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Graco 308149P User's Manual

1. KEY A Pump U Hydraulic Supply Line Shutoff Valve B 200 Liter 55 Gallon Air Powered Ram V Hydraulic Return Line Shutoff Valve C Hydraulic Supply Line Y Ground Wire required see page 7 for D Hydraulic Return Line installation instructions E Drain Line from pressure reducing valve AA Hydraulic Return Line Filter F Pressure Gauge G3 Flow Gontro valve AIR FILTER FOR RAM AIR SHUTOFF VALVE FOR RAM H Pressure Reducing Valve y a sAceumulator MAIN AIR LINE FLUID HEADER PIPE K Drain Line from motor drip pan ath L 3 in Diameter L Fluid Regulator S M Fluid Drain Valve required V N Electrically Conductive Fluid Supply Hose m m m P Fluid Shutoff Valve A R Gun Valve Swivel J S Airless Spray Gun 2 B B or Dispensing Valve de Y L P L P T Ram Air Regulator asti G 2 S E 7 T HYDRAULIC o E POWER SUPPLY HL aL T E S R uN M i N N mei NY SR g AA DRAINAGE K paca CONTAINER Fig 4 10 308149 Installation HYDRAULIC POWERED PUMPS SYSTEM ACCESSORIES A WARNING A flu
2. psi bar cycles min MPa 16 32 48 6064 80 gpm 2400 lpm 168 hyd 16 8 A oil 2000 20 140 76 0 14 0 u 1600 ae Cc 112 a 11 2 MB N W 1200 ye ae hydraulic oil dii 5 8 4 consumption A 8 800 C 7 56 30 4 5 6 400 4 28 15 2 2 8 0 gpm 0 2 4 6 8 10 liters min 7 6 15 2 22 8 30 4 38 0 FLUID FLOW TEST FLUID 100 000 CENTIPOISE SEALANT To find Fluid Outlet Pressure MPa bar psi at a specific fluid flow Ipm gpm and operating hydraulic oil 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 pressure A 10 5 MPa 105 bar 1500 psi Hydraulic Oil Pressure B 7 4 MPa 74 bar 1050 psi Hydraulic Oil Pressure C 4 2 MPa 42 bar 600 psi Hydraulic Oil Pressure psi A cycles min S 8 16 24 32 40 gpm 2400 Dm 168 hyd 16 8 oil 2000 20 140 76 0 14 0 w 1600 A 16 E 112 60 8 11 2 oO B ul 1200 12 a 84 45 6 Q 84 z 8 800 e VG 30 4 400 hydraulic oil 4 28 consumption 15 2 2 8 0 gpm 0 1 2 3 4 5 liters min 3 8 7 6 11 4 15 2 19 0 FLUID FLOW TEST FLUID 4 000 000 CENTIPOISE SILICON To find Pump Hydraulic Oil Consumption lpm or gpm at a specific fluid flow Ipm gpm and hydraulic oil pressure MPa bar psi 1 Locate desired flow along bottom of chart 2 Read vertical line up to intersection wi
3. psi bar cycles min MPa 8 16 24 32 40 1200 scfm 84 m3 min 8 4 1000 N A 200 70 5 60 7 0 160 800 E 56 4 48 D 5 6 B iu 600 120 a 42 3 36 A 42 Ta 400 C 80 28 A 2 24 2 8 200 B 40 14 1 12 1 4 C 0 gpm 0 1 2 3 4 5 liters min 3 8 7 6 11 4 15 2 19 0 FLUID FLOW TEST FLUID 4 000 000 CENTIPOISE SILICON To find Pump Air Consumption m3 min or scfm at a specific fluid flow Ipm gpm and air pressure MPa bar psi 1 Locate desired flow along bottom of chart 2 Read vertical line up to intersection with selected air consumption curve gray Follow right to scale to read air consumption Technical Data Model 222829 Quiet Bulldog Pump Rati a x canili ahs aca ae aoa eats Maximum fluid working pressure Maximum air input pressure Pump cycles per 3 8 liters 1 gal pater ata eaves ne 8 3 MPa 83 bar 1200 psi L ARIA ie A 8 12 1 Quiet Bulldog Air Motor 0 7 MPa 7 bar 100 psi Recommended pump speed for continuous operation 60 cycles per min Maximum flow 0 000 e cece eee eee Air motor piston effective area Stroke length annaa Displacement pump effective area Maximum pump operating temperature AIM iNIGUSIZO cyra niena iena Fluid outlet size Weight Displacement Pump Weight Wetted parts Carbon Steel Chrome Zinc and Electroless Nickel Plating 28 5 liters min 7 5 gpm at 60 cycles min irani
4. See page 2 for Table of Contents PROVEN QUALITY LEADING TECHNOLOGY ma 4 GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 STS Copyright 2002 Graco Inc is registered to 1 S EN ISO 9001 dd Table of Contents WAIMIAGS lt aa a N 2 ha etna ah Smee ek LE praia heats 3 Installationi ini tet patate 7 Installation Air Powered Pumps 8 Installation Hydraulic Powered Pumps 10 Operation Maintenance A osi 12 Air Powered Models 12 Hydraulic Powered Models 14 Service Troubleshooting Chart 15 Required Tools eee eee eee 16 2 308149 Disconnecting the Displacement Pump 16 Reconnecting the Displacement Pump 18 Displacement Pump Service 19 Parts Drawings and Lists Pump Assemblies eee eee 25 Displacement Pump eee eee 28 Technical Data and Performance Charts 30 Dimensions LL 36 Mounting Hole Layout 37 Graco Standard Warranty e 38 Graco Information cece eee eee 38 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 44 WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can c
5. 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 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 Air and Fluid Hoses Be sure all air hoses H and fluid hoses N are prop erly sized and pressure rated for your system Use only electrically conductive hoses Fluid hoses must have spring guards on both ends Mounting Accessories A WARNING For Model 222940 Premier Pump do not lift the pump by the lift ring when the total weight exceeds 550 Ib 250 kg 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 pages 36 and 37 If you are mounting the pump on a ram refer to the separate ram manual for installation and operation instructions 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 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 easily accessible from the pump and is located dow
6. Displacement Pump Weight Wetted parts Carbon Steel Chrome Zinc and Electroless Nickel Plating 28 5 liters min 7 5 gpm at 60 cycles min LIRA re TA ERT 248 cm 38 5 in 2 CREA E i E 120 mm 4 75 in CRE aE ela 21 cm 3 255 in 2 AE AA Cep 65 5 C 150 F 3 4 npsm f 1 1 2 npt m approx 65 kg 142 lb approx 37 kg 81 Ib 304 and 17 4 PH Grades of Stainless Steel E52100 Alloy Steel Ductile Iron Acetal PTFE Ultra High Molecular Weight Polyethylene Fluid Outlet Pressure Black Curves Air Consumption Gray Curves KEY NOTE Recommended pump speed for continuous operation to shaded area 60 com psi bar cycles min MPa 16 32 48 60 64 80 1200 scfm 84 m3 min 8 4 aa A ui 1000 70 5 60 7 0 y em be 56 B A S iu 600 120 a 42 B 3 36 A 42 D 28 2 24 2 8 C 200 40 14 1 12 1 4 0 gpm 0 2 4 6 8 10 liters min 7 6 15 2 22 8 30 4 38 0 FLUID FLOW TEST FLUID 100 000 CENTIPOISE SEALANT To find Fluid Outlet Pressure MPa bar psi at a specific fluid flow Ipm gpm and operating 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 pressure 30 308149 A 0 7 MPa 7 bar 100 psi Air Pressure B 0 49 MPa 4 9 bar 70 psi Air Pressure C 0 28 MPa 2 8 bar 40 psi Air Pressure
7. aw thread sealant and torque to approx 125 137 N m 92 101 ft lb 01173 Fig 9 16 Take the intake valve assembly removed in step 9 and unscrew the packing nut 9 from the valve body 10 Using an o ring pick remove the glands 16 41 and v packings 40 and 42 from the valve body Remove the seal 43 from the packing nut See the Detail in Fig 10 NOTE The seal 43 is press fit in the packing nut and may require cutting to ease removal 17 Unscrew the bleeder valve plug 35 completely from the valve housing 34 Clean the valve threads and the bleed hole in the valve housing It is not necessary to remove the valve housing from the outlet housing 19 18 Remove the packing nut 2 from the outlet hous ing 19 Remove the throat packings 22 24 and glands 21 23 from the outlet housing 19 Do not remove the fluid outlet nipple 20 and o ring 25 from the outlet housing unless they need replacement 19 Inspect all parts for damage Clean all parts and threads with a compatible solvent Reassemble as explained on page 22 Service THROAT PACKING DETAIL DETAIL OF O YA ES PISTON CHECK VALVE gt 24 22 A a Sa 34M 227 N S 01120 I 4 NE DETAIL OF N Z INTAKE CHECK VALVE A Piston check valve A see detail at right wi 12 Intake check valve w Pa AA see detail at right A
8. close the hydraulic supply line valve first then the return line valve 4 Unlock the gun valve safety latch 5 Hold a metal part of the gun valve firmly to the side of a grounded metal pail and trigger the gun valve to relieve pressure 6 Lock the gun valve safety latch 7 Open the drain valve required in your system and or the pump bleeder valve having a container ready to catch the drainage 8 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 nozzle or hose end coupling and relieve pressure gradually then loosen completely Now clear the tip nozzle or hose Packing Nut Wet Cup Fill the packing nut wet cup 2 1 3 full with Graco Throat Seal Liquid TSL or compatible solvent See Fig 5 Using the supplied wrench 104 adjust the packing nut weekly so it is just snug do not overtigh ten Follow the Pressure Relief Procedure above before adjusting the packing nut 12 308149 Flushing the Pump 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 before using the pump A WARNING Before operating the pump ground the system as explained under FIRE AND EXPLOSIO
9. continuous operation c 0 28 MPa 2 8 bar 40 psi Air Pressure to shaded area 50 com psi psi bar cycles min bar cycles min MPa 16 32 4850 64 80 MPa 8 16 24 32 40 4000 4000 280 280 28 0 scfm 28 0 scfm or N m3 min 300 N m3 min 24 5 A 24 5 A 3000 300 3000 300 210 A 8 40 210 8 40 w 21 0 w 21 0 2500 250 2500 A 175 N 7 00 a 175 N 7 00 DN 17 5 B w 17 5 B Li 2000 B20 W 2000 200 a 140 5 60 a 140 5 60 Q 14 0 a 140 3 1500 150 3 1500 130 n 105 4 20 n 105 A 4 20 10 5 Sc C 400 10 5 PC 100 1 1 Di 250 e 5 2 50 7 0 7 0 500 30 500 C 30 35 1 40 35 1 40 3 5 3 5 0 0 gpm 0 2 4 6 8 10 gpm 0 1 2 3 4 5 liters min 7 6 15 2 22 8 30 4 38 0 liters min 3 8 7 6 11 4 15 2 19 0 FLUID FLOW FLUID FLOW TEST FLUID 100 000 CENTIPOISE SEALANT TEST FLUID 4 000 000 CENTIPOISE SILICON To find Fluid Outlet Pressure MPa bar psi at a specific fluid flow To find Pump Air Consumption m3 min or scfm at a specific fluid lpm gpm and operating air pressure MPa bar psi flow Ipm gpm and air pressure MPa bar psi Ay LpcalS doalrea levcalongiLolom akchare 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 gray Follow right to scale to read air co
10. gun or valve S dispenses the fluid The gun shown in Fig 3 is a high pressure dispensing gun for highly viscous fluids e A gun swivel R allows freer gun movement 308149 9 Installation HYDRAULIC POWERED PUMPS NOTE Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the A CAUTION parts drawing It is very important to keep the hydraulic supply system clean at all times Be sure that all hydraulic fluid lines are absolutely clean Blow out the lines with air and flush thoroughly with solvent before connecting to the hydraulic motor to avoid introduc ing harmful contaminants into the motor Plug the Accessories are available from your Graco If you supply your own accessories be sure they are ade quately sized and pressure rated to meet the system s requirements The Typical Installation shown in Fig 4 is only a guide hydraulic lines immediately when they are discon for selecting and installing system components and nected accessories Contact your Graco distributor for assis tance in designing a system to suit your particular needs Do not exceed 37 8 liter min 10 gpm hydraulic oil volume to the motor to avoid pump stalling For optimum pump performance keep the tempera ture of the hydraulic oil below 54 C 130 F
11. pump e Before servicing the equipment follow the Pressure Relief Procedure on page 12 to prevent the equipment from starting unexpectedly 4 308149 44 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 Electrically 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 Keep a fire extinguisher in the work 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
12. pump to protect the parts from corrosion Troubleshooting 1 Relieve the pressure A WARNING 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 12 PROBLEM CAUSE SOLUTION Pump fails to operate Restricted line or inadequate air hydraulic Clear increase air hydraulic supply supply closed or clogged valves Check that valves are open Obstructed fluid hose or gun valve Open clear use hose with larger ID fluid hose ID is too small Fluid dried on the displacement rod Clean always stop pump at bottom of stroke keep wet cup 1 3 filled with compatible solvent Dirty worn or damaged motor parts Clean or repair see separate motor manual Pump operates but out Restricted line or inadequate air hydraulic Clear increase air hydraulic supply put low on both strokes supply closed or clogged valves Check that valves are open Obstructed fluid hose or gun valve Open clear use hose with larger ID fluid hose ID is too small Air leaking into supply container Check ram plate seal Fluid too heavy for pump priming Use bleeder valve see pages 12 and 14 use ram Worn packings in displacement pump Replace packings Pump operates but out Fluid too heavy for pump priming Use bleeder valve see pages 12 and 14 use ram put low on downstroke Held open or
13. the piston 6 and the shoulder of the rod 1 5 Apply thread sealant to the bottom threads of the piston and the top threads of the priming piston rod 12 Using an adjustable wrench on the flats of the rod screw the rod into the piston Torque to 125 137 N m 92 101 ft lb Be careful not to create burrs on the flats of the rod 6 Slide the rod guide 18 onto the priming piston rod 12 making certain that the end nearest the valve stop VS goes on the rod first See the Detail in Fig 11 7 With the beveled side facing up press the seal 43 into the recess of the intake packing nut 9 until it snaps into place The nose of the seal should be flush with or slightly recessed into the face of the packing nut 22 308149 8 Lubricate the intake valve packings and the inner diameter of the valve body 10T Install the pack ings one at a time in the following order with the lips of the v packings facing up the female gland 41 one PTFE v packing 40 one UHMWPE v packing 42 PTFE 40 UHMWPE 42 and the male gland 16 Screw the intake packing nut 9 into the valve body 10 handtight See the Detail in Fig 11 9 Slide the assembled intake valve onto the priming piston rod 12 making certain that the packing nut 9 goes on the rod first Push the valve assembly up the rod stopping before it reaches the rod guide 18 10 Hold the valve body 10 steady with a wrench while using an adjustable wre
14. up to intersection with selected air consumption pressure curve gray Follow right to scale to read air consumption 308149 33 Technical Data Model 222940 Premier Pump Ratio Seria te a bo Fact dia la 39 1 Premier Air Motor Maximum fluid working pressure 00 eee eee eee 26 9 MPa 269 bar 3900 psi Maximum air input pressure 0 cece eee 0 7 MPa 7 bar 100 psi Pump cycles per 3 8 liters 1 gal LL 8 Recommended pump speed for continuous operation 50 cycles per min Maximum flow cee eee eee 23 75 liters min 6 25 gpm at 50 cycles min Air motor piston effective area 800 cm 38 5 in 2 Stroke length ce ii Li eri TON a 120 mm 4 75 in Displacement pump effective area 21 cm 3 255 in 2 Maximum pump operating temperature e ee 65 5 C 150 F Air inlet SIZE si E Meee to ine Leaded ees 3 4 npsm f Fluid o tlet Sizo Sess ct fein Geass eae deen yee ads 1 1 2 npt m Weight urta nale aa approx 113 kg 248 Ib Displacement Pump Weight nenene naaa approx 37 kg 81 Ib Wetted parts Carbon Steel Chrome Zinc and Electroless Nickel Plating 304 and 17 4 PH Grades of Stainless Steel E52100 Alloy Steel Ductile Iron Acetal PTFE Ultra High Molecular Weight Polyethylene 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 NOTE Recommended pump speed for
15. worn intake valve or seals Held open or worn intake valve or seals or worn intake valve or seals Clear valve Clear valve replace seals 0 seals Pump operates but out Held open or worn piston valve or seals ee valve replace seals put low on upstroke Erratic or accelerated Exhausted fluid supply Refill and prime pump speed Fluid too heavy for pump priming Use bleeder valve see pages 12 and 14 use ram Held open or worn piston valve or seals Clear valve replace seals Worn packings in displacement pump Replace packings 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 hydraulic power just enough to start the pump If the pump starts when the air hydraulic power is turned on the obstruction is in the fluid hose or gun NOTE If you experience air motor icing contact your Graco distributor 308149 15 Service A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 12 Required Tools Torque wrench Bench vise with soft jaws Rubber mallet Hammer O ring pick 13 mm 1 2 in dia brass rod Set of socket wrenches Set of adjustable wrenches 24 in adjustable wrench Thread lubricant Thread sealant Loctite 2760 or equivalent NOTE Service Tool 109508 is available
16. 3 for parts ADAPTER connecting rod NUT coupling WRENCH packing nut PUMP displacement See pages 28 29 for parts NUT hex M16 x 2 0 ROD tie 560 mm 22 06 shoulder to shoulder COLLAR coupling ROD connecting Parts Model 222902 Pump Series B Model 246937 Pump Series A with Viscount Hydraulic Motor 01403B Qty dA Ad AL a Nd These parts are included in Connection Kit 235421 which may be purchased separately 107 101 g NS Ref Part No No 101 235345 102 184595 103 184096 104 184278 105 222810 105 246934 106t 106166 1074 184596 108t 184130 Description HYDRAULIC MOTOR Viscount See 307158 for parts ADAPTER connecting rod NUT coupling WRENCH packing nut PUMP displacement 222902 only See pages 28 29 for parts PUMP displacement 246937 only See pages 28 29 for parts NUT hex M16 x 2 0 ROD tie 315 mm 12 40 shoulder to shoulder COLLAR coupling 0916A Qty A A ll a 3 3 2 These parts are included in Connection Kit 222976 which may be purchased separately 308149 27 Parts Model 222810 Series B Model 246934 Series A Displacement Pump 308149 28 Parts Model 222810 Series B These parts are included in Repair Kit 222860 which may Model 246934 Series A li i Displacement Pump T These parts are included in Intake Valve Repair Kit Ref Part 222974 which may be purchased separately The kit
17. 4 48 3 56 NB Hl 600 120 De 3 36 a 42 Q 42 D d 400 80 28 A 2 24 2 8 B 200 40 14 1 12 1 4 C 0 gpm 0 1 2 3 4 5 liters min 3 8 7 6 11 4 15 2 19 0 FLUID FLOW TEST FLUID 4 000 000 CENTIPOISE SILICON To find Pump Air Consumption m3 min or scfm at a specific fluid flow Ipm gpm and air pressure MPa bar psi 1 Locate desired flow along bottom of chart 2 Read vertical line up to intersection with selected air consumption curve gray Follow right to scale to read air consumption 308149 31 Technical Data Model 222835 and 246936 King Pump Ratios t Wage ea a Lea Ada ia 24 1 Standard King Air Motor Maximum fluid working pressure Maximum air input pressure Pump cycles per 3 8 liters 1 gal Air motor piston effective area Stroke length nean Displacement pump effective area Maximum pump operating temperature Air IMOUSIZE in seiner ha bance t Fluid outlet size Weight Displacement Pump Weight Wetted parts a a NO 8 Recommended pump speed for continuous operation Maximum HOW nananana 16 6 MPa 166 bar 2400 psi 0 7 MPa 7 bar 100 psi 50 cycles per min 23 75 liters min 6 25 gpm at 50 cycles min 506 cm 78 5 in 2 120 mm 4 75 in 21 cm 3 255 in 2 65 5 C 150 F 3 4 npsm f 1 1 2 npt m approx 73 kg 160 Ib approx 37 kg 81 Ib Carbon Steel Chrome Zinc and Electroless Nickel Plating 304 and 17 4 PH G
18. 46935 Pump Series A 12 1 Ratio with Bulldog Air Motor 101 S S amp gt 104 Ref Part No No 101 208356 102t 184451 103 184096 104 184278 105 222810 105 246934 106 106166 1074 184452 108t 184130 These parts are included in Connection Kit 235414 which Description AIR MOTOR Bulldog See 307049 for parts ADAPTER connecting rod NUT coupling WRENCH packing nut PUMP displacement 222828 only See pages 28 29 for parts PUMP displacement 246935 only See pages 28 29 for parts NUT hex M16 x 2 0 ROD tie 265 mm 10 43 shoulder to shoulder COLLAR coupling may be purchased separately 0917A Parts Model 222829 Pump Series A 12 1 Ratio with Quiet Bulldog Air Motor 101 107 Qty dA A AL a 106 9 SS NS 104 0918A at E Ref Part No No Description 4 1 101 215255 AIR MOTOR Bulldog quiet 1 See 307304 for parts 1 102 184451 ADAPTER connecting rod 1034 184096 NUT coupling 1 104 184278 WRENCH packing nut 105 222810 PUMP displacement 1 See pages 28 29 for parts 3 106 106166 NUT hex M16 x 2 0 107t 184452 ROD tie 265 mm 10 43 3 shoulder to shoulder 2 108 184130 COLLAR coupling may be purchased separately 308149 3 2 These parts are included in Connection Kit 235414 which 25 Model 222835 Pump Series B Model 246936 Pump Series A 24 1 Ratio with King Air Motor 105 106 107 108 P
19. Fig 4 using adapters as necessary e Install a fluid shutoff valve P at each gun drop to isolate the gun and fluid accessories for servic ing e Install a fluid drain valve M near the pump fluid outlet and at each gun station The drain valves are required in your system to relieve fluid pressure in the displacement pump hose and gun see the WARNING at left Drain valves at the gun stations may be mounted in the base of a fluid regulator L using an adapter e A fluid regulator L controls fluid pressure to the gun valve and dampens pressure surges e A gun or valve S dispenses the fluid The gun shown in Fig 4 is a high pressure dispensing gun for highly viscous fluids e A gun swivel R allows freer gun movement 308149 11 Operation ALL MODELS Pressure Relief Procedure A WARNING SKIN INJECTION HAZARD Fluid under high pressure can be in jected 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 e check or service any of the system equipment e or install or clean the spray tip nozzle 1 Engage the gun valve trigger safety 2 Shut off the air or hydraulic supply to the pump 3 In air powered systems close the bleed type master air valve required in your system In hydraulic powered systems
20. Instructions Parts List CARBON STEEL Check Mate 2100 Pumps 3 3 0p Part No 222828 Pump Series A Part No 246935 Pump Series A 12 1 Ratio with Bulldog Air Motor 8 3 MPa 83 bar 1200 psi Maximum Fluid Working Pressure 0 7 MPa 7 bar 100 psi Maximum Air Input Pressure Part No 222829 Pump Series A 12 1 Ratio with Quiet Bulldog Air Motor 8 3 MPa 83 bar 1200 psi Maximum Fluid Working Pressure 0 7 MPa 7 bar 100 psi Maximum Air Input Pressure Part No 222835 Pump Series A Part No 246936 Pump Series A 24 1 Ratio with King Air Motor 16 6 MPa 166 bar 2400 psi Maximum Fluid Working Pressure 0 7 MPa 7 bar 100 psi Maximum Air Input Pressure Part No 222901 Pump Series B 24 1 Ratio with Quiet King Air Motor 16 6 MPa 166 bar 2400 psi Maximum Fluid Working Pressure 0 7 MPa 7 bar 100 psi Maximum Air Input Pressure Part No 222940 Pump Series A 39 1 Ratio with Premier Air Motor 26 9 MPa 269 bar 3900 psi Maximum Fluid Working Pressure 0 7 MPa 7 bar 100 psi Maximum Air Input Pressure Part No 222902 Pump Series B Part No 246937 Pump Series A with Viscount Hydraulic Motor 15 9 MPa 159 bar 2300 psi Maximum Fluid Working Pressure 10 MPa 103 bar 1500 psi Maximum Hydraulic Input Pressure Important Safety Instructions i uni Part No Ay Read all warnings and instructions in this manual 222835 Save these instructions Shown a iu
21. MWPE 22 and the female gland 21 Apply thread lubricant to the packing nut 2 and install it loosely in the outlet housing Lubricate the seal 39 and place it on the top edge of the cylinder 4 Set the outlet housing 19 on top of the cylinder Install the six long capscrews 32 through the outlet housing 19 and into the intake housing 17 Using a socket wrench torque the screws oppositely and evenly to 244 264 N m 180 195 ft lb Remove the pump from the vise and place it on its side Check that the flats of the priming piston rod 12 are accessible below the intake housing 17 If not tap on the top of the displacement rod 1 with a rubber mallet until the flats are exposed Slide the priming piston guide 13 onto the rod 12 until it stops Then install the priming piston 15 with the flat side facing up toward the pump Apply thread sealant to the threads of the priming piston nut 14 Hold the rod 12 steady with an adjustable wrench on the flats and screw the nut 14 onto the rod with another wrench Torque to 97 106 N m 71 78 ft lb See Fig 12 308149 A15 14 AA AN Flat side must face up Apply thread sealant Torque to 97 106 N m 71 78 ft b 01165 Fig 12 21 Reconnect the displacement pump to the air motor as explained on page 18 22 Allow 2 hours for the thread sealant to cure before returning the pump to service Model 222828 Pump Series A Model 2
22. N HAZARD and Grounding on page 5 AIR POWERED MODELS Starting and Adjusting the Pump Supply fluid to the pump per the requirements of your system Refer to Fig 3 on page 8 Be sure the air regulator F is closed Then open the pump s bleed type master air valve E Hold a metal part of the spray gun dis pensing valve S firmly to the side of a grounded metal pail and hold the trigger open Now slowly open the air regulator until the pump starts Cycle the pump slowly until all the air is pushed out and the pump and hoses are fully primed Release the spray gun dispensing valve trigger and engage the safety latch The pump should stall against pressure when the trigger is released If the pump fails to prime properly open the bleeder valve plug 35 slightly Use the bleed hole on the underside of the valve body 34 as a priming valve until the fluid appears at the hole See Fig 5 Close the plug 35 NOTE When changing fluid containers with the hose and gun already primed open the bleeder valve plug 35 to assist in priming the pump and venting air before it enters the hose Close the bleeder valve when all air has been eliminated A WARNING To reduce the risk of fluid injection do not use your hand or fingers to cover the bleed hole when priming the pump Operation AIR POWERED MODELS With the pump and lines primed and with adequate air pressure and volume supplied the pump will start an
23. No No Description Qty includes one seal item 39 184002 ROD displacement sst 1 Replacement Danger and Warning labels tags and cards 2 184006 PACKING NUT WET CUP A iene aa eee glaa carbon steel 222810 only 1 2 246965 PACKING NUT WET CUP These parts are included in Repair Kit 234419 which may carbon steel 246934 only be purchased separately 4 4 184393 CYLINDER pump sst 1 5 184394 GUIDE piston sst 1 i a 6 184441 PISTON sst 4 PTFE Packing Conversion Kit 222861 TE 184395 SEAL piston UHMWPE Use to convert the pump to all PTFE throat and intake 8 184444 SEAT piston sst 1 packings Must be purchased separately Includes instruc 9 189727 NUT packing intake valve tions carbon steel 1 10T 184496 VALVE BODY intake carbon steel 1 111 184495 SEAT intake valve carbon steel 1 Leather Packing Conversion Kit 222862 ie Lera ELIO piston gt 1 Use to convert the pump to leather throat and intake pack 3 89988 priming piston sst 1 ings with a PTFE backup Must be purchased separately 14 112733 NUT priming piston carbon steel 1 Includes instructions 15 190276 PISTON priming carbon steel 1 16 184221 GLAND intake valve male sst 1 S 17 184413 HOUSING intake ductile iron 1 Ink Pump Conversion Kit 249032 18 184415 GUIDE rod sst 1 y Use t rt th f 222810 style to 24 4 style 19 222920 HOUSING outlet ductile iron 1 ia dona al o SPS aio 20 184279 FITTING outlet 1 1 2 npt m x M42 x 20 carbon st
24. Remove only if damaged a Remove and clean plug 17 Torque to 30 38 Nem 22 28 ft lb Lap ES ae A orque to m A IS A Inspect mating surfaces 13 ES 0920A 15 14 01166A Fig 10 308149 21 Service Reassembly Refer to Fig 11 for reassembly 1 Install the intake valve seat 111 in the intake housing 17 with the large bevel of the seat facing the bottom of the housing Lubricate the seal 39 T and install it in the housing Set the intake housing aside 2 Install the piston seal 7 on the piston seat 8 Place the seat in a vise and close the jaws tight enough to hold it securely without placing too much stress on the part Apply thread sealant to the threads of the seat and the piston guide 5 Screw the guide onto the seat 8 Tighten using a brass rod until the guide is securely seated approximately 125 137 N m 92 101 ft lb See Figs 9 and 11 3 Place the flats of the piston 6 in a vise Apply thread sealant to the threads of the rod 1 and the top threads of the piston Set the piston seat guide assembly onto the piston NOTE Service Tool 109508 is available as an acces sory The tool fits over the top of the displacement rod 1 making it easier to apply a 24 inch adjustable wrench or 3 4 in drive socket when connecting the rod to the piston 6 4 Screw the rod 1 into the piston 6 hand tight Torque the rod to 459 481 N m 338 354 ft lb There will be a small gap between the top of
25. ana ra 248 cm 38 5 in 2 Lt ao oi A 120 mm 4 75 in INI RE ER 21 cm 3 255 in 2 alia i tn tthe E pie fa 65 5 C 150 F 3 4 npsm f 1 1 2 npt m approx 65 kg 142 lb approx 37 kg 81 Ib 304 and 17 4 PH Grades of Stainless Steel E52100 Alloy Steel Ductile Iron Acetal PTFE Ultra High Molecular Weight Polyethylene KEY Fluid Outlet Pressure Black Curves Air Consumption Gray Curves NOTE Recommended pump speed for continuous operation to shaded area 60 com psi bar cycles min MPa 16 32 48 6064 80 1200 scfm di m3 min Ag A 1000 200 70 5 60 7 0 al Gn v 160 Cc 56 m B A 4 48 D 5 6 iu 600 120 a 42 B 3 36 O 42 5 D i 400 80 28 2 24 2 8 C 200 40 14 1 12 1 4 0 gpm 0 2 4 6 8 10 liters min 7 6 15 2 22 8 30 4 38 0 FLUID FLOW TEST FLUID 100 000 CENTIPOISE SEALANT To find Fluid Outlet Pressure MPa bar psi at a specific fluid flow Ipm gpm and operating 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 pressure A 0 7 MPa 7 bar 100 psi Air Pressure B 0 49 MPa 4 9 bar 70 psi Air Pressure C 0 28 MPa 2 8 bar 40 psi Air Pressure psi bar cycles min MPa 8 16 24 32 40 1200 scfm 84 m8 min 8 4 1000 S A 200 70 5 60 7 0 160 800 E 56
26. and national guidelines Always wear protective eyewear gloves clothing and respirator as recommended by the fluid and solvent manufacturer 308149 5 Notes 6 308149 Installation Grounding 44 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 M 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 mm2 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 Air and hydraulic hoses use only electrically conductive hoses Fluid hoses use only electrically conductive fluid hoses Air compressor or hydraulic power supply follow manufacturer s recommendations Spray gun dispensing valve grounding is obtained through connection to a properly grounded fluid hose and pump Fluid supply container according to
27. art No 245111 184451 184096 184278 222810 246934 106166 184452 184130 Description AIR MOTOR King See 309347 for parts ADAPTER connecting rod NUT coupling WRENCH packing nut PUMP displacement 222835 only See pages 28 29 for parts PUMP displacement 246936 only See pages 28 29 for parts NUT hex M16 x 2 0 ROD tie 265 mm 10 43 shoulder to shoulder COLLAR coupling Parts Model 222901 Pump Series B 0914A Qty A SL 1A These parts are included in Connection Kit 235414 which may be purchased separately 26 308149 24 1 Ratio with Quiet King Air Motor 102t 103 104 105 106 107 108 Part No 220106 184451 184096 184278 222810 106166 184452 184130 Description AIR MOTOR King quiet See 309348 for parts ADAPTER connecting rod NUT coupling WRENCH packing nut PUMP displacement See pages 28 29 for parts NUT hex M16 x 2 0 ROD tie 265 mm 10 43 shoulder to shoulder COLLAR coupling 0915A Qty dA A AA a These parts are included in Connection Kit 235414 which may be purchased separately Model 222940 Pump Series A 39 1 Ratio with Premier Air Motor Ref No 101 102 103 104 105 1064 107 108 1094 Part No 222800 184582 184096 184278 222810 106166 184381 184130 184556 Description AIR MOTOR Premier See 30821
28. as an acces sory The tool fits over the top of the displacement rod making it easier to apply a 24 inch adjustable wrench or 3 4 in drive socket when connecting or disconnect ing the rod from the piston assembly Disconnecting the Displacement Pump A WARNING Keep hands and fingers away from the priming piston during operation and whenever the pump is charged with air hydraulic fluid to reduce the risk of injury On the pump downstroke the priming piston extends beyond the intake housing to pull the material into the pump The priming piston works under extreme force During operation and when ever the pump is charged with air hydraulic fluid the priming piston can severely injury or amputate a hand or finger or break a tool caught between it and the intake housing Always relieve the pres sure before checking clearing cleaning flushing or servicing any part of the pump On King and Bulldog air powered pumps the air motor piston located behind the air motor shield moves when air is supplied to the motor Never operate the pump with the air motor shield re moved On Premier air powered pumps the rocker arms located beneath the rocker arm covers move when air is supplied to the motor Never operate the pump with the rocker arm covers removed Before servicing the pump relieve the pressure to prevent the pump from starting accidentally 16 308149 1 Flush the pump if possible Stop the pump at the bottom o
29. ause the equipment to rupture or malfunction and result in serious injury ES 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 pages 30 35 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 equipment manuals Read the fluid and solvent manufacturer s warnings Do not kink or overbend hoses or 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 308149 3 44 WARNING SKIN INJECTION HAZARD Spray from the gun valve hose leaks or ruptured components can inject fluid into your body and cause extr
30. d stop as the gun valve is opened and closed Ina 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 to get the desired results Higher pressures cause premature tip nozzle and pump wear 44 WARNING To reduce the risk of overpressurizing your system which could result in component rupture and cause serious injury never exceed the specified maxi mum incoming air pressure to the pump see the Technical Data on pages 30 35 Never allow the pump to run dry of the fluid being pumped A dry pump will quickly accelerate to a high speed possibly damaging itself A pump runaway valve C which shuts off the air supply to the pump if the pump accelerates beyond the pre set speed is available See Fig 3 on page 8 If your pump acceler ates quickly or is running too fast stop it immediately and check the fluid supply If the supply container is empty and air has been pumped into the lines refill the container and prime the pump and the lines with fluid or flush and leave it filled with a compatible solvent Be sure to eliminate all air from the fluid system 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 12 For overnight shu
31. e KEY Fluid Outlet Pressure Black Curves A 0 63 MPa 6 3 bar 90 psi Air Pressure Air Consumption Gray Curves B 0 49 MPa 4 9 bar 70 psi Air Pressure 28 MPa 2 8 bar 40 psi Air P NOTE Recommended pump speed for continuous operation s SNS ee ar 40 psi AlrEressure to shaded area 50 cpm psi psi e cycles min scfm DE cycles min scfm S 16 32 4850 64 80 Rmn a 8 16 24 32 40 m3 min 2000 N 300 2000 300 140 A 8 40 140 N 8 40 14 0 14 0 A 1600 A 240 1600 240 112 6 72 112 6 72 11 2 B 1 2 N B te te gt 1200 180 5 1200 180 2 84 B 5 04 2 84 5 04 W 8 4 i 8 4 a i 120 2 80 C 120 Q smc 3 3 56 C 3 36 3 56 A L 56 L 56 B 400 60 400 60 28 1 68 28 C 1 68 2 8 2 8 0 0 gpm 0 2 4 6 8 10 gpm 0 1 2 3 4 5 liters min 7 6 15 2 22 8 30 4 38 0 liters min 3 8 7 6 11 4 15 2 19 0 FLUID FLOW FLUID FLOW TEST FLUID 100 000 CENTIPOISE SEALANT TEST FLUID 4 000 000 CENTIPOISE SILICON To find Fluid Outlet Pressure MPa bar psi at a specific fluid flow To find Pump Air Consumption m3 min or scfm at a specific fluid Ipm gpm and operating air pressure MPa bar psi flow Ipm gpm and air pressure MPa bar psi la peale Uesirad Mo alero bolton rovchatk 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
32. eel 1 21 184185 GLAND throat female sst 1 22 109265 V PACKING throat UHMWPE 3 23 184235 GLAND throat male sst 1 24 109315 V PACKING throat PTFE 222810 only 2 24T 109317 V PACKING throat PTFE 246934 only 2 25 109213 O RING PTFE 32 109203 SCREW cap hex hd 5 8 11 unc 2A x a 12 305 mm 6 34 165702 BODY bleeder valve 3 8 18 npt x 1 2 20 unf 2b 1 35 190128 PLUG valve 1 2 20 unf 2a 1 39 tt 184072 SEAL Acetal 3 40 109301 V PACKING intake valve PTFE 2 41 184171 GLAND intake valve female sst 1 42 t 109251 V PACKING intake valve UHMWPE 2 43 189724 SEAL UHMWPE 1 44A 184090 PLATE warning not shown 1 45A 184293 PLATE warning not shown 1 46A 172477 TAG warning not shown 1 47A 172479 TAG warning not shown 1 308149 29 Technical Data Model 222828 and 246935 Bulldog Pump Ration cena lia a bated See a tee Maximum fluid working pressure Maximum air input pressure Pump cycles per 3 8 liters 1 gal A ar 8 3 MPa 83 bar 1200 psi PER iaia li eater E 8 12 1 Standard Bulldog Air Motor 0 7 MPa 7 bar 100 psi Recommended pump speed for continuous operation 60 cycles per min Maximum flow LL Air motor piston effective area Stroke length n nnnaeunaeuna nanana Displacement pump effective area Maximum pump operating temperature Air inlet SiZ sr ii Fluid outlet size Weight
33. emely 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 surgi cal treatment Do not point the gun valve at anyone or at any part of the body Do nat 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 valve when spraying 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 whenever you are instructed to relieve pres sure stop spraying clean check or service the equipment and install or clean the spray tip nozzle 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 sti 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
34. f its stroke Relieve the pressure 2 Disconnect the air or hydraulic hose Plug all hydraulic hoses immediately to prevent contami nation of the hydraulic system Hold the fluid outlet fitting 20 with a wrench to keep it from being loosened while you disconnect the fluid hose 3 Disconnect the displacement pump 105 from the motor 101 as follows Be sure to note the relative position of the pump s fluid outlet to the air or hydraulic inlet of the motor If the motor does not require servicing leave it attached to its mounting 44 CAUTION Be sure to use at least two people when lifting moving or disconnecting the 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 ram be sure to support the displacement pump while it is being discon nected to prevent it from falling and causing injury or property damage Do this by securely bracing the pump or by having at least two people hold it while another disconnects it 4 Using an adjustable wrench unscrew the coupling nut 103 Remove the coupling collars 108 Take care not to lose or drop them See Fig 6 5 Holdthe tie rod flats with a wrench to keep the rods from turning Unscrew the nuts 106 from the tie rods 107 Carefully remove the displacement pump 105 from the motor 101 6 Referto page 19 for displacement pump service To service the air or hydraulic
35. ge 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 the
36. he 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 char
37. id drain valve M is required in your system to help reduce the risk of serious injury including fluid injection and splashing of fluid in the eyes or on the skin if you are adjusting or repairing the pump 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 Mounting Accessories Mount the pump A to suit the type of installation planned Fig 4 on page 10 illustrates a ram mounted pump in a multi gun header system Pump dimensions and the mounting hole layout are shown on pages 36 and 37 If you are mounting the pump on a air powered ram refer to the separate ram manual for installation and operation instructions and recommended air accesso ries Filters Be sure your hydraulic power supply is equipped with a suction filter to the hydraulic pump and a system return line filter AA of 10 micron size Carefully follow the manufacturer s recommendations on reservoir and filter cleaning and periodic changes of hydraulic fluid Use only Graco approved hydraulic oil Order Part No 169236 5 gal 19 liter or 207428 1 gal 3 8 liter Do not substitute a lower grade oil or one with a lower flash point Hydraulic Lines The motor has a 3 4 npt f hydraulic oil supply fitting and a 1 npt f hydraulic oil return fitting Use a mini mum 13 mm 1 2 in ID hydraulic supply line anda minimum 16 mm 5 8 in ID
38. ime properly open the bleeder valve 35 slightly Use the bleed hole on the underside of the valve body 34 as a priming valve until the fluid appears at the hole See Fig 10 Close the plug 35 NOTE When changing fluid containers with the hose and gun already primed open the bleeder valve plug 35 to assist in priming the pump and venting air before it enters the hose Close the bleeder valve when all air has been eliminated 44 WARNING To reduce the risk of fluid injection do not use your hand or fingers to cover the bleed hole when priming the pump With the pump and lines primed and with adequate hydraulic volume supplied the pump will start and stop as the gun valve is opened and closed In a circulating system the pump will speed up or slow down on demand until the hydraulic power supply is shut off Use the fluid pressure gauge F and flow control valve G to control the pump speed and the fluid outlet pressure Always use the lowest hydraulic flow and pressure necessary to get the desired results Higher pressures cause premature tip nozzle and pump wear 14 308149 44 WARNING To reduce the risk of overpressurizing your system which could result in component rupture and cause serious injury never exceed 10 MPa 103 bar 1500 psi Maximum Hydraulic Input Pressure to the pump or 15 9 MPa 159 bar 2300 psi Maxi mum Fluid Working Pressure see the Technical Data on page 35 To prevent overpressur
39. izing the hydraulic motor or its seals always shut off the supply line valve U first then shut off the return line valve V 44 CAUTION Do not allow the hydraulic oil temperature to exceed 54 C 130 F The pump seals will wear faster and leakage may occur if the pump is operated at higher oil temperatures Never allow the pump to run dry of the fluid being pumped A dry pump will quickly accelerate to a high speed possibly damaging itself If your pump acceler ates quickly or is running too fast stop it immediately and check the fluid supply If the supply container is empty and air has been pumped into the lines refill the container and prime the pump and the lines with fluid or flush and leave it filled with a compatible solvent Be sure to eliminate all air from the fluid system 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 12 For overnight shutdown relieve the pressure Stop the pump at the bottom of the stroke to prevent fluid from drying on the exposed displacement rod and damaging the throat packings Always flush the pump before the fluid dries on the displacement rod Never leave water or water based fluid in the pump overnight First flush with water or a compatible solvent then with mineral spirits Relieve the pressure but leave the mineral spirits in the
40. lent to the rod adapter and air motor piston threads and then torque as specified in Fig 6 1 Use at least two people to hold the displacement pump while another reconnects it to the motor see the CAUTION above Orient the pump s fluid outlet to the air or hydraulic inlet as was noted in step 3 under Disconnecting the Displacement Pump Position the displacement pump 105 on the tie rods 107 See Fig 6 18 308149 Screw the nuts 106 onto the tie rods 107 and torque as noted in Fig 6 Place the coupling nut 103 on the displacement rod 1 then place the coupling collars 108 into the nut Loosely screw the coupling nut onto the connecting rod adapter 102 or connecting rod 109 Model 222940 only Hold the adapter or connecting rod flats with a wrench to keep it from turning Use an adjustable wrench to tighten the coupling nut Torque as noted in Fig 6 Torque the packing nut 2 to 135 169 N m 100 125 ft lb 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 Turn on the air or hydraulic power supply On hydraulic pumps open the hydraulic return line valve first then the supply line valve Run the pump slowly to ensure that it is operating properly Service Displacement Pump Disassembly When disassembling the pump lay out all the removed parts in sequence to ease reassembly Clean all parts wi
41. luid Regulator Fluid Drain Valve required Electrically Conductive Fluid Supply Hose Fluid Shutoff Valve Gun Valve Swivel Airless Spray Gun or Dispensing Valve Ram Air Regulator Ground Wire required see page 7 for installation instructions lt ANONDUZZFA FLUID HEADER PIPE 3 in Diameter K MAIN AIR LINE 4 J Y D L u La e Bl Fb 1 O z pel Sa E gt Fig 3 8 308149 01177A Installation AIR POWERED PUMPS SYSTEM ACCESSORIES 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
42. motor refer to the separate motor manual supplied Service King Bulldog and Viscount Pumps Model 222835 Shown Premier Pumps Model 222940 Shown 101 0914A YAN 106 AN Torque to 129 142 N m 95 105 ft Ib A Torque to 129 142 N m 95 105 ft lb A Torque to 196 210 N m 145 155 ft lb A Torque to 312 340 N m 230 250 ft lb Torque to 135 169 N m 100 125 ftHb A Apply Loctite 2760 or equivalent to threads 01403B A Square hole is for use with torque wrench Fig 6 308149 17 Service Reconnecting the Displacement Pump A CAUTION Be sure to use at least two people when lifting moving or disconnecting the 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 ram be sure to support the displacement pump while it is being discon nected to prevent it from falling and causing injury or property damage Do this by securely bracing the pump or by having at least two people hold it while another disconnects it NOTE On Premier models ensure that the rod adapt er 102 has not loosened during maintenance Proper torque is necessary to prevent the rod adapter from loosening during the pump operation If the rod adapter 102 has loosened during mainte nance remove the adapter and apply Loctite 2760 or equiva
43. nch to tighten the packing nut 9 See Fig 8 Torque to 97 106 N m 71 78 ft lb Use a hammer and brass rod to carefully drive the valve assembly further up the rod until it reaches the stop VS 11 Remove the displacement rod 1 from the vise Place the cylinder 4 sideways in the vise with soft jaws 12 Lubricate the seal 39 and place it on the bottom of the cylinder 4 The cylinder is symmetrical so either end can be the bottom See Fig 11 13 Slide the displacement rod 1 piston assembly intake valve assembly and priming piston rod 12 into the cylinder 4 from the bottom until the mating surfaces of the rod guide 18 and cylinder 4 meet 14 Put the intake housing 17 upright in a vise making sure it is off center so there is sufficient clearance for the priming piston rod 12 to be lowered through the housing Take the rod and cylinder assembly and lower it into the intake housing until the rod guide 18 bottoms on the intake seat 11 and the priming piston rod 12 protrudes from the bottom of the intake housing 17 15 Screw the bleeder valve plug 35 into the valve housing The plug has two sets of threads When reassembling be sure to screw the plug fully into the valve housing NOTE It is not ordinarily necessary to remove the outlet nipple 20 and o ring 25 However if they were replaced because of damage lubricate the o ring 25 and place it on the nipple 20 Screw the nip
44. 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 308149 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 www graco com PRINTED IN U S A 308149 05 1992 Revised 4 2006 38 308149
45. nstream 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 bleed type master air valve 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 swivel air inlet It mounts to a ram and has ports for connecting lines to air accessories such as the ram air regulator T e An air line filter J removes harmful dirt and moisture from the compressed air supply 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 positions shown in Fig 3 using adapters as necessary e Install a fluid shutoff valve P at each gun drop to isolate the gun and fluid accessories for servic ing e Install a fluid drain valve M near the pump fluid outlet and at each gun station The drain valves are required in your system to relieve fluid pressure in the displacement pump hose and gun see the WARNING at left Drain valves at the gun stations may be mounted in the base of a fluid regulator L using an adapter e A fluid regulator L controls fluid pressure to the gun valve and dampens pressure surges e A
46. nsumption 34 308149 Technical Data Model 222902 and 246937 Viscount Pump Maximum fluid working pressure Maximum hydraulic oil input pressure Pump cycles per 3 8 liters 1 gal CR 15 9 MPa 159 bar 2300 psi nv aera tanner 10 5 MPa 105 bar 1500 psi Recommended pump speed for continuous operation 60 cycles per min Maximum HOW annannnnaa eaa Hydraulic motor piston effective area Stroke length nnaannnanna aeaa Displacement pump effective area Maximum pump operating temperature Hydraulic oil inlet size Fluid outlet size Welgh Ets ais Displacement Pump Weight 28 5 liters min 7 5 gpm at 60 cycles min LIRA ari 31 6 cm2 4 9 in 2 PRE CRT eae tanta 120 mm 4 75 in Bie ide ia nen chan do a 21 cm 3 255 in 2 PINE DEAE epi a ve 65 5 C 150 F REPARTI ait tant 3 4 npt f RA RR eek Sern A 1 1 2 npt m scalzi aladino approx 89 kg 196 Ib Lari a i approx 37 kg 81 Ib Wetted parts Carbon Steel Chrome Zinc and Electroless Nickel Plating 304 and 17 4 PH Grades of Stainless Steel E52100 Alloy Steel Ductile Iron Acetal PTFE Ultra High Molecular Weight Polyethylene Fluid Outlet Pressure Black Curves Hydraulic Oil Consumption Gray Curves KEY NOTE Recommended pump speed for continuous operation to shaded area 60 com
47. of the intake housing 17 See Fig 10 If the seat is difficult to remove turn the housing upside down and drive the seat out using a hammer and brass rod 11 Examine the mating surfaces of the seat 11 and the intake valve body 10 for damage 12 Slide the rod guide 18 off the priming piston rod 12 Unscrew the priming piston rod from the piston 6 Run a finger over the surface of the rod to check for scratches or scoring NOTE Service Tool 109508 is available as an acces sory The tool fits over the top of the displacement rod 1 making it easier to apply a 24 inch adjustable wrench or 3 4 in drive socket when disconnecting the rod from the piston 6 13 Place the flats of the piston 6 in a vise Unscrew the displacement rod 1 from the piston 6 Lift the piston seat and guide assembly off the piston Inspect the mating surfaces of the piston 6 and piston seat 8 for damage See the Detail in Fig 10 14 Remove the displacement rod 1 from the vise and inspect it for scratches and scoring by running a finger over the surface 15 Place the piston seat and guide assembly in the vise and close the jaws on the flats of the seat 8 just tight enough to hold the part Slide a brass rod through the openings in the piston guide 5 and unscrew it from the seat as shown in Fig 9 Re move the piston seal 7 20 308149 8 13 mm 1 2 in Diameter Brass Rod When reassembling items 5 and 8 ap
48. ple into the outlet housing 19 Torque to 156 171 N m 115 126 ft lb THROAT PACKING DETAIL 21 Ja 22 A amp e e D aa 24 5 Piston check valve see detail at right Intake check valve see detail at right Remove only if damaged Torque to 156 171 N m 115 126 ftHb Screw plug completely into valve housing Lips of v packings must face down Lips of v packings must face up Large bevel must face down Apply lubricant to inner diameter Flat side must face up Apply thread sealant Torque to 97 106 N m 71 78 ft lb Torque to 244 264 N m 180 195 ft lb Torque to 125 137 N m 92 101 ft lb Torque to 135 169 N m 100 125 ft lb Torque to 459 481 N m 338 354 ft lb Torque to 30 38 N m 22 28 ft lb Fig 11 wr l ae ed Service Ji A W a AS LA K 39 13 15 N 144 4N 0920A INTA P 40 42 6 Ve 40 as DETAIL OF ISTON CHECK VALVE 01120 DETAIL OF INTAKE CHECK VALVE 16 41 01166A 308149 23 16 17 18 19 20 24 Service Lubricate the throat packings and glands and install them in the outlet housing 19 one at a time in the following order with the lips of the v pack ings facing down the male gland 23 one UHMWPE v packing 22 one PTFE v packing 24 UHMWPE 22 PTFE 24 UH
49. r 5 Lift the cylinder 4 up off the intake housing 17 The displacement rod 1 piston assembly intake valve assembly and priming piston rod 12 will come with the cylinder 6 Place the cylinder 4 sideways in a vise with soft jaws Using a rubber mallet on the end of the priming piston rod 12 drive the displacement rod 1 and piston assembly out the top of the cylinder Continue to pull the rod out of the cylinder until the priming piston rod 12 comes free 7 Remove the seal 39 from the bottom of the cylinder 4 Hold the cylinder up to the light at an angle to examine the inside surface for scoring or damage 8 Place the flats of the displacement rod 1 ina vise Using a 13 mm 1 2 in diameter brass rod pry the intake check valve assembly away from the rod guide 18 far enough to apply wrenches to the valve assembly See Fig 7 INTAKE CHECK VALVE A 13 mm 1 2 in Diameter Brass Rod 01171 Fig 7 9 Hold the valve body 10 steady with a wrench on the flats Using an adjustable wrench loosen the intake packing nut 9 to decrease tension on the priming piston rod 12 Now slide the intake valve assembly off the rod and set it aside See Fig 8 Hold valve body 10 steady Loosen intake packing nut 9 When reassembling items 9 and 10 torque to 97 106 N m 71 78 ft lb See page 22 ree Fig 8 308149 19 Service 10 Pull the seal 39 and seat 11 out the top
50. rades of Stainless Steel E52100 Alloy Steel Ductile Iron Acetal PTFE Ultra High Molecular Weight Polyethylene KEY Fluid Outlet Pressure Black Curves Air Consumption Gray Curves NOTE Recommended pump speed for continuous operation to shaded area 50 com psi bar cycles min scfm MPa 16 32 4850 64 80 m min 2000 nN 300 140 A 8 40 14 0 1600 A 240 112 B 6 72 11 2 E gt 1200 B 180 2 84 5 04 i 8 4 a Q ann c 120 3 56 3 36 L 56 400 60 28 1 68 2 8 0 gpm 0 2 4 6 8 10 liters min 7 6 15 2 22 8 30 4 38 0 FLUID FLOW TEST FLUID 100 000 CENTIPOISE SEALANT To find Fluid Outlet Pressure MPa bar psi at a specific fluid flow lpm gpm and operating 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 pressure 32 308149 A 0 63 MPa 6 3 bar 90 psi Air Pressure B 0 49 MPa 4 9 bar 70 psi Air Pressure C 0 28 MPa 2 8 bar 40 psi Air Pressure psi bar cycles min scfm MPa 8 16 24 32 40 M3 min 2000 300 140 8 40 140 NA 1600 240 112 6 72 112 NB E 5 1200 180 6 84 5 04 8 4 a A 800 S C 120 2 56 A 336 u 56 B 400 60 28 C 1 68 2 8 I n 0 gpm 0 1 2 3 4 5 liters min 3 8 7 6 11 4 15 2 19 0 FLUID FLOW TEST FLUID 4 000 000 CENTIPOISE SILICON To find Pump Air Cons
51. return line On the hydraulic supply line C install the following accessories in the order shown in Fig 4 using adapt ers as necessary e A shutoff valve U to isolate the pump for servic ing e A fluid pressure gauge F to monitor hydraulic oil pressure to the motor and to avoid overpressurizing the motor or displacement pump and a pressure and temperature compensated flow control valve G to prevent the motor from running too fast and possibly damaging itself e A pressure reducing valve H with a drain line E running into the hydraulic return line D e An accumulator J to reduce the hammering effect caused by the motor reversing direction On the hydraulic return line D install the following accessories in the order shown in Fig 4 using adapt ers as necessary e A shutoff valve V to isolate the pump for servic ing e A filter AA of 10 micron size Hydraulic Motor Drip Pan The hydraulic motor has a drip pan to collect any leakage that may occur Connect a 6 mm 1 4 in ID drain line K to the barbed hose fitting on the drip pan and place the free end in a suitable container to re ceive the drainage Fluid Supply Hoses Be sure the fluid supply hose N is properly sized and pressure rated for your system Use only electrically conductive hoses Fluid hoses must have spring guards on both ends Fluid Line Accessories Install the following accessories in the positions shown in
52. tdown relieve the pressure Stop the pump at the bottom of the stroke to prevent fluid from drying on the exposed displacement rod and damaging the throat packings Always flush the pump before the fluid dries on the displacement rod Never leave water or water based fluid in the pump overnight First flush with water or a compatible solvent then with mineral spirits Relieve the pressure but leave the mineral spirits in the pump to protect the parts from corrosion Model 222835 Shown Bleed hole must 1 face down 34 35 A 0913A Fig 5 308149 13 Operation HYDRAULIC POWERED MODELS Starting and Adjusting the Pump Supply fluid to the pump per the requirements of your system Refer to Fig 4 on page 10 Check the hydraulic fluid level before each use and add fluid as necessary Make certain that the supply line shutoff valve U and the return line shutoff valve V are closed then start the hydraulic power supply Hold a metal part of the gun valve S firmly to the side of a grounded metal pail and hold the trigger open Open the return line shutoff valve V first then slowly open the supply line shutoff valve U Cycle the pump slowly until all the air is pushed out and the pump and hoses are fully primed Release the spray gun dispensing valve trigger and engage the trigger safety The pump should stall against pressure when the trigger is released If the pump fails to pr
53. th a compatible solvent and inspect them for wear or damage Refer to Fig 10 NOTE Repair Kit 222860 is available to replace the packings and seals Parts included are denoted with an asterisk for example 7 Repair Kit 222974 is available to repair the intake valve Parts included are denoted with a symbol for example 10T For the best results use all the new parts in the kits Conversion Kit 222861 is available to convert the pump to all PTFE v packings and Conversion Kit 222862 is available to convert to leather v packings See page 29 1 Remove the displacement pump from the air motor as explained on page 16 2 Hold the flats of the priming piston rod 12 with an adjustable wrench and use a second wrench to unscrew the priming piston nut 14 from the rod Slide the priming piston 15 and guide 13 off the rod Inspect the outer surface of the guide 13 and the inner and outer surfaces of the piston 15 for scoring wear or other damage 3 Stand the pump upright in a vise Loosen the packing nut 2 using the packing nut wrench 104 supplied or a hammer and brass rod Using a socket wrench remove the six capscrews 32 4 Tap the underside of the outlet housing 19 with a rubber mallet to loosen the housing from the cylinder 4 Lift the outlet housing off the pump and set it aside Be careful not to scratch the displacement rod 1 while removing the housing Remove the seal 39 from the top of the cylinde
54. th oil consumption curve gray Follow right to scale to read oil consumption 308149 35 Dimensions Model 222835 Shown 0913 222828 1333 6 a 540 5 T 793 1 pe 664 7 TE 256 8 9 246935 52 5 in 21 28 in 31 22 in 26 17 in 10 11 in 1349 1 a 556 a 793 1 fn 664 7 i 256 8 a 53 11 in 21 89 in 31 22 in 26 17 in 10 11 in 222835 1376 1 a 583 20 793 1 a 664 7 ps 256 8 9 246936 54 18 in 22 95 in 31 22 in 26 17 in 10 11 in 1385 6 mm 592 5 mm 793 1 mm 664 7 mm 256 8 mm 54 55 in 23 33 in 31 22 in 26 17 in 10 11 in 1530 7 a 428 8 T 1101 9 aa 969 5 E 565 1 ta 60 31 in 16 89 in 43 41 in 38 20 in 22 26 in 222902 1415 3 ay 622 2 S 793 1 pl 664 7 i 256 8 HA 246937 55 72 in 24 5 in 31 22 in 26 17 in 10 11 in 36 308149 Mounting Hole Layouts Bulldog King and Viscount Pumps 94 28 mm 3 712 101 6 mm 94 28 mm 4 0 3 712 11 1 mm 0 437 DIA 4 Three M16 x 2 0 88 mm Holes 3 464 0653 Premier Pumps 135 0 mm 67 5mm 5 3 in 116 9 mm 4 6 in 87 9 mm 3 5 in Three M16 x 2 0 Holes Three 3 8 16 Mounting Studs 101 5 mm 4 0 in 2 0 in 06555 308149 37 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 With t
55. umption m3 min or scfm at a specific fluid flow Ipm gpm and air pressure MPa bar psi 1 Locate desired flow along bottom of chart 2 Read vertical line up to intersection with selected air consumption curve gray Follow right to scale to read air consumption Technical Data Model 222901 Quiet King Pump Ratios SS a ida deine aida 24 1 Quiet King Air Motor Maximum fluid working pressure 000 e eee eee 16 6 MPa 166 bar 2400 psi Maximum air input pressure 0 0 c cece eee 0 7 MPa 7 bar 100 psi Pump cycles per 3 8 liters 1 gal eee eens 8 Recommended pump speed for continuous operation 50 cycles per min Maximum flow LL 23 75 liters min 7 5 gpm at 50 cycles min Air motor piston effective area eee 506 cm 78 5 in 2 Stroke length a eie a AE eee A E a ees 120 mm 4 75 in Displacement pump effective area 1 1 ee eee ees 21 cm 3 255 in 2 Maximum pump operating temperature 00 e eee eee ees 65 5 C 150 F AIrDIGBSIZO i Aia Bead RR Ae 3 4 npsm f Fl id outlet SIZE iiss tie tara cen headend ra ni pria 1 1 2 npt m Weight orere fe La approx 73 kg 160 lb Displacement Pump Weight anana approx 37 kg 81 Ib Wetted parts Carbon Steel Chrome Zinc and Electroless Nickel Plating 304 and 17 4 PH Grades of Stainless Steel E52100 Alloy Steel Ductile Iron Acetal PTFE Ultra High Molecular Weight Polyethylen
56. your local code 7 Object being sprayed according to your local code All solvent pails used when flushing according to 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 continuity To maintain grounding continuity when flushing or relieving pressure always hold a metal part of the spray gun dispensing valve firmly to the side of a grounded metal pail then trigger the gun valve T1052 Fig 2 08164 308149 7 Installation AIR POWERED PUMPS NOTE Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawings Accessories are available from your Graco distributor If you supply your own accessories be sure they are adequately sized and pressure rated to meet the system s requirements KEY Pump 200 Liter 55 Gallon Air Powered Ram Pump Runaway Valve Air Line Lubricator Bleed Type Master Air Valve required for pump Pump Air Regulator Air Manifold Electrically Conductive Air Supply Hose Air Line Filter MOOD cron The Typical Installation shown in Fig 3 is only a guide for selecting and installing system components and accessories Contact your Graco distributor for assis tance in designing a system to suit your particular needs Bleed Type Master Air Valve for accessories F

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