Graco Hydra-Clean 1040 Gebrauchs- und Pflegehandbuch

Repair/Parts

SaniForce® SaniForce®

SaniForce®1040 1040

1040Air Air

Air- -

-Operated Operated

OperatedHigh High

High

Sanitation Sanitation

SanitationDiaphragm Diaphragm

DiaphragmPump Pump

Pump3A6780E

For For

Fortransfer transfer

transferof of

of󰘱uids 󰘱uids

󰘱uidsin in

insanitary sanitary

sanitaryapplications. applications.

applications.Not Not

Notapproved approved

approvedfor for

foruse use

usein in

inexplosive explosive

explosiveatmospheres atmospheres

atmospheresor or

hazardous hazardous

hazardous(classi󰘰ed) (classi󰘰ed)

(classi󰘰ed)locations locations

locationsunless unless

unlessotherwise otherwise

otherwisestated. stated.

stated.See See

SeeApprovals Approvals

Approvalspage page

pagefor for

formore more

moreinformation. information.

information.

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.

120psi(0.8MPa,8bar)MaximumFluid

WorkingPressure

120psi(0.8MPa,8bar)MaximumAir

InputPressure

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..................................18

Parts..................................................................20

Diaphragms.................................................23

TechnicalSpeci󰘰cations......................................25

Related Related

RelatedManuals Manuals

Manuals

ManualNumberTitle

3A5999SaniForceHighSanitationDiaphragmPumps,Operation

23A6780E

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,suchassolvent,inwork work

workarea area

areacanigniteorexplode.Solvent󰘱owingthrough

theequipmentcancausestaticsparking.Tohelpprevent󰘰reandexplosion:

•Useequipmentonlyinwellventilatedarea.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and

plasticdropcloths(potentialstaticarc).

•Groundallequipmentintheworkarea.SeeGrounding Grounding

Groundinginstructions.

•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.

•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable

fumesarepresent.

•Useonlygrounded󰘱uidlines.

•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.

•Check󰘱uidlines,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.

3A6780E3

Warnings

WARNING

EQUIPMENT EQUIPMENT

EQUIPMENTMISUSE MISUSE

MISUSEHAZARD HAZARD

HAZARD

Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated

systemcomponent.SeeTechnical Technical

TechnicalSpeci󰘰cations Speci󰘰cations

Speci󰘰cationsinallequipmentmanuals.

•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical

Technical

Speci󰘰cations Speci󰘰cations

Speci󰘰cationsinallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.

Forcompleteinformationaboutyourmaterial,requestSafetyDataSheet(SDS)from

distributororretailer.

•TurnoffallequipmentandfollowthePressure Pressure

PressureRelief Relief

ReliefProcedure Procedure

Procedurewhenequipmentisnotinuse.

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine

manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals

andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Route󰘱uidlinesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhot

surfaces.

•Donotkinkoroverbend󰘱uidlinesoruse󰘱uidlinestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

TOXIC TOXIC

TOXICFLUID FLUID

FLUIDOR OR

ORFUMES FUMES

FUMESHAZARD HAZARD

HAZARD

Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,

inhaled,orswallowed.

•ReadSafetyDataSheet(SDS)toknowthespeci󰘰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.

43A6780E

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

WettedSection

Material

DriveCenterSectionandAir

ValveMaterial

ManifoldsSeatsChecksDiaphragmsSealsCerti󰘰ca-

tion

NOTE: NOTE:

NOTE:Somecombinationsarenotpossible.Pleasecheckwithyourlocalsupplier.

Pump Pump

PumpWetted Wetted

WettedSection Section

Section

Material Material

Material

Drive Drive

DriveType Type

TypeCenter Center

CenterSection Section

Sectionand and

andAir Air

AirValve Valve

Valve

Material Material

Material

Manifolds Manifolds

Manifolds

1040 1040

1040HS HS

HSHighSanitationP P

PPneumatic

S01A S01A

S01A

StainlessSteel,for

allbut2-piecePS

diaphragms

SSA SSA

SSAStainlesssteel,

TriClamp,center-ported

PH PH

PHPharmaceuticalS03A S03A

S03AStainlessSteel,PH,

forallbut2-piecePS

diaphragms

SSB SSB

SSBStainlesssteel,DIN,

center-ported

SP1A SP1A

SP1A

StainlessSteel,

PSdiaphragms,

for2-piecePS

diaphragmsonly

SP3A SP3A

SP3AStainlessSteel,

PH,for2-piecePS

diaphragmsonly

Seat Seat

SeatMaterial Material

MaterialChecks Checks

ChecksDiaphragm Diaphragm

DiaphragmMaterial Material

MaterialSeals Seals

SealsCerti󰘰cation Certi󰘰cation

Certi󰘰cation

SS SS

SS316Stainless

Steel,BallBN BN

BNBuna-NBN BN

BNBuna-N21 21

21EN10204

type2.1

CW CW

CWPolychloroprene

WeightedBallFK FK

FKFKM

FluoroelastomerEP EP

EPEPDM31 31

31EN10204

type3.1

FK FK

FKFKM

Fluoroelastomer

Ball

PO PO

POPTFE/EPDM

OvermoldFK FK

FKFKM

PT PT

PTPTFEBallPS PS

PSPTFE/

Santoprene,2

piece

SP SP

SPSantopreneBallSP SP

SPSantoprene

3A6780E5

OrderingInformation

Approvals Approvals

Approvals

Allpumpsareapprovedto:

II2GD

ExhIIAT6...T3Gb

ExhIIIBT160°CDb

Modelswhichusediaphragmmaterials

codedPOorPScombinedwithPTball

checkscomplywith:

EC1935/2004

DiaphragmmaterialscodedPScombined

withPTballcheckscomplywith:

ClassVI

Allmodelsareapprovedto:

All󰘱uidcontactmaterialsareFDAcompliant

andmeettheUnitedStatesCodeofFederal

Regulations(CFR)

ATEXT-coderatingisdependentonthetemperatureofthe󰘱uidbeingpumped.Fluidtemperatureislimited

bythematerialsofthepumpinteriorwettedparts.SeeTechnicalSpeci󰘰cations,page25,forthemaximum

󰘱uidoperatingtemperatureforyourspeci󰘰cpumpmodel.

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.

63A6780E

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

overmoldeddiaphragmrepair

procedure.

Reducedpump

performance.

Restrictedexhaust.Removerestriction.

Loosesuctionline.Tighten.

Ruptureddiaphragm.Replace.Seestandardor

overmoldeddiaphragmrepair

procedure.

Airbubblesin󰘱uid.

Looseinletmanifold,damagedseal

betweenmanifoldand󰘱uidcover,or

damagedgaskets.

Tightenmanifoldclampsorreplace

gasketsorseatingsurfaces.

Loosesanitaryclamp.Tightenclamp.

Damagedorworngasket.Replacegasket.

Leakininletoroutlet

sanitary󰘰tting.

Misalignmentofinlet/outlet󰘱uidline

orpipe.

Use󰘱exible󰘱uidlinesatpumpinlet

andoutlet.

Manifoldsdonot󰘰tfor

installationonto󰘱uid

covers.

Useofincorrectaircovergaskets

resultsinmisalignment.

Installcorrectaircovergasketsfor

thetypeofdiaphragmsinuse.See

Partslistforcorrectgasket.

3A6780E7

Troubleshooting

Problem Problem

ProblemCause Cause

CauseSolution Solution

Solution

Diaphragmruptured.Replace.Seestandardor

overmoldeddiaphragmrepair

procedure.

Fluidinexhaustair.

Loosediaphragmplate.Tightenorreplace.Seestandard

orovermoldeddiaphragmrepair

procedure.

Wornairvalveblock,plate,pilot

block,u-cups,orpilotpino-rings.

Repairorreplace. Pumpexhaustsexcessive

airatstall.

Wornshaftseals.Replace.Seestandardor

overmoldeddiaphragmrepair

procedure.

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.

83A6780E

Repair

Repair Repair

Repair

Pressure Pressure

PressureRelief Relief

ReliefProcedure Procedure

Procedure

FollowthePressureReliefProcedure

wheneveryouseethissymbol.

Thisequipmentstayspressurizeduntilpressureis

manuallyrelieved.Tohelppreventseriousinjury

frompressurized󰘱uid,suchassplashing󰘱uid,

followthePressure Pressure

PressureRelief Relief

ReliefProcedure Procedure

Procedurewhenyou

stopdispensingandbeforecleaning,checking,or

servicingtheequipment.

1.Closethemasterairvalve(A)toshutofftheair

tothepump.

2.Openoutbound󰘱uidvalvetorelieve󰘱uid

pressurefromthepump.

3.If󰘱uidisstillintheoutbound󰘱uidlines,isolate

this󰘱uidasfollows:

a.For For

Forsimple simple

simpletransfer transfer

transferapplications, applications,

applications,openeither

the󰘱uidshutoffvalve(J)orthe󰘱uiddrain

valve(K).

b.For For

Forcirculating circulating

circulatingapplications, applications,

applications,ensurethatthe

󰘱uidshutoffvalve(J)isclosedandopenthe

󰘱uiddrainvalve(K).

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.

3A6780E9

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,page20.Thebearingsaretaperedand,

ifdamaged,mustberemovedfromtheoutside.

Thisrequiresdisassemblyofthe󰘱uidsection.

SeeCenterSectionRepair,page18.

7.Cleanallpartsandinspectforwearordamage.

Replaceasneeded.

Reassemble Reassemble

ReassembleAir Air

AirValve Valve

Valve

NOTE: NOTE:

NOTE:Ifrepairsinvolveremoving

󰘱uidcovers,performthestepsin

ReassembletheOvermoldedDiaphragms,page16,

priortoreassemblyoftheairvalve.Theairvalve

con󰘰gurationwillbemodi󰘰edtoaid󰘱uidcover

installation.

1.Ifthecentersectionwasdisassembledto

replacethebearings(113,115),complete

theCenterSectionRepair,page18,before

continuingwiththeairvalvereassembly.

2.Installthevalveplate(110)inthecavity,seal

down.Installthethreescrews(107),usinga

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

wrench.Tightenuntilthescrewsbottomouton

thehousing.

3.Installano-ring(108)oneachpilotpin(112).

Greasethepinsando-rings.Insertthepinsinto

thebearings,

narrow narrow

narrow

end󰘰rst.

4.Installu-cups(106)oneachactuatorpiston

(114),sothelipsofthepackingsfacethe

narrow narrow

narrow

endofthepistons.

5.Lubricatetheu-cups(106)andactuatorpistons

(114).Inserttheactuatorpistonsinthebearings

(115),

wide wide

wide

end󰘰rst.Leavethenarrowendof

thepistonsexposed.

6.Greasethelowerfaceofthepilotblock(116)and

installsoitstabssnapintothegroovesonthe

endsofthepilotpins(112).

7.Greasethelowerfaceofthevalvecarriage(105).

8.Installthevalvecarriage(105)soitstabsslipinto

thegroovesonthenarrowendoftheactuator

pistons(114).

103A6780E

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