Graco Hydra-Clean 1040 User manual

Instructions - Parts List
SaniForce™
Diaphragm Pumps
1040, 1590, and 2150 Models 311879ZAC
EN
For use in sanitary applications. For professional use only.
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 this
manual. Save these instructions.
Refer to the appropriate Pump Matrix on page 26, 34,
or 42 to determine the model number of your pump.
See page 3 for approval information.
1590 Models TI8926a
TI8924a
TI8928a
2150 Models
1040 Models

2311879ZAC
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pump and Repair Kit Matrix - 1040 Models . . . . . 26
Available 1040 Configurations . . . . . . . . . . . . . 27
Parts - 1040 Models . . . . . . . . . . . . . . . . . . . . . . . . 28
Dimensional Drawing - 1040 Models . . . . . . . . . . 31
Technical Data - 1040 Models . . . . . . . . . . . . . . . . 32
Performance Chart - 1040 Models . . . . . . . . . . . . 33
Pump and Repair Kit Matrix - 1590 Models . . . . . 34
Available 1590 Configurations . . . . . . . . . . . . . 35
Parts - 1590 Models . . . . . . . . . . . . . . . . . . . . . . . . 36
Dimensional Drawing - 1590 Models . . . . . . . . . . 39
Technical Data - 1590 Models . . . . . . . . . . . . . . . . 40
Performance Chart - 1590 Models . . . . . . . . . . . . 41
Pump and Repair Kit Matrix - 2150 Models . . . . . 42
Available 2150 Configurations . . . . . . . . . . . . . . 43
Options for Ram Mounting . . . . . . . . . . . . . . . . . 43
Parts - 2150 Models . . . . . . . . . . . . . . . . . . . . . . . . 44
Parts - 2150 Models for Ram Mounting . . . . . . . . 48
Dimensional Drawing - 2150 Models . . . . . . . . . . 50
Technical Data - 2150 Models . . . . . . . . . . . . . . . . 52
Performance Chart - 2150 Models . . . . . . . . . . . . 53
Graco Warranties . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 54

Models
311879ZAC 3
Models
* FA pumps have painted aluminum center sections that may exhibit signs of corrosion depending on cleaning
solutions used.
Model Connections Description Approvals
FD1___ Flange
1040 AODD Pump
FD7___ DIN
*FA1___ Flange
*FA7___ DIN
FD2___ Flange
1590 AODD Pump
FD8___ DIN
*FA2___ Flange
*FA8___ DIN
FD3___ Flange
2150 AODD Pump
FD9___ DIN
*FA3___ Flange
*FA9___ DIN
24G743 Flange
2150 AODD Pump
for Ram Mounting
24G744 Flange
*FA1111 Flange
1040 AODD Pump
*FA7111 DIN
FD1111 Flange
FD7111 DIN
FD1211 Flange
*FA2111 Flange
1590 AODD Pump
*FA8111 DIN
FD2111 Flange
FD2113 Flange
FD8111 DIN
FD2211 Flange
*FA3111 Flange
2150 AODD Pump
*FA9111 DIN
FD3111 Flange
FD9111 DIN
FD3211 Flange
II 2 G
II 2 G

Models
4311879ZAC
Material Certification
Reference: SaniForce Product Family
Issue Date: November 1, 2011
All fluid contact materials in the SaniForce product family are FDA-Compliant and meet the United States
Code of Federal Regulations (CFR) Title 21, Section 177 or are of a corrosion resistant grade Stainless
Steel. This includes the below product groups:
1. SaniForce 515, 1040, 1590, 2150 Air-Operated Double Diaphragm Pumps
2. SaniForce 1590, 3150 HS Air-0perated Double Diaphragm Pumps
3. SaniForce 1590, 3150 HS 3-A Certified Air-Operated Double Diaphragm Pumps
4. SaniForce 5:1, 6:1 and 12:1 Air-Operated Piston Pumps
5. SaniForce Diaphragm Pump and Piston Pump Drum Unloaders
6. SaniForce Diaphragm Pump and Piston Pump Bin Evacuation Systems
Bradley A. Byron
Quality Manager
Graco Inc.

Warnings
311879ZAC 5
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. When
these symbols appear in the body of this manual, refer back to these Warnings. Additional, product-specific warnings
may be found 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.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow the Pressure Relief Procedure when you stop spraying 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.

Warnings
6311879ZAC
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. Turn off all 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.
• 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.
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
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, hearing loss,
inhalation of toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNING

Installation
311879ZAC 7
Installation
General Information
• FA pumps have painted aluminum center sections
that may exhibit signs of corrosion depending on
cleaning solutions used.
• The typical installations shown in Figs. 2-4 are only
guides 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 28-30, 36-38, and 44-46.
Tightening Clamps Before First Use
After you unpack the pump, and before you use it for the
first time, check all clamps and tighten as necessary.
Grounding
•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.
238909 Ground Wire and Clamp.
FIG. 1
•Fluid hoses: Use only grounded hoses with a maxi-
mum 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 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.
The pump is very heavy (see Technical Data on pages
32, 40, and 51 for specific weights). If the pump must
be moved, follow the pressure relief procedure on
page 12 and have two people to lift the pump by grasp-
ing the outlet manifold securely or use appropriate lift-
ing equipment.
To reduce the risk of serious injury due to burns, insu-
late and/or label the pump before pumping hot fluids.
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
"
Y
W

Installation
8311879ZAC
Mountings
• Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as well
as the stress caused during operation.
• For all mountings, be sure the pump is bolted
directly to the mounting surface.
• 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.
Air Line
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 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. Install a grounded, flexible air hose (A) between the
accessories and the 1/2 npt(f) pump air inlet (N).
See Fig. 5. Use a minimum 3/8 in. (9.5 mm) ID air
hose. Screw an air line quick disconnect coupler (D)
onto the end of the air hose (A), and screw the mat-
ing fitting into the pump air inlet snugly.
Fluid Suction Line
1. Use flexible, grounded fluid hoses.
2. For best sealing results, use a standard tri-clamp or
DIN style sanitary gasket of a flexible material such
as EPDM, Buna-N, fluoroelastomer, or silicon.
3. 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 ineffi-
cient pump operation.
4. At inlet fluid pressures greater than 15 psi (0.1 MPa,
1 bar), diaphragm life will be shortened.
5. See the Technical Data on pages 32, 40, and 51
for maximum suction lift (wet and dry).
NOTICE
The pump exhaust air may contain contaminants. Ven-
tilate to a remote area if the contaminants could affect
your fluid supply. See Air Exhaust Ventilation on
page 11.
A bleed-type master air valve (B) is required in the sys-
tem to relieve air trapped between this valve and the
pump. Trapped air can cause the pump to cycle unex-
pectedly, 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.
In the step below, do not connect the quick-disconnect
coupler (D) on the air hose to the mating fitting on the
pump until you are ready to operate the pump. Con-
necting the coupler too early can result in unintentional
operation of the pump, leading to serious injury from
moving parts, splashing fluid in the eyes or on the skin,
and contact with hazardous fluids.

Installation
311879ZAC 9
Fluid Outlet Line
1. Use flexible grounded fluid hoses (L).
2. For best sealing results, use a standard tri-clamp or
DIN style sanitary gasket of a flexible material such
as EPDM, Buna-N, fluoroelastomer, or silicon
3. Install a fluid drain valve (J) near the fluid outlet. See
the WARNING above, and FIG. 2.
4. Install a shutoff valve (K) in the fluid outlet line.
FIG. 2 Typical Floor-Mount Installation
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.
TI8930a
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
G Flexible fluid suction line
J Fluid drain valve (required)
K Fluid shutoff valve
L Flexible fluid line
Y Ground wire (required; see page
7 for installation instructions)
E
F
CB
A
K
L
J
G
Y
D

Installation
10 311879ZAC
Changing the Orientation of the Fluid Inlet
and Outlet Ports
The pump is shipped with the ports facing the same
direction. To reverse the orientation of the ports:
1. Remove the clamps holding the inlet and/or outlet
manifold to the covers.
2. Reverse the manifold and reattach. Install and
tighten clamps snugly.
FIG. 3
Key:
N 1/2 npt(f) air inlet port
P Muffler (air exhaust
port is 3/4 npt(f)
R Fluid inlet port
S Fluid outlet port
113 Manifold clamps
3 Air valve screws
Torque to
28-30 in-lb
(3.2-3.7 N•m)
1
1
N
3 113 S
R
P
106 TI8926a