Graco Husky 1040 Operation manual

Instructions - Parts List
ACETAL, POLYPROPYLENE, AND PVDF
Husky™1040 Air-Operated
Diaphragm Pumps 308443ZAE
EN
1–inch AODD pump for fluid transfer applications. 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.

2308443
Table of Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Repairing the Air Valve . . . . . . . . . . . . . . . . 16
Ball Check Valve Repair . . . . . . . . . . . . . . . 18
Diaphragm Repair . . . . . . . . . . . . . . . . . . . 19
Bearing and Air Gasket Removal . . . . . . . . 23
Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Repair Kit Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . 33
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Performance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Technical Data and Performance Chart . . . . . . . . . . 35
Graco Standard Husky Pump Warranty . . . . . . . . . . 36
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Models
*NOTE: Refer to the Pump Matrix on page 26 to determine the Model No. of your pump.
NOTE: Plus Models include stainless steel center sections.
**CERTIFICATION NOTE: Acetal Pump Models D71______ and D81______ are certified:
II 2 GD
Ex h IIC 66°...135°C Gb
Ex h IIIC 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______ Polypropylene Pumps
*D82______ Polypropylene Pumps, Remote
*D75______ PVDF Pumps
*D85______ PVDF Pumps, Remote
*DR2______ Polypropylene Plus Pumps
*DS2______ Polypropylene Plus Pumps, Remote
*DR5______ PVDF Plus Pumps
*DS5______ PVDF Plus Pumps, Remote
24B754 PVDF Plus Pump with overmolded diaphragms
24B755 Polypropylene Plus Pump with overmolded diaphragms
24B756 Polypropylene Pump with overmolded diaphragms
24B757 Polypropylene Pump with overmolded diaphragms and sst seats
24B831 PVDF Pump with overmolded diaphragms

308443 3
Warnings
Symbols
Warning Symbol
WARNING
WARNING
Caution Symbol
This symbol alerts you to the possibility of serious injury
or death if you do not follow the instructions.
CAUTION
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the
instructions.
INSTRUCTIONS
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 expose
Graco hoses to temperatures above 82 °C (180 °F) or below –40 °C (–40 °F).
•Do not lift pressurized equipment.
•Comply with all applicable local, state, and national fire, electrical, and safety regulations.

WARNING
4308443
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 11.
•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 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 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 11.
•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 5
Installation
General Information
•The Typical Installations shown in Figs. 2 is only a
guide for selecting and installing system
components. Contact your Graco distributor for
assistance in planning a system to suit your needs.
•Always use Genuine Graco Parts and Accessories.
•Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 29–31.
WARNING
1. Read TOXIC FLUID HAZARD 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
fasteners. Although pump use varies, a general
guideline is to retorque fasteners every two months.
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.

6308443
Grounding
WARNING
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 mm2)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 at 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.
Fig. 1
•Air and fluid hoses: Use only grounded hoses with a
maximum of 500 ft (150 m) combined hose length to
ensure grounding continuity.
•Air compressor: Follow the manufacturer’s
recommendations.
•All solvent pails used when flushing: Follow the local
code. Use only 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.
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 not
conductive. Attaching the ground wire to the
grounding screw will ground only the air motor. When
pumping conductive flammable fluids, always ground
the entire fluid system by making sure the fluid
system has an electrical path to a true earth ground
(see Fig. 2). Never use a polypropylene or PVDF
pump with non-conductive flammable fluids as
specified by your local fire protection code.
US Code (NFPA 77 Static Electricity) recommends a
conductivity greater than 50 x 10-12 Siemans/meter
(mhos/meter) over your operating temperature range
to reduce the hazard of fire. Consult your fluid
supplier to determine the conductivity or resistivity of
your fluid. The resistivity must be less than 2 x 1012
ohm-centimeters.
To reduce the risk of static sparking, ground the
pump and all other equipment used or located in the
pumping area. Check your local electrical code for
detailed grounding instructions for your area and type
of equipment.
Y
W

308443 7
Installation
Air Line
WARNING
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 accesso-
ries 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 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.
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
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 6 for
installation instructions)
ECBA
N
F
SKL
H
G
J
R
D
Y
FLOOR MOUNT TYPICAL INSTALLATION
Fig. 2 _____________________________________________________________________________________
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.

8308443
Installation
Mountings
CAUTION
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.
5. Prolonged exposure to UV radiation will degrade
natural polypropylene components of the pumps. To
prevent potential injury or equipment damage, do
not expose pump or the plastic components to direct
sunlight for prolonged periods.
Installation of Remote Pilot Air Lines
1. Refer to Parts Drawings. Connect air line to pump
as in preceding steps.
2. Connect 1/4 in. O.D. tubing to push type connectors
(14) on air motor of pump.
NOTE: by replacing the push type connectors, other
sizes or types of fittings may be used. The new fittings
will require 1/8 in. npt threads.
3. Connect remaining end of tubes to external air
signal, such as Graco’s Cycleflo (P/N 195264) or
Cycleflo II (P/N 195265) controllers.
NOTE: the air pressure at the connectors 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 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 34 for maximum
suction lift (wet and dry).
Fluid Outlet Line
WARNING
1. Use grounded fluid hoses (L). The pump fluid out-
let (S) is 1” npt(f). See Fig. 5. Refer to Flange Con-
nections on page 9.
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.
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 11.
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.

308443 9
Installation
Flange Connections
The fluid inlet and outlet ports are 1” raised face flanges.
Connect 1” flanged plastic pipe to the pump as follows.
You will need:
•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.
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
KEY
A Flanged plastic pipe
B PTFE gasket
C Bolt
D Lockwasher
E Flat washer
F Nut
R 1”fluid inlet flange
S 1” fluid outlet flange
E
FS
B
A
E
D
C
R
31
42
Torque to 10 to 15 ft-lb (14-20 N-m).
Do not over-torque.
1
1
1
Fig. 3

10 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 32.
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
101 Covers
102 Fluid inlet manifold
103 Fluid outlet manifold
106 Manifold screws
112 Manifold screws
Acetal Model Shown
N
P
103
106 S
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
V1
2
3
Fig. 5
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.