Hitachi 236464 User's Manual
Contents
1. e A bleed type master air valve E is required in your system to relieve air trapped between it and the air motor when the valve is closed see the WARNING above Be sure the bleed valve is eas ily accessible from the pump and is located downstream from the air regulator e An air regulator F controls pump speed and out let pressure by adjusting the air pressure to the pump Locate the regulator close to the pump but upstream from the bleed type master air valve 8 308350 e A pump runaway valve C senses when the pump is running too fast and automatically shuts off the air to the motor A pump which runs too fast can be seriously damaged e An air manifold G has a 3 4 npsm f swivel air inlet It mounts to the pump support bracket and provides ports for connecting lines to air powered accessories e An air line filter J removes harmful dirt and moisture from the compressed air supply Also install a drain valve W at the bottom of each air line drop to drain off moisture e A second bleed type air valve K isolates the air line accessories for servicing Locate upstream from all other air line accessories Fluid Line Accessories Install the following accessories in the locations shown in Fig 2 using adapters as necessary e A fluid filter L with a 60 mesh 250 micron stainless steel element to filter particles from the fluid as it leaves the pump e A fluid drain valve M which is required i2. stop spraying clean check or service the equipment and install or clean the spray tip Tighten all fluid connections before operating the equipment Check the hoses tubes and couplings daily Replace worn damaged or loose parts immediately Permanently coupled hoses cannot be repaired replace the entire hose Use only Graco approved hoses Do not remove any spring guard that is used to help protect the hose from rupture caused by kinks or bends near the couplings MOVING PARTS HAZARD st Moving parts such as the air motor piston can pinch or amputate your fingers e Keep clear of all moving parts when starting or operating the pump e Before servicing the equipment follow the Pressure Relief Procedure on page 10 to prevent the equipment from starting unexpectedly 4 308350 A WARNING 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 Ground the equipment and the object being sprayed Refer to Grounding on page 7 If there is any static sparking or you feel an electric shock while using this equipment stop spray ing 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 sprayed Keep the spray area free of debris including solvent rags and gasoline Electri
3. 13 kg 29 Ib 304 440 and 17 4 PH Grades of Stainless Steel Tungsten Carbide PTFE Leather Sound Pressure Levels dBa measured at 1 meter from unit a Input Air Pressures at 15 cycles per minute 0 28 MPa 2 8 bar 0 48 MPa 4 8 bar 0 63 MPa 6 3 bar 0 7 MPa 7 bar 40 psi 70 psi 90 psi 100 psi Bulldog 82 4 dB A 87 3 dB A 88 5 dB A 90 0 dB A Reduced Icing Quiet Bulldog 81 5 dB A 83 6 dB A 85 6 dB A 85 8 dB A Sound Power Levels dBa tested in accordance with ISO 9614 2 ae Input Air Pressures at 15 cycles per minute 0 28 MPa 2 8 bar 0 48 MPa 4 8 bar 0 63 MPa 6 3 bar 0 7 MPa 7 bar 40 psi 70 psi 90 psi 100 psi Bulldog 91 6 dB A 95 9 dB A 97 4 dB A 98 1 dB A Reduced Icing Quiet Bulldog 90 2 dB A 93 5 dB A 94 9 dB A 93 3 dB A 308350 25 Technical Data KEY Fluid Outlet Pressure Black Curves A 0 7 MPa 7 bar 100 psi Air Pressure Air Consumption Gray Curves B 0 49 MPa 4 9 bar 70 psi Air Pressure C 0 28 MPa 2 8 bar 40 psi Air Pressure psi cycles min MPa bar 13 26 39 52 65 78 scfm 5000 60 m8 min 250 35 0 350 7 00 4000 200 28 0 280 A 5 60 cr gt 3000 150 H 210 210 L 4 20 Ww B A 2000 100 g 14 0 140 2 80 1000 C 50 7 0 70 1 40 0 gpm9 0 0 5 1 0 1 5 2 0 2 5 3 0 liters min 1 9 3 8 5 7 7 6 9 5 11 4 FLUID FLOW NO 10 WEIGHT OIL To find Fluid Outlet Pressure MPa bar psi at a specific fluid flow To find Pump Air Con
4. 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 document 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 Graco Information TO PLACE AN ORDER contact your Graco distributor or call one of the following numbers to identify the distributor closest to you 1 800 367 4023 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 Sales Offices Minneapolis Detroit International Offices Belgium Korea Hong Kong Japan www graco com PRINTED IN USA 308350 05 2000 Revised 02 2003 28 308350
5. lb 4 Screw the coupling nut onto the motor shaft W loosely Hold the motor shaft flats with a wrench to keep it from turning Use an adjustable wrench to tighten the coupling nut Torque to 195 210 Nem 145 155 ft lb 5 Reconnect all hoses Reconnect the ground wire if it was disconnected Fill the packing nut 8 1 3 full of Graco Throat Seal Liquid or compatible solvent 6 Turn on the air supply Run the pump slowly to ensure proper operation A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 10 7 Before returning the pump to production relieve the pressure and retorque the packing nut 8 to 61 75 Nem 45 55 ft lb Model 237634 Shown AN Torque to 61 75 Nem 45 55 ft lb AA Torque to 195 210 Nem 145 155 ft lb A Torque to 68 81 Nem 50 60 ft lb Fig 4 Service 110 04377 308350 15 Service DISPLACEMENT PUMP SERVICE Disassembly When disassembling the pump lay out all the removed parts in sequence to ease reassembly NOTE Packing Repair Kits are available For the best results use all the new parts in the kit Kit parts are marked with an asterisk for example 3 You can also convert the pump to different packing materials Refer to page 24 1 Place the pump lengthwise in a large vise with the jaws on the outlet housing 6 as shown in Fig 5 Using the supplied wrenc
6. the cylin der Install the seal 11 on the top of the cylinder 2 Lubricate the seal and the top threads of the cylinder Place the outlet housing 6 in a vise as shown in Fig 8 Slide the displacement rod 1 up into the outlet housing then screw the cylinder 2 into the outlet housing handtight The threads will engage easily until the seal 11 contacts the sealing surface of the outlet housing The top of the rod will protrude from the packing nut 8 AN Torque to 325 353 Nem 240 260 ft lb A Lubricate A Torque to 190 217 Nem 140 160 ft lb 05127 AN Torque to 61 75 Nem 45 55 ft lb AA Torque to 325 353 Nem 240 260 ft lb A Torque to 258 285 Nem 190 210 ft lb VAN Lubricate A Apply thread sealant Throat Packing Detail Service A Lips face up A Lips face down See the Throat Packing Detail at left A See the Piston Packing Detail at left AN Torque to 190 217 Nem 140 160 ft lb Displacement Pump 236458 Shown see page 24 for options 8 Ref fo 6 Ref Piston Packing Detail a Displacement Pump 236458 Shown see page 24 for options 9 Ref 11 Ref Fig 9 RX 2 Ref 12 hee 7 Ref A P AA 11 A 30 C 2 q 1a 9 L 7A 10 A x p pie 6 S A L S p Pa JN FR ears 13 05468 308350 19 10 A Lubricate Service Ins
7. FACE UP 3 184222 GLAND male stainless steel 4 184172 GLAND female stainless steel 18 109252 V PACKING UHMWPE 19 184302 V PACKING leather E OM M Kit also includes items 11 12 13 and 30 see page 23 LUBRICATE PACKINGS UHMWPE PTFE Packing Kit 237609 Optional Ref Part THROAT PACKINGS PISTON PACKINGS No No Description Qty LIPS FACE DOWN LIPS FACE UP 4 3 3 184222 GLAND male stainless steel a 4 184172 GLAND female stainless steel X FN 18 109252 V PACKING UHMWPE 19 109302 V PACKING PTFE ROMP Kit also includes items 11 12 13 and 30 see page 23 LUBRICATE PACKINGS 24 308350 Technical Data A WARNING Be sure that all fluids and solvents used are chemically compatible with the Wetted Parts listed below Always read the manufacturer s literature before using fluid or solvent in this pump Category Data Maximum fluid working pressure 28 3 MPa 283 bar 4100 psi Maximum air input pressure 0 7 MPa 7 bar 100 psi Ratio 41 1 Pump cycles per 3 8 liters 26 1 gallon Fluid flow at 60 cycles per minute 8 7 liters min 2 3 gpm Air motor piston effective area 248 cm2 38 in 2 Stroke length 120 mm 4 75 in Displacement pump effective 6 cme 0 93 in 2 area Maximum operating temperature 82 C 180 F Air inlet size 3 4 npsm f Fluid inlet size 1 1 2 npt f Fluid outlet size 3 4 npt f Pump weight approx 39 kg 86 Ib Displacement pump weight approx
8. ING 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 The 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 two 2 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
9. If your pump is running too fast stop it immediately and check the fluid supply If the container is empty and air has been pumped into the lines refill the con tainer and prime the pump and the lines or flush and leave it filled with a compatible solvent Eliminate all air from the fluid system 9 With the pump and lines primed and with ade quate air pressure and volume supplied the pump will start and stop as you open and close the gun In a circulating system the pump will speed up or slow down on demand until the air supply is shut off A WARNING COMPONENT RUPTURE HAZARD To reduce the risk of overpressurizing O Rag your system which could cause compo nent rupture and serious injury never exceed the specified Maximum Incoming Air Pres sure to the pump see Technical Data page 25 10 Use the air regulator F to control pump speed and fluid pressure Always use the lowest air pressure necessary to get the desired results Higher pressures cause premature tip and pump wear 308350 11 Operation Maintenance Shutdown and Care of the Pump A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 10 For overnight shutdown stop the pump at the bottom of its stroke to prevent fluid from drying on the ex posed displacement rod and damaging the throat packings Relieve the pressure Always fl
10. Instructions Parts List LZ S STAINLESS STEEL Dura Flo 600 Pumps _ sosssor B With Severe Duty Rod and Cylinder Read warnings and instructions k See page 2 for model numbers and maximum working pressures See page 2 for models that are x zG certified and C approved 04373 Model 686615 A Model 237634 Model 236464 LU Ce PROVEN QUALITY LEADING TECHNOLOGY ae on GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 GIS Copyright 2002 Graco Inc is registered to I S EN ISO 9001 B G List of Models Displacement Pump Part No Pump Part No Maximum Fluid Maximum Air and Series Pump Model and Series Ratio Working Pressure Input Pressure 237634 Bulldog 28 3 MPa 283 bar 0 7 MPa 7 bar Series A i 4100 psi 100 psi 236464 Reduced Icing 28 3 MPa 283 bar 0 7 MPa 7 bar Series A Quiet Bulldog 4100 psi 100 psi This model is x 2G certified and C approved Table of Contents Warg e eI AAEE ot KEN EERE AN 3 Parts Drawings and Parts Lists 21 WiStalAtOM cc lt ci2 a r EEANN Sloe eae E a at Peds 7 Pump Assembies eee aeee 21 Operation Maintenance eee 10 Displacement Pump eee 23 Troubleshooting Chart eee eee 13 Technical Data A de eee eee 25 SEVICE s K A h X R beee ee bene beh eee dew tie A 14 DIM NSIONS 4906 whee lee bee eek ee dee ihe hee 27 Re
11. cally disconnect all equipment in the spray area Extinguish all open flames or pilot lights in the spray area Do not smoke in the spray area Do not turn on or off any light switch in the spray area while operating or if fumes are present Do not operate a gasoline engine in the spray area 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 308350 5 Notes 6 308350 Installation General Information NOTE Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing NOTE Always use Genuine Graco Parts and Acces sories available from your Graco distributor Refer to Product Data Sheet Form No 305724 If you supply your own accessories be sure they are adequately sized and pressure rated for your system Grounding A WARNING FIRE AND EXPLOSION HAZARD Before operating the pump ground the system as explained below Also read the section FIRE AND EXPLOSION HAZARD on page 5 1 Pump u
12. conductive hoses Fluid hoses must have spring guards on both ends Use a whip hose P and a swivel R between the main fluid hose N and the gun S to allow freer gun movement Mounting Accessories Mount the pump A to suit the type of installation planned Fig 2 illustrates a wall mount system Pump dimensions and the mounting hole layout are shown on page 27 If you are using a floor stand refer to its separate manual for installation and operation instructions 308350 7 Installation System Accessories continued A WARNING A bleed type master air valve E and a fluid drain valve M are required in your system These accessories help reduce the risk of serious injury including fluid injection and splashing of fluid in the eyes or on the skin and injury from moving parts if you are adjusting or repairing the pump The bleed type master air valve relieves air trapped between this valve and the pump after the air is shut off Trapped air can cause the pump to cycle unexpectedly Locate the valve close to the pump Order Part No 107141 The fluid drain valve assists in relieving fluid pres sure in the displacement pump hose and gun Triggering the gun to relieve pressure may not be sufficient Order Part No 235992 Air Line Accessories Install the following accessories in the locations shown in Fig 2 using adapters as necessary e An air line lubricator D provides automatic air motor lubrication
13. e equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accor dance with Graco s written recommendations This warranty does 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 INCLUD
14. ed Clear the air line increase the air supply ate Check that the valves are open The fluid hose or gun is obstructed Clear the hose or gun use a hose with a larger ID Fluid has dried on the displacement rod Clean the rod always stop the pump at the bottom of its stroke keep the wet cup 1 3 filled with a compatible solvent Air motor parts are dirty worn or dam Clean or repair the air motor aged see the separate motor manual The pump operates The air line is restricted or the air supply Clear the air line increase the air supply but the output is low on is inadequate Valves are closed or Check that the valves are open both strokes The fluid hose or gun is obstructed Clear the hose or gun the fluid hose ID is too small use a hose with a larger ID Worn packings in the displacement Replace the packings pump Air motor parts are dirty worn or dam Clean or repair the air motor aged see the separate motor manual Held open or worn intake valve Clear or service the intake valve The pump operates Held open or worn intake valve Clear or service the intake valve but the output is low on the downstroke The pump operates Held open or worn piston valve Clear the piston valve replace the packings but the output is low on or packings the upstroke The pump s speed is The fluid supply is exhausted Refill the supply and prime the pump erratic or accelerated Held ope
15. h 110 loosen but do not remove the packing nut 8 Fig 5 16 308350 2 Using a 2 3 4 in socket or a pipe wrench un screw the intake valve 5 from the intake housing 7 Be careful to catch the intake ball 13 as you remove the intake valve so that it does not fall and suffer damage Remove the seal 30 from the intake valve Inspect the ball and the seat D of the intake valve for wear or damage 3 Using a pipe wrench remove the intake housing 7 from the cylinder 2 NOTE These instructions are written with the pump separating at joint A If it separates at joint B disas semble it at that joint place the intake housing 7 ina vise and continue with step 4 4 Using a pipe wrench unscrew the cylinder 2 The displacement rod 1 may come with the cylinder A Torque to 325 353 Nem 240 260 ft lb A Lubricate A Torque to 190 217 Nem 140 160 ft lb 04492A Service 6 Shine a light into the cylinder 2 to inspect the A CAUTION inner surface for scoring or wear Remove the two seals 11 from the cylinder To reduce the possibility of costly damage to the rod 1 and cylinder 2 always use a plastic or wooden block to help drive the rod out of the cylin der Never hit the rod with a hammer 7 Place the flats of the piston seat housing 10 ina vise as shown in Fig 7 5 Turn the cylinder 2 upside down and strike the 8 Using an adjustable wrench unscrew the piston top
16. hen loosen completely Now clear the tip or hose 10 308350 Packing Nut Wet Cup Before starting fill the packing nut 8 1 3 full with Graco Throat Seal Liquid TSL or compatible solvent See Fig 3 A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure at left The packing nut is torqued at the factory and is ready for operation If it becomes loose and there is leaking from the throat packings relieve pressure then torque the nut to 61 75 Nem 45 55 ft lb using the supplied wrench 110 Do this whenever necessary Do not overtighten the packing nut Torque to 61 75 Nem 45 55 ft lb Model 237634 Shown 110 04373 Fig 3 Operation Maintenance Flush the Pump Before First Use The pump is tested with lightweight oil which is left in to protect the pump parts If the fluid you are using may be contaminated by the oil flush it out with a compatible solvent See Flushing on page 12 Starting and Adjusting the Pump 1 See Fig 2 Connect the suction kit T to the pump s fluid inlet Place the tube into the fluid supply A CAUTION To prevent intake valve damage always apply PTFE tape to the female threads of the intake valve before connecting a suction hose or fitting to the intake 2 Close the air regulator F 3 Open the pump s bleed type master air valve E 4 Hold a metal part of
17. ipment 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 expose Graco hoses to temperatures above 82 C 180 F or below 40 C 40 F Wear hearing protection when operating this equipment Do not lift pressurized equipment Comply with all applicable local state and national fire electrical and safety regulations 308350 3 A WARNING INJECTION HAZARD Spray from the gun hose leaks or ruptured components can inject fluid into your body and cause extremely serious injury including the need for amputation Fluid splashed in the eyes or on the skin can also cause serious injury Fluid injected into the skin might look like just a cut but it is a serious injury Get immediate medi cal attention Do not point the gun at anyone or at any part of the body Do not put your hand or fingers over the spray tip Do not stop or deflect leaks with your hand body glove or rag Do not blow back fluid this is not an air spray system Always have the tip guard and the trigger guard on the gun when spraying Check the gun diffuser operation weekly Refer to the gun manual Be sure the gun trigger safety operates before spraying Lock the gun trigger safety when you stop spraying Follow the Pressure Relief Procedure on page 10 whenever you are instructed to relieve pres sure
18. less steel tie rods order 04377 Ref No PartNo Description Qty 101 208356 AIR MOTOR Bulldog See 307049 for parts 1024 176529 LABEL warning 105t 190000 ROD tie 224 mm 8 82 shoulder to shoulder 3 106T 186925 NUT coupling 1 107T 184129 COLLAR coupling 2 108T 106166 NUT hex M16 x 2 0 3 109 236458 PUMP displacement See page 23 for parts 1 110T 112887 WRENCH spanner 1 A Replacement Danger and Warning labels tags and cards are available at no cost Part No 236464 Pump Series A 41 1 Ratio with Reduced Icing Quiet Bulldog Air Motor 1024 101 t105 110t TThese parts are included in Connection Kit 235417 For applications requiring stainless steel tie rods order Connection Kit 235418 04497 Ref No PartNo Description Qty 101 237001 AIR MOTOR Bulldog See 307304 for parts 1 1024 176529 LABEL warning 1 105T 190000 ROD tie 224 mm 8 82 shoulder to shoulder 3 106T 186925 NUT coupling 1 107T 184129 COLLAR coupling 2 108t 106166 NUT hex M16 x 2 0 3 109 236458 PUMP displacement See page 23 for parts 1 110T 112887 WRENCH spanner 1 A Replacement Danger and Warning labels tags and cards are available at no cost 308350 21 Part No 686615 Pump Series A 25 1 Ratio with Senator Air Motor Ref No 101 1024 105T 106T 107T 108T 22 Part No 217540 176529 190000 186925 184129 106166 308350 101 t105 9204C De
19. n or worn piston valve Clear the piston valve replace the packings or packings Held open or worn intake valve Clear or service the intake valve To determine if the fluid hose or gun is obstructed relieve the pressure Disconnect the fluid hose and place a container at the pump fluid outlet to catch any fluid Turn on the air just enough to start the pump If the pump starts when the air is turned on the obstruction is in the fluid hose or gun NOTE If you experience air motor icing call your Graco distributor 308350 13 Service Required Tools Set of adjustable wrenches Large pipe wrench 2 3 4 in socket wrench Torque wrench Rubber mallet O ring pick Large vise Plastic or wooden block approximately 6 in square x 1 in thick Thread lubricant 6 Thread sealant Disconnecting the Displacement Pump 1 Flush the pump if possible Stop the pump at the bottom of its stroke A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 10 2 Relieve the pressure 3 Disconnect the air hose and fluid hose 4 Disconnect the displacement pump 109 from the motor 101 as follows Note the relative position of the pump s fluid outlet U to the air inlet V of the motor If the motor does not require servicing leave it attached to its mounting A CAUTION Be sure to use two people when lifting moving
20. n your system helps relieve fluid pressure in the hose and gun see the WARNING at left e A gun S dispenses the fluid The gun shown in Fig 2 is an airless spray gun for light to medium viscosity fluids e A gun swivel R allows freer gun movement e A suction kit T allows the pump to draw fluid from a supply container A CAUTION To prevent intake valve damage always apply PTFE tape to the female threads of the intake valve before connecting a suction hose or fitting to the intake Installation TYPICAL INSTALLATION KEY A Pump d Air Line Filter R Gun Swivel B Wall Bracket K Bleed Type Master Air Valve S Airless Spray Gun C Pump Runaway Valve for accessories T Suction Kit D Air Line Lubricator L Fluid Filter Y Ground Wire and Clamp E Bleed Type Master Air Valve M Fluid Drain Valve required required see page 7 required for pump N Electrically Conductive for installation instructions F Pump Air Regulator Fluid Supply Hose W Air Line Drain Valve G Air Manifold P Fluid Whi
21. of the rod 1 on a plastic or wooden block until ball housing 9 from the piston seat housing Be the piston comes free Pull the rod and piston from careful to catch the piston ball 12 as you sepa the cylinder being careful not to scratch the parts rate the piston seat housing and ball housing so See Fig 6 that it does not fall and suffer damage 9 Examine the displacement rod 1 for scratches or other damage Only if the rod needs replace ment place the piston ball housing 9 in a vise and unscrew the rod using an adjustable wrench on the flats of the rod 10 Remove the glands and v packings P and the ball 12 from the piston seat housing 10 Inspect the ball seat E and ball guides F for wear or damage See Fig 9 11 Unscrew the packing nut 8 from the outlet hous ing 6 Remove the glands and v packings T See Fig 9 04518 12 Clean all parts with a compatible solvent and Fig 6 inspect them for wear or damage A Torque to 258 285 Nem 190 210 ft lb 04495 04494 Fig 7 308350 17 Service Reassembly If it was necessary to remove the piston ball housing 9 from the displacement rod 1 clean the threads of the rod and the ball housing and apply thread sealant Screw the ball housing onto the rod hand tight Place the flats of the piston ball housing in a vise and torque the rod to 258 285 Nem 190 210 ft lb See Fig 9 For standard displacement pump 236458
22. or disconnecting the entire pump This pump is too heavy for one person If you are disconnecting the displacement pump from a motor which is still mounted for example on a wall bracket only one person is required The displacement pump weighs approximately 13 kg 29 Ib If the pump is mounted on a cart slowly tip the cart backward until the handle rests on the ground then disconnect the displacement pump 14 308350 5 Using an adjustable wrench or hammer and punch unscrew the coupling nut 106 from the motor shaft W Do not lose or drop the coupling collars 107 See Fig 4 6 Hold the tie rod flats with a wrench to keep the rods from turning Unscrew the nuts 108 from the tie rods 105 Carefully remove the displacement pump 109 from the motor 101 7 Refer to page 16 for displacement pump service To service the air motor refer to the separate motor manual supplied Reconnecting the Displacement Pump 1 Make sure the coupling nut 106 and the coupling collars 107 are in place on the displacement rod 1 See Fig 4 2 Have one person hold the displacement pump while another reconnects it to the motor see the CAUTION at left Orient the pump s fluid outlet U to the air inlet V as was noted in step 4 under Disconnecting the Displacement Pump Position the displacement pump 109 on the tie rods 105 3 Screw the nuts 108 onto the tie rods 105 and torque to 68 81 Nem 50 60 ft
23. p Hose H Electrically Conductive Air Supply Hose J K y MAIN AIR LINE HIT i c C H R P L w S N 7 LS ia um T E 04496 Fig 2 308350 9 Operation Maintenance Pressure Relief Procedure A WARNING INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally Fluid under high pressure can be injected through the skin and cause serious injury To reduce the risk of an injury from injection splashing fluid or moving parts follow the Pressure Relief Procedure whenever you e are instructed to relieve the pressure e stop spraying 6 check or service any of the system equipment or install or clean the spray tips 1 Lock the gun trigger safety 2 Shut off the air supply to the pump 3 Close the bleed type master air valve required in your system 4 Unlock the gun trigger safety 5 Hold a metal part of the gun firmly to the side of a grounded metal pail and trigger the gun to relieve pressure 6 Lock the gun trigger safety 7 Open the drain valve required in your system having a container ready to catch the drainage 8 Leave the drain valve open until you are ready to spray again If you suspect that the spray tip or hose is completely clogged or that pressure has not been fully relieved after following the steps above very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually t
24. place the piston packings on the piston seat housing 10 in the following order with the lips of the v pack ings facing up the female gland 4 one PTFE v packing 18 four leather v packings 19 and the male gland 3 See the Piston Packing Detail in Fig 9 NOTE To convert the pump to a different packing material see page 24 Place the flats of the piston seat housing 10 ina vise Apply thread sealant to the threads of the piston seat housing Place the ball 12 on the seat Screw the piston ball housing 9 onto the piston seat housing hand tight then torque to 258 285 Nem 190 210 ft lb See Fig 7 Fig 8 308350 4 For standard displacement pump 236458 lubricate the throat packings and place them in the outlet housing 6 in the following order with the lips of the v packings facing down the male gland 3 four leather v packings 19 one PTFE v pack ing 18 and the female gland 4 See the Throat Packing Detail in Fig 9 NOTE To convert the pump to a different packing material see page 24 5 D Lubricate the threads of the packing nut 8 and loosely install it in the outlet housing 6 Lubricate the piston packings Slide the displace ment rod 1 and piston assembly down into the cylinder 2 The cylinder is symmetrical so either end may face up Use a rubber mallet to drive the rod into the cylinder until the piston seat housing 10 is located in the middle of
25. quired Tools eee eee eee eee 14 Mounting Hole Layout 002 eee 27 Disconnecting the Displacement Pump 14 Warranty e ite ae RE RT E 79 eam Re eas 28 Reconnecting the Displacement Pump 14 Graco Information cece eee eee 28 Displacement Pump Service 16 2 308350 Symbols Warning Symbol Caution Symbol This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions or destruction of equipment if you do not follow the instructions A WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury eg NA 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 uncertain about usage 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 system component Refer to the Technical Data on page 25 for the maximum working pressure of this equipment Use fluids and solvents which are compatible with the equipment wetted parts Refer to the Tech nical Data section of all equ
26. s steel 1 are available at no cost 10 222929 HOUSING seat piston valve stainless steel w tungsten carbide seat 1 11 109205 SEAL PTFE 2 12 101822 BALL piston stainless steel 0 625 16 mm dia 1 13 102973 BALL intake stainless steel 1 1 4 31 8 mm dia 17 101748 PLUG pipe socket hd 3 8 npt 20A 172477 TAG warning not shown 21A 172479 TAG warning not shown 8 30 166073 SEAL PTFE we Throat A Packing Piston Packing Stack SY k k k k k see page 24 Stack see page 24 eee 12 04371A 308350 23 Packing Kits Leather Packing Kit 237234 for Standard Displacement Pump 236458 Series A Ref Part THROAT PACKINGS PISTON PACKINGS 3 184222 GLAND male stainless steel 2 4 184172 GLAND female stainless steel 2 18 109302 V PACKING PTFE 2 19 184302 V PACKING leather 8 18 Kit also includes items 11 12 13 and 30 see page 23 0805 0806 LUBRICATE PACKINGS Teflon Packing Kit 237236 Optional Ref Part THROAT PACKINGS PISTON PACKINGS No No Description Qty LIPS FACE DOWN LIPS FACE UP 3 184222 GLAND male stainless steel 2 3 4 184172 GLAND female stainless steel 2 S 18 109302 V PACKING PTFE 10 Ss Kit also includes items 11 12 13 and 30 see page 23 0805 LUBRICATE PACKINGS 0806 UHMWPE Leather Packing Kit 237238 Optional Ref Part THROAT PACKINGS PISTON PACKINGS No No Description Qty LIPS FACE DOWN LIPS
27. scription AIR MOTOR Senator See 307592 for parts LABEL warning ROD tie 224 mm 8 82 shoulder to shoulder NUT coupling COLLAR coupling NUT hex M16 x 2 0 Qty UN U 1024 113 T These parts are included in Connection Kit 235417 For applications requiring stainless steel tie rods order 111 Connection Kit 235418 Ref No Part No 109 241177 110t 112887 111 190737 112 184392 113 190293 9204A Description Qty PUMP displacement See page 23 for parts WRENCH spanner CYLINDER intake HOUSING valve PLUG valve ai mk zek Kh G A Replacement Danger and Warning labels tags and cards are available at no cost Parts NOTE The parts listed on this page are common to all Ref Part displacement pumps covered in this manual Refer to No No Description Qty page 24 for the different packing configurations available 1 190172 ROD displacement stainless steel 1 l E l 2 184503 CYLINDER stainless steel 1 These parts are included in Repair Kit 237234 which may 5 236585 VALVE intake stainless steel be purchased separately for standard Displacement w tungsten carbide seat 1 Pump 236458 See page 24 They are also included in 6 237731 HOUSING outlet stainless steel 1 Optional Kits 237236 237238 and 237609 7 190394 HOUSING intake stainless steel 1 8 236578 PACKING NUT stainless steel 1 A Replacement Danger and Warning labels tags and cards 9 189406 HOUSING ball piston stainles
28. se a ground wire and clamp See Fig 1 Loosen the grounding lug locknut W and washer X Insert one end of a 1 5 mm 12 ga minimum ground wire Y into the slot in lug Z and tighten the locknut securely Connect the other end of the wire to a true earth ground Order Part No 237569 Ground Wire and Clamp W SY 0864 Fig 1 2 Air and fluid hoses use only electrically conductive hoses 3 Air compressor follow manufacturer s recommen dations 4 Spray gun ground through connection to a prop erly grounded fluid hose and pump 5 Fluid supply container follow your local code 6 Object being sprayed follow your local code 7 Solvent pails used when flushing follow your local code Use only metal pails which are conductive placed on a grounded surface Do not place the pail on a nonconductive surface such as paper or cardboard which interrupts the grounding continu ity 8 To maintain grounding continuity when flushing or relieving pressure hold a metal part of the spray gun firmly to the side of a grounded metal pail then trigger the gun System Accessories Fig 2 is only a guide for selecting and installing sys tem components and accessories Contact your Graco distributor for assistance in designing a system to suit your particular needs Air and Fluid Hoses Be sure all air hoses H and fluid hoses N and P are properly sized and pressure rated for your system Use only electrically
29. sumption m3 min or scfm at a specific fluid lpm gpm and operating air pressure MPa bar psi 1 Locate desired flow along bottom of chart flow Ipm gpm and air pressure MPa bar psi 1 Locate desired flow along bottom of chart 2 Follow vertical line up to intersection with selected fluid outlet pressure curve black Follow left to scale to read fluid outlet 2 Read vertical line up to intersection with selected air consumption 26 pressure 308350 curve gray Follow right to scale to read air consumption Dimensions Mounting Hole Layout 94 28 mm 3 712 Model 237634 Shown 94 28 mm Three M16 x 2 0 Holes 04373 Sed Pump C Model 237634 1105 mm 561 mm 544 mm 257 mm 1 1 2 in 3 4 npt f 3 4 npsm f 1 1 2 in 43 50 in 22 09 in 21 42 in 10 12 in npt f npt f in f f in f f 594 mm 257 mm 1 1 2 in 3 4 npt 3 4 npsm 1 1 2 in 23 38 in 10 12 in npt npt peti C a a SP ee 236464 1155mm 561mm 45 47 in 22 09 in 308350 27 Graco Standard 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 by an authorized Graco distributor 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 twelve months from the date of sale repair or replace any part of th
30. tall the seal 30 on the intake valve 5 Lubri cate the seal and the threads of the intake valve One end of the intake housing 7 has a rounded ball cavity S on the inside see Fig 9 Install the ball 13 in this cavity then screw the intake valve 5 into the intake housing handtight See Fig 10 The threads will engage easily until the seal contacts the sealing surface of the intake housing Orient so the end with the ball cavity S see Fig 9 faces the ball 13 A5 04493A Fig 10 20 308350 11 12 13 14 15 Install the seal 11 on the bottom of the cylinder 2 See Fig 8 Lubricate the seal and the threads of the cylinder Screw the intake housing 7 onto the cylinder handtight The threads will engage easily until the seal contacts the sealing surface of the intake housing Using a pipe wrench torque the intake housing 7 to 325 353 Nem 240 260 ft lb This will also torque the cylinder 2 into the outlet housing 6 See Fig 8 Using a 2 3 4 in socket or a pipe wrench torque the intake valve 5 to 190 217 Nem 140 160 ft Ib Torque the packing nut 8 to 61 75 Nem 45 55 ft lb Reconnect the displacement pump to the air motor as explained on page 14 Parts Part No 237634 Pump Series A 41 1 Ratio with Bulldog Air Motor 1024 tThese parts are included in Connection Kit 235417 For applications requiring Connection Kit 235418 stain
31. the gun S firmly to the side of a grounded metal pail and hold the trigger open 5 Slowly open the regulator until the pump starts 6 Cycle the pump slowly until all air is pushed out and the pump and hoses are fully primed 7 Release the gun trigger and lock the trigger safety The pump should stall against pressure 8 If the pump fails to prime properly open the drain valve M Use the drain valve as a priming valve until the fluid flows from the valve Close the valve FOR MODEL 686615 ONLY If the pump fails to prime properly open the bleeder valve plug 113 slightly Use the bleed hole on the underside of the valve body 112 as a priming valve until the fluid appears at the hole see parts page 22 Close the plug A WARNING INJECTION HAZARD ba To reduce the risk of fluid injection do not use your hand or fingers to cover the bleed hole on the underside of the bleeder valve body 112 when priming the pump Use a crescent wrench to open and close the bleeder plug 113 Keep your hands away from the bleed hole NOTE When changing fluid containers with the hose and gun already primed open the drain valve M or the bleeder valve plug 113 for model 686615 to help prime the pump and vent air before it enters the hose Close the drain valve or the plug for model 686615 when all air is eliminated A CAUTION Do not allow the pump to run dry It will quickly accelerate to a high speed causing damage
32. ush the pump before the fluid dries on the displacement rod See Flushing below Flushing A WARNING FIRE AND EXPLOSION HAZARD Before flushing read the section FIRE AND EXPLOSION HAZARD on page 5 Be sure the entire system and flushing pails are properly grounded Refer to Grounding on page 7 12 308350 Flush with a fluid that is compatible with the fluid you are pumping and with the wetted parts in your system Check with your fluid manufacturer or supplier for recommended flushing fluids and flushing frequency Always flush the pump before fluid dries on the dis placement rod A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 10 1 Relieve the pressure 2 Remove the spray tip from the gun 3 Hold a metal part of the gun firmly to the side of a grounded metal pail 4 Start the pump Always use the lowest possible fluid pressure when flushing 5 Trigger the gun 6 Flush the system until clear solvent flows from the gun 7 Relieve the pressure Troubleshooting Chart A WARNING 1 Relieve the pressure 2 Check all possible causes and problems before To reduce the risk of serious injury whenever you disassembling the pump are instructed to relieve pressure always follow the Pressure Relief Procedure on page 10 PROBLEM CAUSE SOLUTION The pump fails to oper Valves are closed or clogg
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