You're right Heather, Humalog isn't FDA approved for the pump. Approval is more of a formality though, and as far as I'm aware Lilly isn't making any plans to have the FDA's blessing any time soon.
Nancy, I've heard a lot of people say that after switching from Humalog to Novolog (Novorapid) they saw a significant decrease in insulin requirements, and also found Novolog to peak and hit a little harder than Humalog. Of course this isn't the same for everyone and YMMV. You might find that you have to tweak his basals or CHO ratios after switching, in which case you may want to have him monitor his BG's a little more frequently. I think if you do a search of the forums you'll find some good personal experiences from members regarding switching analogue insulins.
Switching reservoirs as well as infusion sets when switching insulin is a good idea. Like David said, don't mix the two.
Good luck and let us know how it turns out

Shy