Graco Husky 1040 Instructions-Parts List Manual Download Page 27

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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 29). 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

, the second digit is always

(zero), and the third is always

. 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 28 to 29.

Part No. 253626:

Husky 1040 HD Overmolded PTFE/EPDM Diaphragm Repair Kit.

Part No. 289224:

Husky 1040 HD Overmolded PTFE/EPDM Diaphragm Repair Kit, with new air side diaphragm

plates.

Part No. 4F396:

Husky 1040 PTFE/Santoprene Backer Diaphragm Repair Kit.

Diaphragm
Pump

Null

Shaft O-ring

- Seats

Balls

Diaphragms

D (for all pumps) 0

(for all pumps)

7 (Plastic)

- 0 (null)

0 (null)

(null)

- 1 (not used)

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)

- 6 (Santoprene

)

6 (Santoprene

)

6 (Santoprene

)

- 7 (buna-N)

7 (buna-N)

- 8 (fluoroelastomer)

8 (fluoroelastomer)

- 9 (polypropylene)

9 (not used)

- A (PVDF)

A (not used)

- G

(Geolast

)

(Geolast

)

(Geolast

)

Summary of Contents for Husky 1040

Page 1: ...s For professional use only Not approved to European explosive atmosphere requirements See Models on page 2 for a list of pump models and descriptions 120 psi 0 8 MPa 8 bar Maximum Fluid Working Pressure 120 psi 0 8 MPa 8 bar Maximum Air Input Pressure Important Safety Instructions Read all warnings and instructions in the manual Save these instructions ...

Page 2: ... T135 C Db ATEX T code rating is dependent on the temperature of the fluid being pumped Fluid temperature is limited by the materials of the pump interior wetted parts See Technical Data for the maximum fluid operating temperature for your specific pump model Model No Description D71______ Acetal Pumps see certification note below D81______ Acetal Pumps Remote see certification note below D72_____...

Page 3: ...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 compa...

Page 4: ...s condition and result in a fire or explosion and serious injury Ground the equipment Refer to Grounding on page 6 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 6 for additional information Consult your fluid supplier to determine the conductivity or resistivity of your fluid If there is any st...

Page 5: ...on page 4 2 Use fluids and solvents which are compatible with the equipment wetted parts Refer to the Technical Data section of all equipment manuals Read the fluid and solvent manufacturer s warnings Tightening Screws Before First Use Before using the pump for the first time check and retorque all external fasteners See Torque Sequence page 32 After the first day of operation retorque the fastene...

Page 6: ...l code 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 4 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...

Page 7: ...ct 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 Key A Air supply hose B 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 H Fluid supply J Fluid d...

Page 8: ...rs must be at least 30 of the air pressure to the motor for the pump to operate Fluid Suction Line 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 6 The pump fluid inlet R is a 1 raised face flange See Flange Connections on page 9 If the fluid inlet pressure to the pump is more than 25 of th...

Page 9: ...her on each bolt Refer to Fig 3 2 Align the holes in the gasket and the pipe flange with the holes in the pump flange 3 Lubricate the threads of the four bolts Install the bolts through the holes and secure with the washers and nuts 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 BOLT TIGHTENING SEQUENCE...

Page 10: ...101 R 112 102 Torque to 80 to 90ft lb 9 to 10 N m See Torque Sequence page 32 1 1 1 Fig 4 Fluid Pressure Relief Valve CAUTION KEY R 1 fluid inlet port S 1 fluid outlet port V Pressure relief valve Part No 112119 stainless steel Install valve between fluid inlet and outlet ports 1 Connect fluid inlet line here 2 Connect fluid outlet line here 3 S R V 1 2 3 Fig 5 Some systems may require installatio...

Page 11: ...phragm ruptures VENTING EXHAUST AIR KEY A Air supply line B 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 P Muffler T Grounded air exhaust hose U Container for remote air exhaust E C B A F U P D T Fig 6 FIRE AND EXPLOSION HAZARD Be sure to read FIRE OR EXPLOSION HAZARD and TOXIC FLUID HAZARD on page 4 ...

Page 12: ...er 5 Close the fluid drain valve J See Fig 2 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 flush...

Page 13: ... in the pump and damaging it Always flush the pump and follow the Pressure Relief Procedure on page 12 before storing it for any length of time Use a compatible solvent Tightening Threaded Connections Before each use check all hoses for wear or damage and replace as necessary Check to be sure all threaded connections are tight and leak free Check fasteners Tighten or retorque as necessary Although...

Page 14: ...orn 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 10 Dispensing valve clogged Relieve pressure and clear valve Pump operates erratically Clogged suction line Inspect clear Sticky or leaking balls 301 Clean or replace See page 18 Diaphragm ruptured Replace ...

Page 15: ...Worn shaft seals 402 Replace See pages 19 to 21 Pump leaks air externally Air valve cover 2 or air valve cover screws 3 are loose Tighten screws See page 17 Air valve gasket 4 or air cover gasket 22 is damaged Inspect replace See pages 16 to 17 and 23 to 24 Air cover screws 25 are loose Tighten screws See pages 23 to 24 Pump leaks fluid externally from ball check valves Loose manifolds 102 103 dam...

Page 16: ... cavity See Fig 8 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 9 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 ho...

Page 17: ...g See Fig 10 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 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 Le...

Page 18: ...e manifold 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 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 11 Be sure ...

Page 19: ...sconnect all hoses 2 Remove the manifolds and disassemble the ball check valves as explained on page 18 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 You must torque the eight long screws 106 first then the short screws 112 Torque to 130 to 150 in lb 14 to 17 N m See Torque Sequence pa...

Page 20: ...m 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 Reassembly Standard Diaphragms 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 pla...

Page 21: ...ained in step 2 This diaphragm will be lifted off the air cover at this point 6 Supply the pump with low pressure air less than 7 psi 0 05 MPa 0 5 bar The diaphragm will very slowly pull onto the air cover Find the pressure that keeps the diaphragm close enough to the secure with the screws but does not let it contact the pilot pin NOTE Do not deform the diaphragm manually The diaphragm needs unif...

Page 22: ...Rounded side faces diaphragm 401 Air Side must face center housing 1 Grease Apply medium strength blue Loctite or equivalent Torque to 20 to 25 ft lb 27to 34 N m at 100 rpm maximum Used on pumps with PTFE diaphragms only 4 24 2 104 3 401 6 403 5 105 4 24 1 3 5 6 4 3 2 1 105 19 402 1 1 403 401 104 24 1 5 4 2 3 3 6 Fig 13 ...

Page 23: ...ckings See Fig 13 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...

Page 24: ...d first Detail of Air Valve Bearings Press fit bearings flush with surface of center housing 1 Apply medium strength blue Loctite or equivalent Torque to 130 to 150 in lb 14 to 17 N m 04158 1 12 2 1 15 1 2 1 16 H 22 19 1 2 2 1 3 M 23 25 3 Fig 14 ...

Page 25: ...308443 25 Notes ...

Page 26: ... except for the serial plate and parts listed in the chart below 24B757 Polypropylene Pump This pump is the same as Model D72311 except for the serial plate and parts listed in the chart below 24B831 PVDF Pump This pump is the same as Model D75A11 except for the serial plate and parts listed in the chart below 246450 Stainless Steel Air Motor Conversion Kit Use kit 246450 and refer to instruction ...

Page 27: ...hragms 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 28 to 29 Part No 253626 Husky 1040 HD Overmolded PTFE EPDM Diaphragm Repair Kit Part No 289224 Husky 1040 HD Overmolded...

Page 28: ...ousing 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 These parts are unique to remote piloted air motor D8 and DS 3 2 4 5 16 17 6 7 8 9 1 12 10 11 20 111 15 402 19 13 11 10 17 22 14 16 18 3 110 25 24...

Page 29: ...cetal 2 16 188610 PIN pilot stainless steel 2 17 157628 O RING buna N 2 18 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 Digit Ref No Part No Description Qty 8 Same as 7 with the following exceptions 1 195921 HOUSING cen...

Page 30: ...ene 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 Digit Ref No Part No Description Qty 5 101 189378 COVER fluid ...

Page 31: ...RING PTFE 8 A 201 189723 SEAT PVDF 4 202 109205 O RING PTFE 8 G 201 194211 SEAT Geolast 4 202 109205 O RING PTFE 8 Digit Ref 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...

Page 32: ...sequence when instructed to torque fasteners 1 Left Right Fluid Cover Torque Bolts to 130 150 in lb 14 17 N m SIDE VIEW 2 Inlet Manifold Torque Bolts to 80 90 in lb 9 10 N m BOTTOM VIEW 3 Outlet Manifold Torque Bolts to 80 90 in lb 9 10 N m TOP VIEW ...

Page 33: ...308443 33 Dimensional Drawings FRONT VIEW PUMP MOUNTING HOLE PATTERN SIDE VIEW ANSI Flange Fluid Outlet 45 ...

Page 34: ...F 65 5 C Air inlet size 1 2 npt f Fluid inlet size 1 Raised Face Flange Fluid outlet size 1 Raised Face Flange Wetted parts Vary by Model See pages 29 and 31 Non wetted external partsaluminum 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 ...

Page 35: ...w left to scale to read fluid outlet pressure Air Consumption Curves A at 120 psi 0 83 MPa 8 3 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 m3 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 vert...

Page 36: ...hip 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 f...

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