Graco 306531Z1 User's Manual
Contents
1. 22 lb 10 kg Mounting Hole Layout 2 Hole Mounting Pattern Two or Four 0 265 7 mm 4 Hole Mounting Pattern Dia Holes on 5 N 127 mm Bolt Circle S C 04127 3 76 2 mm Dia 30653171 23 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 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 the2. i Moving parts can pinch or amputate your fingers e Keep clear of all moving parts when starting or operating the pump e Before checking or servicing the equipment follow the Pressure Relief Procedure on page 8 to prevent the equipment from starting unexpectedly 30653121 3 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 Before operating this equipment electrically disconnect all equipment in the spray area Before operating this equipment extinguish all open flames or pilot lights in the spray area Do not smoke in the spray area Do not turn on or off any light switch in the spray area while operating or if fumes are present Do not operate a gasoline engine in the spray area TOXIC FLUID HAZARD Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin inhaled or swallowed Know t
3. 41 to move the piston down Be sure the o ring 27 is in place at the top of the cylinder 51 and screw the cap nut into the cylinder Screw the connecting rod 10 into the piston rod 41 and secure with the pin 4 Manually push on the piston rod 41 to move the piston 59 up as far as it will go Screw the riser tube 12 into the base 55 Use a 1 4 diameter rod spanner wrench or torque wrench to tighten the packing nut 42 Tighten snugly and then tighten an additional 1 2 turn 20 25 ft lbs Install the muffler plate 20 or 40 using the six screws 24 Connect an air hose and run the pump slowly about 30 psi 2 1 bar to see that it operates smoothly Remount the pump and reconnect the ground wire 30653121 15 Displacement Pump Service Before you start 1 Have all necessary parts on hand Whenever you replace the packings also replace the glands and bearing If you are using a repair kit use all the parts for the best results See the parts pages to order the kits 2 Displacement Pump Repair Kit 206925 includes repair parts for the pump throat and piston Parts included in the kit are marked with one asterisk for example 6 in the text and drawings 3 To replace the throat packings which are included in Repair Kit 206728 refer to the Air Motor and Throat Disassembly on page 13 Displacement Pump Disassembly 44 WARNING To redu
4. Qty sch WO sch sch Pw A a ANA UI SH AH M Ad NN _ These parts are included in Muffler Repair Kit 222559 which may be purchased separately T These parts are included in Air Motor Repair Kit 206728 which may be purchased separately 30653121 21 Notes 22 306531Z1 Dimensions 3 8 npt f Air Inlet 1 4 npt f Fluid Outlet Model 206405 13 inches 830 mm Model 206699 26 69 inches 677 7 mm Model 206700 33 62 inches 854 mm SA 04217B UA Technical Data Maximum Working Pressure 2700 psi 186 bar Fluid pressure ratio 15 1 Air operating range 40 to 180 psi 3 to 12 bar Air motor effective diameter 3 in 76 mm SOKE nh ug beeen eye ace 3 in 76 mm 17 cfm gallon pumped at 100 psi 0 476 m liter at 7 bar up to 30 cfm with pump operated at 180 psi and 66 cycles min up to 0 84 m min with pump operated at 12 bar and 66 cycles min Air consumption Pump cycles per gallon liter 90 24 Delivery 0 66 gallons minute 3 liters minute Maximum recommended pump speed 66 cycles min 0 7 gpm 32 liter min Recommended speed for optimum pump life 15 to 25 cycles per min Wetted parts Carbon Steel Brass Copper Aluminum PTFE Nitrile Rubber Leather Approximate weight
5. order Part No 222011 N TI1052 Fig 2 306531Z1 7 Operation Pressure Relief Procedure A WARNING A WARNING Never operate the pump with the warning plate 20 or the identification plate 40 removed These plates protect your fingers from pinching or am putation by moving parts in the air motor SKIN INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally Fluid under high pressure can be injected through the skin and cause serious injury To reduce the risk of an injury from injection splashing fluid or moving parts follow the Pressure Relief Procedure whenever you e are instructed to relieve the pressure stop spraying Starting and Adjusting the Pump 1 With the air regulator E closed open the bleed type master air valve F R 2 Connect the air hose check or service any of the system equipment e or install or clean the spray tips 3 Trigger the spray gun N into a grounded metal 1 Lock the spray gun trigger safety pail making firm metal to metal contact 2 Close the pump air regulator Close the bleed type master air valve required in your system 4 Open the pump air regulator E slowly just until 3 Unlock the gun trigger safety the pump is running When the pump is primed and all air has been pushed out of the lines re 4 Hold a metal part of the spray gun firmly to a lease the spray gun trigger
6. 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 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 wa
7. the text and drawings e Displacement Pump Repair Kit 206925 Parts included in this kit are marked with one asterisk i e 6 in the text and drawings e Two accessory tools should be ordered Use Padded Pliers 207579 to grip the trip rod without damaging its surface Use Gauge 171818 to ensure the proper clearance between the poppets and seat of the transfer valve Air Motor amp Throat Disassembly 44 WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 8 1 Flush the pump 2 Relieve the pressure before proceeding 3 Disconnect the hoses remove the pump from its mounting and clamp the air motor base 55 ina vise 4 Use a strap wrench on the riser tube 12 to screw it out of the air motor base 55 5 Pull the connecting rod 10 down as far as it will go 6 Usea hammer and punch to remove the roll pin 4 Unscrew the connecting rod 10 See Fig 6 44 CAUTION Do not damage the plated surface of the trip rod 54 Damaging the surface of the trip rod can result in erratic air motor operation Use the special Padded Pliers Part Number 207579 to grasp the rod 7 Manually push up on the piston rod 41 to move the piston assembly 59 up as far as it will go Unscrew the cap nut 47 Pull the nut up Grip the trip rod 54 with padded pliers and screw the nut off the rod See Fig 6 To a
8. ING piston 1 15 160941 BEARING press fit brass 1 16 160942 SEAL piston PTFE 1 17 160943 PACKING block nitrile rubber 1 51 18 160944 BEARING piston brass 1 19 160945 SEAT piston reversible 1 1 1 1 20 234578 PLATE warning with muffler 55 21 183326 STOP ball 57 22 191080 HOUSING intake valve 24 100078 SCREW hex washer hd mach 58 8 32 x 3 8 12 59 25 101578 CAPSCREW hex hd Nylock 60 5 16 18 x 7 8 6 63 27 156698 O RING nitrile rubber 1 28 158360 YOKE rod trip 1 29 158362 PIN toggle 2 30 158364 PIN pivot 2 31 167585 SPRING helical compression 2 32t 158367 GROMMET rubber 2 e 33t 160261 NUT adjusting 4 34t 160618 WIRE lock 2 35 172867 ACTUATOR valve 1 361 160621 O RING nitrile rubber 1 Part No 160623 160624 160625 234577 160639 160640 160641 160644 236079 160932 164704 162391 168851 168852 160613 170709 203965 204896 102975 172866 15K534 116343 162718 Description ARM toggle O RING nitrile rubber O RING nitrile rubber PLATE identification with muffler ROD piston NUT packing WASHER backup PACKING flat leather VALVE poppet GASKET copper NUT cylinder cap V PACKING leather GLAND male BEARING throat CYLINDER air motor POPPET valve urethane ROD trip BASE air motor SCREW rd hd mach 6 32 x 1 4 CLIP spring PISTON air motor SCRE
9. Instructions Parts List GRACO 15 1 Fire Ball 300 Pumps 30653121 For pumping petroleum based undercoating material 2700 psi 18 6 MPa 186 bar Maximum Working Pressure 180 psi 1 2 Ma 12 bar Maximum Air Input Pressure Model No 206405 Series K 35 Ib pail size Model No 206699 Series J 120 Ib drum size Model No 206700 Series J 400 Ib drum size Important Safety Instructions Read all warnings and instructions in this manual Save these instructions A WARNING This product is designed to be used for pumping non corrosive and non abrasive fluids only Any other use can cause unsafe operating conditions and result in component rupture fire or explosion which can cause serious injury including skin injection Table of Contents Warming ae a kd 2 Installation 6 Operation us eh eet mO DAN Wee NG pa 8 Maintenance ee eeee 10 Troubleshooting Guide 12 Air Motor Service aaa 13 Displacement Pump Service 16 STE EENEG 18 EI Mounting Hole Layout 23 Model 206405 Shown Dimensional Drawings 23 Technical Data 23 T Graco Warranty lusslsselllusssss 24 Graco Phone Numbers 5 24 PROVEN QUALITY LEADING TECHNOLOGY Symbols Caution Symbol Warning Symbol This symbol alerts you to the possibility of damage to This symbol alerts you to the possibility of serious or destruct
10. W ground ADAPTER 3 8 npt m x 1 4 npt f These parts are included in Pump Repair Kit 206925 which may be purchased separately 30653121 Qty AA NSAN UI sch Ap Ad AN NN _ These parts are included in Muffler Repair Kit 222559 which may be purchased separately T These parts are included in Air Motor Repair Kit 206728 which may be purchased separately 19 Parts Model 206699 Series J N 120 Ib drum size PA D KOS a Model 206700 Series J 47 7 400 Ib drum size ng 04214B 20 306531Z1 Parts Model 206699 Series J 120 Ib drum size Ref No Part No 2 100114 3 100400 4 101579 6 150451 7 t 150694 10 160688 161050 12 160938 161051 13 160939 14 160940 15 160941 16 160942 17 160943 18 160944 19 160945 20 234578 21 183326 22 191080 24 100078 25 101578 27 156698 28 158360 29 158362 30 158364 31 167585 32t 158367 Description Qty BALL steel 0 44 11 2 mm dia BALL steel 0 75 19 mm dia PIN roll 0 12 3 2 mm dia 0 75 19 mm long GASKET copper GASKET copper qty 1 in kits 206925 and 206728 ROD connecting 18 15 16 481 mm long For Model 206699 ROD connecting 25 7 8 657 mm long For Model 206700 TUBE riser 25 3 8 645 mm long For Model 206699 TUBE riser 32 5 16 821 mm long For Model 206700 BODY piston COUPLING piston BEARING press fit brass SEAL piston PTFE PACKING
11. With sufficient air grounded metal waste container and trigger the supplied the pump starts when the spray gun is gun to relieve the fluid pressure triggered and shuts off when the trigger is re leased 5 Lock the gun trigger safety 6 Open the pump drain valve required with your P pump ued y 5 Adjust the air regulator just until you get adequate system and leave it open until you are ready to spray again If you suspect that the spray tip or hose is clogged or that fluid pressure is not fully relieved after following the steps above very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually Clear the tip or hose obstruction 44 WARNING COMPONENT RUPTURE HAZARD Overpressurizing any component can GU Yam result in rupture fire explosion property damage and serious injury To reduce the risk of overpressurizing know the Maximum Working Pressure of the lowest rated component in your system and limit the air to the pump so that you never exceed that pressure flow from the spray gun Always run the pump at the lowest speed necessary 44 CAUTION 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 prime the pump and l
12. block nitrile rubber BEARING piston brass SEAT piston reversible PLATE warning with muffler STOP ball HOUSING intake valve SCREW hex washer hd mach 8 32 x 3 8 CAPSCREW hex hd Nylock 5 16 18 x 7 8 O RING nitrile rubber YOKE rod trip PIN toggle PIN pivot SPRING helical compression GROMMET rubber 1 1 CC A l l l l l l la c 12 N NNN Q Model 206700 Series J 400 Ib drum size Ref No 33t 341 35 36t 37 38 39t 40 These parts are included in Pump Repair Kit 206925 Part No 160261 160618 172867 160621 160623 160624 160625 234577 160639 160640 160641 160644 236079 160932 161435 162391 168851 168852 160613 170709 203965 204896 102975 172866 15K534 116343 162718 Description NUT adjusting WIRE lock ACTUATOR valve O RING nitrile rubber ARM toggle O RING nitrile rubber O RING nitrile rubber PLATE identification with muffler ROD piston NUT packing WASHER backup PACKING flat leather VALVE poppet GASKET copper NUT cylinder cap V PACKING leather GLAND male BEARING throat CYLINDER air motor POPPET valve urethane ROD trip BASE air motor SCREW rd hd mach 6 32 x 1 4 CLIP spring PISTON air motor SCREW ground ADAPTER 3 8 npt m x 1 4 npt f which may be purchased separately
13. ce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 8 1 Flush the pump 2 Relieve the Pressure 3 Disconnect the hoses remove the pump from its mounting and clamp the air motor base in a vise 4 Unscrew the intake valve body 22 from the riser tube 12 See Fig 9 Disassemble the intake valve 14 5 Clean and inspect the parts for wear or damage Lao and replace parts as needed Unless further A service is needed reassemble and reinstall the 2 intake valve using liquid sealant on the male 19 threads See Fig 9 6 HW 6 Usea strap wrench on the riser tube 12 to screw 17 ul 18 it out of the air motor base 55 Carefully inspect 15 _ LH the smooth inner surface of the cylinder for scoring 1 N 16 or irregular surfaces Such damage causes prema 13 ture packing wear and leaking so replace the part Ea a 22 if damaged 24 7 Unscrew the piston body 13 from the piston 7 3 coupling 14 Remove the ball 2 seat 19 gasket 6 bearing 18 packing 17 and seal 16 Do not remove the press fit brass bearing Fig 9 15 See Fig 9 04212B 16 30653121 Displacement Pump Service NOTE If the pressure fit brass bearing 15 needs to 10 Install the gasket 7 Screw the riser tube 12 be replaced clamp it in a vise and drive the pis
14. e exhaust valve poppets 531 into the valve actuator 35 and clip off the top part shown with dotted lines See Fig 8 Install the grommets 321 in the valve actuator 85 Install the trip rod 54 in the piston 59 Place the trip rod yoke 28 and valve actuator 35 on the trip rod Be sure the o ring 36 is in place and that the valve actuator is supported by the spring clips 58 and reassemble the valve mechanism See Fig 7 TA Air Motor Service Install the bottom adjusting nuts 33 on the poppet valve stems 451 and screw the stems into the grommets 321 Screw the top nuts 331 on the stems Before installing the lockwires 341 in the adjusting nuts use the gauge 171818 to adjust the transfer valve so there is 0 145 in 3 7 mm clearance between the poppets and the seat when it is open See Fig 8 44 WARNING To reduce the risk of pinching or amputating your fingers always keep fingers clear of the toggle assemblies M Install the springs 31 and pivot pins 30 on the toggle arms 37 Snap the toggles to the up position Refer to Fig 7 Carefully lower the cylinder 51 over the piston 59 and onto the base 55 Secure with the six screws 25 9 10 11 12 13 14 Manually push on the piston rod 41 to move the piston 59 up as far as it will go Grip the trip rod 54 with padded pliers and screw the cylinder cap nut 47 onto the trip rod Pull the piston rod
15. ety regulations 2 306531Z1 44 WARNING SKIN INJECTION HAZARD Spray from the gun 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 surgical treatment Do not point the gun at anyone or at any part of the body Do not put your hand or fingers over the spray tip Do not stop or deflect leaks with your hand body glove or rag Do not blow back fluid this is not an air spray system Always have the tip guard and the trigger guard on the gun when spraying Check the gun diffuser operation weekly Refer to the gun manual Be sure the gun trigger safety operates before spraying Close the gun ball valves when you stop spraying Lock the gun trigger safety when you stop spraying Follow the Pressure Relief Procedure on page 8 if the spray tip clogs and before cleaning checking or servicing the equipment Tighten all fluid connections before operating the equipment Check the hoses tubes and couplings daily Replace worn or damaged parts immediately Do not repair high pressure couplings you must replace the entire hose Fluid hoses must have spring guards on both ends to help protect them from rupture caused by kinks or bends near the couplings MOVING PARTS HAZARD
16. he 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 4 30653121 Notes 30653121 5 Installation o 5 y T KEY Electrically Conductive Air Hose Female Quick Disconnect Coupler Male Quick Disconnect Fitting Air Line Filter Air Regulator and Gauge Bleed Type Master Air Valve Air Line Lubricator Pump Runaway Valve Pump Air Inlet Ground Wire 1 2 in Pressure Drain Valve Electrically Conductive Fluid Hose uu Spray Gun zsra Ionmonu gt 04209 Fig 1 NOTE Reference numbers and letters in parentheses System Accessories in the text refer to the callouts in the figures and the parts drawings A WARNING Figure 1 is only a guide to selecting and installing optional and required accessories For help in design ing a system to suit your needs contact your Graco distributor To reduce the risk of serious injury including skin injection splashing in the eyes or on the skin and injury from moving parts if you are adjusting or repairing the pump two accessories are requ
17. hours 1 Relieve the pressure Follow the Pressure Relief Procedure on page 8 2 Using a 1 4 nut driver remove the six screws 24 from one of the muffler plates 20 or 40 and remove the muffler plate See Fig 4 3 Check to see that the air motor piston is at the top of the stroke If it is not first read the warning above Then while keeping your fingers away from moving parts apply very low pressure air to the air inlet to move the piston up Close the air regulator and disconnect the air supply hose Refer to Fig 3 4 Use a 1 4 diameter rod spanner wrench or torque wrench to tighten the packing nut First loosen the nut then tighten snugly and finally tighten an additional 1 2 turn 20 25 ft lbs See Fig 5 5 Replace the muffler cover and the six screws See Fig 4 6 Reconnect the air line After the pump is started it should run at 40 psi 276 MPa 2 8 bar with no load Startup may require additional air pressure PISTON FLUID A OUTLET WEEP HOLE LOCATED OPPOSITE FLUID OUTLET Fig 3 AND IN BOTTOM OF BASE Fig 4 PACKING NUT 1 4 DIA ROD Fig 5 30653121 11 Troubleshooting 44 WARNING A WARNING To reduce the risk of serious injury whenever you Never operate the pump with the warning plate are instructed to relieve pressure always follow the 20 or the identification plate 40 removed These Pressure Relief Procedure on page 8 plates protect your fingers fr
18. ides easily into them See Fig 7 Remove the trip rod yoke 28 actuator 35 and trip rod 54 See Fig 7 Check the exhaust valve poppets 531 for cracks To remove the exhaust valve poppets 531 stretch them out and cut them with a sharp knife Remove one muffler plate 20 or 40 Pull the piston 59 up out of the base Remove the throat packing nut 42 and packings See Fig 6 30653121 5 N 8 TEM UU ww N 0 145 3 7 mm 451 59 Cutaway View AN Cut off tops of poppets as indicated by dotted lines 04119 Fig 8 Reassembly 1 Clean all the parts in a compatible solvent and inspect for wear or damage Check the polished surfaces of the piston 59 piston rod 41 and cylinder wall 51 for scratches or wear A scored rod will cause premature packing wear and leak ing Use all the repair kit parts and replace other parts as necessary Lubricate all parts with a light waterproof grease One at a time install these parts in the base 55 the gland 49 five v packings 48 with lips facing down bearing 50 backup washer 43 flat packing 44 and loosely screw in the packing nut 42 Be sure the o rings 38 amp 391 are in place See Fig 6 Pull th
19. ines with fluid or flush it and leave it filled with a compatible solvent Be sure to eliminate all air from the fluid lines Use a pump runaway valve K to automatically shut off the pump if it starts to run too fast 6 Readand follow the instructions supplied with To determine the fluid output pressure using the air each component in your system regulator reading multiply the pump ratio by the air pressure you set on the regulator gauge Example 7 Ifthe pump will be unattended for any period of 15 1 ratio x 100 psi air 1500 psi fluid output 15 1 ratio x 7 bar air 2 105 bar fluid output 8 30653121 time or to shut off the system at the end of the work shift always follow the Pressure Relief Procedure at the left Notes 30653121 9 Maintenance Shutdown and General Care Flushing To reduce the risk of serious injury whenever you To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the are instructed to relieve pressure always follow the Pressure Relief Procedure on page 8 Pressure Relief Procedure on page 8 1 To reduce the risk of skin injection static sparking e Always relieve the pressure when you shut down or splashing Relieve the Pressure before flush the pump ing e f you are pumping fluid that dries or sets up flush 2 Remove the spray tip with a compatible solvent as often as necessary to 3 Hold a metal part of the gun firmly to the side
20. ion of equipment if you do not follow the injury or death if you do not follow the instructions instructions 44 WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury S 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 not sure 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 stated on the equipment or in the Technical Data for your equipment Do not exceed the maximum working pressure of the lowest rated component in your system Use fluids and solvents which are compatible with the equipment wetted parts Refer to the Tech nical Data section of all equipment manuals Read the fluid and solvent manufacturer s warnings Handle hoses carefully Do not use hoses to pull equipment Route hoses away from traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 66 C 150 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 saf
21. ir supply e Adrain valve L is required near the pump fluid outlet to relieve fluid pressure in the pump hose and gun Order Part No 210657 e Install an electrically conductive fluid hose M and spray gun N Grounding Proper grounding is an essential part of maintaining a safe system To reduce the risk of static sparking ground the pump Check your local electrical code for detailed grounding instructions for your area and type of equipment Be sure to ground all of this equipment e Pump use a ground wire and clamp as shown below e Truck bed or platform according to your local code e Fluid hoses use only electrically conductive hoses e Air compressor follow manufacturer s recommen dations e Spray gun grounding is obtained through connec tion to a properly grounded fluid hose and pump e Object being sprayed according to local code e Fluid supply container according to local code e All solvent pails used when flushing or relieving pressure always hold a metal part of the gun firmly to the side of a grounded metal pail then trigger the gun To ground the pump To ground the pump use a ground wire and clamp as shown below Remove the ground screw Z and insert through the eye of ring terminal at end of ground wire Y Fasten the ground screw back onto the pump and tighten securely Connect the other end of the ground wire to a true earth ground See Fig 2 To order a ground wire and clamp
22. ired in your system a bleed type master air valve F Mount the pump to suit the type of installation planned and a pressure drain valve L See page 23 for dimensions and mounting hole layout The bleed type master air valve F relieves air trapped between it and the air motor after the air supply is shut off Trapped air can cause the air motor to cycle unexpectedly if you are adjusting or repairing the pump Install the valve near the pump air inlet within easy reach of the pump The pressure drain valve L assists in relieving fluid pressure in the displacement pump hoses and gun Triggering the spray gun to relieve pres sure may not be sufficient 6 30653121 Installation 44 CAUTION Provide a bracket for mounting the air accessories The fittings are not strong enough to support the accessories and may cause one or more to break NOTE Install the accessories in the order shown in Figure 1 e A pump runaway valve H shuts off the air to the pump if the pump accelerates beyond the pre ad justed setting A pump which runs too fast can be seriously damaged e An air line lubricator G provides automatic air motor lubrication e A bleed type master air valve F relieves air trapped between it and the motor when the valve is closed Order Part No 107142 e The air regulator E controls pump speed and pressure e An air line filter D removes harmful dirt and contaminants from your compressed a
23. o make changes at any time without notice This manual contains English MM 306531 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 1996 Graco Inc is registered to ISO 9001 www graco com Revised 05 2009 24 306531Z1
24. of a prevent buildup in the pump and hoses grounded metal pail Use the lowest possible fluid pressure when flushing e After every 40 hours of operation adjust the pack ing nut 42 as described on page 11 Lubrication The accessory air line lubricator G provides automat ic air motor lubrication For daily manual lubrication follow this procedure 1 Disconnect the regulator 2 Place about 15 drops of light machine oil in the pump air inlet Reconnect the regulator Turn on the air supply to blow oil into the motor 10 30653121 Maintenance Packing Nut Adjustment 44 WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 8 44 WARNING Keep your hand and fingers away from the piston when it is moving As the piston moves into the pump base it can amputate fingers or break tools caught between the moving parts Note the pinch point shown in Fig 3 Be sure all air and fluid pressure is fully relieved before adjusting the piston or packing nut to reduce the risk of amputation NOTE Perform this adjustment if a material drips steadily from the air motor weep hole which indicates the packings are too loose b the pump requires more than 50 psi 345 MPa 3 4 bar air pressure to cycle when the gun is triggered which indicates the pack ings are too tight or c the pump has been in opera tion for 40
25. om pinching or ampu tation by moving parts in the air motor Relieve the Pressure before you check or service any NOTE Check all other possible problems and solu System equipment tions before disassembling the pump problem eases Sn Pump fails to operate Low air supply pressure or restricted air Increase air supply clear lines Continuous air exhaust Worn or damaged air motor gasket Service air motor packing seal etc Erratic pump operation Empty fluid supply container Refill and reprime or flush Held open or worn intake valve or Clear service piston packings Pump operates but output is low Held open or worn piston Clear service on the up stroke or packings Pump operates but output is low Held open or worn intake valve Clear service on the down stroke Pump operates but output is low Low air supply pressure or Increase air supply clear on both strokes restricted air lines Follow the Pressure Relief Procedure on page 8 Disconnect the fluid hose If the pump starts when the air is turned on again the hose or gun is clogged 12 30653121 Air Motor Service 44 CAUTION Before you start e Have all necessary parts on hand Always replace the glands and bearing when replacing the pack ings Use all the parts in the repair kits for the best results See page 18 to order the kits e Air Motor Repair Kit 206728 Parts included in this kit are marked with a dagger for example 361 in
26. rranty 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 la suite de ou en rapport directement ou indirectement avec les procedures concern es Graco Phone Numbers For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call one of the following numbers to identify the distributor closest to you 1 800 533 9655 Toll Free 612 623 6928 612 378 3590 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 t
27. ton into the air motor base 55 body 13 out with a plastic hammer The new bearing must be started onto the piston body squarely 11 Reinstall the ball 3 gasket 7 ball stop 21 and other gasket 7 in the intake valve housing 22 8 Clean and inspect the parts and replace any that Screw the housing onto the riser tube 12 are worn or damaged Be sure to check the copper gasket 46 in the motor base 55 Lubricate the 12 Be sure the ground wire is connected before parts with a light waterproof grease regular operation of the pump 9 Install the seal 16 packing 17 bearing 18 gasket 6 seat 19 and ball 2 on the piston body 13 The check ball seat 19 may be re versed to provide a new seat Screw the piston body 13 into the piston coupling 14 30653121 17 Model 206405 Series K 35 Ib pail size 18 30653121 UN VA e O _ N A M 04213B Model 206405 Series K 35 Ib pail size Ref Ref No Part No Description Qty No 2 100114 BALL steel 0 44 11 2 mm dia 1 37 3 100400 BALL steel 0 75 19 mm dia 1 38 4 101579 PIN roll 0 12 3 2 mm dia 39t 0 75 19 mm long 3 40 6 150451 GASKET copper 1 7 t 150694 GASKET copper 41 qty 1 in kits 206925 and 206728 3 42 10 165970 ROD connecting 43 5 1 4 133 mm long 1 44 12 165971 TUBE riser 451 11 11 16 297 mm long 1 13 160939 BODY piston 1 14 160940 COUPL
28. void damaging the cylinder wall lift the cylinder 51 straight up off the piston 59 Never tilt the cylinder as it is being removed 8 Remove the six screws 25 See Fig 6 Pull the cylinder 51 straight up off the piston 59 9 Usea screwdriver to push down on the trip rod yoke 28 and snap the toggles down See Fig 7 38 391 42 44 10 AN See detail below 50 48 2N 49 AN Lips of v packings must face down 04210B Fig 6 306531Z1 13 Air Motor Service 331 45t 321 58 53t 331 45t A To remove toggles push in swing up ease out AN Push toggles M in and then up shown in down position Turn wires up 04118 Fig 7 10 Remove the lockwires 341 from the adjusting nuts 331 of the transfer valves Screw the top nuts off Screw the poppet valve stems 451 out of the grommets 321 and the bottom nuts 30 Take the valve poppets off the stems and squeeze them firmly to check for cracks See Fig 7 44 WARNING To reduce the risk of pinching or amputating your fingers always keep fingers clear of the toggle assemblies M 11 12 13 14 Grip the pivot pins 30 with pliers Compress the springs 31 and swing the toggle assembly M up and away from the piston lugs L Remove the parts Check to see that the valve actuator 35 is supported by the spring clips 58 but sl
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