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Hitachi FD2 1590 manual

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Table of contents for the manual

  • Page 1

    311879F Instr uctions - P ar ts List Sanitar y Series FD A-Compliant Diaphra gm Pumps For use in sanitary applications. Model FD1___ 1040 FD A Model FD2___ 1590 FD A Model FD3___ 2150 FD A 120 psi (0.8 MP a, 8 bar) Maxim um Air/Fluid W or king Pressure Impor tant Sa fety Instruc tions Read all warnings and inst r uctions in this manual. Sav e these[...]

  • Page 2

    2 311879F Contents Cer tificate of Conformance . . . . . . . . . . . . . . . . . . 3 W arnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Maintenance . . . . . . . . . .[...]

  • Page 3

    Certificate of Confo rmance 311879F 3 Cer tificate of Conf ormance P ar t Number : All FD1, FD2, FD3 models Description: FD A-Compliant Diaphr agm Pump Materials of Construction: All fluid co ntacted materials are FD A- compliant and meet CFR Title 21, Section 177. Bradle y A. Byron QMS Management Representativ e Graco Inc.[...]

  • Page 4

    Warnings 4 311879F Wa r n i n g s The f ollowing w ar nings are f or the setup , use , grounding, maintenance , and repair of this equipment . The exclama- tion point symbol alerts you to a gener al warning and the hazard symbol refers to procedure-specific risk. Ref er bac k to these wa r nings. Add itional, product- specific w arnings may be f ou[...]

  • Page 5

    Warning 311879F 5 T O XIC FLUID OR FUMES HAZARD T o xic fluids or fumes can cause serious injur y or death if splashed in the e y es or on skin, inhaled, or s wal- lowe d. • Read MSDS’ s to know the specific hazards of the flu ids you are using. • Store hazardous fluid in app rov ed containers , and dispose of it according to applicab le guid[...]

  • Page 6

    Installation 6 311879F Installation General Information • The typical installat ions shown in Figs . 2-4 are only guides f or selecting an d installing system compo- nents . Contact y our Graco d istributor f or assistance in planning a system to suit your needs. • Alwa ys use genuin e Graco par ts and accessories. • Ref erence n umbers and l[...]

  • Page 7

    Installation 311879F 7 Mountings • Be sure the mounting surf ace can suppor t the weight of the pum p , hoses, and acces sorie s, as well as the stress caused during oper ation. • F or all mountings, be sure the pump is bolted directly to the mount ing surface . • F or ease of oper ation and service, mount the pump so the air v alv e cov er ([...]

  • Page 8

    Installation 8 311879F Fluid Outlet Line 1. Use fle xib le grounded fluid ho ses (L). 2. F or best sealing results , use a standard T ri-Clamp® style sanitar y gasket of a fle xible material such as EPDM, Buna-N, fluoroelastomer , or silicon 3. Install a fluid dr ain v alve ( J) near the fluid outle t. See the WA R N I N G above , and F IG . 2. 4.[...]

  • Page 9

    Installation 311879F 9 Changing the Or ientation of t he Fluid Inlet and Outlet P orts The pump is ship ped with the ports f acing the same direction. T o rev erse th e or ientation of th e por ts : 1. Remov e the clamps holdi ng the inlet and/or outlet manifold to the cov ers. 2. Re verse t he manif old and reattach. Install an d tighten clamps sn[...]

  • Page 10

    Installation 10 311879F Air Exhaust V entilation The air exhaust por t is 3/4 npt( f). Do not res trict th e air e xhaust por t. Excessiv e exhaust restriction can cause erratic pum p operation. T o provide a remote exhaust: 1. Remov e the mu ffler (P) from the pump air exhau st por t. 2. Install a gr ounded air e xhaust hose (T) and connect the mu[...]

  • Page 11

    Operation 311879F 11 Operation Pressure Relief Procedure 1. Shut off the ai r to the pump. 2. Open the dispensing v alv e, if used. 3. Open th e fluid drain valv e to r elie ve fluid pressure, having a container ready to cat ch the drainage . Sanitize the Pump Befo re First Use It is the user’ s responsibility to properly sanitize the pump before[...]

  • Page 12

    Operation 12 311879F[...]

  • Page 13

    Maintenance 311879F 13 Maintenance Lubrication The air v alve is d esigned to operate unlubricated, ho w- e ver if lubrication is desir ed, ev ery 500 hours of opera- tion (or mont hly) remov e the hose fro m the pump air inlet and add two drops of machine oil to the air inlet. Flushing Inser t suction tube in to cleaning solution. Open air regu- l[...]

  • Page 14

    Troubleshooting 14 311879F T r oub leshooting • Relie ve the pressure bef ore chec king or ser vicing the equipment. • Chec k all possible prob lems and causes bef ore dis- assemblin g the pump . T o reduce the risk of serious injury , whene v er you are instructed to relie v e pressure, alw a ys fo llow the Pres- sure Relief Procedur e on page[...]

  • Page 15

    Troubleshooting 311879F 15 Leak in inlet or outlet sa nitar y fit- ting. Loose sanitar y clamp. Tighten clamp. Damaged or w or n gask et. Replace gask et. Misalignment of in let/outlet hose or pipe. Use fle xible hoses at pump i nlet and outlet. Gasket does not seal. Use a stand ard sanitar y gas ket of fle xi- bl e material such as EPDM, Buna-N, f[...]

  • Page 16

    Service 16 311879F Service Repairing the Air V alve T ool Required • T orque wrench • T orx (T20) scr ewdriver or 7 mm (9/32 in .) sock et wrench • Needle-nose pliers • O-ring pick • Lithium base g rease Disassemb ly 1. Relie ve the pressure . 2. With a T orx (T 20) screwdriver or 7 m m (9/32 in.) sock et wrench, remov e the six screws (3[...]

  • Page 17

    Service 311879F 17 F IG . 5 F IG . 6 F IG . 7 F IG . 8 TI9086A 2 2 2 4† 3 T orque to 52-60 in-lb (5.6-6.8 N • m ) TI9087A Detail 5 †6 †7 2 1 3 2 3 See detail at right Grease Grease low er face 18† 5 3 1 TI9088A TI9089A 2 1 3 4 11 12 17† 15 16 4 1 2 Inser t narrow end first Grease Install with lips facing narrow end of piston (11) Inser [...]

  • Page 18

    Service 18 311879F Ball Chec k V alve Repair T ools Required • O-ring pick Disassemb ly 1. Relie ve th e pressure. Disconnect all hoses . 2. Remov e the pump from it s mounting. 3. Remove the clamps (106 ) holding th e outlet mani- f old (103) to the fluid co vers (101 ). See F IG . 9. 4. Remov e the o-rings (202), seats (201), and balls (301) fr[...]

  • Page 19

    Service 311879F 19 Standard Diaphra gm Repair T ools Required • T orque wrench • 15 mm soc ket wr ench • 19 mm open end wrench • O-ring pick • Lithium-b ase grease Disassemb ly 1. Relie ve the pressure . 2. Remov e the manif olds and disassemble the ball chec k valv es as e xplained on page 18. 3. Remov e the clamps ( 106) holding the f l[...]

  • Page 20

    Service 20 311879F 4. Loosen b ut do not remov e the diaphr agm shaft bolts (107), usin g a 15 mm so ck et wrench o n both bolts. See F IG . 11. 5. Unscre w one bolt from the diaphragm shaft (24) and remov e the o-ring (108), fluid side diaphragm plate (105), diaphr agm (403), bac ker (40 1) used only on PTFE models , and air side diaphr agm plate [...]

  • Page 21

    Service 311879F 21 F IG . 11 TI8935a TI8933a TI8934a Cutaw ay vie w , with diaphragm s in place Lips face out of housing (1). Rounded side faces diaphragm (401). Air side must f ace center housing (1). Grease. Apply medium strength (blue) Loctite ® or equivalent. T orque to 60-70 ft-lb (81-95 N•m) at 100 r pm maximum. Back er used on pumps with [...]

  • Page 22

    Service 22 311879F Heavy-Duty Diaphra gm Repair T ools Required • T orque wrench • 19 mm open end wrench • O-ring pick • Lithium-b ase grease Disassemb ly 1. Relie ve the pressure . 2. Remove the manif olds and dis assemble the ball chec k valv es as e xplained on page 18. 3. Remov e the clamps (106) holding the fluid cov ers (101) to the a[...]

  • Page 23

    Service 311879F 23 Reassembl y 1. Install the shaft u-cup pac kings (402*) so the lips f ace out of the housing (1 ). Lubricate the pac kings. See F IG . 13. 2. Assemble the air s ide plate (104) onto the dia- phragm (4 03). The wide, r adiused side of the plate must f ace the diaphr agm. Apply medium-str ength (blue) Loctite ® or equ ivalent t o [...]

  • Page 24

    Service 24 311879F Bearing and Air Gasket Remov al T ools Required • T orque wrench • 10 mm soc ket wr ench • Bearing puller • O-ring pick • Press, or bloc k and malle t Disassemb ly 1. Relie ve the pressure . 2. Remove the manif olds and dis assemble the ball chec k valv es as e xplained on page 18. 3. Remove the fluid cov ers and diap h[...]

  • Page 25

    Service 311879F 25 F IG . 14 TI9093A TI9092a 2 1 3 Inser t bear ings tapered end first Press-fit bearings flush with surface of center housing (1) Apply medium strength (blue) Loctite ® or equiva lent. T orque to 130-150 in-lb (15-17 N•m) 1 2 12 1 16 19 H 22 M 23 25 15 2 1 3 1 2 Detail of air v alve bea rings[...]

  • Page 26

    Pump Matrix - 1040 26 311879F Pump Matrix - 1040 1040 FD A-Compliant Stainle ss Steel Sanitary Pumps Y our Model No . is marked on the pump’ s serial plate. T o determine the Model No . of your pump from the f ollow- ing matrix, select the six digits which describe y our pump , working from le ft to right. The first thr ee digits are alwa ys FD1,[...]

  • Page 27

    Repair Kit Matrix - 1040 311879F 27 Repair Kit Matrix - 1040 For 1040 Stainless Steel Sanitary Pumps Repair Kits ma y be ordered separat ely . T o repair the air v alve , order P art No. 255061 (see page 28). P arts included in the Air V alve Repair Kit are mark ed with a symbol in the par ts list, f or example (4†). T o repair y our pump , selec[...]

  • Page 28

    Parts - 1040 28 311879F P ar ts - 1040 3 †4 5 6† 7† 8† 19 402* 15 1 111 20 †18 16 †17 11 †10 2 104 24 25 22 11 10† 17† 202 * 201 301 * 103 110 ▲ 105 403* 401* 202* 201 301* 101 108* 107 1 Used on pumps with PTFE diaphragms only . These par ts are included in the Pump Repair Kit which may be purchased separately . Refer to the Re[...]

  • Page 29

    Parts - 1040 311879F 29 Air Motor P ar ts List (Matrix Column 2) † These par ts are included in Air V alve Repair kit 255061 which ma y be purchased separate ly . Ref. P art No. Description Qty 1 15K009 HOUSING, center; SST 1 2 15A735 CO VER, air valv e; SST 1 3 116344 SCREW , mach, hex flange hd; M5 x 0.8; 12 mm (0.47 in.) 9 4† 188618 GASKET ,[...]

  • Page 30

    Parts - 1040 30 311879F Fluid Section P ar ts Li st (Matrix Column 3) * These par ts are included in the Pump Repair Kit wh ich ma y be purchased separately . Ref er to the Repair Kit Matr ix on page 27 to deter mine the correct kit for y our pump. ▲ Replacement Danger and W ar ning labels, tags, and cards are av ailable at no cost. Seat P ar ts [...]

  • Page 31

    Dimensional Drawing - 1040 311879F 31 Dimensional Dra wing - 1040 1040 FD A !IR)NLET NPTF !IR%XHAUST MUFFLERINCLUDED NPTF IN MM IN MM IN MM IN MM IN [...]

  • Page 32

    Technical D ata - 1040 32 311879F T e c hnical Data - 1040 Santoprene ® is a registered t rademark of the M onsanto Co . Loctite ® is a registered tradema rk of the Loctite Corporation. * Displacement per cycle ma y v ary based on suctio n condi tion, discharge head, air pressure, and fluid type . ** Noise le vels me asured with the pump mounted [...]

  • Page 33

    Performance Chart - 1040 311879F 33 P erf ormance Char t - 1040 T est Conditions: Pump tested in wat er with inlet submerged Fluid Pressure Curves A at 120 psi (0.7 MPa, 7 bar) operating air pres sure B at 100 psi (0.7 MPa, 7 bar) operating air pres sure C at 70 psi (0.48 MP a, 4.8 bar ) operating air pressur e D at 40 psi (0.28 MP a, 2.8 bar ) ope[...]

  • Page 34

    Pump Matrix - 1590 34 311879F Pump Matrix - 1590 1590 FD A-Compliant Stainle ss Steel Sanitary Pumps Y our Model No . is marked on the pump’ s serial plate. T o determine the Model No . of your pump from the f ollow- ing matrix, select the six digits which describe y our pump , working from le ft to right. The first thr ee digits are alwa ys FD2,[...]

  • Page 35

    Repair Kit Matrix - 1590 311879F 35 Repair Kit Matrix - 1590 For 1590 Stainless Steel Sanitary Pumps Repair Kits ma y be ordered separat ely . T o repair the air v alve , order P art No. 255061 (see page 28). P arts included in the Air V alve Repair Kit are mark ed with a symbol in the par ts list, f or example (4†). T o repair y our pump , selec[...]

  • Page 36

    Parts - 1590 36 311879F P ar ts - 1590 3 †4 5 6† 7† 8† 19 402* 15 1 111 20 †18 16 †17 11 †10 2 104 24 25 22 11 10† 17† *202 201 *301 103 110 ▲ 105 403* 401* 201 101 108* 107 1 Used on pumps with PTFE diaphragms only . These par ts are included in the Pump Repair Kit which may be purchased separately . Refer to the Repair Kit Mat[...]

  • Page 37

    Parts - 1590 311879F 37 Air Motor P ar ts List (Matrix Column 2) † These par ts are included in Air V alve Repair Kit 255061 which ma y be purchased separately . Ref. P art No. Description Qty 1 15K009 HOUSING, center; SST 1 2 15A 735 C O VER, air va lve; SST 1 3 116344 SCREW , mach, hex flange hd; M5 x 0.8; 12 mm (0.47 in.) 9 4† 188618 GASKET [...]

  • Page 38

    Parts - 1590 38 311879F Fluid Section P ar ts Li st (Matrix Column 3) Seat P ar ts List (Matrix Column 4) * These par ts are included in the Pump Repair Kit wh ich ma y be purchased separately . Ref er to the Repair Kit Matr ix on page 35 to deter mine the correct kit for y our pump. ▲ Replacement Danger and Warning labels, tags and cards are av [...]

  • Page 39

    Dimensional Drawing - 1590 311879F 39 Dimensional Dra wing - 1590 1590 FD A &OURIN MM DIAMETERHOLES IN MM IN MM !IR)NLET NPTF !IR%XHAUST MUFFLERINCLUDED NPTF IN ?[...]

  • Page 40

    Technical D ata - 1590 40 311879F T e c hnical Data - 1590 Santoprene ® is a registered t rademark of the M onsanto Co . Loctite ® is a registered tradema rk of the Loctite Corporation. * Displacement per cycle ma y v ary based on suctio n condi tion, discharge head, air pressure, and fluid type . ** Noise le vels me asured with the pump mounted [...]

  • Page 41

    Performance Chart - 1590 311879F 41 P erf ormance Char t - 1590 T est Conditions: Pump tested in wat er with inlet submerged Fluid Pressure Curves A at 120 psi (0.7 MPa, 7 bar) operating air pres sure B at 100 psi (0.7 MPa, 7 bar) operating air pres sure C at 70 psi (0.48 MP a, 4.8 bar) operating ai r pressure D at 40 psi (0.28 MP a, 2.8 bar) opera[...]

  • Page 42

    Pump Matrix - 2150 42 311879F Pump Matrix - 2150 2150 FD A-Compliant Stainle ss Steel Sanitary Pumps Y our Model No . is marked on the pump’ s serial plate. T o determine the Model No . of your pump from the f ollow- ing matrix, select the six digits which describe y our pump , working from le ft to right. The first thr ee digits are alwa ys FD3,[...]

  • Page 43

    Repair Kit Matrix - 2150 311879F 43 Repair Kit Matrix - 2150 For 2150 Stainless Steel Sanitary Pumps Repair Kits ma y be ordered separat ely . T o repair the air v alve , order P art No. 255061 (see page 28). P arts included in the Air V alve Repair Kit are mark ed with a symbol in the par ts list, f or example (4†). T o repair y our pump , selec[...]

  • Page 44

    Parts - 2150 44 311879F P ar ts - 2150 1 Used on PTFE models only . These par ts are included in the Pump Repa ir Kit which ma y be purchased separately . Refer to the Repair Kit Matr ix on page 42 to deter mine the cor- rect kit f or your pump . These par ts are included in Air V alve Repair Kit 255061 wh ich ma y be pur- chased separately . Repla[...]

  • Page 45

    Parts - 2150 311879F 45 Air Motor P ar ts List (Matrix Column 2) † These par ts are included in Air V alve Repair Kit 255061 which ma y be purchased separately . Ref. P art No. Description Qty 1 15K009 HOUSING, center; SST 1 2 15A 735 CO VER, air valv e; SST 1 3 116344 SCREW , mach, hex flange hd; M5 x 0.8; 12 mm (0.47 in.) 9 4† 188618 GASKET ,[...]

  • Page 46

    Parts - 2150 46 311879F Fluid Section P ar ts Li st (Matrix Column 3) Seat P ar ts List (Matrix Column 4) * These par ts are included in the Pump Repair Kit wh ich ma y be purchased separately . Ref er to the Repair Kit Matr ix on page 42 to deter mine the correct kit for y our pump. ▲ Replacement Danger and Warning labels, tags and cards are av [...]

  • Page 47

    Dimensional Drawing - 2150 311879F 47 Dimensional Dra wing - 2150 2150 FD A !IR)NLET NPTF !IR%XHAUST MUFFLERINCLUDED NPTF IN MM IN MM IN MM IN MM IN?[...]

  • Page 48

    Technical D ata - 2150 48 311879F T e c hnical Data - 2150 Santoprene ® is a registered t rademark of the M onsanto Co . Loctite ® is a registered tradema rk of the Loctite Corporation. * Displacement per cycle ma y v ary based on suctio n condi tion, discharge head, air pressure, and fluid type . ** Noise le vels me asured with the pump mounted [...]

  • Page 49

    Performance Chart - 2150 311879F 49 P erf ormance Char t - 2150 T est Conditions: Pump tested in wat er with inlet submerged Fluid Pressure Curves A at 120 psi (0.7 MP a, 7 bar) operating air p ressure B at 100 psi (0.7 MP a, 7 bar) operating air p ressure C at 70 psi (0 .48 MP a, 4.8 ba r) operating air pressure D at 40 psi (0.28 MP a, 2.8 b ar) o[...]

  • Page 50

    All written and visual data contained in this document reflects the latest product information available at the time of publica tion. Graco reserves the right to make changes a t any time without notice. This manual contains English. MM 311879 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. P.O. BOX 14[...]