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s-ffiffirs
INSTRUCTI@;N
L!S
T
ORACO
First
choice when
quality
cguits.'*
308-479
,
Rev.
G
\
Supersedes Rev. A
and PCNs B td E
'
(includes
Rev. F)
1
G
T
;
.r,,Ti,'
.---.:-'
;
ALUMINUM AND STAINLESS STEEL
!
''n,Husky
*'
1040
Air-Operated
.
:,.t.
i
J
.,;
I
:.
l;r,f
:.;
;'
Di,aphrcigm
,Pumps
120
psi (0.84
MPi,'8.4 bar)-:AttaxiiAuq
Fluid WorXing
Pressure
120
psi
(0.84
MPa,
8.4
ba\
Maximum Air lnput Pressure
lr
I
(
,t
'-1
'
*Model
No, D73-_
Aluminum Pumps
:
*Modet
tto. oza-T stainless steel
Fr-p=
*NOTE:
Referto
the Pump'Matrix on
page
22 to
determine the Model
No.
of
your pump.
US
and Foreign Patents Pending
1
ii
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C€
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.UE
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Aluminum
Model Shown
v2632
GRACO INC.
,.,,s
.
...
i,.\
4:!
"(
P.O. BOX'.I2t41
MINNEAPOLIS,
MN
5540-1441
[,
r1a_i
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,
*..,@cgflYRtcHT
1994, GRACO
tNC.
..
--*-
-:9raco
lirc. is registered
to l.S. EN ISO 9001
.\.!
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j..'
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Y'
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This manual
contains important
warnings and information.
READ AND
KEEP FOR REFERENCE.
-
INSTRUCNONS
_",'m
-'
t
,\
Table
of
Contents
Safety
Warnings
Symbols
lnstallation,..,
Qperation:....
Maintenance . . .
Troubleshooting
Service,
Pump Matrii.. .
Repair Kit Matrix
Parts .
Dimensional Drawings . :.. :. :.. i. . :.
Technical Data and
Performance
Chart
Warranty
Graco Phone Number
Warning Symbol
This
symbol
alerts
you
to the
possibility
of serious
injury or death if
you
do not follow the instructions.
'Caution
Symbot
This
symbolalerts
you
to the
possibility
of damage to
or destruction of equipment if
you
do not follow the
instructions.
*
'Ji1'"
Symbols
r ' o1'
,ltt
2
2
4
10
11
"
12
14
22
23
24
28
29
32
32
[W
A
CEUTION
EQUIPMENT MISUSE HAZARD
Equipment misuse
can cause
the
equipment
to'rupture
or
malfunction
and
result
in serious injury.
o
This
equipment is
for
professional
use
only.
.
Read all
instruction
manuals, tags, and labels before
operating the equipment.
o
Use the equipment only for its
intended
purpose.
lf
you
are not sure, call
your
Graco
distributor:
o
Do
not alter
or
modiff this
equipment.
.
Check equipment daily. Repair or replace worn or damaged
parts
immediately.
o
Do not
exceed
the maximum working
pressure
of
the lowest
rated component in
your
system.
This
equipment
has a 120
psi (0.84
MPa,8.4 bar) maximum
working
pressure
at 120
psi
(0.84
MPa,
8.4
bar) maximum incoming air
pressure.
o
Use
nuiOs
and solvents which are compatible with the equipment wetted
O"nr.
*"r", to
the
Tech-
nical Data seclion of all equipment manuals. Read the fluid and
solvent manufacturer's wam-
i
ings.
i
o
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
.
Do not use hoses to
pull
equipment.
o
Route hoses away from traffic areas, sharp edges, moMng
parts,
and hot
surfaces. Do not ex-
pose
Graco
hoses
to
temperatures
above 82'C
(180'D
or below
*40"C
(*40"D.
o
Do not lift
pressurized
equipment.
.
Comply
with
all
applicable local,
state, and national fire, electrical, and
safety
regulations.
2
308-479
I
?
a
-
A
N
ii*til*u
#fl\
TOXIC FLUID
HAZARD
Hazardous
fluid
or.toxic
fumes
can cause serious injury or death if
splashed in the
eyes or on the
'r
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 nationalguidelines.
:
.
Always wear
protective
eyewear,
gloves,
clothing
and respirator
as recommended
by the
fluid
and solvent manufacturer.
.
o
Pipe and dispose
of the exhaust air safely, away fom
people,
animals, and food handling
areas.
lf the diaphragm fails, the fluid
is exhausted along with the air.
See Air Exhaust
Ventilation on
page
8.
ilH:::;il::::]l*ffi:,
names
orsparks can cause,
r,,.",.0o,"
conoitiqn ano
result in a fire
or explosion and serious injury.
o
Ground the
equipment. Referto Grounding on
page
4.
o
lf
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
identiff and
correct
the
problem.
I
o
Provide fresh air ventilation to
avoid the buildup of flammable fumes from
solvents or the fluid
being
sprayed.
.
Pipe and dispose
of
the
exhaust.air safely, away,fom,all'iourees of ignition. lf the'diaphragm'
fails, the fluid is
exhausted
along
with the air. See Air Exhaust Ventilation
on
page
8.
o
Keep the work area free
of
debris, including
solvent,
rags,
and
gasoline.
l'
.
Electrically disconnect all
equipment
in the
work area.
j
'i
o
Extinguish all
open
flames
or
pilot
lights in
the work area.
l
o
Do not
smoke in the work area.
:
:
,
"
i
o
Do not turn
on or off
any light
switch
in the
work area while operating or if fum'es are
present.
o
Do not
operate
a
gasoline
engine in the work area.
,
nt
N,/
m
C
Ui:
.t
308-479 3
.l
lnstal,lation
General lnformation
.
The Typical lnstallations shown
in
Figs.
24 are
only
guides
for selecting and installing system
components. Contact
your
Graco distributor
for
assistance in
planning
a system
to
suit
your
needs.
o
Always
use
Genuine Graco
Parts and Accessories.
Referto Product Data Sheet 305-588.
o
Reference numbers and letters in
parentheses
refer
to the callouts
in the figures and the
parts
lists on
pages
24-25.
o'
Aluminum Husky 1040 Pump
Model No.239-823,
with straight-thread manifolds,
is available and can
be
ordered separately.
Grounding
To
reduce the risk
of
static"sparking,
ground
the
pump
and
all
oth'er 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.
o
Pump:
Connect
a
ground
wire and
clamp
as shown
in Fig. 1. Loosen the
grounding
lug locknut
(VV)
and
washer
(X).
lnsert
one end of a
12
ga
(1.5
mm2)
minimum
ground
wire
(Y)
into the slot in the
lug
(4
and tighten the locknut securely. Connect
the
clamp
end of the
ground
wire to a true earth
ground.
Order
Part No.
222-011 Ground
\Mre and Clamp.
Z
x
W
Fig. 1
02646
o
Air and fluid hoses: Use
only
grounded
hoses with
a
maximum
of 500
ft
(150
m)
combined
hose
length to
ensure
grounding
continuity.
o
Air
compresson
Follow
the
manufacturer's
recommendations.
o
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.
.
Fluid
supply container:
Follow thg local,code
.-1.,,s
1u.li.
*1!
4
Y
+
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.
1. Read TOXIC FLUID HAZARD on
page
3
2. Use
fluids and
solvents
which are compatible
with
the
equipment
wetted
parts.
Refer
to the
Technica! Data section of
all equipment manu-
als. Read the
fluid
and solvent
manufacturer's
warnings.
W
nt
Nl/
FIRE AND EXPLOSION
HAZARD
This
pump
must be
grounded.
Before
operating the
pump, ground
the system
as explained below.
Also, read the sec-
tion FIRE AND EXPLOSION
HAZARD,
on
page
3.
W
4 308-479
!nstallation
Mountings
A
CEUTION
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.
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.
Air Line
lnstall the air line accessories
as shown in Figs.
24 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. lnstall 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.
''
Lbcate one bleed-type mlster 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. The air line filter
(F)
removes harmful dirt and
.
moisture from the
compressed air supply.
2. lnstall
a
grounded,
flexible
air
hose
(A)
between
the accessories
and lhe 112 npt(f)
pump
air
inlet
(N).
See
Fig.5.
Use a minimum
3/8'(9.5
mm) lD
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
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. lf the fluid inlet
pressure
to the
pump
is more than
25o/o
of
lhe
outletworking
pressure,
the ballcheck
valves will not
close
fast
enough, resulting in
inefiicient
pu
mp operation.
3. At inlet fluid
pressures
greater
than 15
psi
(0.1
MPa, 1 bar),
diaphragm life will be
shortened.
I
4. See the Technical
Data on
page
29 for maximum
suction lift
(wet
and dry)
Fluid
Outlet
Line
1. Use
grounded
fluid
hoses
(L).
The
pump
fluid
outlet
(S)
is 1l npt(f).
See
Fig.
5. Screw the fluid
fitting into the
pump
outlet securely.
i
.t''
2. lnstall a fluid drbin
valve
(J)
near the fluid
outlet.
See
the
WARNING above, and Figs. 24
on
pages
6 and 7.
3. lnstalla shutoff valve
(K)
in the fluid outlet line
A bleed-type master air valve
(B)
is
required in
your
system to'relieve airtrapped
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.
W
D
7
A
fluid drain valve,
(J)
is required to relieve
pres-
sure in the hose if it is
plugged.
The drain valve
l
reduces the risk
of serious injury including
splash-
ing in the eyes or
on
the
skin, or contamination
I
from hazardous
fluids when relieving
pressure.'ln=
stall the valve close to the
pump
fluid
outlet. See
Fig.
3.
IIIAENINTC
308-479
r
5
'I
lnstallation
KEY FOR FIG.2
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
G Fluid Suction Line
H
Bung
Adapter
J Fluid Drain Valve
(required)
K Fluid ShutoffValve
L Fluid Line
Y Ground V1/ire
(required;
see
page
4
.
for installation instructions)
TYPICAL BUNG-MOU
NT INSTALLATION
E F CB
A
L
D
J
Y
H
tJ
z
02648
Fig. 2
E F CB
.
TYPICAL
FLOOR-MOUNT
INSTALLATION
L
KEY FOR FIG.3
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
.
G
Fluid
Suction
Line
J
Fluid Drain Valve
(required)
K Fluid ShutoffValve
L Fluid
Line
Y
Ground
Wre
(required;
see
page
4
for installation
instructions)
A
K
J
Y
Fig.3
.
6 308-479
G
D
02651
I
!nstallation
KEY FOR FIG.4
A Air
Supply
Line
B Bleed-Type Master Air Valve
(required
for
pump)
C
Air Regulator
D Air Line Quick Disconnect
E Master Air \hlve
(for
accessories)
F Air Line Filter
G
Fluid
Suction
Line
J Fluid Drain \hlve
(required)
K Fluid ShutofiValve
L Fluid Line
M
\
hll Mounting
Bracket
Y
Ground \Mre
(reguired;
see
page
4
for installation instructio ns)
EFCB
D
G
TYPICAL
WALL.MOU NT INSTALLATION
AK
M
J
Y
02649
Fig.4
Changing the
Orientation
of the
Fluid lnlet
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.
2. Reverse the manifold and reattach. lnstallthe
screws and torque to 120-150 in-lb
(14-17
N.m).
KEY
N 1/2 npt(f) Air lnlet Port
P Muffler;.Air Exhau$ Port is
3/4
npt(f)
R 1'npt(f) Fluid lnlet Port
S 1'npt(f)
Fluid
Outlet Port
1
06
Manifold and
Cover Screws
3 Air Valve Screws
A
A
Apply mediurn-
strength
(blue)
Loc-
tite@
or equivalent
to
the threads, and
torque to 12G-150
r
inJb
(14-17
N.m).
Torque to
38-43
in-lb
(4.4-5.0
N.m).
106
a
S
1064
R
s263?
Ag
N
P
.s'c'&f,rr:*
Fig.5
308-479 7
FIRE AND EXPLOSION HAZARD
Be sure to read and follow the warnings
and
precautions
regarding
TOXIC
FLUID HAZARD, and FIRE OR EXPLO-
,
SION
HAZARD on
page
3, before op-
erating this
pump.
Be sure the system
is
properly
ventilated
for
your
type of installation.
You must
vent
the
exhaust
to a
safe
place,
away fom
people,
animals, food handl-
ing 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
appropri-
ate container
at the
end of
the air
exhaust
line to
catch the
fluid.
See Fig. 6.
nt
Nl/
W
lnstallation
Air Exhaust Ventilation
The air exhaust
port
is
3/4 npt(D. Do
not
restrict the air
exhaust
port.
Excessive
exhaust
restriction
can cause
eriatic
pump
operation.
To
provide
a remote exhaust:
1. Remove the mufiler
(P)
from the
pump
air exhaust
port.
2. lnstall a
grounded
air exhaust hose
([)
and
connect
the mufiler
(P)
to the
other end of
the
hose. The minimum
size
for the air
exhaust
hose
is
3/4 in.
(19
mm) lD. lf a hose longer than 15 ft
(4.57
m) is required, use a larger diameter hose.
Avoid sharp bends or kinks in the hose.
3.
Place a container
(U)
at the
end of
the
air exhaust
line
to catch fluid
in
case a diaphragm ruptures.
See Fig.6.
'VENTING
EXHAUSTAIR
E
,F
C B \
i
KEY
A Air Supply Line
B Bleed-Type Masler 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
02650
A
T
D
U
P
Fig.6
"
8 308-479
Fluid Pressure
Relief Kit
KEY
R 1" npt(f)
optional
Fluid
lnlet Port
S 1" npt(f)
Optional
Fluid
Outlet Port
V Pressure Relief
Kit
A
A
A
lnstall kit between fluid inlet and outlet manifolds.
Connect fluid inlet line here.
Connect fluid
outlet line here.
!nstallation
As
r\n
vl\
02653
Fig.7
A
CNUTION
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.
Thermalexpansion
of
fluid in
the outlet line
can cause overpressurization.
This
can occurwhen 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 in-
take valve of the
piston
pump
does not close, causing fluid to back up in the outlet line.
308-1479 I
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
'
o
Check,
clean
or service
any
system equipment
o
lnstall or clean fluid nozzles
W
Operation
Pressure Relief Procedure
1.
Shut off
the airto the
pump.
2.
Open
the dispensing valve,
if
used
3. Open
the fluid drain valve to relieve allfluid
pressure,
having a
container
ready to catch the
drainage.
Flush the Pump Before
First Use
The
pump
was tested in water.
lf 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
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
flttings securely.
3. Place the
suction
tube
(if
used).in the fluid to be,
pumped. ;
NOTE: lf
the
fluid inlet
pressure
to the
pump
is more
lhan
25% of the butlet
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. lf
the
fluid hose has a dispensing device, hold it
'
open
while
continuing
with the following
step.
8. Slowly open
the air regulator
(C)
untilthe
pump
-
starts to cycle.
Allow the
pump
to
cycle slowly
until
all air is
pushed
out of
the lines and the
pump
is
primed.
lf
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
At
the end of the work shift,
relieve the
pressure
/
To reduce the risk of serious injury whenever
you
are
instructed to relieve
pressure,
always
follow
the
Pressure Relief Procedure at left.
IIIr/TENINTC
7
TOXIG 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.
lf dropped, the
fluid
section
may rupture. Always follow the Pressure
Relief
Procedure Warning above
before lifting the
pump
tlilillir
fiil
ITAENINTC
i
10 308-479
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