Graco 308479M ALUMINUM AND STAINLESS STEEL Husky 1040 Air-Operated Diaphragm Pumps Owner's Manual

INSTRUCTIONS–PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
308–479
First choice when
quality counts.
Rev. M
Supersedes Rev. L
INSTRUCTIONS
ALUMINUM AND STAINLESS STEEL
Husky 1040 Air-Operated
Diaphragm Pumps
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
*Model No. D73–______ Aluminum Pumps
*Model No. D74–______ Stainless Steel Pumps
Model No. 232–501 Private-Label Aluminum 1040 Pump (See page 22.)
*NOTE: Refer to the Pump Matrix on page 22 to
determine the Model No. of your pump.
US and Foreign Patents Pending
Aluminum Model Shown
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN
Graco Inc. is registered to I.S. EN ISO 9001
55440–1441
Symbols
Table of Contents
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Repair Kit Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 28
Technical Data and Performance Chart . . . . . . . . . . 29
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 32
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
D This equipment is for professional use only.
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.
D Do not use hoses to pull equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
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.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
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 8.
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.
D Ground the equipment. Refer to Grounding on page 4.
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.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
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 8.
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.
Installation
General Information
Grounding
D The Typical Installations shown in Figs. 2–4 are
only guides for selecting and installing system
components. 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 section FIRE AND EXPLOSION HAZARD,
on page 3.
D Always use Genuine Graco Parts and Accessories.
Refer to Product Data Sheet 305–588.
D Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 24–25.
D Aluminum Husky 1040 Pump Model No. 239–823,
with straight-thread manifolds, is available and can
be ordered separately.
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.
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. Ground all of this equipment.
D Pump: Connect a ground wire and clamp as shown
in Fig. 1. Loosen the grounding lug locknut (W) and
washer (X). Insert one end of a 12 ga (1.5 mm@)
minimum ground wire (Y) into the slot in the lug (Z)
and tighten the locknut securely. Connect the clamp
end of the ground wire to a true earth ground.
Order Part No. 222–011 Ground Wire and Clamp.
1. Read TOXIC FLUID HAZARD on page 3.
2. 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.
Y
Tightening Screws Before First Use
After you unpack the pump, and before you use it for
the first time, check and retorque external fasteners.
Retorque the fluid cover screws first, then the manifold
screws. This keeps the manifolds from interfering with
tightening the fluid covers. See the Service section for
torque specifications.
After the first day of operation, check and retorque the
fasteners again. Although the recommended
frequency for retorquing fasteners varies with pump
usage, a general guideline is to retorque fasteners
every two months.
W
X
Z
Fig. 1
D Air and fluid hoses: Use only grounded hoses with
a maximum of 500 ft (150 m) combined hose
length to ensure grounding continuity.
D Air compressor: Follow the manufacturer’s
recommendations.
D All solvent pails used when flushing: Follow the
local code. Use only 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.
D Fluid supply container: Follow the local code.
02646
Installation
Mountings
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 8.
2. Install a grounded, flexible air hose (A) between
the accessories and the 1/2 npt(f) pump air inlet
(N). See Fig. 5. Use a minimum 3/8” (9.5 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.
Fluid Suction Line
D Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as
well as the stress caused during operation.
D For all mountings, be sure the pump is bolted
directly to the mounting surface.
D 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.
D Rubber Foot Mounting Kit 236–452 is available to
reduce noise and vibration during operation.
Air Line
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. 3.
1. Install the air line accessories as shown in Figs.
2–4 on pages 6 and 7. 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.
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.
c.
1. Use grounded fluid hoses. The pump fluid inlet (R)
is 1” npt(f). See Fig. 5. Screw the fluid fitting into
the pump inlet securely.
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.
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 29 for maximum
suction lift (wet and dry).
Fluid Outlet Line
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. 3.
1. Use grounded fluid hoses (L). The pump fluid
outlet (S) is 1” npt(f). See Fig. 5. Screw the fluid
fitting into the pump outlet securely.
2. Install a fluid drain valve (J) near the fluid outlet.
See the WARNING above, and Figs. 2–4 on
pages 6 and 7.
3. Install a shutoff valve (K) in the fluid outlet line.
The air line filter (F) removes harmful dirt and
moisture from the compressed air supply.
308-479
5
Installation
KEY FOR FIG. 2
A
B
C
D
E
F
G
H
J
K
L
Y
TYPICAL BUNG-MOUNT INSTALLATION
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
Fluid suction line
Bung adapter
Fluid drain valve (required)
Fluid shutoff valve
Fluid line
Ground wire (required; see page 4
for installation instructions)
E
F
C
B
A
K
L
D
J
Y
H
G
02648
Fig. 2
TYPICAL FLOOR-MOUNT INSTALLATION
KEY FOR FIG. 3
A
B
C
D
E
F
G
J
K
L
Y
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
Fluid suction line
Fluid drain valve (required)
Fluid shutoff valve
Fluid line
Ground wire (required; see page 4
for installation instructions)
F
C
B
A
K
L
D
G
J
Y
02651
Fig. 3
6
E
308-479
Installation
KEY FOR FIG. 4
A
B
Air supply line
Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
G Fluid suction line
J Fluid drain valve (required)
K Fluid shutoff valve
L Fluid line
M Wall mounting bracket
Y Ground wire (required; see page 4
for installation instructions)
TYPICAL WALL-MOUNT INSTALLATION
E
F
C
B
A
K
L
D
J
Y
G
M
02649
Fig. 4
Changing the Orientation of the Fluid Inlet
and Outlet Ports
On aluminum pumps, the fluid inlet and outlet
manifolds have threaded ports on both ends. The
pump is shipped with a plug installed in one end of
each manifold, and the opposite end open. See Fig. 5.
To change the orientation of the inlet and/or outlet port,
remove the plug from one end of a manifold and install
it in the opposite end.
On stainless steel pumps, the fluid inlet and outlet
manifolds have threaded ports on one end only. The
pump is shipped with the ports facing the same
direction. To reverse the orientation of the ports:
1. Remove the screws and nuts holding the inlet
and/or outlet manifold to the covers.
KEY
N 1/2 npt(f) air inlet port
P Muffler. Air exhaust port is 3/4 npt(f)
R 1 npt(f) fluid inlet port
1
S 1 npt(f) fluid outlet port
106 Manifold and cover screws
3 Air valve screws
2
Apply mediumstrength (blue) LoctiteR or equivalent to
the threads, and
torque to 120–150
in-lb
(14–17 N.m).
Torque to 38–43 in-lb
(4.4–5.0 N.m).
106
2
1
S
3
N
106
1
2. Reverse the manifold and reattach. Install the
screws and torque to 120–150 in–lb (14–17 N.m).
P
R
02632
Fig. 5
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
To provide a remote exhaust:
FIRE AND EXPLOSION HAZARD
Be sure to read and follow the warnings
and precautions regarding TOXIC
FLUID HAZARD, and FIRE OR EXPLOSION HAZARD on page 3, before operating this pump.
1. Remove the muffler (P) from the pump air exhaust
port.
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.
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.
3. Place a container (U) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures.
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.
VENTING EXHAUST AIR
KEY
A
B
E
F
C
C
D
E
F
P
T
U
B
A
D
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
02650
Fig. 6
Installation
Fluid Pressure Relief Kit
CAUTION
Pressure Relief Kit 235–409 (V) is available for Aluminum Pumps, to prevent overpressurization and rupture of
the pump or hose. See Fig. 7. The kit includes instructions.
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).
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.
3
S
KEY
R
S
V
1 npt(f) optional fluid inlet port
1 npt(f) optional fluid outlet port
Pressure relief kit
1
Install kit between fluid inlet and outlet manifolds.
2
Connect fluid inlet line here.
3
Connect fluid outlet line here.
2
R
V
1
02653
Fig. 7
Operation
Pressure Relief Procedure
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
D
D
D
D
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. 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.
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
To reduce the risk of serious injury,
splashing in the eyes or on the skin, and
toxic fluid spills, never move or lift a
pump under pressure. If dropped, the fluid section
may rupture. Always follow the Pressure Relief
Procedure Warning above before lifting the pump.
1. Be sure the pump is properly grounded. Refer to
Grounding on page 4.
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.
10
308-479
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.
4. Place the end of the fluid hose (L) into an
appropriate container.
5. Close the fluid drain valve (J).
6. Close the pump air regulator (C). 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.
Pump Shutdown
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.
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
and retorque all threaded connections at least every
two months. Retorque the fluid cover screws first,
followed by the manifold screws.
CAUTION
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
WARNING
The recommended frequency for retorquing of
fasteners varies with pump usage; a general guideline
is to retorque fasteners every two months.
Preventive Maintenance Schedule
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.
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
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.
308-479
11
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
D Relieve the pressure before checking or servicing
the equipment.
D 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 16.
Pump will not cycle, or cycles once
and stops.
Air valve is stuck or dirty.
Disassemble and clean air valve.
See pages 14–14. 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
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 16.
Diaphragm ruptured.
Replace. See pages 17–19.
Restricted exhaust.
Remove restriction.
Suction line is loose.
Tighten.
Diaphragm ruptured.
Replace. See pages 17–19.
Loose inlet manifold (102), damaged seal between manifold and
seat (201), damaged o-rings (202).
Tighten manifold bolts (106) or replace seats (201) or o-rings (202).
See page 16.
Loose diaphragm shaft bolt (107).
Tighten or replace (pages 17–19).
Damaged o-ring (108).
Replace. See pages 17–19.
Pump operates erratically.
Air bubbles in fluid.
12
308-479
Troubleshooting
PROBLEM
CAUSE
SOLUTION
Fluid in exhaust air.
Diaphragm ruptured.
Replace. See pages 17–19.
Loose diaphragm shaft bolt (107).
Tighten or replace (pages 17–19).
Damaged o-ring (108).
Replace. See pages 17–19.
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
14–14.
Worn shaft seals (402).
Replace. See pages 17–19.
Pump exhausts excessive air at
stall.
Pump leaks air externally.
Air valve cover (2) or air valve cover Tighten screws. See page 14.
screws (3) are loose.
Air valve gasket (4) or air cover
gasket (22) is damaged.
Inspect; replace. See pages 14–14,
20–21.
Air cover screws (25) are loose.
Tighten screws. See pages 20–21.
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 replace seats (201) or o-rings (202).
See page 16.
308-479
13
Service
Repairing the Air Valve
1. If you replaced the bearings (12, 15), reinstall as
explained on page 20. Reassemble the fluid
section.
Tools Required
D Torque wrench
D Torx screwdriver or 8 mm (5/16”) socket wrench
D Needle-nose pliers
D O-ring pick
D Lithium base grease
NOTE: Air Valve Repair Kit 236–273 is available.
Refer to page 23. 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 10.
1. Relieve the pressure.
2. With a torx screwdriver or 8 mm (5/16”) socket
wrench, remove the six screws (3), air valve cover
(2), and gasket (4). See Fig. 8.
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. 9.
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
push pins. See Fig. 10.
5. Inspect the valve plate (8) in place. If damaged,
use a torx screwdriver or 8 mm (5/16”) socket
wrench to remove the three screws (3). Remove
the valve plate (8) and seal (9). See Fig. 11.
6. Inspect the bearings (12, 15) in place. See Fig. 10.
The bearings are tapered and, if damaged, must
be removed from the outside. This requires
disassembly 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 14.
14
308-479
Reassembly
2. 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. 11.
3. Install the valve plate (8) in the cavity. The plate is
reversible, so either side can face up. Install the
three screws (3), using a torx screwdriver or 8 mm
(5/16”) socket wrench. Tighten until the screws
bottom out on the housing. See Fig. 11.
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. 10.
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. 10.
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. 10.
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. 9.
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. 9.
9. Install the valve carriage (5) so its tabs slip into the
grooves on the narrow end of the actuator pistons
(11). See Fig. 9.
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 screwdriver or 8 mm
(5/16”) socket wrench. Torque to 38–43 in–lb
(4.3–4.9 N.m). See Fig. 8.
Service
2
Torque to 38–43
in–lb
(4.3–4.9 N.m).
3
2
2
4{
1
Insert narrow end first.
2
Grease.
3
Install with lips facing
narrow end of piston (11).
4
Insert wide end first.
10{ 2
3
11
4
12
2
02644
Fig. 8
Detail
1
See Detail at right.
2
Grease.
3
Grease lower face.
5
2
{6
3
{7
18{
Fig. 9
5
15 16
1
02643
Fig. 10
1
Rounded side must face down.
3
2
Tighten screws
until they bottom
out on the housing.
8
1
3
17{
2
{9
1
02642
02645
Fig. 11
Service
Ball Check Valve Repair
2
Apply medium-strength (blue) LoctiteR or equivalent to
the threads, and torque to 120–150 in–lb (14–17 N.m).
Arrow (A) must point toward outlet manifold (103).
3
Beveled seating surface must face the ball (301).
4
Not used on some models.
1
Tools Required
D Torque wrench
D 10 mm socket wrench
D O-ring pick
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.
Aluminum Model Shown
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
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
201*
3
202*
4
101
1. Relieve the pressure. Disconnect all hoses.
A
2. Remove the pump from its mounting.
2
3. Using a 10 mm socket wrench, remove the four
bolts (106) and nuts (114, used on stainless steel
pumps only) holding the outlet manifold (103) to
the fluid covers (101). See Fig. 12.
4. Remove the o-rings (202, not used on some
models), seats (201), and balls (301) from the
manifold (103).
301*
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).
201*
3
202*
4
Reassembly
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. 12. Be sure the ball checks and
manifolds are assembled exactly as shown. The
arrows (A) on the fluid covers (101) must point
toward the outlet manifold (103).
102
106
Fig. 12
1
02647A
Service
Diaphragm Repair
Tools Required
D Torque wrench
D 10 mm socket wrench
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
D 15 mm socket wrench (aluminum models) or
1” socket wrench (stainless steel models)
1. Relieve the pressure.
D 19 mm socket wrench
2. Remove the manifolds and disassemble the ball
check valves as explained on page 16.
D O-ring pick
D Lithium-base grease
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 (401*). Use all the parts in the kit for the best
results.
3. Using a 10 mm socket wrench, remove the screws
(106) holding the fluid covers (101) to the air
covers (23). Pull the fluid covers (101) off the
pump. See Fig. 13.
1
Apply medium-strength (blue) LoctiteR or
equivalent to the threads, and torque to
120–150 in–lb (14–17 N.m).
2
Arrow (A) must point toward air valve (B).
B
23
101
A
2
106
1
02635A
Fig. 13
308-479
17
Service
4. Loosen but do not remove the diaphragm shaft
bolts (107), using a 15 mm socket wrench (1” on
stainless steel models) on both bolts.
5. Unscrew one bolt from the diaphragm shaft (24)
and remove the o-ring (108), fluid side diaphragm
plate (105), PTFE R diaphragm (403, used on
PTFE models only), diaphragm (401), and air
side diaphragm plate (104). See Fig. 14.
6. Pull the other diaphragm assembly and the
diaphragm shaft (24) out of the center housing (1).
Hold the shaft flats with a 19 mm socket wrench,
and remove the bolt (107) from the shaft.
Disassemble the remaining diaphragm assembly.
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.
NOTE: On stainless steel pumps only, the fluid side
diaphragm plate (105) is stainless steel. This plate is
not stamped with its part number. Be sure to install
this plate on the fluid side of the diaphragm.
c.
OnPTFE models only, install the PTFE R
diaphragm (403*). Make certain the side
marked AIR SIDE faces the center
housing (1).
d. Install the diaphragm (401*) on the bolt. Make
certain the side marked AIR SIDE faces the
center housing (1).
e. Install the air side diaphragm plate (104) so
the rounded side faces the diaphragm (401).
This plate is used on all models, and is
stamped with its part number.
f.
Apply medium-strength (blue) LoctiteR or
equivalent to the bolt (107) threads. Screw the
bolt into the shaft (24) hand tight.
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.
3. Grease the length and ends of the diaphragm shaft
(24), and slide it through the housing (1).
9. Clean all parts and inspect for wear or damage.
Replace parts as needed.
4. Assemble the other diaphragm assembly to the
shaft as explained in step 2.
Reassembly
1. Install the shaft u-cup packings (402*) so the lips
face out of the housing (1). Lubricate the
packings. See Fig. 14.
5. Hold one shaft bolt (107) with a wrench and torque
the other bolt to 20–25 ft–lb (27–34 N.m) at 100
rpm maximum.
2. Install the diaphragm assembly on one end of the
shaft (24) as follows:
a. Install the o-ring (108*) on the shaft bolt (107).
b. Install the fluid side diaphragm plate (105) on
the bolt so the rounded side faces the
diaphragm (401).
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 the screws (106). Secure the
covers with the screws handtight. See Fig. 13.
Using a 10 mm socket wrench, torque the screws
oppositely and evenly to 120–150 in–lb (14–17
N.m).
7. Reassemble the ball check valves and manifolds
as explained on page 16.
18
308-479
Service
19
402*
1
105 2
107
5
403*
1
24
4
104
2
3
401*
3
6
1
02638A
02637A
Cutaway View, with Diaphragms in Place
Cutaway View, with Diaphragms Removed
24
4
104
2
401*
3
403*
3
6
105
2
108*
1
24
107
4
5
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) LoctiteR or
equivalent. Torque to 20–25 ft-lb (27–34 N-m) at 100
rpm maximum.
6
Used on pumps withPTFE R diaphragms only.
02636A
Fig. 14
308-479
19
Service
Bearing and Air Gasket Removal
Tools Required
Reassembly
1. If removed, install the shaft u-cup packings (402*)
so the lips face out of the housing (1).
D Torque wrench
D 10 mm socket wrench
D Press, or block and mallet
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.
Disassembly
NOTE: Do not remove undamaged bearings.
3. Reassemble the air valve as explained on page
14.
D Bearing puller
D O-ring pick
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
1. Relieve the pressure.
2. Remove the manifolds and disassemble the ball
check valves as explained on page 16.
3. Remove the fluid covers and diaphragm
assemblies as explained on page 17.
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. 15.
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. 14.
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. Install the screws (25),
handtight. Apply medium-strength (blue) LoctiteR
or equivalent to the threads of the screws (25).
See Fig. 15. Using a 10 mm socket wrench, torque
the screws oppositely and evenly to 130–150 in–lb
(15–17 N.m).
6. Install the diaphragm assemblies and fluid covers
as explained on page 17.
7. Reassemble the ball check valves and manifolds
as explained on page 16.
Service
12
1
Insert bearings tapered end first.
2
Press-fit bearings flush with surface of center housing (1).
3
Apply medium-strength (blue) LoctiteR or equivalent.
Torque to 130–150 in–lb (15–17 N.m).
15
1
1
2
2
02640
Detail of Air Valve Bearings
1
16
19
2
1
H
22
M
23
25
3
02639A
Fig. 15
308-479
21
Pump Matrix
Husky 1040 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 r balls, and PTFE r
diaphragms is Model D 7 3 – 9 1 1. To order replacement parts, refer to the part lists on pages 24–25. The digits
in the matrix do not correspond to the ref. nos. in the parts drawing and lists.
Diaphragm
Pump
Air Motor
Fluid Section
–
Seats
Balls
Diaphragms
232–501*
aluminum
aluminum
–
Hytrelr
acetal
Hytrelr
D (for all pumps)
7 (aluminum)
1 (not used)
–
1 (not used)
1 (PTFE r)
1 (PTFE r)
2 (not used)
–
2 (acetal)
2 (acetal)
2 (not used)
3 (aluminum)
–
3 (316 sst)
3 (316 sst)
3 (not used)
4 (sst)
–
4 (17–4 PH sst)
4 (440C sst)
4 (not used)
5 (not used)
–
5 (Hytrelr)
5 (not used)
5 (Hytrelr)
C (aluminum
BSPT)
–
6 (Santoprener)
6 (Santoprener)
6 (Santoprener)
D (sst BSPT)
–
7 (not used)
7 (buna-N)
7 (buna-N)
–
8 (Vitonr)
8 (Vitonr)
8 (Vitonr)
–
9 (polypropylene)
9 (not used)
9 (not used)
–
A (Kynarr)
A (not used)
A (not used)
* 232–501, Aluminum 1040 Pump, Series A
Model No. 232–501 is a private-label aluminum 1040 pump. Other than the label, it is the same
as Model No. D73–525.
Repair Kit Matrix
For Husky 1040 Aluminum and Stainless Steel Pumps, Series A
Repair Kits may be ordered separately. To repair the air valve, order Part No. 236–273 (see page 25). Parts
included in the Air Valve Repair Kit are marked with a symbol in the parts list, for example (4{).
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 r balls, and PTFE r 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 24–25.
Diaphragm
Pump
Null
Shaft O-ring
–
Seats
Balls
Diaphragms
D (for all pumps)
0 (for all pumps)
7 (PTFE r)
–
0 (null)
0 (null)
0 (null)
–
1 (not used)
1 (PTFE r)
1 (PTFE r)
–
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 (Hytrelr)
5 (not used)
5 (Hytrelr)
–
6 (Santoprener)
6 (Santoprener)
6 (Santoprener)
–
7 (not used)
7 (buna-N)
7 (buna-N)
–
8 (Vitonr)
8 (Vitonr)
8 (Vitonr)
–
9 (polypropylene)
9 (not used)
9 (not used)
–
A (Kynarr)
A (not used)
A (not used)
Parts
Air Motor Parts List (Matrix Column 2)
Fluid Section Parts List (Matrix Column 3)
Ref.
Digit No.
Part No.
Description
Qty
Ref.
Digit No.
Part No.
Description
Qty
7
1
188–838
HOUSING, center; alum.
1
3
101
188–840
COVER, fluid; aluminum
2
2
188–854
COVER, air valve; alum.
1
102
188–841
1
3
112–179
SCREW; M5 x 0.8;
12 mm (0.47 in.)
9
MANIFOLD, inlet;
aluminum
103
188–842
1
4{
188–618
GASKET, cover; foam
1
MANIFOLD, outlet;
aluminum
5
188–855
CARRIAGE; aluminum
1
104
188–607
PLATE, air side;
aluminum
2
6{
108–730
O-RING; nitrile
1
105
188–607
2
7{
188–616
BLOCK, air valve; acetal
1
PLATE, fluid side;
aluminum
8
188–615
PLATE, air valve; sst
1
106
112–178
SCREW; M8 x 1.25;
25 mm (1 in.)
24
9{
188–617
SEAL, valve plate; bunaN
1
107
189–044
BOLT; M12 x 1.75;
35 mm (1.38 in.); sst
2
10{
112–181
PACKING, u-cup; nitrile
2
108*
104–319
O-RING; PTFE r
2
11
188–612
PISTON, actuator; acetal
2
LABEL, warning
1
188–613
BEARING, piston; acetal
2
110
Y
188–970
12
15
188–611
BEARING, pin; acetal
2
111
112–182
MUFFLER
1
16
188–610
PIN, pilot; stainless steel
2
113
112–183
PLUG: 1” npt; cst
2
17{
157–628
O-RING; buna-N
2
114
None
Not Used
0
18{
188–614
BLOCK, pilot; acetal
1
101
188–860
COVER, fluid; sst
2
19
188–609
BEARING, shaft; acetal
2
102
188–862
MANIFOLD, inlet; sst
1
20
104–029
STUD, grounding
1
103
188–861
MANIFOLD, outlet; sst
1
21
104–582
WASHER, tab
1
104
188–607
PLATE, air side;
aluminum
2
22
188–603
GASKET, air cover; foam
2
105
188–960
PLATE, fluid side; sst
2
23
188–839
COVER, air; aluminum
2
106
112–178
188–608
SHAFT, diaphragm; sst
1
SCREW; M8 x 1.25;
25 mm (1 in.)
24
24
25
112–178
SCREW; M8 x 1.25;
25 mm (1 in.)
12
107
189–044
BOLT; M12 x 1.75;
35 mm (1.38 in.); sst
2
108*
104–319
O-RING; PTFE r
2
110
Y
188–621
LABEL, warning
1
111
112–182
MUFFLER
1
113
None
Not Used
0
114
112–257
NUT, hex; M8 x 1.25; sst
8
4
continued
Parts
3
11
2
10{
4{
{17
5
16
{18
6{
7{
3
8
9{
16
17{
113
2
12
Y110
10{
11 22
106
23
25
15
*402
20 21
1
19
103
24
104
111
401*
403*
Used on pumps withPTFE r diaphragms only.
2
Not used on stainless steel pumps.
3
Not used on aluminum pumps.
4
Not used on all models.
* 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.
{
202*
105
201*
108*
107
Aluminum Model Shown
1
301*
1
4
202*
4
106
114
3
101
2
113
*301
202*
4
202*
4
*201
These parts are included in Air Valve Repair Kit 236–273,
which may be purchased separately.
Y Replacement Danger and Warning labels,
tags and cards are available at no cost.
102
02633C
106
Parts
Fluid Section Parts List (Matrix Column 3)
(continued)
Ref.
Digit No.
Part No.
Description
Qty
C
101
188–840
COVER, fluid; aluminum
2
102
192–070
MANIFOLD, inlet;
aluminum; BSPT
1
103
192–071
MANIFOLD, outlet;
aluminum; BSPT
1
104
188–607
PLATE, air side;
aluminum
2
105
188–607
PLATE, fluid side;
aluminum
2
106
112–178
SCREW; M8 x 1.25;
25 mm (1 in.)
24
107
189–044
BOLT; M12 x 1.75;
35 mm (1.38 in.); sst
2
D
Digit
Ref.
No.
Part No.
Description
Qty
2
201*
188–604
SEAT; acetal
4
202*
109–205
O-RING; PTFE r
8
201*
188–707
SEAT; 316 stainless steel
4
202*
109–205
O-RING; PTFE R
8
201*
188–708
SEAT; 17-4 stainless steel
4
202*
109–205
O-RING; PTFE r
8
201*
188–711
SEAT; Hytrelr
4
202
None
Not Used
0
201*
191–595
SEAT; Santoprene
4
202*
109–205
O-RING; PTFE r
8
201*
188–712
SEAT; Viton
4
202
None
Not Used
0
201*
189–722
SEAT; polypropylene
4
202*
109–205
O-RING; PTFE r
8
201*
189–723
SEAT; Kynar
4
202*
109–205
O-RING; PTFE r
8
3
4
5
6
8
108*
104–319
O-RING; PTFE r
2
110
Y
188–970
LABEL, warning
1
111
112–182
MUFFLER
1
113
113–991
PLUG: 1” BSPT; cst
2
114
None
Not Used
0
101
188–860
COVER, fluid; sst
2
102
192–068
MANIFOLD, inlet; sst;
BSPT
1
103
192–069
MANIFOLD, outlet; sst;
BSPT
1
104
188–607
PLATE, air side;
aluminum
2
105
188–960
PLATE, fluid side; sst
2
106
112–178
SCREW; M8 x 1.25;
25 mm (1 in.)
24
107
189–044
BOLT; M12 x 1.75;
35 mm (1.38 in.); sst
2
108*
104–319
O-RING; PTFE r
2
110
Y
188–621
LABEL, warning
1
111
112–182
MUFFLER
1
113
None
Not Used
0
114
112–257
NUT, hex; M8 x 1.25; sst
8
Seat Parts List (Matrix Column 4)
9
A
Parts
Ball Parts List (Matrix Column 5)
Diaphragm Parts List (Matrix Column 6)
Digit
Ref.
No.
Part No.
Description
Qty
Digit
Ref.
No.
Part No.
Description
Qty
1
301*
112–088
BALL; PTFE r
4
1
401*
188–606
2
2
301*
112–254
BALL; acetal
4
DIAPHRAGM, backup;
Hytrelr
3
301*
103–869
BALL; 316 stainless steel
4
402*
112–181
PACKING, u-cup; nitrile
2
4
301*
102–973
BALL; 440C stainless
steel
4
403*
188–605
DIAPHRAGM; PTFE r
2
401*
188–606
DIAPHRAGM; Hytrelr
2
402*
112–181
PACKING, u-cup; nitrile
2
401*
188–857
DIAPHRAGM; Santoprene
2
402*
112–181
PACKING, u-cup; nitrile
2
401*
188–859
DIAPHRAGM; buna-N
2
402*
112–181
PACKING, u-cup; nitrile
2
401*
188–858
DIAPHRAGM; Viton
2
402*
112–181
PACKING, u-cup; nitrile
2
5
5
301*
112–089
BALL; Hytrelr
4
6
301*
112–092
BALL; Santoprene
4
7
301*
112–090
BALL; buna-N
4
8
301*
112–184
BALL; Viton
4
6
7
8
Dimensional Drawings
FRONT VIEW
6.0 in.
(152 mm)
PUMP MOUNTING
HOLE PATTERN
12.0 in.
(305 mm)
1/2 npt(f)
Air Inlet
1
1 npt(f)
Optional
Fluid Outlet
Four 0.5 in.
(12.5 mm)
diameter holes
5.0 in.
(127 mm)
5.5 in.
(139.5 mm)
12.28 in.
(312 mm)
14.0 in.
(355.5 mm)
13.28 in.
(337.5 mm)
9.1 in.
(231.1 mm)
1
1
1 npt(f)
Optional
Fluid Inlet
3/4 npt(f)
Air Exhaust
(muffler
included)
1.0 in.
(25.5 mm)
.125 in.
(3 mm)
5.5 in.
(139.5 mm)
7437A
1 npt(f)
Fluid
Outlet
3.95 in.
(100 mm)
On aluminum pumps only.
WALL BRACKET
MOUNTING HOLE PATTERN
(Viewed from Wall)
5.38 in.
(136.7 mm)
SIDE VIEW
45°
6.24 in.
(158.5 mm)
02681
Four 0.437 in. (11.1
mm)
diameter holes
5.0 in.
(127 mm)
9.25 in.
(235 mm)
1 npt(f)
Fluid Inlet
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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, full flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 dBa
* Sound Power Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 dBa
* Noise Level at 70 psi and 50 cpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 dBa
Maximum operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150_F (65.5_C);
200_F (93.3_C) for models with PTFE r diaphragms
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt(f)
Fluid inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1” npt(f)
Fluid outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1” npt(f)
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vary by Model. See pages 24–25.
Non-wetted external parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aluminum, 302 stainless steel, polyester (labels)
Weight
Aluminum pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 lb (8.2 kg)
Stainless steel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 lb (15.0 kg)
PTFE , Vitonr, and Hytrelr
Santoprener is a registered trademark of the Monsanto Co.
Kynarr is a registered trademark of Atochem North America, Inc.
Loctiter is a registered trademark of the Loctite Corporation.
*
Noise levels measured with the pump mounted on the floor, using Rubber Foot Kit 236–452. Sound power
measured per ISO Standard 9614–1.
Performance Chart
Example of Finding Pump Air Consumption and Air Pressure at a Specific Fluid Delivery and Discharge Head:
To supply 20 gpm (76 liters) fluid flow (horizontal scale) at 40 psi (0.28 MPa, 2.8 bar) discharge head pressure (vertical scale) requires approximately 20 scfm (0.56 m#/min) air consumption at 70 psi (0.48 MPa, 4.8 bar) inlet air pressure.
psi
feet
(MPa, bar)
(meters)
280
120
(85.3)
A
(0.8, 8)
INLET AIR PRESSURES
A 120 psi air (0.8 MPa, 8 bar)
B 100 psi air (0.7 MPa, 7 bar)
240
C 70 psi air (0.48 MPa, 4.8 bar)
(73.2)
100
E
D 40 psi air (0.28 MPa, 2.8 bar)
B
(0.7, 7)
200
(61.0)
F
80
(0.56, 5.6)
160
(48.8)
C
60
(0.42, 4.2)
120
(36.6)
G
40
(0.28, 2.8)
80
(24.4)
40
(12.2)
20
(0.14, 1.4)
0
0
AIR CONSUMPTION
E 10 scfm (0.28 m#/min)
F 20 scfm (0.56 m#/min)
G 30 scfm (0.84 m#/min)
H 40 scfm (1.12 m#/min)
D
0
H
5
(19)
10
(38)
15
(57)
20
(76)
25
(95)
30
(114)
35
(132)
40
(151)
45
(170)
FLUID FLOW GPM (lpm)
TEST CONDITIONS
Pump tested in water withPTFE r diaphragm and
inlet submerged.
KEY
FLUID PRESSURE AND FLOW
SCFM AIR CONSUMPTION
Manual Change Summary
This manual went from Rev. L to Rev. M to make the following changes:
D Retorquing instructions are changed on pages 4 and 11.
D Ref. No. 3 in the Air Motor Parts List on page 24 is changed to Part No. 112–179 and is not included in Air
Valve Repair Kit 236–273.
D Ref. No. 6 in the Seat Parts List on page 26 is changed from Part No. 190–212 to 191–595.
D HytrelR ball (Ref. No. 5) Part No. 112–089 is added to the Ball Parts List on page 27.
D BSPT threaded inlet manifold (Ref. No. 102) and outlet manifold (Ref. No. 103) are added to Pump Matrix on
page 22 and Fluid Section Parts List on page 26.
308-479
31
Graco Standard 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 by an authorized Graco distributor 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 twelve months 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 two (2) 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.
Graco Phone Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–367–4023 Toll Free
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.
Sales Offices: Minneapolis, Detroit, Los Angeles
Foreign Offices: Belgium, Canada, England, Korea, France, Germany, Hong Kong, Japan
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN
55440–1441
http://www.graco.com
e1998–1994 Graco Inc. 308–479 April 1998 PRINTED IN U.S.A.

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