Graco Hydra-Clean 1040 Manual

Repair/PartsList

SaniForce®1040Air-Operated

HighSanitationDiaphragmPump

3A6780D

For For

Foruse use

usein in

insanitary sanitary

sanitaryapplications. applications.

applications.

For For

Forprofessional professional

professionaluse use

useonly. only.

only.

Important Important

ImportantSafety Safety

SafetyInstructions Instructions

Instructions

Readallwarningsandinstructionsinthismanualandrelated

manualsbeforeusingtheequipment.Save Save

Saveall all

allinstructions. instructions.

instructions.

Maximumworkingpressure:120psi

(0.8MPa,8bar)

Seepage6forapprovals.

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents

Contents

RelatedManuals................................................2

Warnings...........................................................3

Con󰘰gurationNumberMatrix...............................5

OrderingInformation...........................................6

Troubleshooting..................................................7

Repair................................................................9

PressureReliefProcedure............................9

AirValveRepair...........................................9

CheckValveRepair.....................................12

StandardDiaphragmRepair.........................13

OvermoldedDiaphragmRepair.....................15

CenterSectionRepair..................................17

Parts..................................................................19

TechnicalData...................................................24

Related Related

RelatedManuals Manuals

Manuals

ManualNumberTitle

3A5999SaniForceHighSanitationDiaphragmPumps,Operation

23A6780C

Warnings

Warnings Warnings

Warnings

Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The

exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c

risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese

Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout

thebodyofthismanualwhereapplicable.

WARNING

FIRE FIRE

FIREAND AND

ANDEXPLOSION EXPLOSION

EXPLOSIONHAZARD HAZARD

HAZARD

Flammablefumes,suchassolventandpaintfumes,inwork work

workarea area

areacanigniteorexplode.Paint

orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reand

explosion:

•Useequipmentonlyinwellventilatedarea.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and

plasticdropcloths(potentialstaticarc).

•Groundallequipmentintheworkarea.SeeGrounding Grounding

Groundinginstructions.

•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.

•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable

fumesarepresent.

•Useonlygroundedhoses.

•Stop Stop

Stopoperation operation

operationimmediately immediately

immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse

equipmentuntilyouidentifyandcorrecttheproblem.

•Keepaworking󰘰reextinguisherintheworkarea.

•Routeexhaustawayfromallignitionsources.Ifdiaphragmruptures,󰘱uidmaybeexhausted

withair.

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.

3A6780C3

Warnings

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,requestSafetyDataSheet(SDS)fromdistributororretailer.

•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.

TOXIC TOXIC

TOXICFLUID FLUID

FLUIDOR OR

ORFUMES FUMES

FUMESHAZARD HAZARD

HAZARD

Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,

inhaled,orswallowed.

•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.

•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.

43A6780C

CongurationNumberMatrix

Con󰘰guration Con󰘰guration

Con󰘰gurationNumber Number

NumberMatrix Matrix

Matrix

Checktheidenti󰘰cationplate(ID)forthe

Con󰘰gurationNumberofyourpump.Usethe

followingmatrixtode󰘰nethecomponentsofyour

pump.

Whenyoureceiveyourpump,recordthe9character

partnumberfoundontheshippingbox(e.g.,

SP1B.0018):_____________

Alsorecordthecon󰘰gurationnumberonthepumpID

platetoassistyouwhenorderingreplacementparts:

_____________________________________

Sample Sample

SampleCon󰘰guration Con󰘰guration

Con󰘰gurationNumber: Number:

Number:1040HS.PSP1ASSASSPTPSEP21 1040HS.PSP1ASSASSPTPSEP21

1040HS.PSP1ASSASSPTPSEP21

1040 1040

1040HS HS

HSP P

PSP1A SP1A

SP1ASSA SSA

SSASS SS

SSPT PT

PTPS PS

PSEP EP

EP21 21

Pump

Model

WettedSectionDriveCenterSectionandAir

Valve

ManifoldsSeatsChecksDiaphragmsSealsCerti󰘰ca-

tion

NOTE: NOTE:

NOTE:Somecombinationsarenotpossible.Pleasecheckwithyourlocalsupplier.

Pump Pump

PumpWetted Wetted

WettedSection Section

SectionDrive Drive

DriveType Type

TypeCenter Center

CenterSection Section

Sectionand and

andAir Air

AirValve Valve

ValveManifolds Manifolds

Manifolds

1040 1040

1040HS HS

HSHighSanitationP P

PPneumaticS01A S01A

S01AStainlessSteelSSA SSA

SSAStainlesssteel,

TriClamp,center-ported

PH PH

PHPharmaceuticalS03A S03A

S03AStainlessSteel,PHSSB SSB

SSBStainlesssteel,DIN,

center-ported

SP1A SP1A

SP1AStainlessSteel,PS

diaphragms

SP3A SP3A

SP3AStainlessSteel,PH,

PSdiaphragms

Seat Seat

SeatMaterial Material

MaterialChecks Checks

ChecksDiaphragm Diaphragm

DiaphragmMaterial Material

MaterialSeals Seals

SealsCerti󰘰cation Certi󰘰cation

Certi󰘰cation

SS SS

SS316Stainless

Steel,BallCW CW

CWPolychloroprene

WeightedBallFK FK

FKFKM

FluoroelastomerEP EP

EPEPDM21 21

21EN10204

type2.1

FK FK

FKFKM

Fluoroelastomer

Ball

PO PO

POPTFE/EPDM

Overmold31 31

31EN10204

type3.1

PT PT

PTPTFEBallPS PS

PSPTFE/

Santoprene,2

piece

SP SP

SPSantopreneBallSP SP

SPSantoprene

3A6780C5

OrderingInformation

Approvals Approvals

Approvals

Modelswhichusediaphragm

materialscodedPOorPS

combinedwithPTballchecks

arecerti󰘰edto:

EC1935

AllModelsarecerti󰘰edto

FDAstandardsand

II2GD

ExhIIAT6...T3GbX

ExhIIIBT160°CDb

Ordering Ordering

OrderingInformation Information

Information

To To

ToFind Find

FindYour Your

YourNearest Nearest

NearestDistributor Distributor

Distributor

1.Visitwww.graco.com.

2.ClickonWhere Where

Whereto to

toBuy Buy

BuyandusetheDistributor Distributor

DistributorLocator. Locator.

Locator.

To To

ToSpecify Specify

Specifythe the

theCon󰘰guration Con󰘰guration

Con󰘰gurationof of

ofa a

aNew New

NewPump Pump

Pump

Please Please

Pleasecall call

callyour your

yourdistributor. distributor.

distributor.

OR OR

UsetheOnline Online

OnlineDiaphragm Diaphragm

DiaphragmPump Pump

PumpSelector Selector

Selectorat at

atwww.graco.com www.graco.com

www.graco.com. .

.Tolocate,searchonselector selector

selector.

To To

ToOrder Order

OrderReplacement Replacement

ReplacementParts Parts

Parts

Please Please

Pleasecall call

callyour your

yourdistributor. distributor.

distributor.

63A6780C

Troubleshooting

Troubleshooting Troubleshooting

Troubleshooting

•FollowthePressureReliefProcedure,page9,

beforecheckingorservicingtheequipment.

•Checkallpossibleproblemsandcausesbefore

disassembly.

Problem Problem

ProblemCause Cause

CauseSolution Solution

Solution

Pumpcyclesatstallor

failstoholdpressureat

stall.

Wornchecksorseatingsurfaces.Replace.

Airvalveisstuckordirty.Disassembleandcleanairvalve.

Use󰘰lteredair.

Checkballisseverelywornand

wedgedinseatormanifold.

Replaceballandseat.

Checkvalveballisseverelywedged

intoseatduetooverpressurization.

PressureReliefProcedure,page9.

Disassembleballcheckassembly

andinspectfordamage.

Cloggeddispensingvalve.Follow

PressureReliefProcedure,page9.

Clearvalve.

Pumpwillnotcycle,or

cyclesonceandstops.

Leakdetectorhasactivatedashut-

downsolenoid.

Investigatefailureandresetleak

detector.

Cloggedsuctionline.Inspect;clear.

Stickyorleakingcheckballs.Cleanorreplace.

Ruptureddiaphragm.Replace.Seestandardor

Overmoldedrepairprocedure.

Pumpoperates

erratically.

Restrictedexhaust.Removerestriction.

Loosesuctionline.Tighten.

Ruptureddiaphragm.Replace.Seestandardor

Overmoldedrepairprocedure.

Airbubblesin󰘱uid.

Looseinletmanifold,damagedseal

betweenmanifoldand󰘱uidcover,or

damagedgaskets.

Tightenmanifoldclampsorreplace

gasketsorseatingsurfaces.

Loosesanitaryclamp.Tightenclamp.

Damagedorworngasket.Replacegasket.

Leakininletoroutlet

sanitary󰘰tting.

Misalignmentofinlet/outlethoseor

pipe.

Use󰘱exiblehosesatpumpinletand

outlet.

Manifoldsdonot󰘰tfor

installationonto󰘱uid

covers.

Useofincorrectaircovergaskets

resultsinmisalignment.

Installcorrectaircovergasketsfor

thetypeofdiaphragmsinuse.See

Partslistforcorrectgasket.

3A6780C7

Troubleshooting

Problem Problem

ProblemCause Cause

CauseSolution Solution

Solution

Diaphragmruptured.Replace.Seestandardor

Overmoldedrepairprocedure.

Fluidinexhaustair.

Loosediaphragmplate.Tightenorreplace.Seestandardor

Overmoldedrepairprocedure.

Wornairvalveblock,plate,pilot

block,u-cups,orpilotpino-rings.

Repairorreplace. Pumpexhaustsexcessive

airatstall.

Wornshaftseals.Replace.Seestandardor

Overmoldedrepairprocedure.

Airvalvecoverisloose.Tightenscrews.

Airvalvegasketoraircovergasket

isdamaged.

Inspect;replace.

Pumpleaksairexternally.

AircoverclampsarelooseTightenclamps.

Pumpleaks󰘱uid

externallyfromballcheck

valves.

Loosemanifolds,damagedseal

betweenmanifoldand󰘱uidcover,or

damagedgaskets.

Tightenmanifoldclampsorreplace

seatsorclamps.

Chattering.Checkvalveballsnotseating

properly/cleanlyduetoimbalance

between󰘱uidinletandoutletline

sizing.Noiseisaccentuatedwith

lightviscosity󰘱uids.

Reducesize/diameterofinletline

relativetooutletline.Outletlinesize

shouldnotexceedpumpsize.

83A6780C

Repair

Repair Repair

Repair

Pressure Pressure

PressureRelief Relief

ReliefProcedure Procedure

Procedure

FollowthePressureReliefProcedure

wheneveryouseethissymbol.

Trappedaircancausethepumptocycle

unexpectedly,whichcouldresultinserious

injuryfromsplashing.FollowthePressure Pressure

PressureRelief Relief

Relief

Procedure Procedure

Procedurewhenyoustoppumpingandbefore

cleaning,checking,orservicingequipment.

1.Shutofftheairtothepump.

2.Openanyavailableoutbound󰘱uidvalveto

relieve󰘱uidpressurefromthepump.

3.If󰘱uidisstillintheoutbound󰘱uidlines,isolate

this󰘱uidasfollows:

a.Closetheoutbound󰘱uidvalves.

b.Slowlyremovethe󰘱uidconnectionsfromthe

pump,andhaveacontainerreadytocatch

any󰘱uidthatrunsout.

Air Air

AirValve Valve

ValveRepair Repair

Repair

ToolsRequired

•Torquewrench

•Torx(T20)screwdriveror7mm(9/32in.)socket

wrench

•Needle-nosepliers

•O-ringpick

•Lithiumbasegrease

Airvalverepairkit255122isavailable.Useallparts

inthekitforbestresults.

Disassemble Disassemble

DisassembleAir Air

AirValve Valve

Valve

1.FollowthePressureReliefProcedure,page9.

2.WithaTorx(T20)screwdriveror7mm(9/32in.)

socketwrench,removethesixscrews(107),air

valvecover(109),andgasket(118).

3.Movethevalvecarriage(105)tothecenter

positionandpullitoutofthecavity.Usinga

needle-nosepliers,pullthepilotblock(116)

straightupandoutofthecavity.

4.Pullthetwoactuatorpistons(114).Removethe

u-cups(106)fromthepistons.Pullthepilotpins

(112).Removetheo-rings(108)fromthepilot

pins.

3A6780C9

Repair

5.Inspectthevalveplate(110)inplace.If

damaged,useaTorx(T20)screwdriveror7mm

(9/32)in.)socketwrenchtoremovethethree

screws(107).Removethevalveplate(110).

6.Inspectthebearings(113,115)inplace.See

Parts,page19.Thebearingsaretaperedand,

ifdamaged,mustberemovedfromtheoutside.

Thisrequiresdisassemblyofthe󰘱uidsection.

SeeCenterSectionRepair,page17.

7.Cleanallpartsandinspectforwearordamage.

Replaceasneeded.

Using

Using Diaphragm

Diaphragm

Diaphragm Install

Install

Install Tool

Tool

If repairs involve removal of 󰘱uid covers, these steps

will ease installation of 󰘱uid c overs. These steps

should be performed prior to reassembly of the air

valve because the air valve con󰘰guration will be

modi󰘰ed to aid 󰘱uid cover installation.

The diaphragm install tool kit 24V543 is available

separately.

1.Iftheairvalveassemblyhasnotbeen

disassembled:

a.Removetheairvalvecover(109)andgasket

(118).

b.Removethevalvecartridge(105)andboth

pistons(114).

c.Insertthetravelrestrictors(2)fromthe

diaphragminstalltoolkitintotheactuator

pistons(E).Lubricatetheu-cupsandinsert

theactuatorpistonsinthebearings(115),

wide wide

wide

end󰘰rst.Leavethenarrowendofthe

pistonsexposed.

d.Proceedtostep4below.

2.Iftheairvalveassemblyhasbeendisassembled,

performstep1throughstep4oftheairvalve

reassemblyprocedure.

3.Installtheu-cups(106)ontotheactuatorpistons

(E)andinsertthetravelrestrictors(2)fromthe

diaphragminstalltoolkitintotheactuatorpistons

(E).Lubricatetheu-cupsandinserttheactuator

pistonsinthebearings(115),

wide wide

wide

end󰘰rst.

Leavethenarrowendofthepistonsexposed.

4.Installthesupplieddiaphragminstalltool(1)so

thatthearrow(A)pointstowardthesideofthe

pumpwiththediaphragmagainsttheaircover.

Installtheairvalvegasket(C)andcover(B).

Snugtheairvalvecoverscrews.

5.Lubricatetheinnersurfaceofbothcoverclamps

withwaterproofsanitarylubricant.Installthe

coverandclamponthesideofthepumpwith

thediaphragmagainsttheaircover.Leavethe

clampslightlytightenedbutlooseenoughto

allowminorcoverrotationtoallowforalignment

withtheinletandoutletmanifolds.

6.Supplythepumpwithlowpressureair,just

enoughtomovethediaphragm.Useabout10to

20psi(0.07MPa,0.7to1.4bar).Shopairmay

beused.Thediaphragmwillshiftsothesecond

󰘱uidcoverwillseatproperly.Keepairpressure

on.

7.Installtheremaining󰘱uidcoverandclamp.

8.Removeairsupplyfrompump.

9.Removetheairvalvecover(B),gasket(C)and

thetool(1).

10.Removethepistons(E)andthetravelrestrictors

(2).

11.Lubricateandinstallthepistons(E).

12.Tocompleteassemblyoftheair

valveassembly,proceedtostep6of

ReassembleAirValve,page11.

103A6780C

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