Graco Husky 1050HP Use and care manual

Repair/Parts
Husky™ 1050HP 2:1
Air-Operated Diaphragm Pump 334390B
EN
1–inch high-pressure pump with modular air valve for fluid transfer applications. For professional use
only.
Important Safety Instructions
Read all warnings and instructions in this manual and in your
Operation manual. Save these instructions.
Maximum Fluid Working Pressure:
250 psi (1.72MPa,17.2bar)
Maximum Air Input Pressure:
125 psi (0.86 MPa, 8.6 bar)
PROVEN QUALITY. LEADING TECHNOLOGY.
Springer Pumps, LLC
Telford, PA 18969
Tel: [phone] / Int'l: 215-949-2900
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Contents
Related Manuals ................................................ 2
Ordering Information........................................... 3
Configuration Number Matrix............................... 4
Warnings ........................................................... 5
Troubleshooting.................................................. 8
Repair................................................................ 10
Pressure Relief Procedure............................ 10
Replace Complete Air Valve ......................... 10
Replace Seals or Rebuild Air Valve ............... 12
Replace Complete High/Low Valve ............... 14
Replace Seals or Rebuild the High/Low
Valve ............................................. 15
Check Valve Repair ..................................... 16
Diaphragm and Center Section Repair........... 17
Torque Instructions ............................................. 24
Notes................................................................. 25
Parts.................................................................. 26
Notes................................................................. 45
Technical Data ................................................... 46
Fluid Temperature Range.................................... 47
Graco Standard Husky Pump Warranty................ 48
Related Manuals
Manual No. Description
334014 Husky 1050HP 2:1 Air-Operated Diaphragm Pump, Operation
2334390B
Springer Pumps, LLC
Telford, PA 18969
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Ordering Information
Ordering Information
To Find Your Nearest Distributor
1. Visit www.graco.com.
2. Click on Where to Buy and use the Distributor
Locator.
To Specify the Configuration of a New
Pump
Please call your distributor.
To Order Replacement Parts
Please call your distributor.
Distributor Note
1. To find part numbers for replacement parts:
a. Use the 20–digit number from the ID plate
on the pump.
b. Use the Configuration Number Matrix on the
next page to understand which parts are
described by each digit.
c. Refer to the main Parts illustration and to the
Parts/Kits Quick Reference. Follow the page
references on these two pages for further
ordering information, as needed.
2. Please call Graco Customer Service to order.
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Configuration Number Matrix
Configuration Number Matrix
Check the identification plate (ID) for the 20–digit
Configuration Number of your pump. Use the
following matrix to define the components of your
pump.
Sample Configuration Number:
1050HP A01A A1 SS SP SP PT
Pump Model Center Section
and Air Valve
Manifolds Seats Balls Diaphragms Manifold
O-Rings
Pump Center Section and Air Valve
Material
Air Valve Manifolds
A1 Aluminum, standard ports, npt
A2 Aluminum, standard ports, bsp
S1 Stainless steel, standard ports, npt
1050HP
Aluminum
Aluminum A01A Standard
S2 Stainless steel, standard ports, bsp
Check Valve Seats Check Valve Balls Diaphragm Material Manifold O-Rings
GE Geolast®CW Polychloroprene
Weighted
BN Buna-N PT PTFE
SP Santoprene®GE Geolast CO Polychloroprene
Overmolded
SS 316 Stainless Steel SP Santoprene PT PTFE/Santoprene
Two-Piece
SS 316 Stainless Steel SP Santoprene
4334390B
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Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer backtothese
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
•Grounda
ll equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use
equipment until you identify and correct the problem.
• Keepaw
orking fire extinguisher in the work area.
• Route exhaust away from all ignition sources. If diaphragm ruptures, fluid may be exhausted
with air.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin
and cause serious injury.
•Foll
ow the Pressure Relief Procedure when you stop spraying/dispensing and before
cleaning, checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
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Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
•Turnoffal
l equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
•Makesure
all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious
chemical reaction and equipment rupture. Failure to follow this warning can result in death,
serious injury, or property damage.
• Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon
solvents or fluids containing such solvents.
• Do not use chlorine bleach.
•Manyo
ther fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure
due to the thermal expansion. Over-pressurization can result in equipment rupture and serious
injury.
• Open a valve to relieve the fluid expansion during heating.
•Rep
lace hoses proactively at regular intervals based on your operating conditions.
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Warnings
WARNING
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing
parts.
•SeeTechnical Data in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into
the air.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:
•Prote
ctive eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
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Troubleshooting
Troubleshooting
Problem Cause Solution
Pump is running too fast, causing
cavitation before prime.
Reduce air inlet pressure.
Check valve ball severely worn or
wedged in seat or manifold.
Replace ball and seat.
Seat severely worn. Replace ball and seat.
Outlet or inlet clogged. Unclog.
Inlet or outlet valve closed. Open.
Inlet fittings or manifolds loose. Tighten.
Pump cycles but will not prime.
Manifold o-rings damaged. Replaceo-rings.
Pump cycles at stall or fails to hold
pressure at stall.
Worn check valve balls, seats, or
o-rings.
Replace.
Air valve is stuck or dirty. Disassemble and clean air valve.
Use filtered air.
Check valve ball severely worn and
wedged in seat or manifold.
Replace ball and seat.
Pilot valve worn, damaged, or
plugged.
Replace pilot valve.
Air valve gasket damaged. Replace gasket.
Dispensing valve clogged. Relieve pressure and clear valve.
Pump will not cycle, or cycles once
and stops.
High/Low valve shift lever is not fully
seated into the High or Low position.
Shift lever all the way into either
High or Low position.
Clogged suction line. Inspect; clear.
Sticky or leaking check valve balls. Clean or replace.
Diaphragm ruptured. Replace.
Restricted exhaust. Remove restriction.
Pilot valves damaged or worn. Replace pilot valves.
Air valve damaged. Replace air valve.
Air valve gasket damaged. Replace air valve gasket.
Air supply erratic. Repair air supply.
Pump operates erratically.
Exhaust muffler icing. Use drier air supply.
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Troubleshooting
Problem Cause Solution
Suction line is loose. Tighten.
Diaphragm ruptured. Replace.
Loose manifolds, damaged seats or
o-rings.
Tighten manifold bolts or replace
seats or o-rings.
Pump cavitation. Reduce pump speed or suction lift.
Air bubbles in fluid.
Loose diaphragm shaft bolt. Tighten.
Diaphragm ruptured. Replace.
Exhaust air contains fluid being
pumped. Loose diaphragm shaft bolt. Tighten or replace.
Moisture in exhaust air. High inlet air humidity. Use drier air supply.
Worn air valve cup or plate. Replace cup and plate.
Damaged air valve gasket. Replace gasket.
Damaged pilot valve. Replace pilot valves.
Pump exhausts excessive air at
stall.
Worn shaft seals or bearings. Replace shaft seals or bearings.
Air valve or fluid cover screws loose. Tighten.
Diaphragm damaged. Replace diaphragm.
Air valve gasket damaged. Replace gasket.
Pump leaks air externally.
High/Low valve shift lever is not fully
seated into the High or Low position.
Shift the lever all the way into either
High or Low position.
Loose manifold screws or fluid cover
screws.
Tighten manifold screws or fluid
cover screws.
Pump leaks fluid externally from
joints.
Manifold o-rings worn out. Replace o-rings.
Pump will operate in the Low
pressure setting, but will not operate
in theHighpressuresetting.
The hoses for the High/Low valve
are not installed correctly.
Install hoses as shown in the figure
on page 10.
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Repair
Repair
Pressure Relief Procedure
Follow the Pressure Relief Procedure
whenever you see this symbol.
This equipment stays pressurized until pressure
is relieved manually. To help prevent serious
injury from pressurized fluid, such as splashing
in the eyes or on skin, follow the Pressure Relief
Procedure when you stop pumping and before you
clean, check, or service the equipment.
1. Shut off the air supply to the pump.
2. Open the dispensing valve, if used.
3. Shift the High/Low pressure lever back and forth
two times. Leave the lever in the “Low” position
as shown in Fig. 1.
Figure 1 High/Low Pressure Lever
4. Openthefluiddrainvalve(installedonthe
system) to relieve all fluid pressure. Have a
container ready to catch the drainage.
Replace Complete Air Valve
Follow these instructions to install Air Valve
Replacement 24W897.
1. Stop the pump. Follow the Pressure Relief
Procedure in the previous section.
2. Disconnect the main air line.
3. Remove four screws (217). Remove the air valve
(212). Remove the six o-rings (208, 209, and
210).
4. To repair the air valve, go to Disassemble the
Air Valve, step 2, in the next section. To install a
replacement air valve, continue with step 5.
5. Install the new o-rings (208, 209, and 210) on
the High/Low manifold, then attach the air valve.
Apply thread lubricant and torque screws (217)
to 80 in-lb (9 N•m).
6. Reconnect the main air line.
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Repair
Apply thread lubricant to threads
before assembly.
Torque screws to 80 in-lb (9 N•m).
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Repair
Replace Seals or Rebuild Air Valve
Follow these instructions to service the air valve with
one of the available repair kits. Air Valve Seal Kit
parts are marked with a †. Air Valve Repair Kit parts
are marked with a ♦. Air Valve End Cap Kit parts
are marked with a ‡. Kit 24W952 also is available to
replace the 6 o-rings between the air valve and the
High/Low manifold.
Disassemble the Air Valve
1. Perform steps 1-3 under
Replace Complete Air Valve, page 10.
2. Use a T8 Torx screwdriver to remove two
screws (309). Remove the valve plate (305), cup
assembly (312-314), spring (311), and detent
assembly (303).
3. Pull the cup (313) off of the base (312). Remove
the o-ring (314) from the cup.
4. Remove the retaining ring (310) from each end
of the air valve. Use the piston (302) to push
the end cap (307) out of one end. Remove the
u-cup seal (308) from the piston. Pull the piston
out of the end and remove the other u-cup seal
(308). Remove the other end cap (307) and the
end cap o-rings (306).
5. Remove the detent cam (304) from the air valve
housing (301).
Reassemble the Air Valve
NOTE: Apply lithium-based grease when instructed
to grease. Order Graco PN 111920.
1. Use all parts in the repair kits. Clean other parts
and inspect for damage. Replace as needed.
2. Grease the detent cam (304♦) and install into
housing (301).
3. Grease the u-cups (308♦†) and install on the
piston with lips facing toward the center of the
piston.
Lips face
down.
Lips face
up.
4. Grease both ends of the piston (302♦) and the
housing bore. Install the piston in the housing
(301), with the flat side toward the cup (313♦).
Be careful not to tear u-cups (308♦†) when
sliding piston into housing.
5. Grease new o-rings (306♦†‡) and install on the
end caps (307‡). Install the end caps into the
housing.
6. Install a retaining ring (310‡) on each end to hold
end caps in place.
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Repair
7. Grease and install the detent assembly (303♦)
into the piston. Install the o-ring (314♦) on the
cup (313♦). Apply a light film of grease to the
outsidesurfaceoftheo-ringandtheinside
mating surface of the base (312♦).
Orient the end of the base that has a magnet
toward the end of the cup that has the larger
cutout. Engage the opposite end of the parts.
Leave the end with the magnet free. Tilt the base
toward the cup and fully engage the parts, using
care so that the o-ring remains in place. Install
the spring (311♦) onto the protrusion on the cup.
Align the magnet in the base with the air inlet and
install the cup assembly. 8. Grease the cup side and install the valve plate
(305♦). Align the small hole in the plate with the
air inlet. Tighten the screws (309♦†) to hold it
in place.
9. Follow steps 5–6 under
Replace Complete Air Valve, page 10,toreplace
the seals and reattach the air valve.
Apply lithium-
based grease.
U-cup lips must
face piston.
Apply lithium-
based grease to
contact surface.
Air inlet.
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Repair
Replace Complete High/Low Valve
1. Stop the pump. Follow the
Pressure Relief Procedure, page 10.
2. Disconnect the main air line. Release the quick
disconnect fittings to remove the air manifold
hoses (108).
3. To repair the High/Low valve, go to Disassemble
the High/Low Valve, step 2, in the next section.
To install a replacement High/Low valve, continue
with step 4.
4. Remove four screws (217). Remove the air valve
(212). Remove the six o-rings (208, 209, and
210).
5. Remove four screws (217). Remove the
High/Low valve (211) and gasket (213).
6. Align the new gasket (213) on the primary center
section, then attach the new High/Low valve
(211). Apply thread lubricant and torque screws
(217) to 80 in-lb (9 N•m).
7. Install the new o-rings (208, 209, and 210) on
the High/Low manifold, then attach the air valve.
Apply thread lubricant and torque screws (217)
to 80 in-lb (9 N•m).
8. Reconnect the main air line and the air manifold
hoses (108).
Apply thread lubricant to threads before
assembly.
Torque screws to 80 in-lb (9 N•m).
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Repair
Replace Seals or Rebuild the High/Low Valve
Follow these instructions to service the High/Low
valve. High/Low Valve Seal Kit 24W949 is available
to replace o-rings 402 and 405. Kit 24W952 also is
available to replace the 6 o-rings between the air
valve and the High/Low manifold. Kit 24W950 is
available to replace the spool (404).
Disassemble the High/Low Valve
1. Follow steps 1 and 2 under
Replace Complete High/Low Valve, page 14.
2. Usea5/16inAllenwrenchtoremovetwoscrews
(407).
3. Remove the High/Low valve (406). Unscrew the
handle (403) from the spool (404), then remove
thespool. Useano-ringpicktoremoveall
o-rings (402 and 405) from the spool.
NOTE: The High/Low manifold block does not
have to be removed from the primary center
section.
Reassemble the High/Low Valve
NOTE: Apply lithium-based grease when instructed
to grease.
1. Use all parts in the seal kit. Clean other parts
and inspect for damage. Replace as needed.
2. Grease two o-rings (402) and install them in the
manifold block (401).
3. Grease and install three o-rings (402 and 405)
on the spool (404).
4. Grease the outside edge, then install the spool
(404) in the High/Low valve (406). Install the
lever (403).
5. Use two screws (407) to reattach the High/Low
valve. Torque to 340–360 in-lb (38–41 N•m).
6. Reconnect the main air line and the air manifold
hoses (108).
Apply lithium-based grease.
Torque to 340–360 in-lb (38–41 N•m).
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Repair
Check Valve Repair
NOTE: Kits are available for new check valve balls
and seats. See Seats and Check Balls
to order kits in the material(s) desired. O-ring and
fastener kits also are available.
NOTE: To ensure proper seating of the check balls,
always replace the seats when replacing the balls.
Also, replace the o-rings every time the manifold is
removed.
Disassemble the Check Valve
1. Follow the Pressure Relief Procedure, page 10.
Disconnect all hoses.
2. Remove the pump from its mounting.
3. Usea10mmsocketwrenchtoremovethe
manifold fasteners (5), then remove the outlet
manifold (3).
4. Remove the o-rings (9), seats (7), and balls (8).
5. Remove the nuts (27).
6. Turn the pump over and remove the inlet
manifold (4).
7. Remove the o-rings (9), seats (7), and balls (8).
Reassemble the Check Valve
1. Clean all parts and inspect for wear or damage.
Replace parts as needed.
2. Reassemble in the reverse order, following all
notes in the illustration. Put the inlet manifold on
first. Be sure the ball checks (7-9) and manifolds
(3, 4) are assembled exactly as shown. The ball
must seat on the chamfered side of the seat.
The arrows (A) on the fluid covers (2) must point
toward the outlet manifold (3).
Figure 2 Check valve assembly
Torque to 100 in-lb (11.3 N·m).
Follow torque sequence. See
Torque Instructions, page 24.
Arrow (A) must point toward outlet
manifold
The chamfered side of the seat must face
the ball.
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Repair
Diaphragm and Center Section Repair
NOTE: See Diaphragms
for replacement diaphragm kits. Center Rebuild
Kit 24W946 also is available. Parts included in the
Center Rebuild Kit are marked with an *. For best
results, use all kit parts.
Disassemble the Fluid Diaphragms
1. Follow the Pressure Relief Procedure, page 10.
2. Remove the manifolds and disassemble
the ball check valves as explained in
Check Valve Repair, page 16.
3. Remove the muffler (18).
4. Usea10mmsocketwrenchtoremovethefluid
cover screws (5), then remove the fluid covers
(2).
5. Bolt-Through Diaphragms: Use a 15 mm socket
wrench to remove the diaphragm shaft bolt (14)
on one side of the pump. If the shaft (206)
remains attached to the bolt, use a wrench on
the flats of the shaft to remove it. Then, remove
all parts of that diaphragm assembly.
Overmolded Diaphragms: The diaphragm (12)
on one side of the pump will screw off by hand.
The diaphragm setscrew should remain attached
to the diaphragm. If the shaft (206) remains
attached to the diaphragm setscrew, use a
wrench on the flats of the shaft to remove it.
Remove the air side diaphragm plate (11).
6. Repeat for the other diaphragm.
Disassemble the Center Section
1. Usea10mmsock
et wrench to remove the
screws (5), then separate the primary air module
(101) from the secondary air module (102).
2. Remove the diaphragm (109), the air plates (103
and 105), and the set screw (104).
3. Inspect the diaphragm shafts (206) for wear or
scratches. If damaged, inspect the bearings
(203) in place. If they are damaged, use a
bearing puller to remove them.
NOTE: Do not remove undamaged bearings.
4. Useano-ringpicktoremovetheu-cuppackings
(202) from the primary air module and the
secondary air module. Bearings (203) can
remain in place.
5. If necessary, use a box end wrench to remove
the pilot valves (205, primary air module) or
the secondary pilot plugs (220, secondary air
module).
6. Remove the pilot valve cartridges only if
necessary due to a known or suspected problem.
After removing pilot valves (primary side) or
secondary pilot plugs (secondary side), use a
hex to remove the cartridges (204), then remove
cartridge o-rings (219). If stripped, cross two
screwdrivers in the shape of an X. Insert the
blades into the area around the 10 mm hex.
Revolve the blades against each other while
holding the tips against the outer area of the
recess to unscrew the cartridge.
NOTE: Do not remove undamaged pilot valve
cartridges.
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Repair
Reassemble the Center Section
Follow all notes in the illustrations. These notes
contain important information.
NOTE: Apply lithium-based grease whenever
instructed to grease.
1. Clean all parts and inspect for wear or damage.
Replace parts as needed.
NOTE: Follow Steps 2–5 for both the Primary Air
Module and the Secondary Air Module.
2. If removed, grease and install the new pilot valve
cartridges (204*) and cartridge o-rings (219*).
Screw in until seated.
NOTE: Cartridges (204*) must be installed before
pilot valves (205*) or secondary pilot plugs (220*).
3. Grease and install the pilot valves (205*, primary
side) or secondary pilot plugs (220*, secondary
side). Torque to 20–25 in-lb (2–3 N•m) at 100
rpm maximum. Do not overtorque.
4. Grease and install the diaphragm shaft u-cup
packings (202*) so the lips face out of the
housing.
5. If removed, insert the new bearings (203*) into
the primary air module and/or the secondary
air module. Use a press or a block and rubber
mallet to press-fit the bearing so it is flush with
the surface of the module.
18 334390B
Springer Pumps, LLC
Telford, PA 18969
Tel: [phone] / Int'l: 215-949-2900
Fax: [phone] / Int'l: 215-721-1296
shop.springerpumps.com
[email protected]

Repair
Primary Air Module
Secondary Air Module
1Apply lithium based grease.
2Lips must face out of housing.
3Cartridges (204) must be installed before pilot valves (205) or secondary pilot plugs (220).
4Torque to 20-25 in.-lb (2-3 N•m).
334390B 19
Springer Pumps, LLC
Telford, PA 18969
Tel: [phone] / Int'l: 215-949-2900
Fax: [phone] / Int'l: 215-721-1296
shop.springerpumps.com
[email protected]

Repair
Reassemble the Fluid Diaphragms
Follow all notes in the illustrations. These notes
contain important information.
NOTE: Apply lithium-based grease whenever
instructed to grease.
1. Assemble the center diaphragm section:
a. Assemble the primary side air plate (105*),
the center diaphragm (109*), and the
secondary side air plate (103*) on the set
screw (104*).
b. IMPORTANT: Themarked“Air”sideofthe
center diaphragm must face the primary air
side plate and the primary air module.
c. Install a shaft (206*) on each end.
d. Tighten until assembly is fully seated and
parts do not freely rotate.
1Rounded side faces diaphragm.
2Apply lithium based grease.
3AIR SIDE markings on center diaphragm
must face the primary air module.
4Torque to 100 in-lb (11.3 N•m).
20 334390B
Springer Pumps, LLC
Telford, PA 18969
Tel: [phone] / Int'l: 215-949-2900
Fax: [phone] / Int'l: 215-721-1296
shop.springerpumps.com
[email protected]