This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D 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.
D 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.
D Do not use hoses to pull equipment.
D 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).
D Wear hearing protection when operating this equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
2308200
Page 3
WARNING
SKIN INJECTION HAZARD
Spray from the spray gun/dispense 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.
D Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
surgical treatment.
D Do not point the gun/valve at anyone or at any part of the body.
D Do not put your hand or fingers over the spray tip/nozzle.
D Do not stop or deflect leaks with your hand, body, glove or rag.
D Do not “blow back” fluid; this is not an air spray system.
D Always have the tip guard and the trigger guard on the spray gun when spraying.
D Check the gun diffuser operation weekly. Refer to the gun manual.
D Be sure the gun/valve trigger safety operates before spraying/dispensing.
D Lock the gun/valve trigger safety when you stop spraying/dispensing.
D Follow the Pressure Relief Procedure on page 8 whenever you: are instructed to relieve pres-
sure; stop spraying/dispensing; clean, check, or service the equipment; and install or clean the
spray tip/nozzle.
D Tighten all fluid connections before operating the equipment.
D Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
D 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
Moving parts, such as the priming piston, can pinch or amputate your fingers.
D Keep clear of all moving parts when starting or operating the pump.
D Keep hands and fingers away from the priming piston during operation and whenever the pump is
charged with air.
D Before servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the
equipment from starting unexpectedly.
3082003
Page 4
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.
D Ground the equipment and the object being sprayed. Refer to Grounding on page 6.
D If there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing/dispensing immediately. Do not use the equipment until you identify and correct the problem.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed/dispensed.
D Keep the spray/dispense area free of debris, including solvent, rags, and gasoline.
D Electrically disconnect all equipment in the spray/dispense area.
D Extinguish all open flames or pilot lights in the spray/dispense area.
D Do not smoke in the spray/dispense area.
D Do not turn on or off any light switch in the spray/dispense area while operating or if fumes are
present.
D Do not operate a gasoline engine in the spray/dispense area.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
4308200
Page 5
Installation
General Information
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawings.
NOTE: If you supply your own accessories, be sure
they are adequately sized and pressure–rated to meet
the system’s requirements.
Fig. 2 is only a guide for selecting and installing system components and accessories. Contact your Graco
distributor for assistance in designing a system to suit
your particular needs.
System Accessories
WARNING
Two accessories are required in your system: a
bleed–type master air valve (J) and a fluid drain
valve (N). These accessories help reduce the risk
of serious bodily injury including fluid injection,
splashing 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 pressure 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 and fluid hoses are properly sized and
pressure-rated for your system. Use only grounded air
and fluid hoses. Fluid hoses must have a braided
stainless steel cover (or have spring guards on both
ends).
Mounting Accessories
Mount the pump (A) to suit the type of installation
planned. The pump dimensions and mounting hole
layouts are shown on pages 28 and 29.
The Typical Installation on page 7 shows the pump
(A) mounted on a pneumatic elevator cart (B). The
pump may also be mounted on a 19 liter (5 gal.) pail
ram. In either case, it is used with a wiper plate (C).
Refer to the separate manuals for the cart, ram, and
wiper plate for further information.
Kits 223881 and 224829 are available to mount the
pump on a 200 liter (55 gallon) ram. Refer to the
separate manuals included with the kits for further
information.
Air Line Accessories
Install the following accessories as shown in Fig. 2,
using adapters as necessary:
D A pump runaway valve (G) 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. Install closest to the pump
air inlet.
D Anair line lubricator (H) provides automatic air
motor lubrication.
D A bleed-type master air valve (J) is required in
your system to relieve air trapped between it and
the air motor when the valve is closed (see the
WARNING at left). Be sure the bleed valve is easily
accessible from the pump, and is located down-stream from the air regulator.
D Anair regulator (K) controls pump speed and
outlet pressure by adjusting the air pressure to the
pump. Locate the regulator close to the pump, but
upstream from the bleed-type master air valve.
D Anair line filter (L) removes harmful dirt and
moisture from the compressed air supply.
D A secondbleed-type air valve (M) isolates the air
line accessories for servicing. Locate upstream
from all other air line accessories.
D An air line quick disconnect coupler (F) is
required for pumps mounted on the pneumatic
elevator cart. The female coupler attaches to the
end of the air hose (D), and the male coupler
screws into the air manifold (E). See the separate
cart manual for further information.
3082005
Page 6
Installation
Fluid Line Accessories
Install the following accessories in the positions shown
in Fig. 2, using adapters as necessary:
D A fluid drain valve (N) is required in your system
to relieve fluid pressure in the hose and gun (see
the WARNING at left). Screw the drain valve into
the open branch of a tee mounted in the fluid line.
Install the drain valve pointing down, but so the
handle points up when opened.
D A fluid regulator (P) controls fluid pressure to the
gun/valve, and dampens pressure surges.
D A gun or valve (S) dispenses the fluid. The gun
shown in the Typical Installation is a dispensing gun
for highly viscous fluids.
D A gun swivel (T) allows freer gun movement.
Grounding
WARNING
W
X
Y
Z
0864
Fig. 1
2. Air and fluid hoses: use only electrically conductive
hoses.
3. Air compressor: follow manufacturer’s recommendations.
4. Spray gun/dispense valve: ground through connection to a properly grounded fluid hose and pump.
5. Fluid supply container: follow your local code.
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE AND EXPLOSIONHAZARD on page 4.
1. Pump: use a ground wire and clamp. See Fig. 1.
Loosen the grounding lug locknut (W) and washer
(X). Insert one end of a 1.5 mm@ (12 ga) minimum
ground wire (Y) into the slot in lug (Z) and tighten
the locknut securely. Connect the other end of the
wire to a true earth ground. Order Part No. 237569
Ground Wire and Clamp.
6. Object being sprayed: follow your local code.
7. All solvent pails used when flushing: follow your
local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not
place the pail on a nonconductive surface, such as
paper or cardboard, which interrupts the grounding
continuity.
8. To maintain grounding continuity when flushing orrelieving pressure, always hold a metal part of the
gun/valve firmly to the side of a grounded metal
pail, then trigger the gun/valve.
6308200
Page 7
MAIN AIR LINE
LM
Installation
KEY
APump
BPneumatic Elevator Cart
CWiper Plate
DAir Hose
EAir Manifold
FAir Line Quick Disconnect Coupler
GPump Runaway Valve
HAir Line Lubricator
JBleed-Type Master Air Valve (required, for pump)
KAir Regulator
LAir Line Filter
MBleed-Type Master Air Valve (for accessories)
NFluid Drain Valve (required)
PFluid Pressure Regulator
RFluid Hose
SGun or Dispensing Valve
TGun/Valve Swivel
YGround Wire (required)
A
H
G
Y
J
D
K
E
F
B
P
N
R
S
T
C
19 LITER (5 GAL.) PAIL
Fig. 2
01058
3082007
Page 8
Operation
7
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or dispensing 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:
D are instructed to relieve the pressure,
D stop spraying/dispensing,
D check or service any of the system equipment,
D or install or clean the spray tip/nozzle.
1. Lock the gun/valve trigger safety.
2. Close the pump’s bleed-type air valve (required in
your system).
Packing Nut/Wet-Cup
Before starting, fill the packing nut (2) 1/3 full with
Graco Throat Seal Liquid (TSL) or compatible solvent.
See Fig. 3. Adjust the packing nut weekly so it is just
snug; do not overtighten.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
Air Motor Plate
3. Shut off the master air bleed valve (required in
your system).
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),
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 or hose end coupling
and relieve pressure gradually, then loosen completely.
Now clear the tip/nozzle or hose.
Fig. 3
2
23
0105
8308200
Page 9
Operation
Flush the Pump Before First Use
The pump is tested with lightweight oil, which is left in
to protect the pump parts. If the fluid you are using
may be contaminated by the oil, flush it out with a
compatible solvent. See Flushing on page 10.
Starting and Adjusting the Pump
WARNING
MOVING PARTS HAZARD
See Fig. 3. The priming piston (23) and
the air motor piston (located behind the
air motor plates) move during operation.
Keep hands and fingers away from the priming
piston (23) during operation and whenever the
pump is charged with air. The priming piston extends beyond the intake cylinder (20) to pull material into the pump and can amputate a hand or finger
caught between it and the intake cylinder. Follow
the Pressure Relief Procedure on page 8,
before checking, clearing, or cleaning the priming
piston to prevent the pump from starting accidentally.
NOTE: When changing fluid containers with the hose
and gun already primed, be sure to open the bleeder
valve (33), to assist in priming the pump and venting
air before it enters the hose. Close the valve when all
air has been eliminated.
WARNING
SKIN INJECTION HAZARD
To reduce the risk of fluid injection, do not use
your hand or fingers to cover the bleed hole on the
underside of the bleeder valve body when priming
the pump. Use a crescent wrench to open and
close the bleeder plug. Keep your hands away from
the bleed hole.
With the pump and lines primed, and with adequate air
pressure and volume supplied, the pump will start and
stop as the spray gun/dispensing valve is opened and
closed.
Use the air regulator (K) 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.
Never operate the pump with the air motor plates
removed.
See the Installation on page 7. If you are using a
pneumatic elevator cart or 19 liter (5 gallon) ram with
the pump, refer to the separate instructions for those
components for set-up and operation instructions.
Lower the pump into a fluid container. Be sure the air
regulator (K) and bleed-type master air valve (J) are
closed. Then open the bleed valve (J). 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.
Cycle the pump slowly until all the air is pushed out
and the pump and hoses are fully primed. Release the
spray gun/dispensing valve trigger and engage the
safety latch. The pump should stall against pressure
when the trigger is released.
If the pump fails to prime properly, open the bleeder
valve (33) slightly. See Fig. 7 on page 16. Use the
bleeder hole (on the underside of the valve housing) as
a priming valve until the fluid appears at the hole.
Close the bleeder valve.
WARNING
To reduce the risk of overpressurizing the system,
which could result in component rupture and cause
serious injury, NEVER exceed the specified maximum incoming air pressure to the pump (see the
Technical Data on pages 24–27).
CAUTION
Do not allow the pump to run dry. It will quickly
accelerate to a high speed, causing damage. A
pump runaway valve (G), which shuts off the air
supply to the pump if the pump accelerates beyond
the pre-set speed, is available. See the Typical
Installation in Fig. 2. If your pump accelerates
quickly, or is running too fast, stop it immediately and
check the fluid supply. If the supply container is
empty and air has been pumped into the lines, refill
the container and prime the pump and the lines with
fluid, or flush and leave it filled with a compatible
solvent. Be sure to eliminate all air from the fluid
system.
3082009
Page 10
Operation
Shutdown and Care of the Pump
For overnight shutdown, stop the pump at the bottom
of the stroke to prevent fluid from drying on the exposed displacement rod and damaging the throat
packings. Relieve the pressure.
Always flush the pump before the fluid dries on the
displacement rod. Refer to Flushing below.
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. Relieve the pressure.
Flushing
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, read the
section FIRE AND EXPLOSION HAZ-ARD on page 4. Be sure the entire
system and flushing pails are properly
grounded. Refer to Grounding on page
6.
Flush with a fluid that is compatible with the fluid you
are pumping and with the wetted parts in your system.
Check with your fluid manufacturer or supplier for
recommended flushing fluids and flushing frequency.
Always flush the pump before fluid dries on the displacement rod.
2. Remove the spray tip/nozzle from the gun/valve.
3. Hold a metal part of the gun/valve firmly to the side
of a grounded metal pail.
4. Start the pump. Always use the lowest possible
fluid pressure when flushing.
5. Trigger the gun/valve.
6. Flush the system until clear solvent flows from the
gun/valve.
7. Relieve the pressure.
10308200
Page 11
Troubleshooting
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. Relieve the pressure.
2. Check all possible problems and causes before
disassembling the pump.
PROBLEM
Pump fails to operate.Restricted line or inadequate air supply Clear*; see Technical Data on pages 24–27.
Pump operates, but
output is low on both
strokes.
Pump operates, but
output is low on downstroke.
Pump operates, but
output is low on upstroke.
Erratic or accelerated
pump speed.
CAUSESOLUTION
Obstructed fluid hose or gun/valve;
fluid hose ID is too small.
Fluid dried on the displacement rod.Clean; see Service on pages 12–19.
Dirty or worn air motor parts.Clean or repair; see separate air motor manual.
Restricted line or inadequate air supply. Clear*; see Technical Data on pages 24–27.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small.
Bleeder valve is open.Close.
Air is leaking into the supply container. Check wiper plate seal.
Fluid is too heavy for pump priming.Use bleeder valve (see page 9); use wiper plate
Worn packings in displacement pump.Replace packings.
Fluid too heavy for pump priming.Use bleeder valve (see page 9); use wiper plate
Held open or worn intake valve or seals. Clear valve; replace seals.
Held open or worn piston valve or seals. Clear valve; replace seals.
Exhausted fluid supply.Refill and prime.
Fluid is too heavy for pump priming.Use the bleeder valve (see page 9); use wiper
Held open or worn piston valve or seals. Clear valve; replace seals.
Held open or worn priming piston.Clear; service.
Worn packings in displacement pump.Replace packings.
Clear*; use a hose with a larger ID.
Clear*; use a hose with a larger ID.
with ram or pneumatic elevator cart.
with ram or pneumatic elevator cart.
plate with ram or pneumatic elevator cart.
* To determine if the fluid hose or gun is obstructed, follow the Pressure Relief Procedure on page 8. Disconnect
the fluid hose and place a container at the pump fluid outlet to catch any fluid. Turn on the air just enough to start
the pump (about 20–40 psi [0.14–0.3 MPa, 1.4–2.8 bar]). If the pump starts when the air is turned on, the obstruction is in the fluid hose or gun.
NOTE: If you experience air motor icing, contact your Graco distributor for assistance.
30820011
Page 12
Service
Required Tools
D Torque wrench
D Bench vise, with soft jaws
D Rubber mallet
D Hammer
D Razor or other sharp tool
D 8 mm (5/16 in.) dia. brass rod
D 8 mm, 11 mm, 15 mm, 25 mm, 3/4 in., and 7/8 in.
open–end wrenches
D 17 mm box or socket wrench
D 22 mm crow’s–foot wrench
D Adjustable wrenches
D 24 in. adjustable wrench
D Thread lubricant
D Anaerobic thread sealant
Disconnecting the Displacement Pump
1. Flush the pump, if possible. Stop the pump at the
bottom of its stroke.
WARNING
2. Relieve the pressure.
3. Disconnect the air hose. Hold the fluid outlet fitting
(7) with an adjustable wrench to keep it from being
loosened while you disconnect the fluid hose.
Remove the pump from its mounting. Note the
relative position of the pump’s fluid outlet to the air
inlet.
4. Using an adjustable wrench, unscrew the coupling
nut (104) from the connecting rod (103). Remove
the coupling collars (105). Take care not to lose or
drop them. See Fig. 4.
5. Hold the tie rod flats with an 11 mm wrench to
keep them from turning. Use the wrench (113)
provided with the pump (or a 17 mm box or socket
wrench) to unscrew the locknuts (106) from the tie
rods (102). Carefully pull the displacement pump
(107) off the air motor (101).
6. Refer to page 14 for displacement pump service.
To service the air motor, refer to the separate air
motor manual, supplied.
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
Keep hands and fingers away from the priming
piston during operation and whenever the pump is
charged with air. On the pump downstroke the
priming piston extends beyond the intake cylinder
to pull the material into the pump. The priming
piston works under extreme force. During operation
and whenever the pump is charged with air, the
priming piston can severely injure or amputate a
hand or finger, or break a tool, caught between it
and the intake cylinder.
The air motor piston (located behind the air motor
plates) also moves when air is supplied to the
motor. NEVER operate the pump with the air motor
plates removed.
12308200
Page 13
Reconnecting the Displacement Pump
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
Service
101
1. Orient the pump’s fluid outlet to the air motor’s air
inlet as was noted in step 3 under Disconnectingthe Displacement Pump. Position the displacement pump (107) on the tie rods (102). See Fig. 4.
NOTE: If you removed the tie rods (102) from the air
motor (101) or air motor adapter plate, reinstall them
using an 11 mm wrench. Torque the rods to 20-25 N.m
(15-18 ft-lb) on Model 222907, and 34-41 N.m (25-30
ft-lb) on Model 222839.
2. Screw the locknuts (106) onto the tie rods (102)
and torque to 34-41 N.m (25-30 ft-lb), using the
wrench (113) provided (or a 17 mm box or socket
wrench).
3. Place the coupling nut (104) on the displacement
rod (1), then place the collars (105) in the nut.
Screw the nut onto the connecting rod (103)
loosely. Hold the connecting rod flats with an
adjustable wrench to keep it from turning. Using an
adjustable wrench, torque the nut to 41-48 N.m
(30-35 ft-lb).
4. Using a torque wrench in the square hole of the
supplied wrench (113), torque the packing nut (2)
to 27-34 N.m (20-25 ft-lb).
5. Mount the pump and reconnect all hoses. Reconnect the ground wire if it was disconnected during
repair. Turn on the air and run the pump slowly.
6. Fill the packing nut/wet-cup 1/3 full of Graco
Throat Seal Liquid or compatible solvent.
108
103
102
105
104
1
1
2
106
113
7
107
1
Torque to 30–35 ft–lb (41–48 NSm).
Torque to 15–18 ft–lb (20–25 NSm) on model 222907; 25–30
2
ft–lb (34–41 NSm) on model 222839.
3
Torque to 20–25 ft–lb (27–34 NSm).
4
Torque to 25–30 ft–lb (34–41 NSm).
Fig. 4
2
3
4
01059
30820013
Page 14
Service
Disassembly
When disassembling the pump, lay out all removed
parts in sequence, to ease reassembly. Refer to Fig. 7.
NOTE: Repair Kit 222784 is available separately to
replace the piston and intake valve seals. For the best
results, use all the new parts in the kit. Kit parts are
marked with one asterisk, for example (8*). See Dis-placement Pump Parts on page 23.
Repair Kit 222785 is available to replace the throat
packings. For the best results, use all the new parts in
the kit. Kit parts are marked with a check mark, for
example (3n).
1. Disconnect the displacement pump from the air
motor as explained on page 12.
2. Place the pump in a vise, with the jaws on the
outlet housing (9).
3. Hold the flats of the priming piston rod (21) with an
8 mm wrench. Using a 3/4 in. wrench, unscrew the
priming piston nut (22) from the rod. Slide the
priming piston (23) and priming piston guide (24)
off the rod. Inspect the surfaces of the guide (24)
and piston (23) for scoring, wear, or other damage.
4. Loosen the packing nut (2) using the packing nut
wrench (113, supplied), or a hammer and brass
rod.
5. Remove the intake cylinder (20), using a 24 in.
adjustable wrench. Remove the seal (19) and seat
(18) from the intake valve housing (16); always
replace the seal with a new one.
6. Unscrew the intake valve housing (16) from the
cylinder (11), using a 24 in. adjustable wrench. Pull
the housing off the pump. The intake check valve
assembly (U) should slide down the priming piston
rod (21) as you remove the housing; if it does not
slide easily, loosen it by firmly tapping the top of
the housing (16) with a rubber mallet. Take care
not to drop the assembly (U) as it comes free. Set
the check valve assembly aside for disassembly
later.
7. Inspect the rod guide (17) while in place in the
housing (16). Remove the rod guide only if it is
visibly damaged. Using a hammer and brass rod,
gently tap around the outer edge of the guide to
loosen it.
8. Push the displacement rod (1) down as far as
possible, then pull it and the priming piston rod
(21) out of the outlet housing (9) and cylinder (11).
9. Remove the packing nut (2) and throat packings
from the outlet housing (9). Do not remove the
fluid outlet nipple (7) and o-ring (8) unless damaged.
10. Unscrew the plug (AA) of the bleeder valve (33)
completely from the valve housing (BB). Do not
unscrew the valve housing from the outlet housing
(9), because the threads may gall. Clean the valve
threads and the bleed hole on the underside of the
valve housing.
11. Use a 24 in. adjustable wrench on the pump
cylinder (11) flats to unscrew it from the housing
(9). Remove the o-rings (10). Inspect the inside of
the cylinder for damage by holding it up to the light
at an angle or running a finger over the surface.
12. Inspect the surface of the displacement rod (1)
and priming piston rod (21) for wear, scoring or
other damage by running a finger over the surface.
13. Use a vise with soft jaws to hold the displacement
rod (1) by its flats. Place a 15 mm wrench on the
piston flats and unscrew the piston (13) and priming piston rod (21) from the displacement rod (1).
Remove the piston guide assembly (V) from the
piston (13), and set aside for disassembly later.
14. It is not necessary to remove the priming piston
rod (21) from the piston (13) unless you see scoring, wear, or other damage to either part. To
disassemble, place the piston flats in a vise. Using
an 8 mm wrench on the rod flats, unscrew the rod.
14308200
Page 15
Service
15. To disassemble the piston guide assembly (V),
place the flats of the piston seat (15) in a vise.
Close the jaws just tight enough to hold the part; it
can be damaged by squeezing it too tightly. Using
an 8 mm (5/16 in.) dia. brass rod, unscrew the
piston guide (12) from the piston seat (15). See
Fig. 5. Remove the piston seal (14); always replace with a new one. Inspect the mating surfaces
of the piston (13) and piston seat (15) for nicks,
scoring or wear.
15
Brass
12
Fig. 5
Rod
0205
16. To disassemble the intake check valve assembly
(U), place the nut (27) in a vise and unscrew the
intake valve body (25) from the nut, using a 25 mm
wrench. See Fig. 6. Remove the seal (30) from the
nut (27) and the other seal (26) from the valve
body; always replace them with new ones. Inspect
the mating surfaces of the intake valve body (25)
and seat (18) for wear, scoring, or other damage.
27
25
Fig. 6
NOTE: The seal (30) is press-fit in the nut (27), and
may require cutting with a razor to ease removal.
17. Inspect all parts and threads, and clean with a
compatible solvent. To reassemble, see page 17.
0206
30820015
Page 16
Service
DETAIL OF THROAT PACKINGS
4
DETAIL OF
PISTON CHECK VALVE
5
6
11 (REF)
12
1
2
3
9
33
8
7
3
BB
AA
1
2
10
11
16 (REF)
14
15
13
10
17 (REF)
21
20
24
23
22
1
Remove.
2
Leave installed; clean bleed hole on underside.
3
Remove only if damaged.
V (See detail at left.)
16
U (See detail below.)
DETAIL OF
INTAKE CHECK VALVE
30
27
25
26
17
18
19
16308200
Fig. 7
01060
Page 17
Service
Reassembly
Refer to Fig. 8 for reassembly.
1. Place an 8 mm (5/16 in.) dia. brass rod lengthwise
in a vise. Install a new piston seal (14*) on the
piston seat (15). Apply thread lubricant to the
threads of the piston guide (12). Place the piston
guide (12) securely on the brass rod. Using a 22
mm crow’s-foot, screw the piston seat (15) into the
piston guide. Torque to 35–41 N.m (26–30 ft-lb).
2. If it was necessary to remove the priming piston
rod (21) from the piston (13), apply thread lubricant
to the female threads of the piston. Place the flats
of the piston (13) in a vise. Hold the flats of the rod
with an 8 mm wrench, and screw the rod into the
piston. Torque to 35-41 N.m (26-30 ft-lb). Be
careful not to create burrs on the flats of the rod.
3. Use a vise with soft jaws to hold the flats of the
displacement rod (1). Install the assembled piston
guide/seat on the piston (13). Apply thread lubricant to the female threads of the piston, and screw
the piston assembly onto the rod, using a 15 mm
wrench on the piston flats. Torque to 35-41 N.m
(26-30 ft-lb). There will be a small gap between the
top of the piston (13) and the shoulder of the rod
(1).
4. Place the outlet housing (9) in a vise. If the bleeder
valve housing (BB) was removed, apply PTFE
tape to the threads and reinstall it in the outlet
housing (9), making sure the bleed hole faces
toward the bottom of the outlet housing. Then
screw the valve plug (AA) fully into the valve
housing (BB).
NOTE: The bleeder valve plug (AA) has two sets of
threads. When reassembling, be sure the plug is fully
screwed into the valve housing (BB).
NOTE: It is not ordinarily necessary to remove the
outlet nipple (7) and o-ring (8*). However, if they were
replaced because of damage, lubricate the o-ring (8*)
and place it on the nipple (7). Screw the nipple into the
outlet housing (9). Torque to 60-84 N.m (44–62 ft-lb).
30820017
Page 18
Service
5. Lubricate the o-rings (10*) and install them on the
cylinder (11). Apply thread lubricant to the top
threads of the cylinder. Using a 24 in. adjustable
wrench on the flats of the cylinder, screw it into the
outlet housing (9). Torque to 159–221 N.m
(117–163 ft-lb).
6. Lubricate the throat packings and glands, and
install them in the outlet housing (9) one at a time
in the following order, with the lips of the v-pack-ings facing down: male gland (6n), UHMWPE
v-packing (5n), PTFE v-packing (3n), UHMWPE
(5n), PTFE (3n), UHMWPE (5n), and female
gland (4n). Apply thread lubricant to the packing
nut (2) and install it loosely in the outlet housing.
7. Carefully insert the displacement rod (1) into the
bottom of the cylinder (11). Push the rod up into
the cylinder and through the outlet housing (9),
until it protrudes from the packing nut (2). Be
careful not to damage the piston seal (14*) while
performing this step.
8. Apply thread lubricant to the bottom threads of the
cylinder (11). Be sure the o-ring (10*) is in place on
the cylinder. Guide the intake valve housing (16)
up onto the priming piston rod (21). Screw the
valve housing onto the cylinder, using a 24 in.
adjustable wrench. Torque to 159–221 N.m
(117–163 ft-lb).
9. If the rod guide (17) was removed from the intake
valve housing (16), reinstall it with the open end
facing down toward the pump intake.
10. With the beveled side facing up, press the seal
(30*) into the recess of the intake packing nut (27)
until it snaps into place. The nose of the seal
should be flush with or slightly recessed into the
face of the packing nut. With the threads facing
down toward the pump intake, slide the nut up
onto the priming piston rod (21) until it clears the
flats of the rod.
11. Lubricate a new intake valve seal (26*) and slide it
onto the rod, being careful not to damage the seal
when passing over the flats of the rod. Slide the
seal up until it reaches the packing nut (27). Apply
thread lubricant to the female threads of the intake
valve body (25), and slide it onto the rod until it
reaches the nut (27).
12. Place a 7/8 in. wrench on the hex of the packing
nut (27) and a 25 mm wrench on the flats of the
valve body (25). Screw the nut into the body,
making certain they remain in position above the
flats of the rod (21). Torque to 35–41 N.m (26–30
ft-lb). Slide the assembled intake check valve (U)
up the priming piston rod and into the rod guide
(17) as far as possible; this may be difficult due to
high friction between the seal (26*) and rod (21).
13. Position the intake valve seat (18) so its large
beveled side faces down toward the pump intake.
Slide the seat (18) onto the priming piston rod (21)
and into the intake valve housing (16) until it seats
on the rod guide (17) . Lubricate a new seal (19*)
and push it up into the beveled gap around the
bottom outer edge of the seat (18). Be sure the
seal is fully and uniformly positioned in the gap.
14. Apply thread lubricant to the threads of the intake
cylinder (20) and screw the cylinder into the intake
valve housing (16), using a 24 in. adjustable
wrench. Torque to 159–221 N.m (117–163 ft-lb).
Installation of the intake cylinder (20) will seat the
parts of the intake valve assembly (U) securely in
the proper position.
15. Slide the priming piston guide (24) onto the rod
(21) until it stops. Then install the priming piston
(23), with the flat side facing up toward the pump.
Apply thread lubricant to the female threads of the
priming piston nut (22). Hold the rod (21) steady
with an 8 mm wrench on the flats, and screw the
priming piston nut (22) onto the rod with a 3/4 in.
wrench. Torque to 35-41 N.m (26-30 ft-lb).
16. Reconnect the displacement pump to the air motor
as explained on page 13.
18308200
Page 19
Service
DETAIL OF THROAT PACKINGS
n4
n5
7
n6
*8
7
8
DETAIL OF
PISTON CHECK VALVE
1 (REF)
11 (REF)
6
3n
1
1
Torque to 35–41 NSm (26–30 ft-lb).
2
If removed, apply PTFE tape to threads.
Bleed hole must face toward bottom of
3
outlet housing (9).
4
Torque to 159–221 NSm (117–163 ft-lb).
5
Flat side must face up.
Apply thread lubricant and torque to
6
35-41 NSm (26-30 ft-lb).
Lips of V–packings must face down.
7
Remove only if damaged. Torque to
8
60–84 NSm (44–62 ft-lb).
9
Apply lubricant to female threads.
10
Apply lubricant to threads.
11
Large bevel must face down.
AA
10*
11
1
2
9
3
33
BB
2
4
12
9
14*
1
15
9
13
10*
16 (REF)
17 (REF)
1
21
20
4
24
23
5
22
6
V (See detail at left.)
16
4
U (See detail below.)
1
10
11
DETAIL OF
INTAKE CHECK VALVE
17
*30
27
*26
25
18
Fig. 8
*19
30820019
01060
Page 20
Model 222839, Series A
23:1 Ratio Monark Pump
(includes items 101–113)
Parts
Ref.
No.Part No.DescriptionQty.
101222791AIR MOTOR, Monark1
(see 307043 for parts)
10224B190KIT, tie rod3
103184162ROD, adapter1
104184100NUT, coupling1
105184131COLLAR, coupling2
106109209NUT, hex, self-locking; with 3
nylon insert; M10 x 1.5
107222814PUMP, displacement1
(see pages 23–22 for parts)
108101946PIN, cotter1
109109212SCREW, cap, socket hd;3
(see 306982 for parts)
10224B190KIT, tie rod3
103184160ROD, adapter1
104184100NUT, coupling1
105184131COLLAR, coupling2
106109209NUT, hex, self-locking; with 3
nylon insert; M10 x 1.5
107222814PUMP, displacement1
(see pages 23–22 for parts)
108101946PIN, cotter1
113184119WRENCH, packing nut1
* These parts are included in Seal Repair Kit 222784,
which may be purchased separately.
{ These parts are included in Throat Packing Conver-
sion Kit 222786, which may be purchased separately.
n These parts are included in Throat Packing Repair
Kit 222785, which may be purchased separately.
l These parts are included in Intake Valve Repair Kit
222908, which may be purchased separately.
} Keep these spare parts on hand to reduce down
time.
30820023
Page 24
Technical Data (222839 Monark)
WARNING
Be sure that all fluids and solvents used are chemically compatible with the
Wetted Parts listed below. Always read the manufacturer’s literature before
using fluid or solvent in this pump.
CategoryData
Maximum fluid working pressure4140 psi (29 MPa, 285 bar)
Maximum air input pressure180 psi (1.2 MPa, 12 bar)
Pump cycles per 3.8 liters (1 gal.)130
Maximum recommended pump speed for continuous
operation
Maximum recommended pump speed60 cycles/min
Maximum flow at 60 cycles/min1.74 liters/min (0.46 gpm)
Air motor effective diameter76 mm (3”)
Stroke length76 mm (3”)
Displacement pump effective area2 cm@ (0.310 in.@)
Maximum pump operating temperature65.5_C (150_F)
Air inlet size3/8 npt (f)
Fluid outlet size1/2 npt (m)
Weight19.5 kg (43 lb)
Wetted partsAISI 304, 316, PH 13–8 MO, and 17–4 PH grades of
Be sure that all fluids and solvents used are chemically compatible with the
Wetted Parts listed below. Always read the manufacturer’s literature before
using fluid or solvent in this pump.
CategoryData
Maximum fluid working pressure4600 psi (32 MPa, 317 bar)
Maximum air input pressure100 psi (0.7 MPa, 7 bar)
Pump cycles per 3.8 liters (1 gal.)100
Maximum recommended pump speed for continuous
operation
Maximum recommended pump speed60 cycles/min
Maximum flow at 60 cycles/min2.28 liters/min (0.6 gpm) at 60 cycles/min
Air motor effective diameter108 mm (4.25”)
Stroke length102 mm (4”)
Displacement pump effective area2 cm@ (0.310 in.@)
Maximum pump operating temperature65.5_C (150_F)
Air inlet size1/2 npt (f)
Fluid outlet size1/2 npt (m)
Weight21.8 kg (48 lb)
Wetted partsAISI 304, 316, PH 13–8 MO, and 17–4 PH grades of
Model 222907 PRESIDENT PUMPModel 222839 MONARK PUMP
7.9 mm
(0.312”)
diameter (2)
diameter (3)
11.4 mm
(0.449”)
63.5 mm
(2.50”)
54.1 mm
(2.130”)
31.25 mm
(1.230”)
62.50 mm
(2.461”)
63.5 mm
(2.50”)
62.50 mm
(2.461”)
38.5 mm
(1.516”)
31.2 mm
(1.230”)
11.4 mm
(0.449”)
diameter (3)
54.1 mm
(2.131”)
02130214
22.2 mm
(0.875”)
44.5 mm
(1.750”)
7.1 mm
(0.281”)
diameter (2)
30820029
Page 30
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 substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the 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 reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Graco Phone Numbers
TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers
to identify the distributor closest to you:
1–800–328–0211 Toll Free
612–623–6921
612–378–3505 Fax
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
30308200
This manual contains English. MM 308200
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC.P.O. BOX 1441MINNEAPOLIS, MN55440–1441
Copyright 1992, Graco Inc. is registered to ISO 9001
www.graco.com
Revised 12/2008
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