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Graco 308148ZAA User's Manual

1. p AA 6 1 a a L uLfo ap IN kl SS Pa l T K 200 LITER 55 GAL DRUM 0627B 308148 11 Installation HYDRAULIC POWERED PUMPS SYSTEM ACCESSORIES A WARNING A fluid drain valve M is required in your system to help reduce the risk of serious injury including skin 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 pressure 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 illustrates a wall mounted system Pump dimensions and the mounting hole layout are shown on pages 38 and 39 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
2. Fig 8 308148 23 Notes 24 308148 Part No 222895 Pump Series B 28 1 Ratio with Quiet King Air Motor Part No 253377 Pump Series A 28 1 Ratio with Quiet King Air Motor Parts Ref No 101 1021 103 1041 105 106 1071 108 109 Part No 220106 235525 184451 184096 184278 222805 687055 106166 184452 184130 249967 Description AIR MOTOR King quiet See 309348 for parts Used on Model 222895 only AIR MOTOR King quiet See 309348 for parts Used on Model 253377 only ADAPTER connecting rod NUT coupling WRENCH packing nut PUMP displacement See pages 28 amp 30 for parts PUMP displacement See pages 28 amp 30 for parts NUT hex M16 x 2 0 ROD tie 265 mm 10 43 in shoulder to shoulder COLLAR coupling INTAKE AND EXHAUST KIT Used on Model 253377 only Qty i h i mb Now t These parts are included in Connection Kit 235414 For applications requiring stainless steel tie rods order Con nection Kit 222913 Detail of Model 253377 109 TI7925A 308148 25 Parts Part Nos C59792 and 222939 Series B Ref ee 233069 233070 234667 234824 241957 NG Cale ARTERIA o Qu 243689 246923 246924 246989 246990 NA SA ee pied i hind l 246991 246992 and 253842 Series A 102 184582 ADAPTER connecting rod 1 Pumps 45 1 Ratio with Premier Air Mot
3. and the return line shutoff valve V are closed To reduce the risk of overpressurizing your system which could result in component rupture and cause 4 Start the hydraulic power supply serious injury never exceed 10 MPa 103 bar 1500 psi Maximum Hydraulic Input Pressure to 5 Hold a metal part of the gun valve S firmly to the the pump or 14 0 MPa 140 bar 2000 psi Maxi side of a grounded metal pail and hold the trigger mum Fluid Working Pressure see the Technical open Data on page 37 6 Open the return line shutoff valve V first then To prevent overpressurizing the hydraulic motor or slowly open the supply line shutoff valve U its seals always shut off the supply line valve U first then shut off the return line valve V 7 Cycle the pump slowly until all air is pushed out and the pump and hoses are fully primed Release ACAUTIN O JI the gun valve trigger and engage the safety latch A CAUTION The pump should stall against pressure when the Do not allow the hydraulic oil temperature to exceed trigger is released 54 C 130 F The pump seals will wear faster and leakage may occur if the pump is operated at higher oil temperatures A WARNING SKIN INJECTION HAZARD 11 Never allow the pump to run dry of the fluid being FEE pumped A dry pump will quickly accelerate to a To reduce the risk of skin injection do not use your high speed possibly damaging itself If your pump hand or fingers to cover the b
4. 2 Lift the outlet housing 19 straight up off the pump Be careful not to scratch the displacement rod 1 while removing the housing 3 Lift the cylinder 7 displacement rod 1 and piston assembly off the intake housing 17 4 Remove the seal 6 ball guide 14 intake ball 16 intake seat housing 15 and o ring 27 from the intake housing 17 Inspect the ball 16 and the ball seat A on the housing 15 for wear or damage 5 Remove the seal 6 from the bottom of the outlet housing 19 Unscrew the packing nut 3 Re move the glands and v packings T from the housing Do not remove the outlet fitting 4 and o ring 5 unless they need replacement 6 Unscrew the handle of the bleeder valve 24 completely from the valve housing 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 20 308148 7 Stand the cylinder 7 upright on a wooden block Using a rubber mallet or an arbor press drive the displacement rod 1 and piston assembly down into the cylinder as far as possible then place the cylinder on its side and continue to drive the rod out the bottom until the piston comes free Pull the rod and piston from the cylinder being careful not to scratch the rod or cylinder A CAUTION To reduce the possibility of costly damage to the rod 1 and cylinder 7 always use a rubber mallet or an arbor press to dr
5. 20 33 see pages 30 and 32 Throat Packings see pages 30 and 32 36 Oi MI si Replaces 34 and 35 on 246987 246988 and 249992 Lee Piston Packings see pages 30 and 32 12 A 308148 29 Displacement Pumps 222805 241956 and 687055 Series A Parts UHMWPE and PTFE Packings with Stainless Steel Cap Screws Ref No 11 13 18 20 257 Part No 184232 184182 109262 109470 184181 Description Qtv GLAND male piston stainless steel 1 GLAND female piston stainless steel 1 V PACKING piston UHMWPE 3 SCREW cap hex hd 5 8 11 unc 2A x 12 in 305 mm stainless steel Used on Models 222805 241956 and 687055 see page 29 6 GLAND female throat stainless steel 1 Displacement Pump 246925 Series A UHMWPE and Leather Packings with Stainless Steel Cap Screws Ref No 11 13 18 20 257 26 28 297 30 33 Part No 184232 184182 109262 109470 184181 109261 184312 184231 184311 184618 Qty GLAND male piston stainless steel 1 GLAND female piston stainless steel 1 V PACKING piston UHMWPE 3 SCREW cap hex hd 5 8 11 unc 2A x 12 in 305 mm stainless steel 6 GLAND female throat stainless steel 1 V PACKING throat UHMWPE 3 V PACKING piston leather 2 4 2 6 Description GLAND male throat stainless steel V PACKING throat leather WASHER flat stainless steel These parts are included in Repair Kit 2
6. 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 33 37 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 308148 3 A WARNING SKIN INJECTION HAZARD Spray from the gun valve hose leaks or ruptured components can inject fluid into your body and cause extremely serious injury including the need for amputation Fluid splashed in the eyes or on the skin can also cause serious injury Fluid injected into the skin might look like just a cut but it is a serious injury Get immediate 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 glov
7. pih a cycles min hyd 18 36 54 60 72 Oil 2500 25 175 A 95 0 17 5 2000 20 140 76 0 14 0 5 1500 15 B 105 57 0 u 10 5 hvdraulic oil G consumption n 10 1000 3 70 C80 L 70 500 S 35 19 0 3 5 0 liters min 7 6 15 2 22 8 30 4 Fluid Outlet Pressure Black Curves A 105 bar 1500 psi Hydraulic Oil Pressure Hydraulic Oil Consumption Gray Curves B 74 bar 1050 psi Hydraulic Oil Pressure c 42 bar 600 psi Hydraulic Oil Pressure NOTE Recommended pump speed for continuous operation 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 to shaded area 60 com FLUID FLOW NO 10 WEIGHT OIL 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 To find Pump Hydraulic Oil Consumption lpm or gpm at a specific fluid flow Ipm gpm and hydraulic oil pressure MPa bar psi 2 Read vertical line up to intersection with oil consumption curve gray Follow right to scale to read oil consumption 308148 37 Dimensions Model 222895 Shown 0566 Pump Model A B c D 222895 253377 1235 1 mm 48 63 in 642 6 mm 25 3 in 592 5 mm 23 33 in 298 0 mm 11 73 in C59792 1160 0 mm 45 7 in 759 0 mm 29 9 in 401 0 mm 15
8. 13 O LUBRICATE PACKINGS PISTON PACKINGS LIPS FACE UP 11 CJ 13m LUBRICATE PACKINGS y N ow a Parts Displacement Pump 249992 Series A UHMWPE Submicron and Leather Packings with Stainless Steel Cap Screws Ref No 11 13 18 25 26 28 29 30 33 Part No 184232 184182 109262 184181 109261 120533 184231 184311 184618 Description Qty GLAND male piston stainless steel 1 GLAND female piston stainless steel 1 V PACKING piston UHMWPE 3 GLAND female throat stainless steel 1 V PACKING piston UHMWPE V PACKING piston UHMWPE S M GLAND male throat stainless steel V PACKING throat leather WASHER flat stainless steel ORH NwW These parts are included in Packing Repair Kit 253744 which may be purchased separately For packing conver sion kits see pages 30 through 32 THROAT PACKINGS PISTON PACKINGS LIPS FACE DOWN LIPS FACE UP IG 31 28 K 4 3 AD 0805 LUBRICATE PACKINGS 0806 308148 31 Parts Packing Conversion Kits Packing Conversion Kit 222846 PTFE Packings THROAT PACKINGS LIPS FACE DOWN PISTON PACKINGS LIPS FACE UP 11 28 S 13 ma 0805 LUBRICATE PACKINGS 0806 Ref Part No No Description Qty 11 184232 GLAND male piston stainless steel 1 13 184182 GLAND female piston stainless steel 1 25 184181 GLAND female throat stainless steel 1 28 109312 V PACKING piston PTFE 5 687057 PAC
9. 7 bar Air Motor 40 psi 70 psi 90 psi 100 psi Sound Power Levels dBa 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 40 psi 70 psi 90 psi 100 psi pene lo fe loo ses 308148 35 Technical Data MODELS C59792 222939 233069 233070 234667 234824 234826 241957 243689 246923 246924 246989 246990 246991 246992 253842 and 249992 PREMIER PUMPS KEY Fluid Outlet Pressure Black Curves A 0 7 MPa 7 bar 100 psi Air Pressure Air Consumption Gray Curves B 0 49 MPa 4 9 bar 70 psi Air Pressure c 0 28 MPa 2 8 bar 40 psi Air Pressure NOTE Recommendedpump speed for continuous operation to shaded area 60 cpm PREMIER AIR MOTORS psi bar cvcles min MPa 18 36 54 60 72 5000 350 scfm 35 0 m3 min 4000 A 400 280 11 20 28 0 f gt 3000 300 B 310 N 8 40 B H LL Wi 21 0 A a A 140 p t 40 6 1000 c 100 70 2 80 7 0 0 liters min 7 6 15 2 22 8 30 4 FLUID FLOW NO 10 WEIGHT OIL 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 1 Locate desired Now along kolemiel g an 1 Locate desired flow along bottom of chart 2 Follow vertical line up to intersection with select
10. 22848 which may be purchased separately For packing conversion kits see pages 30 through 32 Ref Part No No 26 109261 28 109312 687057 29 184231 30 109311 Description Qt V PACKING throat UHMWPE V PACKING piston PTFE PACKING graphite PTFE Used on Model 687055 GLAND male throat stainless steel V PACKING throat PTFE These parts are included in Packing Repair Kit 222845 which may be purchased separately For packing conver sion kits see pages 30 through 32 THROAT PACKINGS LIPS FACE DOWN Displacement Pump 246987 and 246988 Series A UHMWPE and Leather Packings with Stainless Steel Cap Screws Ref Part No No 11 184232 13 184182 18 109262 20 109470 25 184181 26 109261 28 184312 29 184231 30 184311 33 184618 30 Qty GLAND male piston stainless steel 1 GLAND female piston stainless steel 1 V PACKING piston UHMWPE 3 SCREW cap hex hd 5 8 11 unc 2A x 12 in 305 mm stainless steel GLAND female throat stainless steel V PACKING throat UHMWPE V PACKING piston leather GLAND male throat stainless steel V PACKING throat leather WASHER flat stainless steel Description OHM WwW O These parts are included in Packing Repair Kit 222850 which may be purchased separately For packing conver sion kits see pages 30 through page 32 308148 THROAT PACKINGS LIPS FACE DOWN PISTON PACKINGS LIPS FACE UP 11 CI
11. 3744 which may be purchased separately Refer to page 29 for assembly detail Technical Data MODELS 222895 AND 253377 KING PUMPS Rallo psa ngn a path ct tae ad Png ORNL hb Bil Anal aa RE theo 28 1 Maximum fluid working pressure a 19 3 MPa 193 bar 2800 psi Maximum air input pressure 0 cece ee eee 0 7 MPa 7 bar 100 psi Pump cycles per 3 8 liters 1 gal 2 0 0 cece eee tenes 9 Recommended pump speed for continuous operation 50 cycles per min Maximum flow ORR eae iene tre erence TAI aA 21 8 liters min 5 8 gpm at 50 cycles min Air motor piston effective area 10 eee eee 506 cm 78 5 in 2 Stroke length sc eco a bana Pa Meee a ea eae NG eae we 120 mm 4 75 in Displacement pump effective area ees 18 cm 2 79 in 2 Maximum pump operating temperature 4 c eee eee eee 65 5 C 150 F Mirinlet SIZO 3 55 i tga GANG UA Rat beeps RK Gp ede 3 4 npsm f Fluid inlet size Fluid outlet size Weight Wetted parts moo oo AA AA 1 1 2 in npt m aha a Ma LANA PLANO KA GAY LNG Ba aod approx 69 kg 152 Ib kera 304 329 and 17 4 PH Grades of Stainless Steel Tungsten Carbide acetal PTFE Ultra High Molecular Weight Polyethylene AA AA ee 2 in npt f i Sound Pressure Levels dBa 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 40 psi
12. 70 psi 90 psi 788 8 82700 060 7 905 5 Sound Power Levels dBa 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 40 psi 70 psi 90 psi 308148 33 Technical Data MODELS 222895 AND 253377 KING PUMPS 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 C 0 28 MPa 2 8 bar 40 psi Air Pressure NOTE Recommended pump speed for continuous operation to shaded area 50 cpm l MODEL 222895 lab QUIET KING AIR MOTOR MPa cvcles min scfm 5 m3 min 18 36 54 2500 250 175 7 00 17 5 NSU A 200 2000 Ee 14 0 NS w B 5 1500 A 159 2 105 4 20 w 10 5 Cc a B Q 100 1000 Pag 3 70 c 2 80 L 70 C 500 50 35 1 40 3 5 0 liters min 7 6 15 2 22 8 30 4 FLUID FLOW NO 10 WEIGHT OIL To find Pump Air Consumption m3 min or scfm at a specific fluid 2 Read vertical line up to intersection with selected air consumption flow Ipm gpm and air pressure MPa bar psi curve gray Follow right to scale to read air consumption 1 Locate desired flow along bottom of chart 34 308148 Technical Data MODELS C59792 222939 233069 233070 234667 234824 234826 241957 243689 246923 246924 246989 246990 246991 246992 253842 and 249992 PREMIER PUMPS RatiOied escape AA 45 1 Maximum fluid
13. 79 in 413 0 mm 16 3 in 222939 233069 233070 234667 241947 243689 246989 246990 246991 246992 246923 246924 249992 222897 1264 8 mm 49 8 in 642 6 mm 25 3 in 622 2 mm 24 5 in 298 0 mm 11 73 in 234824 1405 0 mm 55 3 in 887 6 mm 34 9 in 867 6 mm 34 16 in 543 0 mm 21 38 in 38 308148 Mounting Hole Layouts King Bulldog and Viscount Pumps 94 28 mm 3 712 in 101 6mm 94 28 mm 4 0in 3 712 in 88 mm DIA 4 3 464 in 0653 Premier Pumps 116 9 mm 4 6 in 87 9 mm 3 5 in Three M16 x 2 0 Holes 06555 308148 39 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 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 n
14. 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 and national guidelines Always wear protective eyewear gloves clothing and respirator as recommended by the fluid and solvent manufacturer 308148 5 Notes 6 308148 Installation Grounding 7 Object being sprayed according to your local code A WA RN l NG 8 All solvent pails used when flushing according to your local code Use only me
15. Instructions Parts List STAINLESS STEEL Dura Flo 1800 Pumps With Severe Duty Rod and Cylinder Part Nos 222895 Pump Series B and 253377 Series A 28 1 Ratio with Quiet King Air Motor 19 3 MPa 193 bar 2800 psi Maximum Fluid Working Pressure 0 7 MPa 7 bar 100 psi Maximum Air Input Pressure Part No 222897 Pump Series B with Viscount Hydraulic Motor 18 MPa 179 bar 2600 psi Maximum Fluid Working Pressure 10 MPa 103 bar 1500 psi Maximum Hydraulic Input Pressure Part Nos C59792 and 222939 Pumps Series B Part Nos 2330697 2330704 2346671 234824 241957 243689 246923 246924 2469891 2469901 2469917 2469921 253842 Pumps Series A 45 1 Ratio with Premier Air Motor 31 MPa 310 bar 4500 psi Maximum Fluid Working Pressure 0 7 MPa 7 bar 100 psi Maximum Air Input Pressure t Not cei 2G Not nor C ce EX Important Safety Instructions Read all warnings and instructions in this manual Save these instructions See page 2 for Table of Contents Part No 222895 Shown C Eiza melai PROVEN QUALITY LEADING TECHNOLOGY GRACO 308148ZAA ENG 0566C Table of Contents CU AA len ities 3 Installation 7 Air Powered Pumps 02000 seers 8 Hydraulic Powered Pumps 10 Operation Maintenance aaa 13 All PUMPS aka mag EAA NA a a 13 Air Powered Pumps 0 0 ee eee 14 H
16. KING graphite PTFE Used on Model 687055 5 29 184231 GLAND male throat stainless steel 1 30 109311 V PACKING throat PTFE 5 687056 PACKING graphite PTFE Used on Model 687055 5 Packing Conversion Kit 222848 UHMWPE and Leather Packings THROAT PACKINGS PISTON PACKINGS LIPS FACE DOWN LIPS FACE UP BEA KI 13m LUBRICATE PACKINGS 0806 Ref Part No No Description Qty 11 184232 GLAND male piston stainless steel 1 13 184182 GLAND female piston stainless steel 1 18 109262 V PACKING piston UHMWPE 3 25 184181 GLAND female throat stainless steel 1 26 109261 V PACKING throat UHMWPE 3 29 184231 GLAND male throat stainless steel 1 31 184312 V PACKING piston leather 2 32 184311 V PACKING throat leather 2 32 308148 Max Life Conversion Kit 288551 Series A Includes parts to convert existing Dura Flo 1800 246987 to Max Life Displacement Pump 249992 Ref Part No No Description Qty 1 15G852 Rod 1 7 15G853 Cylinder 1 11 184232 GLAND male piston stainless steel 1 12 253743 Housing 1 13 184182 GLAND female piston stainless steel 1 15 253742 Housing 1 253744 Seals Kit 18 109262 V PACKING piston UHMWPE 3 25 184181 GLAND female throat stainless steel 1 26 109261 V PACKING piston UHMWPE 3 28 120533 V PACKING piston UHMWPE S M 2 29 184231 GLAND male throat stainless steel 1 30 184311 V PACKING throat leather 4 These parts are included in Packing Repair Kit 25
17. Use bleeder valve see pages 14 and 15 use ram Worn packings in displacement pump Replace packings Pump operates but out Held open or worn intake valve Clear valve service put low on downstroke Fluid too Fluid too heavy for pump priming for Fluid too heavy for pump priming priming Use bleeder valve see pages 14 and 15 use ram bleeder valve see Use bleeder valve see pages 14 and 15 use ram 14 and 15 use ram Pump operates but out Held open or worn piston valve or packings Clear valve replace packings 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 14 and 15 use ram Held open or worn piston valve or packings Clear valve replace packings Held open or worn intake valve Clear valve service 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 16 308148 Service REQUIRED TOOLS e Set of socket wrenches A WARNING She eas For Models 222939 and C59792 Premier Pumps Torque ee do not lift the pump by the lift ring when
18. 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 A fluid filter L with a 60 mesh 250 micron stainless steel element to filter particles from the fluid as it leaves the pump It includes a fluid drain valve M which is required in your system to relieve fluid pressure in the hose and gun see the WARNING at left e A gun or valve S dispenses the fluid The gun shown in Fig 3 is an airless spray gun for light to medium viscosity fluids e A gun swivel R allows freer gun movement e A suction kit T allows the pump to draw fluid from a 200 liter 55 gallon drum 308148 9 Installation HYDRAULIC POWERED PUMPS NOTE Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing NOTE 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 Fig 4 is only a guide for selecting and installing sys tem components and accessories Contact your Graco distributor for assistance in designing a system to suit your particular needs 10 308148 A CAUTION It is very important to keep the hydraulic supply system clean at all times Be sure that all hydra
19. alve grounding is obtained Ge through connection to a properly grounded fluid hose and pump 6 Fluid supply container according to your local 308148 7 Installation AIR POWERED PUMPS NOTE Reference numbers and letters in parentheses Fig 3 is only a guide for selecting and installing sys in the text refer to the callouts in the figures and the tem components and accessories Contact your Graco parts drawing distributor for assistance in designing a system to suit f r particular needs NOTE Accessories are available from your Graco pone distributor If you supply your own accessories be sure they are adequately sized and pressure rated to meet the system s requirements TYPICAL INSTALLATION KEY A Pump H Electrically Conductive Air Supply Hose P Fluid Whip Hose B Wall Bracket J Air Line Filter R Gun Valve Swivel C Pump Runaway Valve K Bleed Type Master Air Valve S Airless Spray Gun D Air Line Lubricator for accessories or Dispensing Valve E Bleed Type Master Air Valve L Fluid Filter T Drum Suction Kit required for pump M Fluid Drain Valve required Y Ground Wire
20. as the gun valve is opened and closed In a circulating svstem the pump will Alwavs flush the pump before the fluid dries on the speed up or slow down on demand until the displacement rod Flush with water or a compatible hvdraulic power supplv is shut off solvent Relieve the pressure after flushing 308148 15 Troubleshooting Chart 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 13 PROBLEM CAUSE SOLUTION Pump fails to operate Restricted line or inadequate air hvdraulic 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 Bleeder valve open Close Fluid too heavy for pump priming
21. aulic supply to the pump 3 In air powered systems close the bleed type master air valve required in your system In hydraulic powered systems close the hydraulic supply line valve first then the return line valve 4 Unlock the gun valve trigger safety 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 trigger safety 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 3 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 Warning above before adjusting the packing nut 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
22. cting rod NUT coupling WRENCH packing nut PUMP displacement mb mk mh See pages 28 amp 30 for parts 1 PUMP displacement See pages 28 amp 30 for parts NUT hex M16 x 2 0 oa ROD tie 315 mm 12 40 in shoulder to shoulder COLLAR coupling N ow t These parts are included in Connection Kit 222976 308148 27 Parts NOTE The parts listed on this page are common to all displacement pumps covered in this manual The pumps use different packing configurations Standard Models 222805 241956 249992 and 687055 use stainless steel cap screws with washers Ref Part No No 1 184276 687118 15G852 3 184458 4 184387 15B316 5 109213 6 184072 7 184461 15G853 9 184283 10 102973 112267 As 15C869 12 222795 253743 28 308148 Description Qty ROD displacement stainless steel used on 222796 222805 222988 246925 687055 C59703 and 246987 1 ROD displacement ceramic used on 241956 and 246988 1 ROD displacement sst used on 249992 only 1 PACKING NUT WET CUP SST 1 FITTING outlet 1 1 2 in npt m x M42 x 20 stainless steel 1 FITTING outlet 3 4 in npt m x M42 x 20 SST used on 687055 O RING PTFE SEAL acetal CYLINDER stainless steel CYLINDER sst used on 249992 only GUIDE ball piston stainless steel 1 BALL piston stainless steel 1 25 in 31 8 mm dia used on 222805 687055 1 BALL piston tungsten 1 25 in 31 8 mm dia
23. e 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 13 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 si Moving parts such as the air motor piston can pinch or amputate your fingers e Keep clear of all moving parts when starting or operating the pump e Before servicing the equipment follow the Pressure Relief Procedure on page 13 to prevent the equipment from starting unexpectedly 4 308148 A WARNING FIRE AND EXPLOSION HAZARD Improper grounding poor ventilation open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury Ground the equipment and the object being sprayed Refer to Grounding on page 7
24. ed 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 consumption 36 308148 KEY Technical Data MODEL 222897 VISCOUNT PUMP Maximum fluid working pressure 00 eee 18 MPa 179 bar 2600 psi Maximum hydraulic oil input pressure 20 0 eee 10 MPa 103 bar 1500 psi Pump cycles per 3 8 liters 1 gal 22 0 cece cette eens 9 Recommended pump speed for continuous operation 60 cycles per min Maximum flow eee eee eee 26 1 liters min 6 9 gpm at 60 cycles min Hydraulic motor piston effective area a 31 6 cm 4 9 in 2 Stroke length eee eee eens 120 mm 4 75 in Displacement pump effective area an 18 cm 2 79 in 2 Maximum pump operating temperature 0 cece eee eee 65 5 C 150 F Hydraulic oil inlet size 2 2 eens 3 4 npt f Fluid inlet SIZE sree cece en wee eee NG KNA eee e ee ee ea ee 2 in npt f Fluid outlet Sizer si Iha mina a Phan khan agen Peal gta us 1 1 2 in npt m Weight ii i Gradina thin Gw Be eta Khan Bp ANN La NA approx 89 kg 196 Ib Wetted parts 304 329 and 17 4 PH Grades of Stainless Steel Tungsten Carbide acetal PTFE Ultra High Molecular Weight Polyethylene MODEL 222897 m psi VISCOUNT HYDRAULIC MOTOR
25. ht exceeds 550 Ib 250 kg Mount the pump A to suit the type of installation planned Fig 3 illustrates a wall mounted system Pump dimensions and the mounting hole layout are shown on pages 38 and 39 If you are using an elevator or a cart refer to the separate manuals supplied with those components 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 eas ily accessible from the pump and is located downstream from the air regulator e An air regulator F controls pump speed and out let pressure by adjusting the air pressure to the pump Locate the regulator close to the pump but upstream from the bleed type master air valve 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 wall bracket and provides ports for connecting lines to air powered accessories e An air line filter J removes harmful dirt and moisture from the compressed air supply e A second bleed type
26. ive the rod out of the cylinder Be sure to place the cylinder on a soft block of wood Never use a hammer to drive the rod NOTE Service Tool 109507 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 assembly 8 Put the flats of the piston seat housing 12 ina vise Unscrew the rod 1 from the housing 12 leaving the ball guide 9 assembled to the rod Be careful to catch the piston ball 10 as you sepa rate the housing 12 and ball guide 9 so that it doesn t fall and suffer damage 9 Remove the glands and v packings P from the piston seat housing 12 Inspect the ball 10 and ball seat B on the housing 12 for wear or dam age 10 Inspect the outer surface of the displacement rod 1 and the inner surface of the cylinder 7 for scoring or wear replace either part if necessary If the rod is being replaced remove the ball guide 9 as explained in step 11 NOTE Do not remove the ball guide 9 from the displacement rod 1 unless either part is damaged 11 Place the flats of the ball guide 9 in a vise Using a 24 in adjustable wrench or 3 4 in drive socket unscrew the rod 1 from the ball guide Service CD i ya mt A 19 K 33 Ad Av Included only on standard Displacement Pump Models 222805 and 687055 with stainless stee
27. l cap screws 20 a 5 Kal N A 0421B Fig 7 308148 21 Service Reassembly 1 Ifit was necessary to remove the ball guide 9 from the displacement rod 1 place the flats of the rod in a vise Apply anti seize lubricant 222955 to the threads and mating faces of the rod and the ball guide Screw the ball guide onto the rod hand tight Remove from the vise See Fig 8 2 Place the female gland 13 on the piston seat housing 12 Install the five v packings P one at a time with the lips facing up Refer to pages 30 and 32 for the correct packing order for your pump Install the male gland 11 NOTE To convert the pump to a different packing material see pages 30 and 32 NOTE Service Tool 109507 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 assembly 3 Apply anti seize lubricant 222955 to the threads and mating faces of the ball guide 9 and piston seat housing 12 Place the flats of the piston seat housing in a vise Place the ball 10 on the piston seat Screw the assembled rod 1 and ball guide 9 onto the piston assembly hand tight then torque to 459 481 N m 338 354 ft lb 4 Use an arbor press to reinstall the rod 1 into the cylinder 7 as follows The cylinder is symmetri cal s
28. leed hole on the accelerates quickly or is running too fast stop it underside of the bleeder valve body 34 when immediately and check the fluid supply If the priming the pump Use a crescent wrench to open supply container is empty and air has been and close the bleeder plug 35 Keep your hands pumped into the lines refill the container and away from the bleed hole prime the pump and the lines with fluid or flush and leave it filled with a compatible solvent Be 8 If the pump fails to prime properly open the sure to eliminate all air from the fluid system bleeder valve 35 slightly Use the bleed hole on the underside of the body 34 as a priming valve Shutdown and Care of the Pump until the fluid appears at the hole See Fig 5 Close the plug 35 A WARNING NOTE When changing fluid containers with the hose To reduce the risk of serious injury whenever you and gun already primed open the bleeder valve 24 are instructed to relieve pressure always follow the to assist in priming the pump and venting air before it Pressure Relief Procedure on page 13 enters the hose Close the bleeder valve when all air has been eliminated For overnight shutdown relieve the pressure Stop l l l l the pump at the bottom of the stroke to prevent fluid 9 With the pump and lines primed and with ade from drving on the exposed displacement rod and quate hvdraulic volume supplied the pump will damaging the throat packings start and stop
29. let housing 19 Set the outlet housing on top of the cylinder 7 Apply thread lubricant to the six long cap screws 20 Install the washers 33 if present and cap screws through the outlet hous ing 19 and thread them loosely by hand into the intake housing 17 Tighten the cap screws oppo sitely and evenly using a socket wrench then torque to 244 264 N m 180 195 ft lb 10 Screw the housing valve 34 into the valve hous ing Torque to 30 28 N m 22 28 ft lb NOTE It is not ordinarily necessary to remove the outlet fitting 4 and o ring 5 However if they were replaced because of damage lubricate the o ring and place it on the fitting Screw the fitting into the outlet housing 19 Torque to 156 171 N m 115 126 ft lb 11 Reconnect the displacement pump to the air motor as explained on page 18 Service N Torque to 156 171 N m 115 126 ft Ib A Torque to 60 74 N m 45 55 ft lb A Torque to 459 481 N m 338 354 ft lb AN Torque oppositely and evenly to 244 264 N m 180 195 ftHb A Apply anti seize lubricant to threads and mating faces A Lubricate VAN Apply thread lubricant Use arbor press to drive into cylinder 7 AA Unscrew plug from valve housing and clean AN Included only on standard T Displacement Pump Mod els 222805 and 687055 with stainless steel cap screws 20 5 Torque to 30 38 N m 22 28 ft lb 16 27 A 0421
30. ly 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 24 to assist in priming the pump and venting air before it enters the hose Close the bleeder valve when all air has been eliminated 5 With the pump and lines primed and with ade quate air pressure and 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 air supply is shut off 14 308148 6 Use the air regulator 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 A 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 33 37 7 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 accelerates quickly or is run
31. n about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the distributor closest to you Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 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 Original instructions This manual contains English MM 308148 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACOINC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 1992 Graco Inc is registered to ISO 9001 www graco com Revised 02 2010 40 308148
32. ning 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 13 For overnight shutdown relieve the pressure Stop the pump at the bottom of its 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 Flush with water or a compatible solvent Relieve the pressure after flushing Operation Maintenance HYDRAULIC POWERED PUMPS Starting and Adjusting the Pump 10 Use the fluid pressure gauge F and flow control valve G to control the pump speed and the fluid 1 Refer to Fig 4 on page 11 Connect the suction kit outlet pressure Always use the lowest hydraulic T to the pump s fluid inlet and place the tube into flow and pressure necessary to get the desired the fluid supply results Higher pressures cause premature tip noz zle and pump wear 2 Check the hydraulic fluid level before each use and add fluid as necessary A WARNING 3 Make certain that the supply line shutoff valve U
33. nty must be brought within two 2 years of the date of sale Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document as well as all documents notices 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 For the latest informatio
34. o either end may face up Lubricate the piston packings P With the piston end facing down lower the rod into the cylinder Start the piston into the cylinder as much as possible then drive the rod and piston the rest of the way into the cylinder with the arbor press A CAUTION To reduce the possibility of costly damage to the rod 1 and cylinder 7 always use an arbor press to drive the rod into the cylinder and be sure to place the cylinder on a soft block of wood Never use a hammer to drive the rod 22 308148 5 Lubricate the o ring 27 and seal 6 Install the o ring on the intake seat housing 15 Install the intake seat housing 15 intake ball 16 ball guide 14 and seal 6 in the intake housing 17 Set the intake housing all the way into the vise 6 Place the cylinder 7 on the intake housing 17 Tap on the top of the displacement rod 1 with a rubber mallet to seat the cylinder 7 Lubricate the throat packings T Place the male gland 29 into the outlet housing 19 Install the five v packings one at a time with the lips facing down Refer to pages 30 and 32 for the correct packing order for your pump Install the female gland 257 NOTE To convert the pump to a different packing material see pages 30 and 32 8 Lubricate the threads of the packing nut 3 and loosely install it in the outlet housing 19 9 Lubricate the seal 6 and install it in the bottom of the out
35. on Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED 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 warra
36. or 617463 ADAPTER 234824 only 1 103 184096 NUT coupling 1 104 184278 WRENCH packing nut 1 105 C59703 PUMP displacement used on C59792 233069 and 233070 See pages 28 amp 30 for parts 1 222805 PUMP displacement used on 222939 See pages 28 amp 30 for parts 1 241956 PUMP displacement used on 241957 and 243689 See pages 28 amp 30 for parts 1 246925 PUMP displacement used on 246923 and 246924 See pages 28 amp 30 for parts 1 249992 PUMP displacement used on 234667 234824 246989 246990 246991 246992 and 253842 See pages 28 amp 30 for parts 1064 106166 NUT hex M16 x 2 0 3 1074 184382 ROD tie 380 mm 14 96 in shoulder to shoulder used on 222939 C59792 241957 243689 246989 3 246990 246991 and 246992 617464 ROD tie 730 25 mm 28 75 in 234824 only 3 1081 184130 COLLAR coupling 2 t These parts are included in Connection Kit 235419 For applications requiring stainless steel tie rods order Con nection Kit 235420 a CKO O o N 10 CI 105 01397C 26 308148 Parts Part No 222897 Pump Series B Ref with Viscount Hydraulic Motor 101 1021 103 104 105 106 1071 108 Part No 235345 184595 184096 184278 222805 687055 106166 184596 184130 Description Qty HYDRAULIC MOTOR Viscount See 308048 for parts ADAPTER conne
37. out with a compatible solvent before using the pump A WARNING For your safety read the warning section FIRE AND EXPLOSION HAZARD on page 5 before flushing and follow all recommendations given there Model 222895 Shown N Bleed hole must face down MI 34 35 N Z hu 0566C Fig 5 308148 13 Operation Maintenance AIR POWERED PUMPS Starting and Adjusting the Pump 1 Refer to Fig 3 on page 8 Connect the suction kit T to the pump s fluid inlet and place the tube into the fluid supply 2 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 dispensing 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 3 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 when the trigger is released A WARNING SKIN INJECTION HAZARD To reduce the risk of skin injection do not use your hand or fingers to cover the bleed hole on the underside of the bleeder valve body 34 when priming the pump Use a crescent wrench to open and close the bleeder plug 35 Keep your hands away from the bleed hole 4 Ifthe pump fails to prime properly open the bleeder valve 35 slight
38. point Hydraulic Lines The motor has a 3 4 npt f hydraulic oil supply fitting and a 1 in npt f hydraulic oil return fitting Use a minimum 13 mm 1 2 in ID hydraulic supply line and a minimum 22 mm 7 8 in ID 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 isolates the pump for service e A fluid pressure gauge F to monitor hydraulic oil pressure to the motor and to avoid overpressur izing the motor or displacement pump and a pres sure and temperature compensated flow con trol 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 run directly to the hydraulic return line D e An accumulator J to reduce the hammering ef fect caused by the motor reversing direction 12 308148 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 isolates the pump for service e A filter AA of 10 micron size Hydraulic Motor Drip Pan The hydraulic motor has a drip pan to collect any leakage Connect a 6 mm 1 4 in ID drain line K to the barbed fitting on the drip pan and place the free end in a container to receive the drainage Fluid Supply Hoses Be sure all fluid supply hoses N and P are properly sized and pressu
39. re rated for your system Use only electrically conductive hoses Fluid hoses must have spring guards on both ends Use a whip hose P and a swivel R between the main fluid hose N and the gun valve S to allow freer gun valve movement Fluid Line Accessories Install the following accessories in the positions shown in Fig 4 using adapters as necessary e A fluid filter L with a 60 mesh 250 micron stainless steel element to filter particles from the fluid as it leaves the pump It includes a fluid drain valve M which is required in your system to relieve fluid pressure in the hose and gun see the WARNING at left e lt A gun or valve S dispenses the fluid The gun shown in Fig 3 is an airless spray gun for light to medium viscosity fluids e A gun swivel R allows freer gun movement e A suction kit T allows the pump to draw fluid from a 200 liter 55 gallon drum Operation Maintenance ALL PUMPS 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 are instructed to relieve the pressure stop spraying dispensing check or service any of the system equipment or install or clean the spray tip nozzle 1 Lock the gun valve trigger safety 2 Shut off the air or hydr
40. required see page 7 F Pump Air Regulator N Electrically Conductive Fluid Supply Hose for installation instructions G Air Manifold J K aye MAIN AIR LINE Ba IHAIN A S N T 200 LITER 55 GAL DRUM Z C 0626C Fig 3 8 308148 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 skin injection and splashing of fluid in the eyes or on the skin and injury from moving parts if you are adjusting or repairing the pump The bleed type master air valve relieves air trapped between this valve and the pump after the air is shut off Trapped air can cause the pump to cycle unexpectedly Locate the valve close to the pump 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 and P are properly sized and pressure rated for your system Use only electrically conductive hoses Fluid hoses must have spring guards on both ends Use a whip hose P and a swivel R between the main fluid hose N and the gun valve S to allow freer gun valve movement Mounting Accessories A WARNING For Models 222939 and C59792 Premier Pumps do not lift the pump by the lift ring when the total weig
41. s Model 222895 Shown Model 222939 Shown 101 Nag 01397D AN Torque to 196 210 N m 145 155 ft Ib A Torque to 129 142 N m 95 105 ft lb A Torque to 135 169 N m 100 125 ft lb A Torque to 312 340 N m 230 250 ft lb A Torque to 192 142 N m 95 105 ft lb VAN Apply Loctite 2760 or equivalent to threads AN Square hole is for use with torque wrench Fig 6 308148 19 Service 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 7 NOTE Repair Kits are available to replace the throat T and piston P packings and to replace the o rings and cylinder seals For the best results use all the new parts in the kit Kit parts are marked with an asterisk for example 11 These kits can also be used to convert the pump to different packing materials Refer to pages 30 and 32 NOTE Standard Displacement Pumps 222805 and 687055 use stainless steel capscrews 20 with wash ers 33 Optional Pumps 222989 236227 and 236231 use carbon steel cap screws and do not include the washers 1 Stand the displacement pump upright in a large vise Loosen but do not remove the packing nut 3 Remove the six long cap screws 20 and washers 33 if present using a socket wrench
42. tal pails which are idea AND Ea baa h conductive placed on a grounded surface Do not plore operating the pump ground the place the pail on a nonconductive surface such as paper or cardboard which interrupts the grounding system as explained below Also read the section FIRE AND EXPLOSION tinuity HAZARD on page 5 al l l l To maintain grounding continuity when flushing or 1 King Pumps use a ground wire and clamp See relieving pressure always hold a metal part of the Fig 1 Remove the ground screw Z and insert spray gun dispensing valve firmly to the side of a through eye of ring terminal at the end of ground grounded metal pail then trigger the gun valve 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 TA All Other Pumps use a ground wire and clamp 7 See Fig 2 Loosen the grounding lug locknut W MEN 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 7 No 237569 Ground Wire and Clamp TI1052 2 Air and hydraulic hoses use only electrically Fig f a conductive hoses W 3 Fluid hoses use only grounded fluid hoses 4 Air compressor or hydraulic power supply follow Y UN manufacturer s recommendations Z 5 Spray gun dispensing v
43. the pump operation If the rod adapter 102 has loosened during mainte nance remove the adapter and apply Loctite 2760 or equivalent to the rod adapter and air motor piston threads and then torque as specified in Fig 6 18 308148 1 Use at least two people to hold the displacement pump while another reconnects it to the motor see the CAUTION at left 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 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 Screw the coupling nut onto the connect ing rod adapter 102 loosely Hold the connecting rod adapter 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 3 to 135 169 N m 100 125 ft lb Reconnect all hoses Reconnect the ground wire if it was disconnected Fill the wet cup 3 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 King Bulldog and Viscount Pumps Premier Pump
44. the total e Rubber mallet weight exceeds 550 Ib 250 kg e Arbor press l e Soft ee block approx 1 square foot in size 3 Disconnect the displacement pump 105 from the e Large vise with soft jaws motor 101 as follows Be sure to note the relative ie lubricant position of the pump s fluid outlet to the air or e Anti seize lubricant 222955 hydraulic inlet of the motor If the motor does not e Loctite 2760 or equivalent require servicing leave it attached to its mounting NOTE Service Tool 109507 is available as an acces A CAUTION sory The tool fits over the top of the displacement rod making it easier to apply a 24 inch adjustable wrench Be sure to use at least two people when lifting or 3 4 in drive socket when connecting or disconnect moving or disconnecting the pump The pump is too ing the rod from the piston assembly heavy for one person If you are disconnecting the displacement pump from a motor which is still mounted for example on a wall bracket be sure to support the displacement pump while it is being disconnected 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 DISCONNECTING DISPLACEMENT 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 13 4 Using adjustable
45. ulic 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 Plus the hydraulic lines immediately when they are discon nected 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 TYPICAL INSTALLATION KEY Pump Wall Bracket Hydraulic Supply Line Hydraulic Return Line Drain Line from pressure reducing valve Pressure Gauge Flow Control Valve Pressure Reducing Valve Accumulator Drain Line from motor drip pan Fluid Filter Fluid Drain Valve required Electrically Conductive Fluid Supply Hose Fluid Whip Hose Gun Valve Swivel WUZETACTIOTNMODOWS 7 H F O o o e NI i C l L HYDRAULIC POWER SUPPLY Tehec U It z u i DRAINAGE CONTAINER Fig 4 CHAD Airless Spray Gun or Dispensing Valve Drum Suction Kit Hydraulic Supply Line Shutoff Valve Hydraulic Return Line Shutoff Valve Ground Wire required see page 7 for installation instructions AA Hydraulic Return Line Filter V
46. used on C59703 241956 and 246925 1 BALL piston silicone nitride 1 25 in 31 8 mm dia used on 246987 246988 and 249992 1 HOUSING seat piston valve stainless steel w tungsten carbide seat 1 HOUSING seat piston valve used on 249992 only 1 No a 14 15 167 kk 17 19 27 34 35 36 184282 222838 253742 110294 C59027 15C868 184390 184389 102857 184392 190293 101748 GUIDE ball intake stainless steel 1 HOUSING seat intake valve stainless steel w tungsten carbide seat 1 HOUSING seat intake valve used on 249992 only 1 BALL intake stainless steel 2 in 50 8 mm dia 1 BALL intake carbide 2 in 50 8 mm dia used on C59703 241956 and 246925 1 BALL intake silicone nitride 2 in 50 8 mm dia used on 246987 246988 and 249992 HOUSING intake stainless steel HOUSING outlet pump O RING PTFE HOUSING valve 3 8 18 npt x 1 2 20 unf 2b not used on 249992 1 PLUG valve 1 2 20 unf 2a not used on 249992 1 PLUG pipe sst Replaces both 34 and 35 on 246987 246988 and 249992 1 soon These parts are included in Packing Repair Kit 222845 which may be purchased separately for Displacement Pumps 222805 241956 and 687055 They are also in cluded in the packing conversion kits described on pages 30 and 32 Included with Packing Repair Kit 249098 i Keep these spare parts on hand to reduce down time 02257 Parts
47. working pressure 0c eee eee eee 31 MPa 310 bar 4500 psi Maximum air input pressure 0 cece eee 0 7 MPa 7 bar 100 psi Pump cycles per 3 8 liters 1 gal tee e eens 8 7 Recommended pump speed for continuous operation 60 cycles per min Maximum flow 00 0 cece eee eee 26 1 liters min 6 9 gpm at 60 cycles min Air motor piston effective area eee 800 cm 38 5 in 2 Stroke lengths s Nana Sau e Mapag ings hanga 120 mm 4 75 in Displacement pump effective area an 18 cm 2 79 in 2 Maximum pump operating temperature 0 cece eee ees 65 5 C 150 F Air inletSiZ iii e Sd etek Sale Rel ance Pa cee e 3 4 npsm f Fluidiinlet SIZE yds nd hae ie dood ANAN OEE nee E be ao oad Mes 2 in npt f Fluid Outlet SI E L A aa maba mba E ambag bA ODA DNA 1 1 2 in npt m Weight aaah eee UA NA ees Ea ai a eens approx 109 kg 240 Ib Wetted parts 304 329 and 17 4 PH Grades of Stainless Steel Tungsten Carbide acetal PTFE Ultra High Molecular Weight Polyethylene Ceramic model 241957 246991 246992 233069 and 233070 only leather models 246923 246924 246989 246990 246991 and 246992 only silicon nitride models 246989 246990 246991 246992 234824 and 253842 only Sound Pressure Levels dBa 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
48. wrenches unscrew the coupling nut 103 from the connecting rod adapter 102 Remove the coupling collars 108 Take care not to lose or drop them See Fig 6 1 Flush the pump if possible Stop the pump at the bottom of its stroke Relieve the pressure 5 Hold the 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 2 Disconnect the air or hydraulic hose Plug all pump 105 from the motor 101 hydraulic hoses immediately to prevent contami nation of the hydraulic system Hold the fluid outlet 6 Refer to page 20 for displacement pump service fitting 4 with a wrench to keep it from being To service the air or hydraulic motor refer to the loosened while you disconnect the fluid hose separate motor manual supplied 308148 17 Service RECONNECTING DISPLACEMENT PUMP A WARNING To reduce the risk of pinching or injuring hands or fingers caught between the hydraulic motor drip pan and the coupling nut always use connecting rod adapter 184595 and tie rods 184596 on Model 222897 Viscount Pump Never use connecting rod adapter 184451 and tie rods 184452 on Model 222897 those parts do not allow sufficient clear ance between the drip pan and coupling nut 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
49. ydraulic Powered Pumps 15 Troubleshooting Chart 000ee eee eee 16 SEVICE Haha tahoe papa a Ba Ga 17 Required Tools aa 17 Disconnecting the Displacement Pump 17 2 308148 Reconnecting the Displacement Pump 18 Displacement Pump Service 20 Parts Drawings and Parts Lists Pump Assemblies 0000s eee 25 Displacement Pumps 000 28 Packing Conversion Kits 32 Technical Data eee ee 33 Dimensions 2 002 e eee eee 38 Mounting Hole Layouts a 39 Warrant paa YA tanith AG tease KAMANDAG 40 Graco Information a 40 Symbols Warning Symbol Caution Symbol This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions or destruction of equipment if you do not follow the instructions A WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury Rg EN 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

Graco 308148ZAA User's Manual

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