Do not lift a pump under pressure. If
dropped, the fluid section may rupture. Always follow the Pressure Relief Procedure above before
lifting the pump.
6. With the pump air regulator (C) closed, open all
bleed-type master air valves (B, E).
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.
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.
308443
11
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. Injury is possible. If pump cycles,
wait until end before proceeding.
3. Pump will operate when air pressure is alternately
applied and relieved to push type connectors (14).
12
308443
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
At the end of the work shift, relieve the pressure.
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. Although
pump use varies, a general guideline is to retorque
fasteners every two months. See Torque Sequence,
page 30.
Do not over-lubricate the pump. Oil is exhausted
through the muffler, which could contaminate your
fluid supply or other equipment. Excessive lubrication can also cause the pump to malfunction.
Flushing and Storage
Preventive Maintenance Schedule
Flush the pump often enough to prevent the fluid you
are pumping from drying or freezing in the pump and
damaging it. Always flush the pump and follow the
Pressure Relief Procedure on page 11 before storing
it for any length of time. Use a compatible solvent.
Establish a preventive maintenance schedule, based
on the pump’s service history. This is especially important for prevention of spills or leakage due to diaphragm failure.
308443
13
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.
Pump will not cycle, or cycles once
and stops.
Air valve is stuck or dirty.
Disassemble and clean air valve.
See pages 16 to 17. 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
18.
Check valve ball (301) is wedged
into seat (201), due to overpressurization.
Install Pressure Relief Valve
(see page 9).
Dispensing valve clogged.
Relieve pressure and clear valve.
Clogged suction line.
Inspect; clear.
Sticky or leaking balls (301).
Clean or replace. See page 18.
Diaphragm ruptured.
Replace. See pages 19 to 21.
Restricted exhaust.
Remove restriction.
Suction line is loose.
Tighten.
Diaphragm ruptured.
Replace. See pages 19 to 21.
Loose inlet manifold (102), damaged seal between manifold and
seat (201), damaged o-rings (202).
Tighten manifold bolts (106 or 112)
or replace seats (201) or o-rings
(202). See page 18.
Loose fluid side plate (105).
Tighten or replace (pages 19 to 21).
Damaged o-ring (108).
Replace. See pages 19 to 21.
Pump operates erratically.
Air bubbles in fluid.
14
308443
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. See page 17.
screws (3) are loose.
Air valve gasket (4) or air cover
gasket (22) is damaged.
Inspect; replace. See pages
16 to 17 and 22 to 23.
Air cover screws (25) are loose.
Tighten screws. See pages
22 to 23.
Pump leaks fluid externally from ball Loose manifolds (102, 103), damcheck valves.
aged seal between manifold and
seat (201), damaged o-rings (202).
Tighten manifold bolts (106 or 112)
or replace seats (201) or o-rings
(202). See page 18.
308443
15
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).
Use all the parts in the kit for the best results.
Disassembly
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. With a Torx (T20) screwdriver or 7 mm (9/32”)
socket wrench, remove the six screws (3), air
valve cover (2), and gasket (4). See Fig. 7.
3. Move the valve carriage (5) to the center position
and pull it out of the cavity. Remove the valve
block (7) and o-ring (6) from the carriage.
Using a needle-nose pliers, pull the pilot block (18)
straight up and out of the cavity. See Fig. 8.
Torque to 50–60 in-lb
(5.6–6.8 N-m).
2
04164B
Fig. 7
1
See Detail at right.
2
Grease.
3
Grease lower face.
4. Pull the two actuator pistons (11) out of the bearings (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. 9.
5
2
6
3
7
18
3
5
1
11
5. Inspect the valve plate (8) in place. If damaged,
use a Torx (T20) screwdriver or 7 mm (9/32”)
socket wrench to remove the three screws (3).
Remove the valve plate (8) and, on aluminum
center housing models only, remove the seal (9).
See Fig. 10.
6. Inspect the bearings (12, 15) in place. See Fig. 9.
The bearings are tapered and, if damaged, must
be removed from the outside. This requires disassembly of the fluid section. See page 22.
16
308443
16
Fig. 8
04165
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. Install the valve plate (8) in the cavity. On aluminum 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”)
socket wrench. Tighten until the screws bottom out
on the housing. See Fig. 10.
12
4. Install an o-ring (17) on each pilot pin (16).
Grease the pins and o-rings. Insert the pins into
the bearings (15), narrow end first. See Fig. 9.
2
17 15 16
1
04159
Fig. 9
1
2
Rounded side must face down (aluminum
center housing models only).
Tighten screws until
they bottom out on the
housing.
3
2
5. Install a u-cup packing (10) on each actuator
piston (11), so the lips of the packings face the
narrow end of the pistons. See Fig. 9.
6. Lubricate the u-cup packings (10) and actuator
pistons (11). Insert the actuator pistons in the
bearings (12), wide end first. Leave the narrow
end of the pistons exposed. See Fig. 9.
8
7. Grease the lower face of the pilot block (18) and
install so its tabs snap into the grooves on the
ends of the pilot pins (16). See Fig. 8.
9 1
8. Grease the o-ring (6) 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. 8.
9. Install the valve carriage (5) so its tabs slip into the
grooves on the narrow end of the actuator pistons
(11). See Fig. 8.
Fig. 10
04160
10. Align the valve gasket (4) 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”) socket wrench. Torque to 28 to 33 in-lb
(3.2 to 3.7 N.m). See Fig. 7.
308443
17
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. Assemble the ball checks exactly
as shown. The arrows (A) on the fluid covers (101)
must point toward the outlet manifold (103).
1
Torque to 80 to 90 in-lb (9 to 10 N-m). See Torque Sequence, page 30.
2
Arrow (A) must point toward outlet manifold (103).
3
Not used on some models.
4
Beveled seating surface must face ball (301).
106
1
NOTE: To ensure proper seating of the balls (301),
always replace the seats (201) when replacing the
balls.
103
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
301*
201*
4
202*
3
A
1. Relieve the pressure. Disconnect all hoses.
2
101
2. Remove the pump from its mounting.
3. Using a 10 mm socket wrench, remove the four
bolts (106) holding the outlet manifold (103) to the
fluid covers (101). See Fig. 11.
301*
201* 4
202* 3
4. Remove the seats (201), balls (301), and o-rings
(202) from the manifold.
102
NOTE: Some models use two o-rings (202), some
models use four o-rings (202), and some models do
not use o-rings.
5. Turn the pump over and remove the inlet manifold
(102). Remove the seats (201), balls (301), and
o-rings (202) from the fluid covers (101).
18
308443
Fig. 11
112
1
04157B
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. Relieve the pressure.
Adjustable wrench
2. Remove the manifolds and disassemble the ball
check valves as explained on page 18.
O-ring pick
3. Using a 10 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. 12.
Lithium-base grease
1
You must torque the eight long screws (106) first, then the short
screws (112). Torque to 130 to 150 in-lb (14 to 17 Nm). See
Torque Sequence, page 30.
2
Arrow (A) must point toward air valve (B).
B
23
101
A
2
113
1
112
106
1
04162B
Fig. 12
308443
19
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. 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 22.
7. 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.
8. Clean all parts and inspect for wear or damage.
Replace parts as needed.
20
308443
Reassembly
1. Grease the shaft u-cup packings (402*) and install
them so the lips face out of the housing (1). See
Fig. 13.
2. Grease the length and ends of the diaphragm shaft
(24), and slide it through the housing (1).
3. Assemble the inner diaphragm plates (104), diaphragms (401*), PTFE diaphragms (403*, if present), and outer diaphragm plates (105) exactly as
shown in Fig. 13. These parts must be assembled
correctly.
4. Apply medium-strength (blue) Loctite or equivalent to the threads of the fluid-side plates (105).
Hold one of the outer plates (105) with a wrench,
and torque the other outer plate to 20 to 25 ft-lb
(27 to 34 N-m) at 100 rpm maximum. Do not
over-torque.
5. 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). Secure the covers
with the screws (106 and 112), handtight. Place
the bolt caps (113*) on the longer screws (106),
and install the longer screws in the top and bottom
holes of the covers. See Fig. 12.
6. First, torque the longer screws (106) oppositely
and evenly to 130 to 150 in-lb (14 to 17 Nm),
using a 10 mm socket wrench. Then torque the
shorter screws (112). See Torque Sequence,
page 30.
7. Reassemble the ball check valves and manifolds
as explained on page 18.
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.
04161B
Fig. 13
308443
21
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. Remove the fluid covers and diaphragm assemblies as explained on page 19.
NOTE: If you are removing only the diaphragm shaft
bearing (19), skip step 4.
Reassembly
1. If removed, install the shaft u-cup packings (402*)
so the lips face out of the housing (1).
2. The bearings (19, 12, and 15) 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.
3. Reassemble the air valve as explained on
page 17.
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.
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) Loctite or equivalent to the threads of
screws (25), and install the screws handtight. See
Fig. 14. Using a 10 mm socket wrench, torque the
screws oppositely and evenly to 130 to 150 in-lb
(14 to 17 Nm).
4. Disassemble the air valve as explained on page
16.
6. Install the diaphragm assemblies and fluid covers
as explained on page 19.
5. Using a 10 mm socket wrench, remove the screws
(25) holding the air covers (23) to the center
housing (1). See Fig. 14.
7. Reassemble the ball check valves and manifolds
as explained on page 18.
6. Remove the air cover gaskets (22). Always replace
the gaskets with new ones.
7. Use a bearing puller to remove the diaphragm
shaft bearings (19), air valve bearings (12) or pilot
pin bearings (15). Do not remove undamaged
bearings.
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. 13.
22
308443
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 Nm).
15
1
1
2
04158
Detail of Air Valve Bearings
16
H
22
M
23
25
19
1
3
2
02639B
Fig. 14
308443
23
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. For example, a
pump with an aluminum air motor, acetal fluid section, polypropylene seats, PTFE balls, and PTFE diaphragms is
Model D 7 1 9 1 1. To order replacement parts, refer to the part lists on pages 26 to 27. The digits in the matrix
do not correspond to the ref. nos. in the parts drawing and lists.
Diaphragm
Pump
D (for all pumps)
Air Motor
Fluid Section
–
Seats
Balls
Diaphragms
7 Aluminum
(standard)
1 (acetal)
–
1 (not used)
1 (PTFE)
1 (PTFE)
8 Aluminum
(remote)
2 (polypropylene)
–
2 (acetal)
2 (acetal)
2 (not used)
R SST (standard)
3 (not used)
–
3 (316 sst)
3 (316 sst)
3 (not used)
S SST (remote)
4 (not used)
–
4 (17–4 PH sst)
4 (440C sst)
4 (not used)
5 (PVDF)
–
5 (TPE)
5 (TPE)
5 (TPE)
–
6 (not used)
6 (Santoprene)
6 (Santoprene)
–
7 (buna–N)
7 (buna-N)
7 (buna-N)
–
8 (fluoroelastomer)
8 (fluoroelastomer)
8 (fluoroelastomer)
–
9 (polypropylene)
9 (not used)
9 (not used)
–
A (PVDF)
A (not used)
A (not used)
–
G (not used)
G (Geolast)
G (Geolast)
246450 Stainless Steel Air Motor Conversion Kit
Use kit 246450 and refer to instruction manual 309643 (included with kit) to convert from aluminum air motor to
stainless steel air motor.
24
308443
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. The first digit is always D, the second digit is always 0 (zero), and the third is always 7. 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 7 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 7 0 0 1. The digits in the matrix do not correspond to the
ref. nos. in the parts drawing and lists on pages 26 to 27.
Diaphragm
Pump
Null
Fluid Section
Material
–
Seats
Balls
Diaphragms
D (for all pumps)
0 (for all pumps)
7 (Plastic)
–
0 (null)
0 (null)
0 (null)
–
1 (not used)
1 (PTFE)
1 (PTFE)
–
2 (acetal)
2 (acetal)
2 (not used)
–
3 (316 sst)
3 (316 sst)
3 (not used)
–
4 (17–4 PH sst)
4 (440C sst)
4 (not used)
–
5 (TPE)
5 (TPE)
5 (TPE)
–
6 (Santoprene)
6 (Santoprene)
6 (Santoprene)
–
7 (buna–N)
7 (buna-N)
7 (buna-N)
–
8 (fluoroelastomer)
8 (fluoroelastomer)
8 (fluoroelastomer)
–
9 (polypropylene)
9 (not used)
9 (not used)
–
A (PVDF)
A (not used)
A (not used)
–
G (Geolast)
G (Geolast)
G (Geolast)
308443
25
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.
These parts are included in Air Valve Repair Kit 236273 (aluminum center housing models), which may be purchased separately.
These parts are included in Air Valve Repair Kit 255061 (stainless steel center housing
models) which may be purchased separately.
Replacement Danger and Warning labels, tags and cards are available at no cost.
}
26
These parts are unique to remote piloted air motor, D8–––– and DS––––
308443
112
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.
Description
Qty
Same as 7 with the following exceptions
1
195921
HOUSING, center;
remote, aluminum
1
23
195917
COVER, air; remote
2
Same as 7 with the following exceptions
1
15K009
HOUSING, center;
stainless steel
1
2
15A735
COVER, air valve;
stainless steel
1
8
15H178
PLATE, air valve,
stainless steel
1
1
9
–
–
–
SEAL, valve plate; buna-N
1
23
15A736
2
112181
PACKING, u-cup; nitrile
2
COVER, air; stainless
steel
11
188612
PISTON, actuator; acetal
2
12
188613
BEARING, piston; acetal
2
13}
104765
PLUG, pipe; headless
2
14}
115671
FITTING, connector;
male
2
15
188611
BEARING, pin; acetal
2
16
188610
PIN, pilot; stainless steel
17
157628
18
4
188618
GASKET, cover; foam
1
5
188855
CARRIAGE; aluminum
1
6
108730
O-RING; nitrile
1
7
188616
BLOCK, air valve; acetal
1
8
188615
PLATE, air valve; sst
9
188617
10
S
Same as 7 with the following exceptions
1
15K009
HOUSING, center;
remote, stainless steel
1
2
15A735
COVER, air valve;
stainless steel
1
8
15H178
PLATE, air valve,
stainless steel
1
2
9
–
–
–
O-RING; buna-N
2
23
15B794
COVER, air; remote,
stainless steel
2
188614
BLOCK, pilot; acetal
1
19
188609
BEARING, shaft; acetal
2
20
116343
SCREW, grounding
1
22
188603
GASKET, air cover; foam
2
23
188839
COVER, air; aluminum
2
24
188608
SHAFT, diaphragm; sst
1
25
115643
SCREW; M8 x 1.25;
25 mm (1 in.)
12
308443
27
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.
2
105
189380
PLATE, fluid side; acetal
2
105
189381
PLATE, fluid side; PVDF
2
106
112560
SCREW; M8 x 1.25;
70 mm (2.76 in.); sst
12
106
112560
SCREW; M8 x 1.25;
70 mm (2.76 in.); sst
12
110
188621
LABEL, warning
1
110
188621
LABEL, warning
1
111
112182
MUFFLER
1
111
112182
MUFFLER
1
112
112559
SCREW; M8 x 1.25;
40 mm (1.57 in.); sst
12
112
112559
SCREW; M8 x 1.25;
40 mm (1.57 in.); sst
12
113*
193282
CAP, bolt; SST
8
113*
193282
CAP, bolt; SST
8
101
189376
COVER, fluid;
polypropylene
2
102
189370
MANIFOLD, inlet;
polypropylene
1
103
189373
MANIFOLD, outlet;
polypropylene
1
104
188607
PLATE, air side; alum.
2
105
189379
PLATE, fluid side;
polypropylene
2
106
112560
SCREW; M8 x 1.25;
70 mm (2.76 in.); sst
12
110
188621
LABEL, warning
1
111
112182
MUFFLER
1
112
112559
SCREW; M8 x 1.25;
40 mm (1.57 in.); sst
12
113*
193282
CAP, bolt; SST
8
2
28
308443
Parts
Seat Parts List (Matrix Column 4)
Diaphragm Parts List (Matrix Column 6)
Ref.
Digit No.
Part No.
Description
Qty
Ref.
Digit No.
2
201*
188604
SEAT; acetal
4
1
202*
109205
O-RING; PTFE
8
201*
188707
SEAT; 316 stainless steel
4
202*
109205
O-RING; PTFE
8
201*
188708
SEAT; 17-4 stainless steel
4
202*
109205
O-RING; PTFE
8
201*
188711
SEAT; TPE
4
202
None
Not Used
0
201*
191595
SEAT; Santoprene
4
202*
114229
O-RING; PTFE encapsulated
8
201*
15B275
SEAT; Buna–N
4
202
None
Not used
0
201*
15B633
SEAT; fluoroelastomer
4
202
None
Not Used
0
201*
189722
SEAT; polypropylene
4
202*
109205
O-RING; PTFE
8
201*
189723
SEAT; PVDF
4
202*
109205
O-RING; PTFE
8
201*
194211
SEAT; Geolast
4
202*
109205
O-RING; PTFE
8
3
4
5
6
7
8
9
A
G
5
6
7
8
G
Part No.
Description
Qty
401*
Not sold
separately
DIAPHRAGM, backup;
polychloropene (CR)
2
402*
112181
PACKING, u-cup; nitrile
2
403*
188605
DIAPHRAGM; PTFE
2
401*
188606
DIAPHRAGM; TPE
2
402*
112181
PACKING, u-cup; nitrile
2
401*
188857
DIAPHRAGM;
Santoprene
2
402*
112181
PACKING, u-cup; nitrile
2
401*
15B499
DIAPHRAGM; buna-N
2
402*
112181
PACKING, u-cup; nitrile
2
401*
15B500
DIAPHRAGM; fluoroelastomer
2
402*
112181
PACKING, u-cup; nitrile
2
401*
194212
DIAPHRAGM; Geolast
2
402*
112181
PACKING, u-cup; nitrile
2
* These parts are included in the pump repair kit, purchased
separately. See Repair Kit Matrix on page 25 to determine
the correct kit for your pump.
Ball Parts List (Matrix Column 5)
Ref.
Digit No.
Part No.
Description
Qty
1
301*
112088
BALL; PTFE
4
2
301*
112254
BALL; acetal
4
3
301*
103869
BALL; 316 stainless steel
4
4
301*
102973
BALL; 440C stainless
steel
4
5
301*
112089
BALL; TPE
4
6
301*
112092
BALL; Santoprene
4
7
301*
15B488
BALL; buna-N
4
8
301*
15B487
BALL; fluoroelastomer
4
G
301*
114751
BALL; Geolast
4
308443
29
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 Nm)
1
13
16
15
14
3
5
8
7
6
4
2
2. Inlet Manifold
Torque bolts to 80–90 in–lb (9–10 Nm)
30
3. Outlet Manifold
Torque bolts to 80–90 in–lb (9–10 Nm)
11
10
9
12
308443
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
5.5 in.
(139.5 mm)
5.0 in.
(127 mm)
9.25 in.
(235 mm)
7337C
308443
31
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 . . . . . . . . . . . . . . . . . . . . . . . . . 276 cpm
Gallons (Liters) per cycle . . . . . . . . . . . . . . . . . . . . . 0.15 (0.57)
Maximum suction lift . . . . . . . . . . . . . 18 ft (5.48 m) wet or dry
Maximum Size pumpable solids . . . . . . . . . . . 1/8 in. (3.2 mm)
* Maximum noise level at 100 psi, 50 cpm . . . . . . . . 89 dBa
Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . 100 dBa
* Noise level at 70 psi, 50 cycles/min: . . . . . . . . . . . . 78 dBa
Maximum operating temperature . . . . . . . . . . . 150F (65.5C)
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt(f)
Fluid inlet size. . . . . . . . . . . . . . . . . . . . 1” Raised Face Flange
Fluid outlet size. . . . . . . . . . . . . . . . . . . 1” Raised Face Flange
32
308443
Wetted parts . . . . . . . . . Vary by Model. See pages 27 and 29
Non-wetted external parts aluminum, 302, 316 stainless steel
polyester (labels)
Weight (approximate) . . . . . . . . . . . . . Polypropylene Models
. . . . . . . . . . . . . . . with aluminum center section: 19 lb (8.6 kg)
. . . . . . . . . . with stainless steel center section : 32 lb (14.6 kg)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acetal Models
. . . . . . . . . . . . . . . with aluminum center section : 22 lb (10 kg)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PVDF Models
. . . . . . . . . . . . . . with aluminum center section: 25 lb (11.3 kg)
. . . . . . . . . . . . with stainless steel center section: 35 lb (16 kg)
Geolast and Santoprene
Monsanto Co.
are registered trademarks of the
Loctite 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.
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. Follow left to scale to read fluid outlet
pressure.
FLUID OUTLET PRESSURE––psi (MPa, bar)
Test Conditions: Pump tested in water with inlet submerged.
120
(0.84, 8.4)
A
100
(0.7, 7)
B
80
(0.55, 5.5)
C
60
(0.41, 4.1)
40
(0.28, 2.8)
D
20
(0.14, 1.4)
0
0
5
(19)
10
(38)
15
20
25
30
35
40
(57)
(76)
(95)
(114)
(133)
(152)
Air Consumption 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 Pump Air Consumption (scfm or
m/min) at a specific fluid flow (gpm/lpm) and
air pressure (psi/MPa/bar):
1. Locate fluid flow rate along bottom of chart.
2. Read vertical line up to intersection with
selected air consumption curve.
3. Follow left to scale to read air consumption.
AIR CONSUMPTION––scfm (cubic meters/min)
FLUID FLOW--gpm (lpm)
60
(1.68)
50
(1.40)
40
(1.12)
A
B
30
(0.84)
C
20
(0.56)
D
10
(0.28)
0
0
5
10
15
20
25
30
35
40
(19)
(38)
(57)
(76)
(95)
(114)
(133)
(152)
FLUID FLOW--gpm (lpm)
308443
33
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 substitution 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 reconnaissent 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 one of the following numbers
to identify the distributor closest to you:
1–800–328–0211 Toll Free
612–623–6921
612–378–3505 Fax
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.
This manual contains English. MM 308443
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
308443 10/1994, Revised 08/2007
34
308443
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