GE WJRR4170 Pressure Washer User Manual
Contents
1. H III Ly f All Sia J p R Pa ae A HE oS Ts Al CEZ qQ q H el ZY SSS AMA a NI N D A 04170B Fig 2 6 308443 Installation Mountings CAUTION 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 10 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 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 connec tors 14 on air motor of2. 000000 16 This symbol alerts you to the possibility of serious Ball Check Valve Repair 000 18 injury or death if you do not follow the instructions Diaphragm Repair 0c eee eee 19 Bearing and Air Gasket Removal 22 Pump Matrix 2 2 c tei ate ee ee dt ae 24 Repair Kit Matrix 00 0 0 eee eee eee 25 Caution Symbol PANS ecw deed emt ee nhewiee bene eet ae Leese edo 26 Torque Sequence 6c cee eee eee eee 30 A CAUTION Dimensional Drawings 0 0 eee eee 31 Technical Data and Performance Chart 32 This symbol alerts you to the possibility of damage to Graco Standard Warranty 000 0005 34 or destruction of equipment if you do not follow the Graco Information 0060e eee ee eee eee 34 instructions A WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury o RA INSTRUCTIONS 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 syst
3. P o oe mee 5 5 in 139 5 mm 5 0 in 127 mm 9 25 in 235 mm 7337C 308443 31 Technical Data Maximum fluid working pressure 120 psi 0 8 MPa 8 bar Air pressure operating range 20 to 120 psi 0 14 to 0 8 MPa 1 4 to 8 bar Maximum air consumption 00e ee 60 scfm Air consumption at 70 psi 20 gom 20 scfm see chart Maximum free flow delivery 42 gpm 159 I min Maximum pump speed 0 eee eee 276 cpm Gallons Liters per cycle 0000 0 15 0 57 Maximum suction lift 18 ft 5 48 m wet or dry Maximum Size pumpable solids 1 8 in 3 2 mm Maximum noise level at 100 psi 50 cpm 89 dBa Sound power level 00000ce eee eaee 100 dBa Noise level at 70 psi 50 cycles min 78 dBa Maximum operating temperature 150 F 65 5 C Airinlet SIZ osole re anea fa piei eee 1 2 npt f Fluid inlet size 1 Raised Face Flange Fluid outlet size uaaa 1 Raised Face Flange 32 308443 Wetted parts Vary by Model See pages 27 and 29 Non wetted external parts aluminum 302 316 stainless steel polyester labels Weight approximate Polypropylene Models eee eee ee eae with aluminum center section 19 Ib 8 6 kg TEETER with stainless steel center section 32 b 14 6 kg site dad pit a Se Rowe aar S
4. Do not operate a gasoline engine in the work area 308443 3 Installation General Information AN 4 The Typical Installation shown in Fig 2 is only a guide 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 26 to 27 A WARNING 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 amp e Read TOXIC FLUID HAZARD on page 3 e Use fluids and solvents that are compatible with the equipment wetted parts Refer to the Tech nical Data section of all equipment manuals Read the fluid and solvent manufacturer s warnings 308443 Tightening Screws Before First Use Before using the pump for the first time check and retorque all external fasteners See Torque Se quence page 30 After the first day of operation retorque the fasteners Although pump use varies a general guideline is to retorque fasteners every two months Installation Grounding A WARNING 2 FIRE AND EXPLOSION HAZARD Mi 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 The acetal pump con
5. Fig 12 308443 19 4 Service Reassembly Unscrew one outer plate 105 from the diaphragm shaft 24 Remove one diaphragm 401 and the inner plate 104 See Fig 13 NOTE PTFE models include a PTFE diaphragm 403 in addition to the backup diaphragm 401 20 Pull the other diaphragm assembly and the dia phragm shaft 24 out of the center housing 1 Hold the shaft flats with a 19 mm open end wrench and remove the outer plate 105 from the shaft Disassemble the remaining diaphragm assembly Inspect the diaphragm shaft 24 for wear or scratches If it is damaged inspect the bearings 19 in place If the bearings are damaged refer to page 22 Reach into the center housing 1 with an o ring pick and hook the u cup packings 402 then pull them out of the housing This can be done with the bearings 19 in place Clean all parts and inspect for wear or damage Replace parts as needed 308443 1 Grease the shaft u cup packings 402 and install them so the lips face out of the housing 1 See Fig 13 Grease the length and ends of the diaphragm shaft 24 and slide it through the housing 1 Assemble the inner diaphragm plates 104 dia phragms 401 PTFE diaphragms 403 if pres ent and outer diaphragm plates 105 exactly as shown in Fig 13 These parts must be assembled correctly Apply medium strength blue Loctite or equiva lent to the threads of the fluid side plates
6. G Geolast G Geolast 246450 Stainless Steel Air Motor Conversion Kit Use kit 246450 and refer to instruction manual 309643 included with kit to convert from aluminum air motor to stainless steel air motor 24 308443 Repair Kit Matrix For Husky 1040 Acetal Polypropylene and PVDF Pumps Series A Repair Kits may be ordered separately To repair the air valve order Part No 236273 for aluminum center housing models and Part 255061 for stainless steel center housing models see page 26 Parts included in the Air Valve Repair Kit are marked with a symbol in the parts list for example 3 To repair your pump select the six digits which describe your pump from the following matrix working from left to right The first digit is always D the second digit is always 0 zero and the third is always 7 The remaining three digits define the materials of construction Parts included in the kit are marked with an asterisk in the parts list for example 201 For example if your pump has polypropylene seats PTFE balls and PTFE diaphragms order Repair Kit D 0 7 9 1 1 If you only need to repair certain parts for example the diaphragms use the O null digits for the seats and balls and order Repair Kit D 0 7 00 1 The digits in the matrix do not correspond to the ref nos in the parts drawing and lists on pages 26 to 27 Diaphragm Fluid Section Pump Material Diaphragms D for all pumps 0 for all pumps 7 Plastic O null
7. 105 Hold one of the outer plates 105 with a wrench and torque the other outer plate to 20 to 25 ft lb 27 to 34 N m at 100 rom maximum Do not over torque Align the fluid covers 101 and the center housing 1 so the arrows A on the covers face the same direction as the air valve B Secure the covers with the screws 106 and 112 handtight Place the bolt caps 113 on the longer screws 106 and install the longer screws in the top and bottom holes of the covers See Fig 12 First torque the longer screws 106 oppositely and evenly to 130 to 150 in Ib 14 to 17 Nem using a 10 mm socket wrench Then torque the shorter screws 112 See Torque Sequence page 30 Reassemble the ball check valves and manifolds as explained on page 18 Service iy 19 402 g pme 04236 02637 Cutaway View with Diaphragms in Place Cutaway View with Diaphragms Removed Lips face out of housing 1 Rounded side faces diaphragm 401 Grease Apply medium strength blue Loctite
8. 188711 SEAT TPE None Not Used 191595 SEAT Santoprene 114229 O RING PTFE encapsu lated 15B275 SEAT Buna N None Not used 15B633 SEAT fluoroelastomer None Not Used 189722 SEAT polypropylene 109205 O RING PTFE 189723 SEAT PVDF 109205 O RING PTFE 194211 SEAT Geolast 109205 O RING PTFE RS rartno pescrision ay 301 112088 BALL PTFE 301 112254 BALL acetal 301 103869 BALL 316 stainless steel 301 102973 BALL 440C stainless 4 steel sor vom fre cor soars enore e 308443 29 Torque Sequence Always follow torque sequence when instructed to torque fasteners 1 Left Right Fluid Covers 3 Outlet Manifold Torque bolts to 130 150 in Ib 14 17 Nem Torque bolts to 80 90 in lb 9 10 Nem AIL XO ERN Ss am JEA KEZ G i TOP VIEW SIDE VIEW 2 Inlet Manifold BOTTOM VIEW 30 308443 Dimensional Drawings 343 mm 7 57 in 192 mm FRONT VIEW 1 2 npt f Air Inlet 42 25 in 16 88 in 311 mm 4 28 5 mm 14 75 in 374 5 mm 9 8 in 249 mm ANSI Flange Fluid Outlet 3 4 npt f 5 5 in Air Exhaust 139 5 mm Port Diameter muffler included 1 15 in 29 mm Eight 0 62 in 16 mm slots SIDE VIEW PUMP MOUNTING HOLE PATTERN 7 eS l Four 0 5 in ANSI Flange 5 0 in i 12 5 mm Fluid Inlet 127 mm diameter holes
9. alum PLATE fluid side polypropylene SCREW M8 x 1 25 70 mm 2 76 in sst LABEL warning MUFFLER SCREW M8 x 1 25 40 mm 1 57 in sst CAP bolt SST Parts 189378 189372 189375 188607 189381 112560 188621 112182 112559 193282 Fluid Section Parts List Matrix Column 3 COVER fluid PVDF MANIFOLD inlet PVDF MANIFOLD outlet PVDF PLATE air side alum PLATE fluid side PVDF SCREW M8 x 1 25 70 mm 2 76 in sst LABEL warning MUFFLER SCREW M8 x 1 25 40 mm 1 57 in sst CAP bolt SST Parts Seat Parts List Matrix Column 4 Diaphragm Parts List Matrix Column 6 188604 SEAT acetal 109205 O RING PTFE 2 401 Notsold DIAPHRAGM backup separately polychloropene CR 402 112181 PACKING u cup nitrile 403 188605 DIAPHRAGM PTFE 5 401 188606 DIAPHRAGM TPE a 112181 PACKING u cup nitrile 401 188857 DIAPHRAGM Santoprene ip tie PACKING u cup nitrile 7 401 15B499 DIAPHRAGM buna N eee PACKING u cup nitrile 401 15B500 DIAPHRAGM fluoroelas tomer A PACKING u cup nitrile G 401 194212 DIAPHRAGM Geolast Barca PACKING u cup nitrile These parts are included in the pump repair kit purchased separately See Repair Kit Matrix on page 25 to determine the correct kit for your pump 188707 SEAT 316 stainless steel 109205 O RING PTFE 188708 SEAT 17 4 stainless steel 109205 O RING PTFE
10. damaged 16 to 17 and 22 to 23 Air cover screws 25 are loose Tighten screws See pages 22 to 23 Pump leaks fluid externally from ball Loose manifolds 102 103 dam Tighten manifold bolts 106 or 112 check valves aged seal between manifold and or replace seats 201 or o rings seat 201 damaged o rings 202 202 See page 18 308443 15 Service Repairing the Air Valve Tools Required e Torque wrench e Torx T20 screwdriver or 7 mm 9 32 socket wrench Needle nose pliers e O ring pick e Lithium base grease NOTE Air Valve Repair Kits 236273 aluminum center housing models and 255061 sst center housing models are available Refer to page 26 Parts included in the kit are marked with a symbol for example 4T Use all the parts in the kit for the best results Disassembly A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 11 1 Relieve the pressure 2 With a Torx T20 screwdriver or 7 mm 9 32 socket wrench remove the six screws 3 air valve cover 2 and gasket 4 See Fig 7 3 Move the valve carriage 5 to the center position and pull it out of the cavity Remove the valve block 7t and o ring 6T from the carriage Using a needle nose pliers pull the pilot block 18 straight up and out of the cavity See Fig 8 4 Pull the two actuator pistons 11 out of the
11. not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or sub stitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above Th
12. pump fluid outlet S is a 1 raised face flange Refer to Flange Connections on page 8 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 308443 7 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 Q 2 Aiea Ce Q O DI Oo 04404B Fig 3 8 308443 Place a lockwasher and a flat washer on each bolt Refer to Fig 3 Align the holes in the gasket and the pipe flange with the holes in the pump flange Lubricate the threads of the four bolts Install the bolts through the holes and secure with the wash ers and nuts Hold the nuts with a wrench Refer to the tighten ing 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 A OQ O Q Q EY Flanged plastic pipe PTFE gasket Lockwasher Flat washer Nut 1 fluid inlet flange 1 fluid outlet flange K A B C Bolt D E F N Torque to 10 to 15 ft lb 14 20 N m Do not over torque Installation Chan
13. the pump to cycle slowly until all air is pushed out of the lines and the pump is primed If 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 308443 11 Operation Operation of Remote Piloted Pumps 1 Follow preceding steps 1 through 7 of Starting and Adjusting Pump 2 Open air regulator C A WARNING The pump may cycle once before the external sig nal is applied Injury is possible If pump cycles wait until end before proceeding 3 Pump will operate when air pressure is alternately applied and relieved to push type connectors 14 12 308443 NOTE Leaving air pressure applied to the air motor for extended periods when the pump is not running may shorten the diaphragm life Using a 3 way solenoid valve to automatically relieve the pressure on the air motor when the metering cycle is complete prevents this from occurring Pump Shutdown A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure at left At the end of the work shift relieve the pressure Maintenance Lubrication The air valve is designed to operate unlubricated however if lubrication is desired every 500 hours of operation or monthly remove the hose from the pump air inlet and add two drops of machine o
14. use a larger diameter hose Avoid sharp bends or kinks in the hose See Fig 6 Place a container U at the end of the air exhaust line to catch fluid in case a diaphragm ruptures VENTING EXHAUST AIR El I 1 ji o H m KEY Air supply line Bleed type master air valve required for pump Air regulator Air line quick disconnect Master air valve for accessories Air line filter Muffler Grounded air exhaust hose Container for remote air exhaust D gt ciHaummoo Fig 6 10 308443 04168A Operation Pressure Relief Procedure A WARNING 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 e Are instructed to relieve pressure e Stop pumping e Check clean or service any system equipment e Install or clean fluid nozzles 1 Shut off the air to the pump 2 Open the dispensing valve if used 3 Open the fluid drain valve to relieve all fluid pres sure having a container ready to catch the drain age Flush the Pump Before First Use Th
15. Instructions Parts List G ACETAL POLYPROPYLENE AND PVDF Husky 1040 Air Operated Diaphragm Pumps ee Acetal Model Shown 120 psi 0 8 MPa 8 bar Maximum Fluid Working Pressure 120 psi 0 8 MPa 8 bar Maximum Air Input Pressure Model No D71___ Acetal Pumps Cais certified Model No D81__ s Acetal Pumps Remote Ediza certified Model No D72___ Polypropylene Pumps Model No D82___ Polypropylene Pumps Remote Model No D75__ PVDF Pumps Model No D85__ PVDF Pumps Remote Model No DR2___ Polypropylene Plus QD Pumps Model No DS2___ Polypropylene Plus N Pumps Remote Model No DR5___ PVDF Plus Pumps Model No DS5___ PVDF Plus Pumps Remote NOTE Refer to the Pump Matrix on page 24 to determine the Model No of your pump NOTE Plus Models include stainless steel center sections Patent No CN ZL94102643 4 FR 9408894 JA 3517270 US 5 368 452 Important Safety Instructions Read all warnings and instructions in this manu al Save these instructions PROVEN QUALITY LEADING TECHNOLOGY Ui osi Copyright 1994 Graco Inc is registered to I S EN ISO 9001 Table of Contents Symbols Safety WarningS 00 cece eee eee eee 2 INStalAtION erron evar nated pe ea dale Rag ees 4 Warning Symbol Operation ide hia iaaa Sas Ue eas 11 Maintenance 0 00 eee 13 Troubleshooting eee eee eee eee eee 14 A WARNING Service f o Repairing the Air Valve
16. Matrix Husky 1040 Acetal Polypropylene and PVDF Pumps Series A Your Model No is marked on the pump s serial plate To determine the Model No of your pump from the following matrix select the six digits which describe your pump working from left to right The first digit is always D designating Husky diaphragm pumps The remaining five digits define the materials of construction For example a pump with an aluminum air motor acetal fluid section polypropylene seats PTFE balls and PTFE diaphragms is Model D 7 1 9 1 1 To order replacement parts refer to the part lists on pages 26 to 27 The digits in the matrix do not correspond to the ref nos in the parts drawing and lists Diaphragm Pump Air Motor Fluid Section Seats Balls Diaphragms D for all pumps 7 Aluminum 1 acetal 1 not used 1 PTFE 1 PTFE standard 8 Aluminum 2 polypropylene 2 acetal 2 acetal 2 not used remote oo R SST standard 3 not used 3 3 316 sst 3 316 sst 3 not used S SST remote 4 not used 4 4 17 4 PH sst 4 440C sst 4 not used aca 5 PVDF 5 TPE 5 TPE 5 TPE 6 6 not used 6 Santoprene 6 Santoprene 7 buna N 7 buna N 7 buna N 8 fluoroelastom 8 fluoroelastom er er 8 ea ud er 9 polypropylene 9 not used 9 not used A PVDF A not used A not used G not used
17. O null O null o z 2 acetal 2 acetal 2 not used 3 316 sst 3 316 sst 3 not used 4 17 4 PH sst 4 440C sst 4 not used 5 TPE 5 TPE 5 TPE 6 Santoprene 6 Santoprene 6 Santoprene 7 buna N 7 buna N 7 buna N 8 fluoroelastom er 9 polypropylene A PVDF G Geolast 308443 25 Parts AN Not used on some models These parts are included in the Pump Repair Kit which may be purchased separately Refer to the Repair Kit Matrix on page 25 to determine the correct kit for your pump 112 i t These parts are included in Air Valve Repair Kit 236273 aluminum center housing mod a els which may be purchased separately m These parts are included in Air Valve Repair Kit 255061 stainless steel center housing models which may be purchased separately A Replacement Danger and Warning labels tags and cards are available at no cost These parts are unique to remote piloted air motor D8 and DS 26 308443 Parts Air Motor Parts List Matrix Column 2 Air Motor Parts List Matrix Column 2 188838 HOUSING center Same as 7 with the following exceptions aluminum 188854 COVER air valve aluminum 116344 SCREW mach hex flange hd M5 x 0 8 12 mm 0 47 in 188618 GASKET cover foam 188855 CARRIAGE aluminum 108730 O RING nitrile 195921 HOUSING center remote aluminum COVER air remote HOUSING center stainless steel CO
18. VER air valve stainless steel 188616 BLOCK air valve acetal 188615 PLATE air valve sst 188617 SEAL valve plate buna N 112181 PACKING u cup nitrile COVER air stainless steel 188612 PISTON actuator acetal 188613 BEARING piston acetal HOUSING center remote stainless steel COVER air valve stainless steel 15H178 PLATE air valve 1 stainless steel 9 15B794 COVER air remote 2 stainless steel 104765 PLUG pipe headless 115671 FITTING connector male 188611 BEARING pin acetal 188610 PIN pilot stainless steel 157628 O RING buna N 188614 BLOCK pilot acetal 188609 BEARING shaft acetal 116343 SCREW grounding 188603 GASKET air cover foam 188839 COVER air aluminum 188608 SHAFT diaphragm sst 115643 SCREW M8 x 1 25 25 mm 1 in 308443 27 Fluid Section Parts List Matrix Column 3 28 308443 189377 189371 189374 188607 189380 112560 188621 112182 112559 193282 189376 189370 189373 188607 189379 112560 188621 112182 112559 193282 COVER fluid acetal MANIFOLD inlet acetal MANIFOLD outlet ace tal PLATE air side alum PLATE fluid side acetal SCREW M8 x 1 25 70 mm 2 76 in sst LABEL warning MUFFLER SCREW M8 x 1 25 40 mm 1 57 in sst CAP bolt SST COVER fluid polypropylene MANIFOLD inlet polypropylene MANIFOLD outlet polypropylene PLATE air side
19. atin E a Er Acetal Models E Hea ES with aluminum center section 22 b 10 kg AE a a Vigate eG tel da a aE oa Peay n oleae at PVDF Models A NEEE R with aluminum center section 25 b 11 3 kg fend soto with stainless steel center section 35 Ib 16 kg Geolast and Santoprene are registered trademarks of the Monsanto Co Loctite is a registered trademark of the Loctite Corporation Noise levels measured with the pump mounted on the floor using Rubber Foot Kit 236452 Sound power measured per ISO Standard 9216 Performance Chart Test Conditions Fluid Pressure Curves at 120 psi 0 7 MPa 7 bar air pressure at 100 psi 0 7 MPa 7 bar air pressure at 70 psi 0 48 MPa 4 8 bar air pressure at 40 psi 0 28 MPa 2 8 bar air pressure 00 W D gt To find Fluid Outlet Pressure psi MPa bar at a specific fluid flow gpm Ipm and operating air pressure psi MPa bar 1 Locate fluid flow rate along bottom of chart 2 Follow vertical line up to intersection with selected fluid outlet pressure curve 3 Follow left to scale to read fluid outlet pressure Air Consumption Curves at 120 psi 0 7 MPa 7 bar air pressure at 100 psi 0 7 MPa 7 bar air pressure at 70 psi 0 48 MPa 4 8 bar air pressure at 40 psi 0 28 MPa 2 8 bar air pressure 00D gt To find Pump Air Consumption scfm or m3 min at a specific fluid flow gpm lpm and air pressure psi MPa bar 1 Locate fluid flow rate along bottom of
20. bear ings 12 Remove the u cup packings 10 from the pistons Pull the pilot pins 16 out of the bearings 15 Remove the o rings 17 from the pilot pins See Fig 9 5 Inspect the valve plate 8 in place If damaged use a Torx T20 screwdriver or 7 mm 9 32 socket wrench to remove the three screws 3 Remove the valve plate 8 and on aluminum center housing models only remove the seal 9 See Fig 10 6 Inspect the bearings 12 15 in place See Fig 9 The bearings are tapered and if damaged must be removed from the outside This requires disas sembly of the fluid section See page 22 16 308443 7 Clean all parts and inspect for wear or damage Replace as needed Reassemble as explained on page 17 Torque to 50 60 in lb 5 6 6 8 N m Fig 7 04164B AN See Detail at right A Grease AN Grease lower face VA 16 04165 Service Insert narrow end first Grease Install with lips facing narrow end of piston 11 gt gt PE Insert wide end first AX 17tm 15 16A 04159 Fig 9 AN Rounded side must face down aluminum 3 A center housing models only of AA Tighten screws until they bottom out on the E housing 04160 Fig 10 Reassembly 1 If you removed the bearings 12 15 install new ones as explained on page 22 Reassemble the fluid section 2 On aluminum center housing models install the valve plate seal 9T into the groove at the bott
21. chart 2 Read vertical line up to intersection with selected air consumption curve 3 Follow left to scale to read air consumption FLUID OUTLET PRESSURE psi MPa bar Pump tested in water with inlet submerged 120 0 84 8 4 A 100 0 7 B 80 0 55 5 5 N 60 c 0 41 4 1 40 0 28 2 8 D 20 0 14 1 4 o 0 5 10 15 20 25 30 35 40 19 38 57 76 95 114 133 152 FLUID FLOW gpm Ipm z 60 B 1 68 o i 50 E 1 40 elet E 40 aE 2 4 12 Te aces E wet oe BY D 30 eet 0 84 etat secre Z o id g oe 2 20 sls Pi F O 0 56 ofa le oO 10 ae sofa Z 028 jet O e27 x o z 0 5 10 15 20 25 30 35 40 19 38 57 76 95 114 133 152 FLUID FLOW gpm Ipm 308443 33 Graco Warranties Graco Standard Husky Pump Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of five years from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does
22. crewdriver or 7 mm 9 32 socket wrench Torque to 28 to 33 in lb 3 2 to 3 7 N m See Fig 7 308443 17 Service Ball Check Valve Repair Tools Required e Torque wrench e 10mm socket wrench e O ring pick Disassembly NOTE A Fluid Section Repair Kit is available Refer to page 25 to order the correct kit for your pump Parts included in the kit are marked with an asterisk for example 201 Use all the parts in the kit for the best results NOTE To ensure proper seating of the balls 301 always replace the seats 201 when replacing the balls A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 11 Relieve the pressure Disconnect all hoses 2 Remove the pump from its mounting 3 Using a 10 mm socket wrench remove the four bolts 106 holding the outlet manifold 103 to the fluid covers 101 See Fig 11 4 Remove the seats 201 balls 301 and o rings 202 from the manifold NOTE Some models use two o rings 202 some models use four o rings 202 and some models do not use o rings 5 Turn the pump over and remove the inlet manifold 102 Remove the seats 201 balls 301 and o rings 202 from the fluid covers 101 18 308443 Reassembly 1 Clean all parts and inspect for wear or damage Replace parts as needed 2 Reassemble in the reverse order following all notes i
23. e buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within six years of the date of sale Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnais sent avoir convenu que la r daction du pr sente doc
24. e pump was tested in water If 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 A WARNING amp TOXIC FLUID HAZARD a Hazardous fluid or toxic fumes can IA cause serious injury or death if splashed in the eyes or on the skin inhaled or swallowed Do not lift a pump under pressure If dropped the fluid section may rupture Always fol low the Pressure Relief Procedure above before lifting the pump 1 Be sure the pump is properly grounded Refer to Grounding on page 5 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 fittings securely 3 Place the suction tube if used in the fluid to be pumped NOTE 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 4 Place the end of the fluid hose L into an appropri ate container 5 Close the fluid drain valve J See Fig 2 6 With the pump air regulator C closed open all bleed type master air valves B E 7 If the fluid hose has a dispensing device hold it open while continuing with the following step 8 Slowly open the air regulator C until the pump starts to cycle Allow
25. ect the packings See Fig 13 22 308443 Reassembly 1 If removed install the shaft u cup packings 402 so the lips face out of the housing 1 The bearings 19 12 and 15 are tapered and can only be installed one way Insert the bearings into the center housing 1 tapered end first Using a press or a block and rubber mallet press fit the bearing so it is flush with the surface of the center housing Reassemble the air valve as explained on page 17 Align the new air cover gasket 22 so the pilot pin 16 protruding from the center housing 1 fits through the proper hole H in the gasket Align the air cover 23 so the pilot pin 16 fits in the middle hole M of the three small holes near the center of the cover Apply medium strength blue Loctite or equivalent to the threads of screws 25 and install the screws handtight See Fig 14 Using a 10 mm socket wrench torque the screws oppositely and evenly to 130 to 150 in Ib 14 to 17 Nem Install the diaphragm assemblies and fluid covers as explained on page 19 Reassemble the ball check valves and manifolds as explained on page 18 Service AN Insert bearings tapered end first A Press fit bearings flush with surface of center housing 1 Apply medium strength blue Loctite or equivalent Torque to 130 to 150 in Ib 14 to 17 Nem SS t MO 04158 Detail of Air Valve Bearings 25 3 02639B Fig 14 308443 23 Pump
26. em 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 ex pose 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 2 308443 A WARNING 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 10 To pump acids always use a PVDF or a polypropylene pump Take precautions to avoid acid or acid fu
27. ging 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 Ib 9 to 10 N m See Fig 4 See Torque Sequence page 30 KEY N 1 2 npt f air inlet port 101 Covers P Muffler air exhaust port 102 Fluid inlet manifold is 3 4 npt f 103 Fluid outlet manifold R 1 fluid inlet port 106 Manifold screws S 1 fluid outlet port 112 Manifold screws A Torque to 80 to 90 in Ib 9 to 10 N m See Torque Sequence page 30 Acetal Model Shown 04155B Fig 4 Fluid Pressure Relief Valve CAUTION Some systems may require installation of a pres sure 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 ambi ent 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 ca
28. il to the air inlet CAUTION Do not over lubricate the pump Oil is exhausted through the muffler which could contaminate your fluid supply or other equipment Excessive lubrica tion can also cause the pump to malfunction Flushing and Storage Flush the pump often enough to prevent the fluid you are pumping from drying or freezing in the pump and damaging it Always flush the pump and follow the Pressure Relief Procedure on page 11 before storing it for any length of time Use a compatible solvent Tightening Threaded Connections Before each use check all hoses for wear or damage and replace as necessary Check to be sure all threaded connections are tight and leak free Check fasteners Tighten or retorque as necessary Although pump use varies a general guideline is to retorque fasteners every two months See Torque Sequence page 30 Preventive Maintenance Schedule Establish a preventive maintenance schedule based on the pump s service history This is especially impor tant for prevention of spills or leakage due to dia phragm failure 308443 13 Troubleshooting 1 Relieve the pressure before checking or servicing A WARNING the equipment To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 11 2 Check all possible problems and causes before disassembling the pump PROBLEM CAUSE SOLUTION Pump cycles at sta
29. ll or fails to hold Worn check valve balls 301 seats Replace See page 18 pressure at stall 201 or o rings 202 Pump will not cycle or cycles once Air valve is stuck or dirty Disassemble and clean air valve and stops See pages 16 to 17 Use filtered air Check valve ball 301 severely Pata ball and seat See page worn and tage in seat 201 or manifold 102 or 103 Check valve ball 301 is wedged Install Pressure Relief Valve into seat 201 due to overpressur see page 9 ization Loose inlet manifold 102 dam Tighten manifold bolts 106 or 112 aged seal between manifold and or replace seats 201 or o rings seat 201 damaged o rings 202 202 See page 18 Loose fluid side plate 105 Tighten or replace pages 19 to 21 Damaged o ring 108 Replace See pages 19 to 21 14 308443 Troubleshooting PROBLEM CAUSE SOLUTION Fluid in exhaust air Diaphragm ruptured Replace See pages 19 to 21 Loose fluid side plate 105 Tighten or replace pages 19 to 21 Pump exhausts excessive air at Worn air valve block 7 o ring 6 Repair or replace See pages stall plate 8 pilot block 18 u cups 16 to 17 10 or pilot pin o rings 17 Worn shaft seals 402 Replace See pages 19 to 21 Pump leaks air externally Air valve cover 2 or air valve cover Tighten screws See page 17 screws 3 are loose Air valve gasket 4 or air cover Inspect replace See pages gasket 22 is
30. mes 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 e Ground the equipment Refer to Grounding on page 5 e 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 5 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 10 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
31. n Fig 11 Assemble the ball checks exactly as shown The arrows A on the fluid covers 101 must point toward the outlet manifold 103 AN Torque to 80 to 90 in Ib 9 to 10 N m See Torque Se quence page 30 A Arrow A must point toward outlet manifold 103 Not used on some models Beveled seating surface must face ball 301 ga 106A 112 AN 04157B Fig 11 Service Diaphragm Repair Disassembly NOTE A Fluid Section Repair Kit is available Refer to page 25 to order the correct kit for your pump Parts Tools Required included in the kit are marked with an asterisk for example 401 Use all the parts in the kit for the best e Torque wrench results A WARNING 10mm socket wrench To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the e 19mm open end wrench Pressure Relief Procedure on page 11 1 Relieve the pressure e Adjustable wrench 2 Remove the manifolds and disassemble the ball check valves as explained on page 18 SQ angiples 3 Using a 10 mm socket wrench remove the screws 106 and 112 holding the fluid covers 101 to the air covers 23 Pull the fluid covers 101 off the e Lithium base grease pump See Fig 12 You must torque the eight long screws 106 first then the short screws 112 Torque to 130 to 150 in lb 14 to 17 Nem See Torque Sequence page 30 AA Arrow A must point toward air valve B 04162B
32. om of the valve cavity The rounded side of the seal must face down into the groove See Fig 10 3 Install the valve plate 8m in the cavity On alumi num center housing models the plate is reversible so either side can face up Install the three screws 3 using a Torx T20 screwdriver or 7 mm 9 32 socket wrench Tighten until the screws bottom out on the housing See Fig 10 4 Install an o ring 17T on each pilot pin 16 Grease the pins and o rings Insert the pins into the bearings 15 narrow end first See Fig 9 5 Install a u cup packing 10T on each actuator piston 11 so the lips of the packings face the narrow end of the pistons See Fig 9 6 Lubricate the u cup packings 10T and actuator pistons 11 Insert the actuator pistons in the bearings 12 wide end first Leave the narrow end of the pistons exposed See Fig 9 7 Grease the lower face of the pilot block 18Tm and install so its tabs snap into the grooves on the ends of the pilot pins 16 See Fig 8 8 Grease the o ring 6T and install it in the valve block 7t Push the block onto the valve carriage 5 Grease the lower face of the valve block See Fig 8 9 Install the valve carriage 5 so its tabs slip into the grooves on the narrow end of the actuator pistons 11 See Fig 8 10 Align the valve gasket 4tm and cover 2 with the six holes in the center housing 1 Secure with six screws 3 using a Torx T20 s
33. om moving parts or contamination c The air line filter F removes harmful dirt and from hazardous fluids See Fig 2 moisture from the compressed air supply 1 Install the air line accessories as shown in Fig 2 2 Install a grounded flexible air hose A between Mount these accessories on the wall or ona the accessories and the 1 2 npt f pump air inlet bracket Be sure the air line supplying the acces N See Fig 2 Use a minimum 3 8 10 mm ID sories is grounded air hose Screw an air line quick disconnect cou pler D onto the end of the air hose A and screw a Install an air regulator C and gauge to control the mating fitting into the pump air inlet snugly Do the fluid pressure The fluid outlet pressure will not connect the coupler D to the fitting until you be the same as the setting of the air regulator are ready to operate the pump KEY A Air supply hose FLOOR MOUNT TYPICAL INSTALLATION B Bleed type master air valve required for pump Air regulator Air line quick disconnect Master air valve for accessories Air line filter Fluid suction line Fluid supply Fluid drain valve required Fluid shutoff valve Fluid line 1 2 npt f air inlet port 1 fluid inlet port 1 fluid outlet port Ground wire required see page 5 for installation instructions lt NDZ ACTIOMMIVO IL l L I Sal l
34. or equiva lent Torque to 20 to 25 ft lb 27 to 34 N m at 100 rpm maximum A A A Air Side must face center housing 1 A A A Used on Models with PTFE diaphragms only 04161B 308443 21 Service Bearing and Air Gasket Removal Tools Required e Torque wrench e 10mm socket wrench e Bearing puller e O ring pick e Press or block and mallet Disassembly NOTE Do not remove undamaged bearings A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 11 1 Relieve the pressure 2 Remove the manifolds and disassemble the ball check valves as explained on page 18 3 Remove the fluid covers and diaphragm assem blies as explained on page 19 NOTE If you are removing only the diaphragm shaft bearing 19 skip step 4 4 Disassemble the air valve as explained on page 16 5 Using a 10 mm socket wrench remove the screws 25 holding the air covers 23 to the center housing 1 See Fig 14 6 Remove the air cover gaskets 22 Always replace the gaskets with new ones 7 Use a bearing puller to remove the diaphragm shaft bearings 19 air valve bearings 12 or pilot pin bearings 15 Do not remove undamaged bearings 8 If you removed the diaphragm shaft bearings 19 reach into the center housing 1 with an o ring pick and hook the u cup packings 402 then pull them out of the housing Insp
35. ound 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 left Fig 2 shows a recommended method of grounding flam mable fluid containers during filling This is only a guide contact your Graco distributor for assistance in grounding your system Fig 1 02646B e Air and fluid hoses Use only grounded hoses with a maximum of 500 ft 150 m combined hose length to ensure grounding continuity e Air compressor Follow the manufacturer s recom mendations e All solvent pails used when flushing Follow the local code Use only grounded metal pails which are conductive Do not place the pail on a non con ductive surface such as paper or cardboard which interrupts the grounding continuity e Fluid supply container Follow the local code 308443 5 Installation Air Line b Locate one bleed type master air valve B A WARNING close to the pump and use it to relieve trapped air See the WARNING at left Locate the other A bleed type master air valve B is required in master air valve E upstream from all air line your system to relieve air trapped between this accessories and use it to isolate them during valve and the pump Trapped air can cause the cleaning and repair pump to cycle unexpectedly which could result in serious injury including splashing in the eyes or on the skin injury fr
36. 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 ends of tubes to external air signal such as Graco s Cycleflo P N 195264 or Cycleflo II P N195265 controllers NOTE the air pressure at the connectors must be at least 30 of the air pressure to the air motor for the pump to operate Fluid Suction Line e f using a conductive Acetal pump use conductive hoses G If using a non conductive polypropy lene or PVDF pump ground the fluid system See Grounding on page 5 e The pump fluid inlet R is a 1 raised face flange See Flange Connections on page 8 e 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 e At inlet fluid pressures greater than 15 psi 104 kPa 1 bar diaphragm life will be shortened e See the Technical Data on page 32 for maximum suction lift wet and dry Fluid Outlet Line A WARNING A fluid drain valve J is required to relieve pres sure in the hose if it is plugged The drain valve reduces the risk of serious injury including splash ing 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 1 Use grounded fluid hoses L The
37. tains 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 al ways 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 poly propylene 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 1071 Siemans me ter 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 Ground all of this equipment e 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 gr
38. ument sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concern es Extended Product Warranty Graco warrants all Husky 205 307 515 716 1040 1590 2150 and 3275 air valve center sections to be free from defects in material and workmanship for a period of fifteen years from date installed in service by the original purchaser Normal wear of items such as packings or seals are not considered to be defects in material and workmanship Five years Graco will provide parts and labor Six to Fifteen years Graco will replace defective parts only Graco Information TO PLACE AN ORDER contact your Graco distributor or call one of the following numbers to identify the distributor closest to you 1 800 328 0211 Toll Free 612 623 6921 612 378 3505 Fax All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice This manual contains English MM 308443 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea www graco com 308443 10 1994 Revised 08 2007 34 308443
39. using fluid to back up in the outlet line KEY R 1 fluid inlet port S 1 fluid outlet port V Pressure relief valve Part No 112119 stainless steel AN Install valve between fluid inlet and outlet ports A Connect fluid inlet line here A Connect fluid outlet line here i A F TRSN 04228B Fig 5 308443 9 Installation Air Exhaust Ventilation A WARNING A 4 FIRE AND EXPLOSION HAZARD Be sure to read FIRE OR EXPLOSION HAZARD and TOXIC FLUID HAZARD on page 3 before operating this pump Be sure the system is properly ventilated for your type of installation You must vent the exhaust to a safe place away from peo ple animals food handling 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 The air exhaust port is 3 4 npt f Do not restrict the air exhaust port Excessive exhaust restriction can cause erratic pump operation To provide a remote exhaust 1 Remove the muffler P from the pump air exhaust port Install a grounded air exhaust hose T and con nect the muffler P to the other end of the hose The minimum size for the air exhaust hose is 3 4 in 19 mm ID If a hose longer than 15 ft 4 57 m is required
Download Pdf Manuals
Related Search