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Graco 308351K User's Manual

1. Instructions F O GRACO CARBON STEEL Check Mate 800 Pumps With Priming Piston and Severe Duty Rod and Cylinder Refer to page 2 for Table of Contents 308351K US Patent Nos 5 147 188 and 5 154 532 Other patents pending Models 236471 Important Safety Instructions and 246942 Read all warnings and instructions in this manual Save these instructions See page 2 for model numbers and maximum working pressures Models 237265 246940 and 246941 Models 198466 and 246938 04995 4990B PROVEN QUALITY LEADING TECHNOLOGY ti1447a mn am GRACOINC PO BOX 1441 MINNEAPOLIS MN 55440 1441 C MEUFIC Copyright 1995 Graco Inc is registered to I S EN ISO 9001 mvp Table of Contents List of Models 2 Reconnecting the Displacement Pump 19 Symbols sts Las redressement 3 Displacement Pump Service 20 Warnings 5s sape oed e erac e pec G6 es 3 PAIS i erena naNO ENE thee mariae SAN adr ata 28 Installation zoe sre Ep Re ate Rae en Re 6 Technical Data and Performance Chart 38 Operation Maintenance 12 Dimensions n ee e ere RUE IEEE 49 Service Mounting Hole Layout 49 Troubleshooting 17 Graco Standard Warranty 50 Required Tools 18 Graco Informat
2. 237274 Pump Series A 31 1 Ratio with Reduced Icing Quiet Bulldog Air Motor Ref Model 237265 Shown No PartNo Description Qty 101 245112 AIR MOTOR Reduced Icing Quiet King Used on Model 237265 only See 309348 for parts 1 220106 AIR MOTOR Quiet King Used on Models 240945 and 253376 only See 309348 for parts 1 237001 AIR MOTOR Reduced Icing Quiet Bulldog 101 Used on Model 237274 only See 307304 for parts 102 190000 ROD tie 224 mm 8 82 shoulder to shoulder 103 106166 NUT hex M16 x 2 0 104 186925 NUT coupling 105 184129 COLLAR coupling 106 236611 PUMP displacement See page 34 for parts 1 237885 PUMP displacement Used on Model 253376 only See manual 308570 for parts 1 109 112887 WRENCH spanner 1 ND 04991B 308351 31 Ref No 1 2 3 5 6 8 9 10 11 12 13 14 15 16 17a 17bA 17c 18 19 32 Part No 189317 237799 190585 113021 106258 109499 237567 189437 189438 189439 189440 189441 189727 189514 189442 184090 100508 184400 189447 308351 Displacement Pump Parts Part No 246939 Series A Description ROD displacement stainless steel PACKING NUT WET CUP carbon steel HOUSING throat seal carbon steel SEAL u cup throat PTFE with stainless steel spring O RING fluoroelastomer SEAL cylinder PTFE HOUSING outlet ductile iron CYLINDER pump stainless steel GUIDE piston
3. Always wear protective eyewear gloves clothing and respirator as recommended by the fluid and solvent manufacturer 308351 5 Installation Grounding Fig 1 6 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 King Pumps use a ground wire and clamp See Fig 1 Remove the ground screw Z and insert through eye of ring terminal at the end of ground wire Y Fasten ground screw back onto pump and tighten securely Connect the other end of the wire to a true earth ground Order Part No 222011 Ground Wire and Clamp All other Pumps use a ground wire and clamp See Fig 2 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 222011 Ground Wire and Clamp TI1052 308351 Ww 0864 Fig 2 2 Airand fluid hoses use only electrically conductive hoses 3 Air compressor follow manufacturer s recommen dations 4 Spray gun dispense valve ground through connec tion to a properly grounded fluid hose and pump Fluid supply container follow your local code 6 Object being sprayed follow your local code 7 All solvent pails used when flushing follow your local code Use only metal pails which
4. to relieve pressure 7 Lockthe gun valve trigger safety 8 In an air powered system open the drain valve required in your system having a container ready to catch the drainage Leave the drain valve open until you are ready to spray dispense again If you suspect that the spray tip nozzle 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 then loosen completely Now clear the tip nozzle or hose Packing Nut Wet Cup Before starting fill the packing nut 2 1 3 full with Graco Throat Seal Liquid TSL or compatible solvent See Fig 5 12 308351 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 128 156 N m 95 115 ft lb using the supplied wrench 109 Do this whenever necessary Do not overtighten the packing nut Bleed hole must face down Torque to 128 156 N m 95 115 ft Ib 04995 Fig 5 Operation 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
5. 109306 V PACKING throat PTFE 5 5 184201 GLAND throat female carbon steel 1 7 184251 GLAND throat male carbon steel 1 23 184246 GLAND intake valve male carbon steel 1 24 109301 V PACKING intake valve PTFE 4 25 184196 GLAND intake valve female carbon steel 1 36 308351 THROAT PACKINGS INTAKE PACKINGS LIPS FACE DOWN LIPS FACE UP LUBRICATE PACKINGS 23 mig 24 lt 195 TO 76 4 7 nm These parts are included in Repair Kit 222865 which may be purchased separately See page 34 for additional parts included in the kit Q 04989 Notes 308351 37 Technical Data Model 236471 and 246942 King Pumps 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 236471 40 MPa 403 bar 5850 psi 246942 48 MPa 483 bar 7000 psi Maximum fluid working pressure Maximum air input pressure 236471 0 6 MPa 6 bar 90 psi 246942 0 7 MPa 7 bar 100 psi Pump cycles per 3 8 liters 1 gal Fluid flow at 60 cycles min Air motor piston effective area Stroke length Displacement pump effective area Maximum pump operating temperature Air inlet size Fluid outlet size Weight Displacement pump weight Wetted parts 1 npt f Carbon Steel Chrome Zinc
6. HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury 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 not sure call your Graco distributor Do not alter or modify this equipment Check equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure stated on the equipment or in the Technical Data for your equipment Do not exceed the maximum working pressure of the lowest rated component in your system Use fluids and solvents which are compatible with the equipment wetted parts Refer to the Tech nical Data section of all equipment 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 308351 3 A WARNING SKIN INJECTION HAZARD Spray from the spray gun dispense valve leaks or ruptured components can inject fluid into your body and cause extremely serious injur
7. Wire required Shutoff Valve see page 6 we Y E D A 01408 Fig 4 10 308351 Installation Hydraulic Powered Pumps CAUTION The Hydraulic Power Supply must be kept clean at all times to avoid damage to the motor and hydraulic power supply 1 Blow out hydraulic lines with air and flush thor oughly before connection to the motor Plug hydraulic inlets outlets and line ends when disconnecting them for any reason Always plug the hydraulic inlets outlets and lines when disconnecting them for any reason to avoid introducing dirt and other contaminants into the system Be sure that your hydraulic power supply is equipped with a suction filter to the hydraulic pump and a system return line filter of 10 micron size Carefully follow the manufacturer s recommendations on reservoir and filter cleaning and periodic changes of hydraulic fluid NOTE Hydraulic fluid is exhausted from differential hydraulic motors only on the upstroke of the operating cycle The oil return line must have at least twice the flow capacity as the oil supply line Otherwise back pressure on the hydraulic motor piston will slow down the motor and the fluid displacement pump resulting in a loss of pump performance On the hydraulic oil supply line P install a shutoff valve G to isolate the system for servicing a fluid pressure gauge H to monitor hydraulic oil pressure to the motor and avoid overpressurizing the motor or displace
8. _4 housing 3 and remove the seal 42 Remove the throat glands and packings T See Fig 10 8 THROAT PACKING DETAIL See Fig 7 4 2 22 3 18 PS M SES Fig 10 Model 236611 Displacement Pump Shown Ne m 21 XS 05002 05002 308351 21 10 11 12 18 A Torque to 125 139 N m 92 102 ft lb A Torque to 324 368 N m 239 271 ft lb AN Lubricate Displacement Pump Service NOTE The seal 39 is press fit in the nut 15 and may require cutting to ease removal Remove the seal 8 from the bottom of the cylin der 10 See Fig 12 Shine a light into the cylinder to examine the inside surface for scoring or dam age Only if the cylinder is damaged or there is evidence of leaking around the top cylinder seal 8 unscrew the cylinder from the outlet housing using a pipe wrench Remove the top cylinder seal Place the flats of the displacement rod 1 in a vise Unscrew the piston 12 from the displace ment rod the priming piston rod 18 will come with it Slide the piston guide 11 and seat 14 off the piston 12 It is not necessary to remove the priming piston rod 18 from the piston 12 unless your inspec tion reveals damage to either part To disas semble place the piston flats in a vise and un screw the rod Place the piston guide 11 in a vise as shown in Fig 11 Using an adjustable wrench unscrew the piston seat 14 fro
9. 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 Maximum fluid working pressure Maximum air input pressure Pump cycles per 3 8 liters 1 gal Fluid flow at 60 cycles min Air motor piston effective area Displacement pump effective area Maximum pump operating temperature Weight Wetted parts Carbon Steel Chrome Zinc and Nickel Plating 304 316 440 and 17 4 PH Grades of Stainless Steel Alloy Steel Ductile Iron PTFE Glass Filled PTFE Ultra High Molecular Weight Polyethylene Sound Pressure Levels dB A measured at 1 meter from unit 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 Air Motor 40 psi 70 psi 90 psi 100 psi Reduced Icing Quiet Bulldog 81 5 dB A 83 6 dB A 85 6 dB A 85 8 dB A Sound Power Levels dB A tested in accordance with ISO 9614 2 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 Air Motor 40 psi 70 psi 90 psi 100 psi Reduced Icing Quiet Bulldog 90 2 dB A 93 5 dB A 94 9 dB A 93 3 dB A 44 308351 To find Fluid Outlet Pressure psi MPa bar at a specific fluid flow Technical Data Model 237274 Reduced Icing Quiet Bulldog Pump Performance Charts Ipm gpm and operating air pressure psi MPa bar 1 Locate desired flo
10. exposed Os x 18 N 22 21 LN Torque to 468 590 N m 345 435 ft Ib Fig 15 18 19 20 Slide the priming piston 21 onto the rod 18 until it stops Hold the rod 18 steady with an adjust able wrench on the flats and screw the seat 22 onto the rod with another wrench Torque to 77 85 N m 57 63 ft lb See Fig 15 Reconnect the displacement pump to the motor as explained on page 19 Allow 2 hours for the thread sealant to cure before returning the pump to service 04993 308351 25 Displacement Pump Service For Pumps 198466 237265 and 236471 only THROAT PACKING DETAIL AN Piston check valve see Fig 12 A Intake check valve see Fig 13 AN Lubricate A Lips of v packings must face down A Screw valve plug 20 completely into valve body 29 A Torque to 128 156 N m 95 115 ft lb A Torque to 176 258 N m 130 190 ft lb Torque to 468 590 N m 345 435 ft lb JA Torque to 125 139 N m 92 102 ft lb Ads Torque to 77 85 N m 57 63 ft lb Optional Displacement Pump 237945 uses all PTFE v packings item 4 05002 Fig 16 26 308351 Displacement Pump Service For Pumps 246938 246940 246941 and 246942 only Servicing the Throat Packings 3 Place the flats of the packing nut 2 in a vise Unscrew the packing housing 3 and discard it NOTE The throat packings are available as a preas and
11. may be contaminated by the oil flush it out with a compatible solvent See Flushing on page 16 Starting and Adjusting the Pump A WARNING MOVING PARTS HAZARD E Keep hands and fingers away from the priming piston 21 during operation and whenever the pump is charged with air The priming piston extends beyond the intake housing 19 to pull material into the pump and can amputate a hand or finger caught between it and the intake housing Follow the Pressure Relief Procedure on page 12 before checking clearing or cleaning the priming piston WARNING SKIN INJECTION HAZARD 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 29 when priming the pump Use a crescent wrench to open and close the bleeder plug 20 Keep your hands away from the bleed hole CAUTION Do not allow the pump to run dry It will quickly accelerate to a high speed causing damage 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 e wH WARNING COMPONENT RUPTURE HAZARD To reduce the risk of overpressurizing your system which could cause compo nent rupture and serious injury neve
12. stainless steel PISTON stainless steel SEAL piston UHMWPE SEAT piston stainless steel NUT packing intake valve carbon steel VALVE BODY intake chrome plated stainless steel HOUSING intake ductile iron LABEL warning SCREW drive ROD priming piston stainless steel CYLINDER intake ductile iron Qty a nr eC Ce Non ND mm WO Ref No 20 21 23 24 25 26 29 30A 37 38 39 42 43 44 45 Part No 190128 276378 184246 109301 184196 109251 165702 172479 189446 189492 189724 166073 195233 195234 195232 Description Qty PLUG bleeder valve carbon steel PISTON priming stainless steel GLAND intake valve male carbon steel V PACKING intake valve PTFE GLAND intake valve female carbon steel V PACKING intake valve UHMWPE BODY bleeder valve carbon steel TAG warning not shown SEAT intake valve chrome plated stainless steel SEAL intake PTFE SEAL intake valve UHMWPE SEAL PTFE WASHER seal backup WASHER scraper WASHER rod scraper These parts are included in Throat Repair Kit 241782 which may be purchased separately N ND 2l ll nm nm S Replacement Danger and Warning labels tags and cards are available at no cost Displacement Pump Parts 308351 33 Part No 236611 198469 and 237945 Series A NOTE Ref No 1 2 3 8 9 10 11 12 13 14 15
13. the packings Remove the washer 46 seal sembled pre lubricated kit For series B pumps order 5 and backup washer 45 from the packing nut Part No 241782 For series A pumps order Part No 237905 Parts included in these kits are marked with an asterisk for example 3 Part No 237905 includes 4 The throat repair kit is preassembled Screw the kit items 3 5 qty 1 6 and 47 into the packing nut 2 making sure that the backup washer 45 seal 5 and washer 46 are properly positioned on top of the packing housing 3 with the lips of the seal facing down Torque the packing housing 3 to 97 106 N m To reduce the risk of serious injury whenever you 71 78 ft See Fig 17 g 3 are instructed to relieve pressure always follow the Pressure Relief Procedure on page12 A WARNING 5 Check that the washer 47 and o ring 6 are 1 Relieve the pressure properly installed on the bottom of the packing housing 3 2 See Fig 17 Unscrew the packing nut 2 using a pipe wrench Remove the o ring 6 and washer 47 from the bottom of the packing housing 3 or 6 Screw the packing nut 2 into the outlet housing from the outlet housing 9 9 Torque to 190 217 N m 140 160 ft lb A Torque to 97 106 N m 71 78 ft lb O A Torque to 190 217 N m 140 160 ft lb r C 2 AN Lips of u cup packing must face down Fig 17 5142C 308351 27 Parts Part No 236471 Pum
14. to get the desired results Higher pressures cause premature tip nozzle and pump wear 308351 13 Operation Hydraulic Powered Systems Refer to the warnings on page 13 1 14 Supply fluid to the pump per the requirements of your system Open the shutoff valves between the pump and supply tanks Open the dispensing valve s or spray gun s To adjust the system perform the following proce dure a Turn on the hydraulic power supply b Open the flow control valve all the way 308351 C Adjust the pressure reducing valve until you get the desired fluid pressure Run the pump until all air is purged from the fluid lines Count the cycle rate of the pump Close the flow control valve until the cycle rate and fluid pressure start to drop Open the flow control valve slightly until the cycle rate and fluid pressure return to the desired level This method of setting the hy draulic controls ensures proper pump opera tion and will prevent pump runaway and dam age if the fluid supply runs out Close the gun or valve Notes 308351 15 Maintenance Shutdown and Care of the Pump CAUTION WARNING Never leave water or water base fluid in the pump overnight If you are pumping water base fluid flush To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief P
15. 0 67 shoulder to shoulder 3 103 106166 NUT hex M16 x 2 0 3 104 186925 NUT coupling 1 105 184129 COLLAR coupling 2 106 198469 PUMP displacement See page 34 for parts 1 109 112887 WRENCH spanner 1 110 198465 FITTING 1 npt 1 111 198477 ADAPTER 1 112 109482 PACKING o ring fluoroelastomer 1 113 198478 KIT accessory intake and exhaust 1 ti1449a 308351 29 Parts Part No 198466 Pump Series A with Viscount II Hydraulic Motor Part No 246938 Pump Series A with Viscount II Hydraulic Motor n 110 109 ne ti1446a 30 308351 Ref No 101 102 103 104 105 106 109 110 111 112 113 Part No 198468 198471 106166 186925 184129 198469 246939 112887 198473 198472 198465 109482 Description MOTOR Viscount II See 307158 for parts ROD tie 235 mm 9 25 shoulder to shoulder NUT hex M16 x 2 0 NUT coupling COLLAR grounding PUMP displacement Used on Model 198466 only See page 34 for parts PUMP displacement Used on Model 246938 only See page 32 for parts WRENCH spanner FITTING reducer FITTING reducer FITTING 1 npt PACKING o ring fluoroelastomer Qty ND Parts Part No 237265 Pump Series B 65 1 Ratio with Reduced Icing Quiet King Air Motor Part No 240945 Pump Series B 65 1 Ratio with Quiet King Air Motor Part No 253376 Pump Series B 65 1 Ratio with Quiet King Air Motor Part No
16. 140 2 tc 3 7 70 LL 0 gpm 0 1 2 3 liters minute 3 8 7 6 11 4 Fluid Outlet Pressure psi cycles per minute MPa bar 10 20 30 40 50 3000 21 210 A ul ra a 2000 g 14 140 E A repel tc a 2 1000 m LL 0 gpm 0 0 0 5 1 0 1 5 2 0 2 5 liters minute 1 9 3 8 5 7 7 6 9 5 To find Pump Air Consumption m3 min or scfm at a specific fluid flow Ipm gp m and air pressure psi MPa bar 1 Locate desired flow along bottom of chart 2 Read vertical line up to intersection with selected air consumption curve d ashes Follow left to scale to read air consumption A 0 7 MPa 7 bar 100 psi air pressure B 0 5 MPa 4 9 bar 70 psi air pressure C 0 3 MPa 2 8 bar 40 psi air pressure Test Fluid No 10 Weight Oil Air Consumption scfm cycles per minute m3 min 21 42 63 150 z 420 o 2 100 A 2 2 80 2 pd A e oa B O 50 PT g 1 40 a ar an c a o gpm 0 1 2 3 liters minute 3 8 7 6 11 4 Test Fluid 4 Million CPS Weldable Rubber Base Sealer scfm m3 min 150 4 20 100 2 80 50 1 40 AIR CONSUMPTION 0 Air Consumption cycles per minute 10 20 30 40 50 A ZA B TZ tt LT i gpm 0 0 0 5 1 0 1 5 2 0 2 5 liters minute 1 9 3 8 5 7 7 6 9 5 308351 43 Technical Data Model 237274 Reduced Icing Quiet Bulldog Pump A WARNING Be sure that all fluids
17. 16 17a 17bA 17c 34 Refer to page 36 for the different packing configurations available Part No 189317 222995 189641 109499 237567 189437 189438 189439 189440 190015 189441 189727 189514 189442 184090 100508 308351 Displacement Pump Parts Description ROD displacement stainless steel PACKING NUT WET CUP carbon steel HOUSING throat packing carbon steel SEAL cylinder PTFE HOUSING outlet ductile iron CYLINDER pump stainless steel GUIDE piston stainless steel PISTON stainless steel SEAL piston UHMWPE Used on Models 236611 and 198469 SEAL piston PTFE Used on Model 237945 only SEAT piston stainless steel NUT packing intake valve carbon steel VALVE BODY intake chrome plated stainless steel HOUSING intake ductile iron LABEL warning SCREW drive Qty ND a Ref No 18 19 20 21 22 29 304 37 38 39 42 Part No 184400 189447 198470 190128 276378 190241 165702 172479 189446 189492 189724 189725 166073 Description ROD priming piston stainless steel CYLINDER intake ductile iron CYLINDER intake carbon steel Used on Model 198469 PLUG bleeder valve carbon steel PISTON priming stainless steel SEAT priming piston stainless steel BODY bleeder valve carbon steel TAG warning not shown SEAT intake valve chrome plated stainless steel SEAL intake PTFE SEAL intake valve UHMWPE Us
18. 40 50 m min 10 20 30 40 50 3000 150 21 210 z 420 W o EE F D 2000 2 100 hi 14 140 mA ns 1 2 80 cc Z a g AT Q 1000 O 50 LL _ gt m1 0 Q _ gpm 0 0 0 5 1 0 1 5 2 0 2 5 gpm 0 0 0 5 1 0 1 5 2 0 2 5 liters minute 1 9 3 8 5 7 7 6 9 5 liters minute 1 9 3 8 5 7 7 6 9 5 308351 47 Technical Data Model 198466 and 246938 Viscount Il Pumps 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 Maximum fluid working pressure Maximum hydraulic fluid input pressure Pump cycles per 3 8 liters 1 gal Fluid flow at 60 cycles min Hydraulic motor piston effective area Displacement pump effective area Maximum pump operating temperature Hydraulic fluid inlet size Weight Wetted parts Carbon Steel Chrome Zinc and Nickel Plating 304 316 440 and 17 4 PH Grades of Stainless Steel Alloy Steel Ductile Iron PTFE Glass Filled PTFE Ultra High Molecular Weight Polyethylene Sound Pressure Levels dB A Sound Power Levels dB A measured at 1 meter from unit tested in accordance with ISO 3744 Hydraulic Input Hydraulic Pressures at 25 cycles min Hydraulic Input Hydraulic Pressures at 25 cycles min Motor 10 MPa 100 bar 1450 psi Motor 10 MPa 100 bar 1450 psi VecounrT 5 dB T0 48 308351 Dimensions and Mounting Hole Layout Model 236471 Shown
19. B 0 5 MPa 4 9 bar 70 psi air pressure C 0 3 MPa 2 8 bar 40 psi air pressure Test Fluid No 10 Weight Oil Fluid Outlet Pressure Air Consumption psi cycles per minute scfm cycles per minute MPa bar 21 42 63 m min 21 42 63 6000 300 42 420 wm z 840 Ww tc F a 4000 1200 tr 2 aA a 7 a C Q B t 2 PF 0 o t gpm 0 1 2 3 gpm 0 1 2 3 liters minute 3 8 7 6 11 4 liters minute 3 8 7 6 11 4 Test Fluid 4 Million CPS Weldable Rubber Base Sealer Fluid Outlet Pressure Air Consumption psi cycles per minute scfm cycles per minute MPa bar 21 42 63 mS min 21 42 63 6000 300 42 420 z 840 w A o tr F D 400 amp 200 Q 28 280 5 5 60 _ tr o ZA n B a 2000 C O 100 3 14 140 n a t 2 80 7 C TE lt T 0 o t gpm 0 1 2 3 gpm 0 1 2 3 liters minute 3 8 7 6 11 4 liters minute 3 8 7 6 11 4 308351 39 Technical Data Models 240945 253376 and 198475 Quiet King Pump and Model 237265 Reduced Icing Quiet King Pump 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 Maximum fluid working pressure Maximum air input pressure Pump cycles per 3 8 liters 1 gal Fluid flow at 60 cycles min Air motor piston effective area Stroke length 120 mm 4 75 in Displacement pump effective area 8 cm 1 24 in 2 Maximum pump operati
20. Clear the valve replace the seals Worn packings in the displacement Replace the packings pump Pump operates but Fluid too heavy for pump priming Use the bleeder valve see page 13 use a ram output low on down stroke Held open or worn intake valve or seals Clear the valve replace the seals Pump operates but Held open or worn piston valve or seals Clear the valve replace the seals output low on upstroke THE TROUBLESHOOTING CHART IS CONTINUED ON PAGE 18 ki To determine if the fluid hose or gun is obstructed follow the Pressure Relief Procedure on page 12 Dis connect the fluid hose and place a container at the pump fluid outlet to catch any fluid Turn on the air or hydraulic power just enough to start the pump If the pump starts the obstruction is in the fluid hose or gun NOTE If you experience air motor icing call your Graco distributor 308351 17 Troubleshooting PROBLEM CAUSE SOLUTION Erratic or accelerated Exhausted fluid supply Refill and prime pump speed Fluid is too heavy for pump priming Use the bleeder valve see page 13 or 14 use a ram Held open or worn piston valve or seals Clear the valve replace the seals Held open or worn priming piston Clear service Worn packings in the displacement Replace the packings Service Required Tools 4 Disconnect the displacement pump 106 from the motor 101 as follows See Fig 6 Be sure to note e Torque wre
21. Part No 236471 246942 237265 240945 253376 237261 246940 241901 237274 237264 246941 198466 246938 A 1376 7 mm 54 20 in 1383 0 mm 54 33 in 1338 0 mm 52 68 in 1494 mm 58 82 in 1388 0 mm 54 65 in 1341 0 mm 52 80 in 1438 86 in 56 65 in 583 0 mm 22 95 in 589 6 mm 23 21 in 544 0 mm 21 42 in 544 0 mm 21 42 in 595 0 mm 23 43 in 548 0 mm 21 57 in 645 16 i 25 4 in 793 7 mm 31 25 in 793 7 mm 31 25 in 793 7 mm 31 25 in 949 0 mm 37 39 in 793 7 mm 31 25 in 793 7 mm 31 25 in 793 7 n 31 25 in All Models except 198466 and 246938 94 28 mm 3 712 Three M16 x 2 0 Holes 0653 188 4 mm 287 2 mm 11 31 in 0 437 in DIA 4 04508 728 5 mm 28 68 in 728 5 mm 28 68 in 257 0 mm 10 12 in 3 4 npsm f 257 0 mm 10 12 in 3 4 npsm f 728 5 mm 28 68 in 884 0 mm 34 82 in 728 5 mm 28 68 in 728 5 mm 28 68 in 728 5 p 28 68 in 257 0 mm 10 12 in 413 0 mm 16 26 in 257 0 mm 10 12 in 257 0 mm 10 12 in 257 0 mm 10 12 in 3 4 npsm f 3 4 npsm f 3 4 npsm f 3 4 npsm f 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 to the original purchaser for use Wit
22. al Fluid flow at 60 cycles min Air motor piston effective area Displacement pump effective area Maximum pump operating temperature Weight Wetted parts Carbon Steel Chrome Zinc and Nickel Plating 304 316 440 and 17 4 PH Grades of Stainless Steel Alloy Steel Ductile Iron PTFE Glass Filled PTFE Ultra High Molecular Weight Polyethylene Sound Pressure Levels dB A measured at 1 meter from unit 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 Air Motor 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 Sound Power Levels dB A tested in accordance with ISO 9614 2 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 Air Motor 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 42 308351 To find Fluid Outlet Pressure psi MPa bar at a specific fluid flow Technical Data Model 237261 246940 and 241901 Bulldog Pump Performance Charts Ipm gpm and operating air pressure psi MPa bar 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 pressure Fluid Outlet Pressure psi cycles per minute MPa bar 21 42 63 3000 21 210 FA _ 4 ul rs A 2000 B a 14
23. alve seal 39 into the recess of the intake valve packing nut 15 until it snaps into place The nose of the seal should be flush with or slightly recessed into the face of the packing nut 3 Place the flats of the valve body 16 in a vise Screw the packing nut into the valve body hand tight Set the intake housing assembly aside AN Lubricate A Lips of v packings must face up A Optional Displacement Pump 237945 uses all PTFE v packings item 24 16 e m sail 39 g 4 Lubricate the piston seal 13 and install it on the piston seat 14 Apply thread sealant to the threads of the seat and the piston guide 11 Screw the guide onto the seat 14 Place the guide in a vise as shown in Fig 11 and torque the seat to 77 85 N m 57 63 ft Ib If it was necessary to remove the priming piston rod 18 from the piston 12 place the flats of the piston in a vise Using an adjustable wrench on the flats of the rod screw the rod into the piston Torque to 125 139 N m 92 102 ft Ib Be careful not to create burrs on the flats of the rod 6 Place the piston seat guide assembly onto the piston 12 so the 45 beveled seating surfaces match Screw the displacement rod 1 into the piston 12 hand tight then torque the rod to 324 368 N m 239 271 ft Ib 15 23 c e 26 AAA D Fig 13 Model 236611 Displacement Pump Shown 04225 308351 23 7 10 Displacement Pump Service If the cylin
24. and Nickel Plating 304 316 440 and 17 4 PH Grades of Stainless Steel Alloy Steel Ductile Iron PTFE Glass Filled PTFE Ultra High Molecular Weight Polyethylene Sound Pressure Levels dB A measured at 1 meter from unit Input Air Pressures at 15 cycles per minute Air Motor 0 3 MPa 2 8 bar 40 psi 0 5 MPa 4 8 bar 70 psi 0 6 MPa 6 2 bar 90 psi mo 8480 827 BU 955509 Sound Power Levels dB A tested in accordance with ISO 9614 2 Input Air Pressures at 15 cycles per minute Air Motor 0 3 MPa 2 8 bar 40 psi 0 5 MPa 4 8 bar 70 psi 0 6 MPa 6 2 bar 90 psi Wm 858480 BEBA TTEA 38 308351 To find Fluid Outlet Pressure psi MPa bar at a specific fluid flow Ipm gpm and operating air pressure psi MPa bar 1 Locate desired flow along bottom of chart Technical Data Model 236471 and 246942 King Pumps Performance Charts To find Pump Air Consumption m3 min or scfm at a specific fluid flow Ipm gpm and air pressure psi MPa bar 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 pressure curve dashes Follow left to scale to read air consumption A 0 6 MPa 62 bar 90 psi air pressure
25. are con ductive placed on a grounded surface Do not place the pail on a nonconductive surface such as paper or cardboard which interrupts the grounding continuity 8 To maintain grounding continuity when flushing or relieving pressure always hold a metal part of the gun valve firmly to the side of a grounded metal pail then trigger the gun valve Installation All Systems NOTE Reference numbers and letters in parentheses in the text refer to the callouts in the figures and parts drawings The Typical Installations shown in Figs 3 and 4 are only guides for selecting and installing system compo nents and accessories Contact your Graco distributor for assistance in designing a system to suit your particular needs Accessories are available from Graco If you supply your own accessories be sure they are adequately sized and pressure rated to meet the system s re quirements System Accessories Air and Fluid Hoses Be sure all air hoses and fluid hoses are properly sized and pressure rated for your system Use only electri cally conductive hoses Fluid hoses must have spring guards on both ends Mounting Accessories Except 198466 198475 and 246938 Mount the pump A to suit the type of installation planned Fig 3 on page 8 illustrates a ram mounted pump in a multi gun header system Pump dimensions and the mounting hole layout are shown on page 49 If you are mounting the pump on a ram refer to the sepa
26. at the packing nut 15 goes on the rod first Push the valve assembly up the rod stopping before it reaches the intake valve housing 17 See Fig 14 Hold the valve body 16 steady with a wrench while using an adjustable wrench to tighten the packing nut 15 See Fig 14 Torque to 97 107 N m 71 79 ft lb Use a rubber mallet on the priming piston rod 18 to drive the valve assem bly up to the stop VS The intake seat 37 is reversible Inspect both sides of the seat and install it with the best side facing into the housing 17 Push it into the hous ing until it seats securely Lubricate the seal 38 and install in the bevel around the bottom of the seat See Fig 16 04992 15 16 17 A Torque to 77 85 N m 57 63 ft lb Displacement Pump Service Screw the intake cylinder 19 into the intake housing 17 Using a pipe wrench on the hex of the cylinder 19 torque the cylinder to 468 590 N m 345 435 ft lb This will also torque the intake valve housing 17 and pump cylinder 10 into the outlet housing 9 See Fig 15 Screw the bleeder valve plug 20 into the valve body 29 The plug has two sets of threads When reassembling be sure to screw the plug complete ly into the valve body See Fig 16 Check that the flats of the priming piston rod 18 are accessible below the intake cylinder 19 If not tap on the top of the displacement rod 1 with a rubber mallet until the flats are
27. der 10 was removed from the outlet housing 9 lubricate the seal 8 and place it on the top of the cylinder The cylinder is symmetri cal so either end can be the top Screw the cylinder into the outlet housing See Fig 16 Lubricate the seal 42 and install it in the groove on the bottom of the packing housing 3 Screw the packing housing into the outlet housing 9 and torque to 176 258 N m 130 190 ft lb See the Detail in Fig 16 Lubricate the throat packings and glands and install them in the packing housing 3 one at a time with the lips of the v packings facing down Install the v packings in the order shown in the Detail in Fig 16 Loosely install the packing nut 2 Lubricate the displacement rod 1 Slide the rod piston assembly and priming piston rod 18 into the cylinder 10 from the bottom until the top of the rod 1 protrudes from the packing nut 2 Hold valve body 16 steady Torque packing nut 15 to 97 107 N m 71 79 ft lb Fig 14 24 308351 11 12 13 14 Lubricate the seal 8 and install it on the bottom of the cylinder 10 Slide the intake valve housing 17 onto the priming piston rod 18 making certain that the smooth surface of the valve stop VS is facing down toward the pump intake Screw the housing onto the cylinder See Fig 16 Lubricate the priming piston rod 18 then slide the assembled intake valve V onto the rod making certain th
28. dries on the dis placement rod 7 Relieve the pressure 16 308351 Troubleshooting 1 Relieve the pressure WARNING 2 Check all possible problems and causes 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 12 PROBLEM CAUSE SOLUTION Pump fails to operate Restricted air or hydraulic line or inade Clear any obstructions check that all valves are quate air supply closed or clogged open increase pressure Obstructed fluid hose or gun valve Open clear use a hose with a larger ID fluid hose ID is too small Fluid dried on the displacement rod Clean always stop the pump at the bottom of its stroke keep the wet cup 1 3 filled with a compat ible solvent Dirty worn or damaged motor parts Clean or repair see the separate motor manual Pump operates but Restricted air or hydraulic line or inade Clear any obstructions check that all valves are output low on both quate air supply closed or clogged open increase pressure strokes Obstructed fluid hose or gun valve Open clear use a hose with a larger ID fluid hose ID is too small Bleeder valve is open Close the valve Air is leaking into the supply container Check the ram plate seal Fluid is too heavy for pump priming Use the bleeder valve see page 13 use a ram Held open or worn intake valve or seals
29. ection with selected air consumption pressure curve dashes Follow left to scale to read air consumption A 0 6 MPa 62 bar 90 psi air pressure B 0 5MPa 4 9 bar 70 psi air pressure C 0 3 MPa 2 8 bar 40 psi air pressure Test Fluid No 10 Weight Oil Fluid Outlet Pressure Air Consumption psi cycles per minute scfm cycles per minute MPa bar 21 42 63 ms min 21 42 63 6000 300 42 420 w A z 840 W F D 4000 B amp 200 28 280 2 5 60 2 Az Q 2000 C O 100 aL Jj 14 140 2 80 0 c 7 LL lt a o 0 o 8 gpm 0 1 2 3 gpm 0 1 2 3 liters minute 3 8 7 6 11 4 liters minute 3 8 7 6 11 4 Test Fluid 4 Million CPS Weldable Rubber Base Sealer Fluid Outlet Pressure Air Consumption psi cycles per minute scfm cycles per minute MPa bar 21 42 63 m min 21 42 63 6000 300 42 420 z 840 w A o F o D 23230 TE 560 ul d Z A Q 2000 C 100 mr B zl 14 140 oce o t 2 80 A ant 4C LL lt a E s 0 o 8 gpm 0 1 2 3 gpm 0 1 2 3 liters minute 3 8 7 6 11 4 liters minute 3 8 7 6 11 4 308351 41 Technical Data Model 237261 246940 and 241901 Bulldog Pumps 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 Maximum fluid working pressure Maximum air input pressure Pump cycles per 3 8 liters 1 g
30. ed on Models 236611 and 198469 SEAL intake valve PTFE Used on Model 237945 only SEAL PTFE 1 1 These parts are included in the pump repair kit See page 36 for the applicable kit for your pump A Replacement Danger and Warning labels tags and cards are available at no cost Displacement Pump Parts b 39 a 15 Intake Packing Stack e See page 36 ND 000 L a Oe 16 37 Throat 2 Packing Stack 38 See page 36 a it l 04989 308351 35 Displacement Pump Parts Part No 236611 and 198469 Series A Standard UHMWPE PTFE Packed Displacement Pump Ref Part No No Description Qty 4 109306 V PACKING throat PTFE 2 5 184201 GLAND throat female carbon steel 1 6 109256 V PACKING throat UHMWPE 3 7 184251 GLAND throat male carbon steel 1 23 184246 GLAND intake valve male carbon steel 1 24 109301 V PACKING intake valve PTFE 2 25 184196 GLAND intake valve female carbon steel 1 26 109251 V PACKING intake valve UHMWPE 2 These parts are included in Repair Kit 222864 which may be purchased separately See page 34 for additional parts included in the kit THROAT PACKINGS INTAKE PACKINGS LIPS FACE DOWN LIPS FACE UP 5 LUBRICATE PACKINGS 23 es 26 Scl dus y S Part No 237945 Series A Optional PTFE Packed Displacement Pump Ref Part No No Description Qty 4
31. formance Charts To find Fluid Outlet Pressure psi MPa bar at a specific fluid flow To find Pump Air Consumption m3 min or scfm at a specific fluid Ipm gpm and operating air pressure psi MPa bar flow Ipm gpm and air pressure psi MPa bar 1 Locate desired flow along bottom of chart 2 Follow vertical line 1 Locate desired flow along bottom of chart 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 pressure curve dashes Follow left to scale to read air consumption A 0 8 MPa 8 4 bar 120 psi air pressure B 0 7 MPa 7 bar 100 psi air pressure C 0 5 MPa 4 9 bar 70 psi air pressure Test Fluid No 10 Weight Oil Fluid Outlet Pressure Air Consumption psi cycles per minute scfm cycles per minute MPa bar 21 42 63 m min 21 42 63 3000 150 21 210 z 4 20 u o F gt 2000 amp 100 3 2 ACT n 9 o x a 1000 O 50 EE B 3 7 70 1 40 dps eem L _ ss 0 o e gpm 0 1 2 3 gpm 0 1 2 3 liters minute 3 8 7 6 11 4 liters minute 3 8 7 6 11 4 Test Fluid 4 Million CPS Weldable Rubber Base Sealer Fluid Outlet Pressure Air Consumption psi cycles per minute scfm cycles per minute MPa bar 10 20 30
32. h 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 the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance 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 c
33. harge 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 INCLUDING 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 t
34. he 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 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 1 800 328 0211 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 MM 308351 Graco Headquarters Minneapolis International Offices Belgium Korea China Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 www graco com PRINTED IN USA 308351K 05 1995 Revised 03 2006 50 308351
35. ig 3 8 308351 Installation Air Powered Pumps WARNING A main air bleed valve C pump air bleed valve E and fluid drain valve M are required 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 main air bleed valve C shuts off the air to the pump and ram The pump air bleed valve E 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 210658 Air Line Accessories Install the following accessories in the order shown in Fig 3 using adapters as necessary e An air line lubricator D provides automatic air motor lubrication Locate in the position shown e A main air bleed valve C is required in your system to shut off the air supply to the pump and ram see the WARNING above When closed the valve will bleed off all air in the ram and pump and the ram will slowly lower Be sure the valve is easily accessible from the pump and is located upstream from the air manifold G e A pump air bleed valve E is required in your sy
36. in valves are required in your system to relieve fluid pressure in the displacement pump hose and gun valve see the WARNING at left Drain valves at the gun valve stations may be mounted in the base of a fluid regulator L using an adapter A fluid regulator L controls fluid pressure to the gun valve and dampens pressure surges A gun or dispense valve S dispenses the fluid The gun shown in Fig 3 is a high pressure dispens ing gun for highly viscous fluids A gun valve swivel R allows freer gun valve movement 308351 9 Installation Hydraulic Powered Pumps KEY A Accessory Pump Stand H Hydraulic Pressure Gauge P N 218742 J Flow Control Valve B Surge Tank P N 218509 or K Pressure Reducing Valve 238983 L Drain Line C 50 mm 2 in Diameter Pipe M Hydraulic Return Line D Full Flow Non Restrictive Shutoff Valve Fluid Shutoff Valve N Accumulator E Fluid Supply Line P Hydraulic Supply Line F Mix Tank Q Hydraulic Return Line G Hydraulic Supply Line Y Ground
37. ion 50 Disconnecting the Displacement Pump 18 List of Models Maximum Fluid Maximum Air Pump Model Working Pressure or Hydraulic Input Pressure 236471 B King 651 40 MPa 403 bar 5850 psi 0 6 MPa 6 bar 90 psi 237265 Reduced Icing 65 1 40 MPa 403 bar 5850 psi 0 6 MPa 6 bar 90 psi Quiet King 240945 B Quietking 65 1 40 MPa 403 bar 5850 psi 0 6 MPa 6 bar 90 psi 253376 B Quietking 65 1 40 MPa 403 bar 5850 psi 0 6 MPa 6 bar 90 psi 237261 Bulldog 21 MPa 214 bar 3100 psi 0 7 MPa 7 bar 100 psi 1 1 241901 Bulldog 31 1 21 MPa 214 bar 3100 psi 0 7 MPa 7 bar 100 psi 55 Gallon 200 Liter Size 1 1 Reduced Icing 3 21 MPa 214 bar 3100 psi 0 7 MPa 7 bar 100 psi Quiet Bulldog i 15 MPa 157 bar 2280 psi 0 8 MPa 8 4 bar 120 psi 237274 237264 198466 246942 246940 246941 246938 19 1 0 8 MPa 8 4 bar 120 psi Viscount ll 40 MPa 403 bar 5850 psi 10 3 MPa 103 bar 1500 psi Viscount II 40 MPa 403 bar 5850 psi 10 3 MPa 103 bar 1500 psi 2 308351 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
38. m the guide Remove the seal 13 always replace it with a new one Inspect the mating surfaces M of the piston 12 and piston seat 14 for damage or wear See Fig 12 To disassemble the intake check valve assembly V place the intake valve body 16 in a vise and unscrew the packing nut 15 Remove the seal 39 from the nut and the glands and packings P from the valve body Inspect the mating surfaces N of the intake valve body 16 and seat 37 for damage or wear See Figs 7 and 13 14 Unscrew the bleeder valve plug 20 completely from the valve body 29 Clean the valve threads and the bleed hole It is not necessary to remove the valve body from the pump outlet housing 9 Inspect all parts for damage Clean all parts and threads with a compatible solvent Reassemble as explained on page 23 AN When reassembling items 11 and 14 apply thread sealant and torque to approx 77 85 N m 57 63 ft lb 03832 Fig 11 DETAIL OF PISTON CHECK VALVE Fig 12 22 308351 NE 10 19 N 14 17a b c N NS N 05002 Displacement Pump Service Reassembly Fig 16 shows a cutaway of the entire pump 1 Lubricate the intake packings and install them in the valve body 16 with the lips of the v pack ings facing up Install the v packings in the order shown in Fig 13 2 With the beveled side facing up press the intake v
39. ment pump a pressure and temperature compensated flow control valve J to prevent the motor from running too fast a pressure reducing valve K with a drain line L running directly into the hydrau lic return line Q and an accumulator N to reduce the hammering effect caused by the motor reversing direction On the hydraulic return line Q install a shutoff valve M for isolating the motor for servicing 308351 11 Operation Pressure Relief Procedure WARNING SKIN INJECTION HAZARD La 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 dispensing check or service any of the system equipment e or install or clean the spray tip nozzle 1 Lock the gun valve trigger safety 2 Shut off the power to the pump 3 In an air powered system close the air regulator and close the bleed type master air valve 4 Ina hydraulic powered system close the hy draulic supply line shutoff valve first then the return line shutoff valve 5 Unlock the gun valve trigger safety 6 Hold a metal part of the gun valve firmly to the side of a grounded metal pail and trigger the gun valve
40. nch the relative position of the pump s fluid outlet X to e Bench vise with soft jaws the motor inlet Y If the motor does not require e Rubber mallet servicing leave it attached to its mounting e Hammer e O ring pick CAUTION e 13mm 1 2 in dia brass rod Be sure to use at least two people when lifting e Set of socket wrenches moving or disconnecting the pump This pump is too e Set of adjustable wrenches heavy for one person If you are disconnecting the displacement pump from a motor which is still e Pipe wrench mounted for example on a ram be sure to support e Packing nut wrench 109 supplied the displacement pump while it is being discon e Thread lubricant nected to prevent it from falling and causing injury or property damage Do this by securely bracing the e Thread sealant pump or by having at least two people hold it while another disconnects it Disconnecting the Displacement Pump 1 Flush the pump if possible Stop the pump at the 5 Using an adjustable wrench or a hammer and bottom of its stroke rod unscrew the coupling nut 104 from the motor shaft Z Do not lose or drop the coupling collars 105 See Fig 6 WARNING 6 Hold the tie rod flats with a wrench to keep the To reduce the risk of serious injury whenever you rods from turning Unscrew the nuts 103 from the are instructed to relieve pressure always follow the tie rods 102 Carefully remove the displacement Pressu
41. ng temperature 82 C 180 F Model 198475 G1 2 Fluid outlet size Weight Wetted parts Carbon Steel Chrome Zinc and Nickel Plating 304 316 440 and 17 4 PH Grades of Stainless Steel Alloy Steel Ductile Iron PTFE Glass Filled PTFE Ultra High Molecular Weight Polyethylene Model 253376 See manual 308570 Sound Pressure Levels dB A measured at 1 meter from unit Input Air Pressures at 15 cycles per minute Air Motor 0 3 MPa 2 8 bar 40 psi 0 5 MPa 4 8 bar 70 psi 0 6 MPa 6 2 bar 90 psi Quen LEE ELLE 575 EN Sound Power Levels dB A tested in accordance with ISO 9614 2 Input Air Pressures at 15 cycles per minute 0 3 MPa 2 8 bar 40 psi 0 5 MPa 4 8 bar 70 psi 0 6 MPa 6 2 bar 90 psi CR ET DE 352 38 40 308351 To find Fluid Outlet Pressure psi MPa bar at a specific fluid flow Ipm gpm and operating air pressure psi MPa bar 1 Locate desired flow along bottom of chart Technical Data Models 240945 253376 and 198475 Quiet King Pump and Model 237265 Reduced lcing Quiet King Pump Performance Charts 2 Follow vertical line up to intersection with selected fluid outlet pressure curve black Follow left to scale to read fluid outlet 1 Locate desired flow along bottom of chart To find Pump Air Consumption m3 min or scfm at a specific fluid flow Ipm gpm and air pressure psi MPa bar 2 Read vertical line up to inters
42. om the intake valve housing 17 The pump may separate at joints A B or C See Fig 8 22 Fig 8 20 308351 NOTE These instructions are written with the pump separating at joint A If it separates at joints B or C disassemble it at that joint place the intake housing 17 in a vise and continue with step 5 5 Unscrew the intake valve housing 17 from the cylinder 10 Pull the housing off the pump The intake check valve assembly V see Fig 7 should slide down the priming piston rod 18 as you remove the housing if it does not slide easily firmly tap on the top of the housing 17 with a rubber mallet to loosen DETAIL OF INTAKE CHECK VALVE 17a b c 05002 17a b c 04993 Displacement Pump Service 2 6 Pull the intake seat 37 and seal 38 out the 2 bottom of the intake valve housing 17 Take care P di not to drop the check valve assembly V as it comes free and set it aside for later See Fig 7 3 tone 2 NOTE If the seat 37 is difficult to remove insert a See Fig 10 ix hammer and brass rod through the top of the housing 17 and drive the seat out A LODYANS 7 Using a rubber mallet drive the displacement rod 1 and the priming piston rod 18 out of the outlet housing 9 and cylinder 10 Inspect the outer surfaces of the rods for damage by running a finger over the surface 8 Unscrew the packing nut 2 Unscrew the packing
43. p Series B 65 1 Ratio with King Air Motor Part No 246942 Pump Series A 65 1 Ratio with King Air Motor Part No 237261 Pump Series A 31 1 Ratio with Bulldog Air Motor Part No 246940 Pump Series A 31 1 Ratio with Bulldog Air Motor Part No 237264 Pump Series A 19 1 Ratio with Senator Air Motor Part No 246941 Pump Series A 19 1 Ratio with Senator Air Motor Part No 241901 Pump Series A 31 1 Ratio with Bulldog Air Motor Ref No PartNo Description Qty 101 245111 AIR MOTOR King Used on Model 236471 and 246942 only See 309347 for parts 1 208356 AIR MOTOR Bulldog Used on Model 237261 246940 and 241901 See 307049 for parts 1 217540 AIR MOTOR Senator Used on Model 237264 and 246941 only See 307592 for parts 1 102 190000 ROD tie 224 mm 8 82 shoulder to shoulder 3 190437 ROD tie 380 mm 14 96 shoulder to shoulder Used on Model 241901 only 3 103 106166 NUT hex M16 x 2 0 3 104 186925 NUT coupling 1 105 184129 COLLAR coupling 2 106 236611 PUMP displacement See page 34 for parts 1 246939 PUMP displacement Used on Model 246942 246940 and 246941 only See page 32 for parts 1 109 112887 WRENCH spanner 1 110 190436 ROD connecting Used on Model 241901 only 1 04994B 28 308351 Parts Part No 198475 Pump Series A 65 1 Ratio with Quiet King Air Motor Ref No PartNo Description Qty 101 235525 AIR MOTOR Quiet King See 309348 for parts 102 198476 ROD tie 271 mm 1
44. pm 0 0 0 5 1 0 1 5 2 0 2 5 liters minute 1 9 3 8 5 7 7 6 9 5 liters minute 1 9 3 8 5 7 7 6 9 5 308351 45 Technical Data Model 237264 and 246941 Senator Pumps 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 Maximum fluid working pressure Maximum air input pressure Pump cycles per 3 8 liters 1 gal Fluid flow at 60 cycles min Air motor piston effective area Displacement pump effective area Maximum pump operating temperature Weight Wetted parts Carbon Steel Chrome Zinc and Nickel Plating 304 316 440 and 17 4 PH Grades of Stainless Steel Alloy Steel Ductile Iron PTFE Glass Filled PTFE Ultra High Molecular Weight Polyethylene Sound Pressure Levels dB A tested at 1 meter from motor Input Air Pressures at 15 cycles per minute 40 psi 70 psi 90 psi 100 psi Air Motor 2 8 bar 280 kPa 4 8 bar 480 kPa 6 bar 600 kPa 7 bar 700 kPa Standard Senator 84 3 dB A 87 8 dB A 89 8 dB A 91 2 dB A Sound Power Levels dB A tested in accordance with ISO 9614 Input Air Pressures at 15 cycles per minute 40 psi 70 psi 90 psi 100 psi Air Motor 2 8 bar 280 kPa 4 8 bar 480 kPa 6 bar 600 kPa 7 bar 700 kPa Standard Senator 91 6 dB A 94 6 dB A 96 4 dB A 97 3 dB A 46 308351 Technical Data Model 237264 and 246941 Senator Pumps Per
45. r exceed the Maximum Input Pressure to the pump see the Technical Data on pages 38 46 Air Powered Systems Supply fluid to the pump per the requirements of your system See Fig 3 Close the air regulator F Open all air bleed valves C E Hold a metal part of the gun valve S firmly to the side of a grounded metal pail and hold the trigger open Slowly open the air regulator until the pump starts Cycle the pump slowly until all air is pushed out and the pump and hoses are fully primed Release the gun valve trigger and lock the trigger safety The pump should stall against pressure If the pump fails to prime properly open the bleeder valve plug 20 slightly Use the bleed hole on the underside of the valve body 29 as a priming valve until the fluid appears at the hole See Fig 5 Close the plug NOTE When changing fluid containers with the hose and gun valve already primed open the bleeder valve plug 20 to help prime the pump and vent air before it enters the hose Close the plug when all air is elimi nated 9 10 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 valve In a circulating system the pump will speed up or slow down on demand until the air supply is shut off Use the air regulator F to control the pump speed and the fluid pressure Always use the lowest air pressure necessary
46. rate ram manual for installation and operation instructions Mounting Kit 222776 is available to mount the pump on a 55 gallon 200 liter ram 308351 7 Installation Air Powered Pumps KEY Pump 200 Liter 55 Gallon Air Powered Ram Main Air Bleed Valve required for pump and ram Air Line Lubricator position only Pump Air Bleed Valve required for pump Pump Air Regulator Air Manifold Electrically Conductive Air Supply Hose Air Line Filter Air Shutoff Valve for accessories Fluid Regulator FACTO MMIOWD z cdo vzz Fluid Drain Valve required Electrically Conductive Fluid Supply Hose Fluid Shutoff Valve Gun Valve Swivel Airless Spray Gun or Dispensing Valve Ram Air Regulator Ram Director Valve Pump Runaway Valve position only Air LIne Drain Valve Ground Wire required see page 6 for installation instructions FLUID HEADER PIPE 8 in Diameter D B J K MAIN AIR LINE A J W L P L P LR Z U c Q 05097 F
47. re Relief Procedure on page 12 pump 106 from the motor 101 2 Relieve the pressure 7 Refer to page 20 for displacement pump service To service the motor refer to the separate motor 3 Disconnect all hoses from the pump and motor manual supplied 18 308351 Service Reconnecting the Displacement Pump 1 Make sure the coupling nut 104 and the coupling collars 105 are in place on the displacement rod 1 See Fig 6 2 Use at least two people to hold the displacement pump while another reconnects it to the motor see the CAUTION on page 18 Orient the pump s fluid outlet X to the air or hydraulic inlet Y as was noted in step 4 under Disconnecting the Dis placement Pump Position the displacement pump 106 on the tie rods 102 3 Screw the nuts 103 onto the tie rods 102 and torque to 68 81 N m 50 60 ft lb 4 Screw the coupling nut onto the motor shaft loose ly Hold the motor shaft Z flats with a wrench to keep it from turning Use an adjustable wrench to tighten the coupling nut Torque to 196 210 N m 145 155 ft Ib 5 Torque the packing nut 2 to 128 156 N m 95 115 ft Ib 6 Reconnect all hoses Reconnect the ground wire if it was disconnected Fill the wet cup 2 1 3 full of Graco Throat Seal Liquid or compatible solvent 7 Turn on the power supply Run the pump slowly to ensure proper operation WARNING To reduce the risk of serious injury whenever you are instructed to
48. relieve pressure always follow the Pressure Relief Procedure on page 12 8 Before returning the pump to production relieve the pressure and retorque the packing nut 2 to 128 156 N m 95 115 ft lb NN Torque to 68 81 N m 50 60 ft lb Torque to 196 210 N m 145 155 ft Ib Torque to 128 156 N m 95 115 ft Ib Square hole is for use with torque wrench 04994 Fig 6 308351 19 Displacement Pump Service Disassembly When disassembling the pump lay out all the removed parts in sequence to ease reassembly Clean all parts with a compatible solvent and inspect them for wear or damage Refer to Fig 9 for a cutaway view of the pump NOTE Packing Repair Kits are available See page 36 For the best results use all the new parts in the kit Kit parts are marked with an asterisk for example 7 1 Remove the displacement pump from the motor as explained on page 18 Place the pump in a vise with the outlet housing 9 positioned as shown in Fig 8 2 Hold the flats of the priming piston rod 18 with an adjustable wrench and use a second wrench to unscrew the priming piston seat 22 from the rod Slide the priming piston 21 off the rod Inspect the inner and outer surfaces of the piston 21 for scoring wear or other damage 3 Loosen the packing nut 2 using the wrench 109 supplied 4 Using a pipe wrench on the hex of the intake cylinder 19 unscrew it fr
49. rocedure on page 12 with water first then with a rust inhibitor such as mineral spirits Relieve the pressure but leave the rust inhibitor in the pump to protect the parts from corrosion For overnight shutdown stop the pump at the bottom of the stroke to prevent fluid from drying on the ex posed displacement rod and damaging the throat A WARNING packings Relieve the pressure ducks To reduce the risk of serious injury whenever you Always flush the pump before the fluid dries on the are instructed to relieve pressure always follow the displacement rod Refer to Flushing below Pressure Relief Procedure on page 12 Flushing Relieve the pressure WARNING 2 Remove the spray tip nozzle from the gun valve FIRE AND EXPLOSION HAZARD Before flushing read the section FIRE 3 Hold a metal part of the gun valve firmly to the side of a grounded metal pail AND EXPLOSION HAZARD on page 5 Be sure the entire system and flush ing pails are properly grounded Refer to Grounding on page 6 4 Start the pump Always use the lowest possible fluid pressure when flushing Flush with a fluid that is compatible with the fluid you 5 Trigger the gun valve are pumping and with the wetted parts in your system Check with your fluid manufacturer or supplier for 6 Flush the system until clear solvent flows from the recommended flushing fluids and flushing frequency gun valve Always flush the pump before fluid
50. stem to relieve air trapped between it and the air motor when the valve is closed see the WARNING at left Be sure the bleed valve is easily accessible from the pump and is located downstream from the air regulator e An air regulator F controls pump speed and outlet pressure by adjusting the air pressure to the pump Locate the regulator close to the pump but upstream from the pump air bleed valve A pump runaway valve V 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 Locate in the position shown An air manifold G has a swivel air inlet It mounts to a ram and has ports for connecting lines to air accessories such as the ram air regulator T and ram director valve U 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 An air shutoff valve K isolates the air line acces sories for servicing Locate upstream from all other air line accessories Fluid Line Accessories Install the following accessories in the positions shown in Figs 3 and 4 using adapters as necessary Install a fluid shutoff valve P at each gun valve drop to isolate the gun valve and fluid accessories for servicing Install a fluid drain valve M near the pump fluid outlet and at each gun valve station The dra
51. sure Relief Procedure on page 12 to prevent the equipment from starting unexpectedly 4 308351 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 6 If there is any static sparking or you feel an electric shock while using this equipment stop spray ing dispensing 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 dispensed Keep the spray dispense area free of debris including solvent rags and gasoline Electrically disconnect all equipment in the spray dispense area Extinguish all open flames or pilot lights in the spray dispense area Do not smoke in the spray dispense area Do not turn on or off any light switch in the spray dispense area while operating or if fumes are present Do not operate a gasoline engine in the spray dispense 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
52. w 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 To find Pump Air Consumption m3 min or scfm at a specific fluid flow Ipm gpm and air pressure psi MPa bar 1 Locate desired flow along bottom of chart 2 Read vertical line up to intersection with selected air consumption pressure curve dashes Follow left to scale to read air consumption A 0 7 MPa 7 bar 100 psi air pressure B 0 5 MPa 4 9 bar 70 psi air pressure C 0 3 MPa 2 8 bar 40 psi air pressure Test Fluid No 10 Weight Oil Fluid Outlet Pressure Air Consumption psi cycles per minute scfm cycles per minute MPa bar 21 42 63 ms min 21 42 63 3000 150 21 210 FA z 420 2 2000 ae B 100 A E o ul 14 140 2 2 80 ps tr 2 Pa a Oo Pd JB a 1000 C E n A d 7 70 z 1 40 9 7 c 253 0 o A gpm 0 1 2 3 gpm 0 1 2 3 liters minute 3 8 7 6 11 4 liters minute 3 8 7 6 11 4 Test Fluid 4 Million CPS Weldable Rubber Base Sealer Fluid Outlet Pressure Air Consumption psi cycles per minute scfm cycles per minute MPa bar 10 20 30 40 50 m3 min 10 20 30 40 50 3000 150 21 210 A z 420 W c F D 2000 amp 100 9 14140 B 5 280 a z fe 7 Bo S 100 c O 50 i gt t 14 A C L T 0 o 6 gpm 0 0 0 5 1 0 1 5 2 0 2 5 g
53. y 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 surgi cal treatment Do not point the gun valve at anyone or at any part of the body Do not put your hand or fingers over the spray tip nozzle 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 valve trigger safety operates before spraying Lock the gun valve trigger safety when you stop spraying Follow the Pressure Relief Procedure on page 12 if the spray tip nozzle clogs and before clean ing checking or servicing the equipment Tighten all fluid connections before operating the equipment Check the hoses tubes and couplings daily Replace worn or damaged parts immediately Do not repair high pressure couplings you must replace the entire hose Fluid hoses must have spring guards on both ends to help protect them from rupture caused by kinks or bends near the couplings MOVING PARTS HAZARD Moving parts such as the priming 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 Pres

Graco 308351K User's Manual

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