Graco DR2, DR5, D72, D82, D81 User Manual
...
Instructions – Parts List
ACETAL, POLYPROPYLENE, AND PVDF
Huskyt1040 Air-Operated
Diaphragm Pumps
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 Acetal Pumps ( certified)
*Model No. D81 Acetal Pumps, Remote ( certified)
*Model No. D72 Polypropylene Pumps
*Model No. D82 Polypropylene Pumps, Remote
*Model No. D75 PVDF Pumps
*Model No. D85 PVDF Pumps, Remote
*Model No. DR2 Polypropylene Plus
Pumps
*Model No. DS2 Polypropylene Plus
Pumps, Remote
*Model No. DR5 PVDF Plus Pumps
*Model No. DS5 PVDF Plus
Pumps, Remote
308443Z
*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.
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1994, Graco Inc. is registered to I.S. EN ISO 9001
04155B
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.
INSTRUCTIONS
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
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 ex-
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
2 308443
pose Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
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 compo-
nents. 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.
Tightening Screws Before First Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque Se-
quence, 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.
4 308443
Grounding
Installation
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, al-
ways 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
ter (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.
–12
Siemans/me-
W
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 recom-
mendations.
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.
02646B
308443 5
Installation
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. 2.
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.
c. The air line filter (F) removes harmful dirt and
moisture from the compressed air supply.
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.
FLOOR MOUNT TYPICAL INSTALLATION
E
FB
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.
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 drain valve (required)
K Fluid shutoff valve
C
A
L Fluid line
N 1/2 npt(f) air inlet port
R 1” fluid inlet port
S 1” fluid outlet port
Y Ground wire (required; see page 5
for installation instructions)
Fig. 2
6 308443
DK
SN
L
Y
H
J
R
G
04170B
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 10.
1. Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as
well as the stress caused during operation.
2. For all mountings, be sure the pump is bolted
directly to the mounting surface.
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.
4. Rubber Foot Mounting Kit 236452 is available to
reduce noise and vibration during operation.
Installation of Remote Pilot Air Lines
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 5.
The pump fluid inlet (R) is a 1” raised face flange.
See Flange Connections on page 8.
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.
At inlet fluid pressures greater than 15 psi
(104 kPa, 1 bar), diaphragm life will be shortened.
See the Technical Data on page 32 for maximum
suction lift (wet and dry).
Fluid Outlet Line
WARNING
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.
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
Flange Connections
Installation
The fluid inlet and outlet ports are 1” raised face
flanges. Connect 1” flanged plastic pipe to the pump
as follows. You will need:
Torque wrench
Adjustable wrench
One 4.25” diameter, 1/8” thick PTFE gasket, with
four 0.62 diameter holes and a 1.15” diameter
center
Four 1/2” x 2.5” bolts
Four 1/2” spring lockwashers
Eight 1/2” flat washers
Four 1/2” nuts.
F
E
S
1. Place a lockwasher and a flat washer 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
1
3
1
Fig. 3
04404B
B
2
4
A
04405
E
D
C
R
Torque to 10 to 15 ft-lb (14-20 N-m).
1
Do not over-torque.
KEY
A Flanged plastic pipe
B PTFE gasket
C Bolt
1
D Lockwasher
E Flat washer
FNut
R 1” fluid inlet flange
S 1” fluid outlet flange
8 308443
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.
KEY
N 1/2 npt(f) air inlet port
P Muffler; air exhaust port
is 3/4 npt(f)
R 1” fluid inlet port
S 1” fluid outlet port
1
Torque to 80 to 90 in-lb (9 to 10 N-m).
See Torque Sequence, page 30.
101 Covers
102 Fluid inlet manifold
103 Fluid outlet manifold
106 Manifold screws
112 Manifold screws
103
1
106
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).
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.
KEY
R 1” fluid inlet port
S 1” fluid outlet port
V Pressure relief valve
Part No. 112119 (stainless steel)
N
P
102
Acetal Model Shown
Fig. 4
112
S
1
Install valve between fluid inlet and outlet ports.
2
Connect fluid inlet line here.
3
Connect fluid outlet line here.
S
3
101
1
V
R
2
1
R
04155B
04228B
Fig. 5
308443 9
Installation
Air Exhaust Ventilation
WARNING
FIRE AND EXPLOSION HAZARD
Be sure to read FIRE OR EXPLOSION
HAZARD and TOXIC FLUID HAZARD
on page 3, before operating this pump.
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.
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
The air exhaust port is 3/4 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
erratic pump operation.
To provide a remote exhaust:
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. See Fig. 6.
3. Place a container (U) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures.
Fig. 6
FBEC
D
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
A
U Container for remote air exhaust
T
U
P
04168A
10 308443
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
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
1. Be sure the pump is properly grounded. Refer to
Grounding on page 5.
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.
4. Place the end of the fluid hose (L) into an appropriate container.
5. Close the fluid drain valve (J). See Fig. 2.
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
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