Graco Hydra-Clean 1040 Parts list manual

Instructions-Parts
ChemSafe™ ChemSafe™
ChemSafe™1040 1040 1040
Air Air
Air- - -Operated Operated OperatedDiaphragm Diaphragm DiaphragmPump Pump Pump334795A
EN
1–inch 1–inch
1–inchhigh high highpurity purity puritypump pump pumpfor for forindustrial industrial industrialapplications.For applications.For applications.Forprofessional professional professionaluse use useonly. only. only.
Not Not
Notapproved approved approvedfor for foruse use usein in inEuropean European Europeanexplosive explosive explosiveatmosphere atmosphere atmospherelocations. locations. locations.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanual.Save Save
Savethese these these
instructions. instructions.
instructions.
100 psi (0.7 MPa, 7.0 bar) Maximum Air
Supply Pressure
100 psi (0.7 MPa, 7.0 bar) Maximum
Fluid Working Pressure
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
Warnings...........................................................3
Con󰘰gurationNumberMatrix...............................6
Installation..........................................................8
GeneralInformation.....................................8
TightenBolts...............................................8
TipstoReduceCavitation.............................8
MountThePump.........................................9
GroundTheSystem.....................................10
AirLines......................................................10
AirExhaustVentilation.................................11
FluidSupplyLine.........................................12
FluidOutletLine...........................................12
Operation...........................................................13
TightenBolts...............................................13
FlushthePumpBeforeFirstUse..................13
StartandAdjustthePump............................13
PressureReliefProcedure............................14
PumpShutdown..........................................14
Maintenance......................................................15
MaintenanceSchedule.................................15
Lubrication...................................................15
TightenThreadedConnections.....................15
FlushingandStorage...................................15
Troubleshooting..................................................16
Repair................................................................18
DisassembletheFluidSection......................18
DisassembletheCenterSection...................19
ReplacetheAirMotor...................................20
ReassembletheCenterSection....................20
ReassembletheFluidSection.......................21
TorqueInstructions.............................................24
Parts..................................................................25
Kits....................................................................28
Dimensions........................................................29
PerformanceCharts............................................30
TechnicalData...................................................31
GracoStandardChemSafePump
Warranty...............................................32
2
334795A

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Tohelp
prevent󰘰reandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareantistaticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
•Routeexhaustawayfromallignitionsources.Ifdiaphragmruptures,󰘱uidmaybeexhausted
withair.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
•Donotoperateelectrostaticgunsinequipmentworkarea.
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
334795A 3

Warnings
WARNING WARNING
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestMSDSfromdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
THERMAL THERMAL
THERMALEXPANSION EXPANSION EXPANSIONHAZARD HAZARD HAZARD
Fluidssubjectedtoheatincon󰘰nedspaces,includinghoses,cancreatearapidriseinpressure
duetothethermalexpansion.Over-pressurizationcanresultinequipmentruptureandserious
injury.
•Openavalvetorelievethe󰘱uidexpansionduringheating.
•Replacehosesproactivelyatregularintervalsbasedonyouroperatingconditions.
PLASTIC PLASTIC
PLASTICPARTS PARTS PARTSCLEANING CLEANING CLEANINGSOLVENT SOLVENT SOLVENTHAZARD HAZARD HAZARD
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.
•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.
•SeeTechnical Technical
TechnicalData Data Datainthisandallotherequipmentinstructionmanuals.Read󰘱uidand
solventmanufacturer’sMSDSsandrecommendations.
4
334795A

Warnings
WARNING WARNING
WARNING
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadMSDSstoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Routeexhaustawayfromworkarea.Ifdiaphragmruptures,󰘱uidmaybeexhaustedinto
theair.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
334795A 5

CongurationNumberMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number Number
Matrix Matrix
Matrix
Checktheidenti󰘰cationplate(ID)forthe
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:1040PT 1040PT
1040PT- - -P01APT3PTPTPOPT P01APT3PTPTPOPT P01APT3PTPTPOPT
1040PT 1040PT
1040PTP01A P01A P01APT3 PT3 PT3PT PT
PTPT PT PTPO PO
POPT PT
PT
PumpModelCenter
Section
andAir
Valve
Fluid
Covers
and
Manifolds
SeatsBallsDiaphragmsManifoldandSeatSeals
Pump Pump
PumpCenter Center
CenterSection Section Sectionand and andAir Air Air
Valve Valve
ValveMaterial Material Material
Fluid Fluid
FluidCovers Covers Coversand and andManifolds Manifolds Manifolds
1040 1040
1040PT PT PT
1in.PTFE
P01A P01A
P01APolypropylene
centerwithnpt
airinlet
PT3 PT3
PT3PTFE,npt
1040 1040
1040UH UH UH
1in.UHMWPE
P03A P03A
P03APolypropylene
centerwith
bsptairinlet
PT4 PT4
PT4PTFE,bspt
UH3 UH3
UH3UHMW,npt
UH4 UH4
UH4UHMW,bspt
Seat Seat
SeatMaterial Material MaterialBall Ball
BallMaterial Material MaterialDiaphragm Diaphragm DiaphragmMaterial Material MaterialManifold Manifold
Manifoldand and andSeat Seat Seat
Seal Seal
SealMaterial Material Material
PT PT
PTPTFEPT PT PTPTFEBN BN BNBunaNPT PT PTPTFE
UH UH
UHUHMWPEEP EP EPEPDM
PO PO
POPTFE/EPDMOvermolded
6 334795A

CongurationNumberMatrix
Models Models
Models
Model Model
ModelPump Pump PumpAir Air
Air& & &Fluid Fluid Fluid
Connection Connection
Connection
Threads Threads
Threads
Fluid Fluid
FluidCovers, Covers, Covers,
Seats, Seats,
Seats,& & &
Manifolds Manifolds
Manifolds
Balls Balls
BallsDiaphragm Diaphragm DiaphragmManifold Manifold
ManifoldSeal Seal Seal
24X424 24X424
24X424bspt bspt
bspt
24X423 24X423
24X423npt npt
npt
PTFE/EPDM PTFE/EPDM
PTFE/EPDM
Overmolded Overmolded
Overmolded
24X542 24X542
24X542bspt bspt
bspt
24X543 24X543
24X543npt npt
nptEPDM EPDM
EPDM
24X494 24X494
24X494bspt bspt
bspt
24X493 24X493
24X493
1 1
1in. in. in.PTFE PTFE PTFE
npt npt
npt
PTFE PTFE
PTFE
Buna Buna
BunaN N N
24X492 24X492
24X492bspt bspt
bspt
24X491 24X491
24X491npt npt
npt
PTFE/EPDM PTFE/EPDM
PTFE/EPDM
Overmolded Overmolded
Overmolded
24X544 24X544
24X544bspt bspt
bspt
24X545 24X545
24X545npt npt
nptEPDM EPDM
EPDM
24X490 24X490
24X490bspt bspt
bspt
24X489 24X489
24X489
1 1
1in. in. in.
UHMWPE UHMWPE
UHMWPE
npt npt
npt
UHMW UHMW
UHMW
PTFE PTFE
PTFE
Buna Buna
BunaN N N
PTFE PTFE
PTFE
334795A
7

Installation
Installation Installation
Installation
General General
GeneralInformation Information Information
TheTypicalInstallationshownisonlyaguidefor
selectingandinstallingsystemcomponents.Contact
yourGracodistributorforassistanceinplanninga
systemtosuityourneeds.AlwaysuseGenuine
GracoPartsandaccessories.Besureallaccessories
areadequatelysizedandpressureratedtomeetthe
system’srequirements.
Referencelettersinthetext,forexample(A),referto
thecalloutsinthe󰘰gures.
Variationsincolorbetweentheplasticcomponents
ofthispumparenormal.Colorvariationdoesnot
affecttheperformanceofthepump.
Storage: Storage:
Storage:Pumpsthatarenotputintooperation
upondeliverymustbestoredappropriately.See
FlushingandStorage,page15.
Tighten Tighten
TightenBolts Bolts Bolts
Beforemountingandusingthepumpforthe
󰘰rsttime,checkandretorqueallexternalbolts.
Removeallprotectiveboltcovers(37).Follow
TorqueInstructions,page24,totightenallbolts.
Replacetheboltcovers(37).Afterthe󰘰rstdayof
operation,retorquethebolts.Retorquetheboltsifthe
pumphasbeenidleforanextendedtime,beenused
inthermalcyclingapplications,beendisassembled,
orifthereisalargedifferencebetweenenvironmental
temperaturesand󰘱uidtemperatures.
Tips Tips
Tipsto to toReduce Reduce ReduceCavitation Cavitation Cavitation
CavitationinanAODDpumpistheformationand
collapseofbubblesinthepumpedliquid.Frequent
orexcessivecavitationcancauseseriousdamage,
includingpittingandearlywearof󰘱uidchambers,
balls,andseats.Itmayresultinreducedef󰘰ciencyof
thepump.Cavitationdamageandreducedef󰘰ciency
bothresultinincreasedoperatingcosts.
Cavitationdependsonthevaporpressureofthe
pumpedliquid,thesystemsuctionpressure,andthe
velocitypressure.Itcanbereducedbychangingany
ofthesefactors.
1.Reducevaporpressure:Decreasethe
temperatureofthepumpedliquid.
2.Increasesuctionpressure:
a.Lowertheinstalledpositionofthepump
relativetotheliquidlevelinthesupply.
b.Reducethefrictionlengthofthesuction
piping.Rememberthat󰘰ttingsaddfriction
lengthtothepiping.Reducethenumberof
󰘰ttingstoreducethefrictionlength.
c.Increasethesizeofthesuctionpiping.
3.Reduceliquidvelocity:Slowthecyclicrateof
thepump.
Pumpedliquidviscosityisalsoveryimportantbut
normallyiscontrolledbyfactorsthatareprocess
dependentandcannotbechangedtoreduce
cavitation.Viscousliquidsaremoredif󰘰culttopump
andmorepronetocavitation.
Gracorecommendstakingalltheabovefactors
intoaccountinsystemdesign.Tomaintainpump
ef󰘰ciency,supplyonlyenoughairpressuretothe
pumptoachievetherequired󰘱ow.
Gracodistributorscansupplysitespeci󰘰c
suggestionstoimprovepumpperformanceand
reduceoperatingcosts.
8 334795A

Installation
Mount Mount
MountThe The ThePump Pump Pump
Toavoidseriousinjuryfromtoxic󰘱uidorfumes:
•Ventilatetoaremotearea.Thepump
exhaustairmaycontaincontaminants.See
AirExhaustVentilation,page11.
•Nevermoveorliftapumpunderpressure.If
dropped,the󰘱uidsectionmayrupture.Always
followthePressureReliefProcedure,page14,
beforemovingorliftingthepump.
1.Besurethemountingsurfacecansupportthe
weightofthepump,hoses,andaccessories,as
wellasthestresscausedduringoperation.
2.Forallmountings,besurethepumpissecured
withscrewsthroughthemountingfeet.Always
mountthepumpupright.
3.Makesurethesurfaceis󰘱atandthatthepump
doesn’twobble.
4.Foreaseofoperationandservice,mountthe
pumpsoairvalve,airinlet,󰘱uidinletand󰘱uid
outletportsareeasilyaccessible.
Accessories/Components Accessories/Components
Accessories/ComponentsNot Not NotSupplied Supplied SuppliedSystem System SystemComponents Components Components
AAirsupplylineJAirinletport(notvisible)
BBleed-typemasterairvalve(required
foryourpump)
KExhaustportandmuf󰘱er
CAir󰘰lter/regulatorassemblyLFluidinletport
DMasterairvalve(toisolatethe
󰘰lter/regulatorforservice)
MFluidoutletport
EGrounded󰘱exible󰘱uidsupplylineNMountingfeet
FFluiddrainvalve(requiredforyour
pump)
GFluidshutoffvalve
HGrounded,󰘱exible󰘱uidoutletline
334795A 9

Installation
Ground Ground
GroundThe The TheSystem System System
Theequipmentmustbegroundedtoreducethe
riskofstaticsparking.Staticsparkingcancause
fumestoigniteorexplode.Groundingprovidesan
escapewirefortheelectricalcurrent.
•Always Always
Alwaysgroundtheentire󰘱uidsystemas
describedbelow.
•Thepumpsarenot not
notconductive.Anysystem
usedtopump󰘱ammable󰘱uidsmustbeproperly
grounded.
•Followyourlocal󰘰recodes.
Beforeoperatingthepump,groundthesystemas
explainedbelow.
•Pump: Pump:
Pump:Always Always Alwaysgroundtheentire󰘱uidsystemby
makingsurethe󰘱uidhasanelectricalpathtoa
trueearthground.
•Air Air
Airand and and󰘱uid 󰘱uid 󰘱uidhoses: hoses: hoses:Useonly󰘱exiblegrounded
hoseswithamaximumof500ft(150m)combined
hoselengthtoensuregroundingcontinuity.
•Air Air
Aircompressor: compressor: compressor:Followmanufacturer’s
recommendations.
•Fluid Fluid
Fluidsupply supply supplycontainer: container: container:Followlocalcode.
•Solvent Solvent
Solventpails pails pailsused used usedwhen when when󰘱ushing: 󰘱ushing: 󰘱ushing:Followlocal
code.Useonlyconductivemetalpails,placed
onagroundedsurface.Donotplacethepail
onanonconductivesurface,suchaspaperor
cardboard,whichinterruptsgroundingcontinuity.
Checkyoursystemelectricalcontinuityafterthe
initialinstallation,andthensetuparegularschedule
forcheckingcontinuitytobesurepropergrounding
ismaintained.
Air Air
AirLines Lines Lines
1.Installanairregulatorandgauge(C)tocontrol
the󰘱uidpressure.The󰘱uidstallpressurewillbe
thesameasthesettingoftheairregulator.
2.Locateableed-typemasterairvalve(B)closeto
thepumpanduseittorelievetrappedair.Be
surethevalveiseasilyaccessiblefromthepump
andlocateddownstreamfromtheregulator.
Trappedaircancausethepumptocycle
unexpectedly,whichcouldresultinserious
injuryfromsplashing.
3.Locateanothermasterairvalve(D)upstream
fromallairlineaccessoriesanduseittoisolate
themduringcleaningandrepair.
4.Anairline󰘰lter(C)removesharmfuldirtand
moisturefromthecompressedairsupply.
5.Installagrounded,󰘱exibleairhose(A)between
theaccessoriesandthe1/4npt(f)or1/4bspt
pumpairinlet.Useahosewithaminimum1/4in.
ID.Ifahoselongerthan10ft(3m)isrequired,
usealargerdiameterhose.
10 334795A

Installation
Air Air
AirExhaust Exhaust ExhaustVentilation Ventilation Ventilation
Ifpumpingtoxic󰘱uids,youmustventtheexhaust
awayfrompeople,animals,foodhandlingareas,
andallsourcesofignition.Followallapplicable
codes.
NOTE: NOTE:
NOTE:Donotrestricttheairexhaustport.Excessive
exhaustrestrictioncancauseerraticpumpoperation.
To To
Toprovide provide providea a aremote remote remoteexhaust: exhaust: exhaust:
1.UseKit17F612(NPT)or17F613(BSPT),sold
separately.
2.Removethemuf󰘱er(U)fromthepumpair
exhaustport(K).
3.Installtheadaptorfromthekit.
4.Installagroundedairexhausthose(S).Ifahose
longerthan10ft(3m)isrequired,usealarger
diameterhose.Avoidsharpbendsorkinksin
thehose.
5.Placeacontainer(T)attheendoftheairexhaust
linetocatch󰘱uidincaseadiaphragmruptures.
Ifthediaphragmruptures,the󰘱uidbeingpumped
willexhaustwiththeair.
JAirinletport(notvisible)TContainerforremoteairexhaust
KExhaustportUMuf󰘱er
SGroundedairexhausthose
334795A
11

Installation
Fluid Fluid
FluidSupply Supply SupplyLine Line Line
1.Usegrounded,󰘱exible󰘱uidhoses(E).See
GroundTheSystem,page10.
2.Iftheinlet󰘱uidpressuretothepumpismore
than25%oftheoutletworkingpressure,the
ballcheckvalveswillnotclosefastenough,
resultingininef󰘰cientpumpoperation.Excessive
inlet󰘱uidpressurealsowillshortendiaphragm
life.Approximately3–5psi(0.02–0.03MPa,
0.21–0.34bar)shouldbeadequateformost
materials.
3.Formaximumsuctionlift(wetanddry),see
TechnicalData,page31.Forbestresults,always
installthepumpascloseaspossibletothe
materialsource.Minimizesuctionrequirements
tomaximizepumpperformance.
Fluid Fluid
FluidOutlet Outlet OutletLine Line Line
1.Usegrounded,󰘱exible󰘱uidhoses.See
GroundTheSystem,page10,
2.Installa󰘱uiddrainvalve(F)nearthe󰘱uidoutlet.
3.Installashutoffvalve(G)inthe󰘱uidoutletline.
12
334795A

Operation
Operation Operation
Operation
Tighten Tighten
TightenBolts Bolts Bolts
Beforemountingandusingthepumpforthe
󰘰rsttime,checkandretorqueallexternalbolts.
Removeallprotectiveboltcovers(37).Follow
TorqueInstructions,page24,totightenallbolts.
Replacetheboltcovers(37).Afterthe󰘰rstdayof
operation,retorquethebolts.Retorquetheboltsifthe
pumphasbeenidleforanextendedtime,beenused
inthermalcyclingapplications,beendisassembled,
orifthereisalargedifferencebetweenenvironmental
temperaturesand󰘱uidtemperatures.
Flush Flush
Flushthe the thePump Pump PumpBefore Before BeforeFirst First FirstUse Use Use
Thepumpwastestedinwater.Ifwatercould
contaminatethe󰘱uidyouarepumping,󰘱ushthe
pumpthoroughlywithacompatiblesolvent.See
FlushingandStorage,page15.
Start Start
Startand and andAdjust Adjust Adjustthe the thePump Pump Pump
NOTICE NOTICE
NOTICE
Toavoiddamagetoyourpump,becertainthatall
pumped󰘱uidsarecompatiblewithwettedparts.
SeeTechnicalData,page31.
1.Besurethepumpisproperlygrounded.See
GroundTheSystem,page10.
2.Check󰘰ttingstobesuretheyaretight.Usea
compatibleliquidthreadsealantonmalethreads.
NOTICE NOTICE
NOTICE
Donotovertighten󰘱uidinletandoutlet󰘰ttings.
Softplasticthreadscanbestrippedeasily.
3.Placethesuctiontube(ifused)in󰘱uidtobe
pumped.
NOTE: NOTE:
NOTE:If󰘱uidinletpressuretothepumpismore
than25%ofoutletworkingpressure,theball
checkvalveswillnotclosefastenough,resulting
ininef󰘰cientpumpoperation.
NOTICE NOTICE
NOTICE
Excessive󰘱uidinletpressurecanreduce
diaphragmlife.
4.Placetheendofthe󰘱uidhoseintoanappropriate
container.
5.Closethe󰘱uiddrainvalve.
6.Backouttheairregulatorknobandopenall
bleed-typemasterairvalves.
7.Ifthe󰘱uidhosehasadispensingdevice,hold
itopen.
8.Slowlyincreaseairpressurewiththeairregulator
untilthepumpjuststartstocycle.Allowthe
pumptocycleslowlyuntilallairispushedoutof
thelinesandthepumpisprimed.
NOTE: NOTE:
NOTE:Uselowestpossibleairpressuretoprime,
justenoughtocyclethepump.Ifthepumpdoes
notprimeasexpected,turnairpressureDOWN. DOWN.
DOWN.
9.Ifyouare󰘱ushing,runthepumplongenoughto
thoroughlycleanthepumpandhoses.
10.Closethebleed-typemasterairvalve.
334795A 13

Operation
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressure
isrelievedmanually.Tohelppreventserious
injuryfrompressurized󰘱uid,suchassplashing
intheeyesoronskin,followthePressureRelief
Procedurewhenyoustoppumpingandbeforeyou
clean,check,orservicetheequipment.
1.Shutofftheairsupplytothepump.
2.Openthedispensingvalve,ifused.
3.Openthe󰘱uiddrainvalvetorelieve󰘱uid
pressure.Haveacontainerreadytocatchthe
drainage.
Pump Pump
PumpShutdown Shutdown Shutdown
Attheendoftheworkshiftandbeforeyoucheck,
adjust,clean,orrepairthesystem,followthe
PressureReliefProcedure,page14.
14
334795A

Maintenance
Maintenance Maintenance
Maintenance
Maintenance Maintenance
MaintenanceSchedule Schedule Schedule
Establishapreventivemaintenanceschedule
basedonthepump’sservicehistory.Scheduled
maintenanceisespeciallyimportanttopreventspills
orleakageduetodiaphragmfailure.Aclogged
muf󰘱ermayrestrictpumpperformance.Inspect
airlinesandmuf󰘱ermediaregularlytomaintain
performance.
Lubrication Lubrication
Lubrication
Thepumpislubricatedatthefactory.Itisdesigned
torequirenofurtherlubricationforthelifeofthe
packings.Thereisnoneedtoaddaninlinelubricator
undernormaloperatingconditions.
Tighten Tighten
TightenThreaded Threaded ThreadedConnections Connections Connections
Beforeeachuse,checkallhosesforwearordamage
andreplaceasnecessary.Checktobesureall
threadedconnectionsaretightandleak-free.Check
mountingbolts.Checkbolts.Tightenorretorqueas
necessary.Althoughpumpusevaries,ageneral
guidelineistoretorqueboltseverytwomonths.See
TorqueInstructions,page24.
Flushing Flushing
Flushingand and andStorage Storage Storage
•Flushbefore󰘱uidcandryintheequipment,atthe
endoftheday,beforestoring,andbeforerepairing
equipment.
•Flushatthelowestpressurepossible.Check
connectorsforleaksandtightenasnecessary.
•Usesolventthatiscompatiblewiththeequipment
wettedpartsandthematerialbeingdispensed.
•Always󰘱ushthepumpandrelievethepressure
beforestoringitforanylengthoftime.
NOTICE NOTICE
NOTICE
Flushthepumpoftenenoughtopreventthe󰘱uid
youarepumpingfromdryingorfreezinginthe
pumpanddamagingit.
Storage: Storage:
Storage:Pumpsmustbestoredinanenvironment
wheretheyareclean,dry,andprotectedfrom
extremetemperatures,UVradiation,andvibration.
Gracorecommendsanambienttemperaturerangeof
60°F-80°F(15°C-25°C),withahumiditylevelbelow
65%.
334795A 15

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
Problem Problem
ProblemCause Cause
CauseSolution Solution Solution
Pumpisrunningtoofast,causing
cavitationbeforeprime.
Lowerinletpressure.
Checkvalveballisseverelywarn
orwedgedinseatormanifold.
Replaceballandseat.
Seatisseverelyworn.Replaceballandseat.
Outletorinletisclogged.Unclog.
Inletoroutletvalveisclosed.Open.
Inlet󰘰ttingsormanifoldsareloose.Tighten.
Pumpcyclesbutwillnotprime.
Manifoldo-ringsaredamaged.Replaceo-rings.
Pumpcyclesatstallorfailstohold
pressureatstall.
Checkvalveballs,seatsoro-rings
areworn.
Replace.
Spoolvalveisstuckordirty.Disassembleandcleanair
valve.Usecleandryair.
Airsupplypressuretoolow.Increaseairsupplypressure.
Spoolvalveiswornordamaged.Replacespoolvalve.
Checkvalveballisseverelyworn
orwedgedinseatormanifold.
Replaceballandseat.
Dispensingvalveisclogged.Relievepressureandclearvalve.
Pumpwillnotcycle,orcyclesonce
andstops.
Diaphragmisruptured.Replace.
Suctionlineisclogged.Inspect;clear.
Checkvalveballsarestickyor
leaking.
Cleanorreplace.
Diaphragmisruptured.Replace.
Exhaustisrestricted.Removerestriction.
Spoolvalveisdamagedorworn.Replacespoolvalve.
Airsupplyiserratic.Repairairsupply.
Pumpoperateserratically.
Exhaustmuf󰘱erisicing.Usedrierairsupply.
Suctionlineisloose.Tighten.
Diaphragmisruptured.Replace.
Manifoldsareloose,orseatsor
manifoldo-ringsaredamaged.
Tightenmanifoldboltsorreplace
seatsand/oro-rings.
Diaphragmglidesealsoro-rings
aredamaged.
Replace.
Airbubblesin󰘱uid.
Pumpiscavitating.Reducepumpspeed,increase
suctionhosediameter,orincrease
inlethead.
Exhaustaircontains󰘱uidbeing
pumped.
Diaphragmisruptured.Replace.
16 334795A

Troubleshooting
Problem Problem
ProblemCause Cause
CauseSolution Solution Solution
Moistureinexhaustair.Inletairhashighhumidity.Usedrierairsupply.
Pumpexhaustsexcessiveairat
stall.
Spoolvalvesealsarewornor
damaged.
Replace.
Fluidcoversareloose.Retorque.
Diaphragmisdamaged.Replace.
Pumpleaksairexternally.
Manifold󰘰ttingsareloose.Retorque.
Fluidcoversareloose.Retorque.
Pumpleaks󰘱uidexternally.
Diaphragmsaredamaged.Replace.
334795A
17

Repair
Repair Repair
Repair
Disassemble Disassemble
Disassemblethe the theFluid Fluid FluidSection Section Section
1.Carefullyremoveallcapplugs(37).Turnthe
pumpupside-down.
2.Usea10mmsockettoremovethebaseplates
(12)andtheinletmanifold(10).
3.Removetheo-ringseals(17),d-rings(21),and
checkballs(22)frominletsideofeach󰘱uidcover
(6).
4.Inspecttheinletballretainers(20).Ifnecessary
toreplace,useahooktoremovewithout
scratchingtheinnerbore.
5.Turnoverthepumpandusea10mmsocketto
removethemanifoldretainer(11)andtheoutlet
manifold(8).
6.Inspectbothmanifolds’(8)&(10)wearableseats
(35)&(36),andreplaceifwornordamaged.
NOTE: NOTE:
NOTE:UseasmallhammerandPVCtool(44)
totapnewwearableseats(35)&(36)intothe
manifolds(8)&(10).
7.Removetheo-ringseal(17)fromtheoutletside
ofeach󰘱uidcover(6).
8.Withoutscratchingtheinnerbore,useahookto
removethetwooutletballretainers(20).
9.Removethecheckballs(22),d-rings(21),and
wearableseats(19)fromtheoutletsideofeach
󰘱uidcover(6).
18 334795A

Repair
10.Toremovethenuts(28)andbolts(24),usetwo
10mmwrenchestoholdononesideandturn
theother.Thenuts(28)willcomeoffofoneside
only.Thenremovethebolts(24).
NOTE: NOTE:
NOTE:Thenutsarepermanentlyaf󰘰xedtoone
endofthebolts.
11.Removethe󰘱uidcoverretainers(9)andthe󰘱uid
covers(6)fromthebody(1).
Disassemble Disassemble
Disassemblethe the theCenter Center CenterSection Section Section
1.Onediaphragm(25)andstrikeplate(4)should
screwoffbyhand.Slidetheseconddiaphragm
andstrikeplateoutwiththeshaft(5).
2.Inspecttheo-ringseals(32)andglideshaftseals
(39).Replaceasneeded.
3.Carefullyremovethecapplugs(37)fromboth
muf󰘱erlocations.
4.Usea4mmAllenwrenchtoremovethescrews
(16)andmuf󰘱ercaps(14).
5.Inspectthemeshbaf󰘱espacers(38)andfelt
muf󰘱ers(15).Replaceasneeded.
6.Usea19mmsocketandthesuppliedtool(42)to
removethesleevespoolassembly(3).
334795A 19

Repair
7.Inspecteachsleevespoolassembly(3)forworn
ordamagedparts.Replaceeachassemblyas
needed.
Replace Replace
Replacethe the theAir Air AirMotor Motor Motor
1.Usethepinwrench(43)toremovetheairmotor
(2)toremovefromthebody(1).
2.Inspecto-rings(33)&(34),andreplaceif
necessary.
3.Applyathin󰘰lmoflubricanttoairmotoro-rings
(34)&(33),andtotheoutsideoftheairmotor(2),
andscrewbackintothebody(1),smallend󰘰rst.
NOTE: NOTE:
NOTE:Becarefulnottoclogairholeswith
lubricant.
NOTE: NOTE:
NOTE:Useonlythelubricantsuppliedwiththe
rebuildkits.
Reassemble Reassemble
Reassemblethe the theCenter Center CenterSection Section Section
1.Carefullylubricatethesleevespoolassembly
o-ringswithathin󰘰lmoftheappropriatelubricant.
NOTE: NOTE:
NOTE:Becarefulnottoclogairholeswith
lubricant.
2.Verifytheo-ringsonthe󰘰rstsleevespool
assembly(3)areproperlyseatedandcarefully
insertitintooneoftheportsofthebody’s(1)
airmotor.
3.Usea19mmsocketandthesuppliedtool(42)
totightenthesleevespoolassembly(3)untilitis
󰘱ushwithsurfaceoftheairmotor.
NOTE: NOTE:
NOTE:Donotovertightenthesleevespool
assembly.
4.RepeatStep3forthesleevespoolassembly(3)
ontheothersideoftheairmotor.
5.Installthemuf󰘱ermedia(alternatingfeltmuf󰘱ers
(15)andmeshbaf󰘱espacers(38))intothe
muf󰘱er.Usethenewfeltmuf󰘱ers(15)supplied
intherebuildkit.Muf󰘱erpartsmustbeplacedin
exactlytheordershownintheillustration.
20 334795A