Graco 237010, 220666, 237013, 237012, 237011 User Manual
...
Instructions–Parts List
STAINLESS STEEL OR CARBON STEEL
Air–Powered Gluttonr
Pumps
100 psi (0.7 MPa, 7 bar) Maximum Incoming Air Pressure
400 Series Pumps
400 psi (2.8 MPa, 28 bar) Maximum Fluid Working Pressure
Model 220663, Series D
Model 237008, Series A
Carbon steel pumps*
Model 220666, Series D
Model 237011, Series A
Stainless steel pumps*
Electro-polished for use with waterborne coatings
1200 Series Pumps
1200 psi (8 MPa, 83 bar) Maximum
Fluid Working Pressure
Model 220664, Series D
Model 237009, Series A
Carbon steel pumps*
307843ZAF
EN
Model 220667, Series D
Model 237012, Series A
Stainless steel pumps*
Electro-polished for use with waterborne coatings
2500 Series Pumps
2500 psi (17 MPa, 170 bar) Maximum Fluid
Working Pressure
Model 220665, Series D
Model 237010, Series A
Carbon steel pumps*
Model 220668, Series D
Model 237013, Series A
Stainless steel pumps*
Electro-polished for use with waterborne coatings
*See TECHNICAL DATA on pages 44 through 46
for a complete materials list.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing and List
400 Series Carbon Steel Pumps, Models 220663 and 237008 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400 Series Stainless Steel Pumps, Models 220666 and 237011 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1200 Series Carbon Steel Pumps, Models 220664 and 237009 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1200 Series Stainless Steel Pumps, Models 220667 and 237012 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2500 Series Carbon Steel Pumps, Models 220665 and 237010 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2500 Series Stainless Steel Pumps, Models 220668 and 237013 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Control Valve 220902 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Valve 221133 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair and Conversion Kits 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Regulator, Lubricator Kit 222345 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Cover Kit 222655 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Tube Kit 223319 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Kit 208259 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data and Performance Chart
400 Series Pumps 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1200 Series Pumps 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2500 Series Pumps 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Drawing 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 307843
Warnings
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
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.
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 at anyone or at any part of the body.
D Do not put your hand or fingers over the spray tip.
D Do not stop or deflect leaks with your hand, body, glove or rag.
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 Do not “blow back” fluid; this is not an air spray system.
D Always have the tip guard and the trigger guard on the gun when spraying.
D Check the gun diffuser operation weekly. Refer to the gun manual.
D Be sure the gun trigger safety operates before spraying.
D Lock the gun trigger safety when you stop spraying.
D Follow the Pressure Relief Procedure on page 10 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
D Tighten all fluid connections before operating the equipment.
D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Perma-
nently coupled hoses cannot be repaired; replace the entire hose.
D Use only Graco approved hoses. Do not remove the spring guard that is used to help protect the
hose from rupture caused by kinks or bends near the couplings.
307843 3
INSTRUCTIONS
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
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.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data section on pages 44 through 46 for the maximum working pressure of this equipment.
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 Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
D Never place your hands on or near the pump fluid inlet. Powerful suction could cause serious
bodily injury.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers or other body parts.
D Keep clear of all moving parts when starting or operating the equipment.
D Before servicing the equipment, follow the Pressure Relief Procedure on page 10 to prevent the
equipment from starting unexpectedly.
D Never operate the motor with the pump housing removed.
4 307843
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. See Grounding on page 7.
D Proper hose grounding continuity is essential in maintaining a grounded spray/dispense system.
Check the electrical resistance of your air and fluid hoses at least once a week. If your hose does
not have a tag on it that specifies the maximum electrical resistance, contact the hose supplier or
manufacturer for the maximum resistance limits. Use a resistance meter in the appropriate range
for your hose to check the resistance. If the resistance exceeds the recommended limits, replace it
immediately.
D 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.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
D Keep the spray area free of debris, including solvent, rags, and gasoline.
D Electrically disconnect all equipment in the spray area.
D Extinguish all open flames or pilot lights in the spray area.
D Do not smoke in the spray area.
D Do not turn on or off any light switch in the spray area while operating or if fumes are present.
D Do not operate a gasoline engine in the spray area.
HAZARDOUS FLUIDS
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
D Be sure all fluids and solvents used are chemically compatible with the wetted parts shown in the
TECHNICAL DATA for your pump model. Always read the fluid and solvent manufacturer’s literature before using the fluid or solvent in this pump.
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.
D Provide for safe piping and disposal of exhaust air.
D Secure the fluid outlet house tightly into the receiving container to prevent the hose from coming
loose and creating a fluid spill.
D Provide proper ventilation in accordance with accepted industry standards and government regula-
tions.
United States Government safety standards have been adopted under the Occupational Safety and Health Act. You
should consult these standards – particularly the General Standards, Part 1910, and the Construction Standards,
Part 1926.
307843 5
Installation
Mounting the Pump
D 400 and 1200 Series Pumps: Mount the pump
with the accumulators in the top position as shown
in Fig. 1. The accumulators must be in the position
shown or the pump will not prime.
D Be sure the pump is securely bolted to its mounting
and that the mounting can support the weight of the
pump, hoses, and stress caused during operation.
D The outlet manifold can be removed and turned 180
degrees to change the direction of the outlet and
ease installation, as shown in Fig. 3.
accumulators
General Information
D The installation shown in Fig. 4 is only a guide for
selecting and installing system components. Contact your Graco distributor for assistance in planning a system to suit your needs.
D See pages 38 through 43 for accessories and kits
available from Graco. Always use Genuine Graco
Parts and Accessories.
D Use a thread sealant compatible with the fluid being
pumped on all male pipe threads. Tighten all connections firmly to avoid air or fluid leaks.
D Reference numbers and letters in parentheses in
the text refer to the figure illustrations.
Fig. 1
6 307843
02321
Installation
Grounding
WARNING
This pump must be grounded. The steps for
grounding may differ from the way you ground
other pumps. Carefully read and follow these
grounding instructions. See FIRE AND EXPLO-
SION HAZARD on page 5 before you operate the
pump.
Static electricity is created by the high-velocity flow of
fluid through the pump and hose. If every part of the
equipment is not properly grounded, sparking may occur. To reduce the risk of static sparking, ground the
pump and all other equipment used or located in the
pumping area. Check your local electrical code for detailed grounding instructions for your area and type of
equipment. Ground all of the following equipment:
D Pump: use a ground wire and clamp as shown in
Fig. 2.
D Fluid and air hoses: use only grounded hoses with
a maximum of 500 feet (150 m) combined hose
length to ensure grounding continuity.
D Air Compressor: Follow the manufacturer’s recom-
mendations.
D Spray gun or dispensing valve: Obtain grounding
through connection to a properly grounded fluid
hose and pump.
D Fluid supply container: Follow the local code.
D Object being sprayed: Follow the local code.
D All solvent pails used when flushing: Follow the
local code. Use only metal pails, which are conductive. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which interrupts the grounding continuity.
To ground the pump: Loosen the grounding lug locknut (W) and washer (X). Insert one end of a 12 ga (1.5
mm@) minimum ground wire (Y) into the slot (Z) of the
grounding lug, and tighten the locknut securely. Connect the clamp end of the ground wire to a true earth
ground. To order a ground wire and clamp, order Part
No. 222011.
Fig. 2
grounding lug
Y
W
X
Z
02322
307843 7
5
Installation
Connect the Fluid Lines
1. Use grounded fluid hoses.
a. The pump fluid outlet (J) on the 400 and
1200 Series Pumps is 1 npt(f) .
b. The pump fluid outlet (J) on the 2500 Series
Pump is 3/4 npt(f).
2. Install a fluid filter (F) and drain valve (E) near the
fluid outlet. See Fig. 3.
WARNING
A fluid drain valve (E) is required in your system to
relieve pressure in the fluid outlet hose (H) if the
hose becomes plugged. See Fig. 3. Install a drain
valve close to the pump’s fluid outlet. The drain
valve reduces the risk of property damage or
serious bodily injury, including splashing in the eyes
or on the skin, or contamination from hazardous
fluids.
3. Install a control device, such as a gun, dispensing
valve, or shutoff valve, on the grounded fluid
hose (H).
Connect the Fluid Suction Line
CAUTION
The pump must be suction fed in order to operate
properly. Pressure feeding or exceeding 15 psi (104
kPa, 1.04 bar) maximum fluid inlet pressure may
cause premature bellows seal failure.
Connect the fluid suction hose (S) to the pump fluid
inlet (M). See Fig. 4.
D The pump fluid inlet (M) is 1.25 npt(f).
D The maximum suction lift is 15 ft (4.57m) for the
400 Series and 1200 Series Pumps, and 6 ft (1.83
m) for the 2500 Series Pump.
WARNING
SUCTION HAZARD
Never place your hands on or near the pump fluid
inlet. Powerful suction could cause serious bodily
injury.
Fig. 3
J
H
F
M
E
0232
8 307843
Installation
3
Connect the Air Lines
1. Install the air line accessories to the left of the
pump as shown in Fig. 4. Mount these accessories
on the wall or on a bracket. Be sure the air line
supplying the accessories is grounded.
2. Install a flexible air hose between the accessories
and the 1/2 in. npt(f) air inlet (G). Use a minimum
1/2 in. ID air hose.
3. Install an air line lubricator (B) upstream from the
pump air inlet for automatic pump lubrication.
4. Install a pump runaway valve (T) to sense when
the pump is running too fast and shut off the air
supply to the motor. To order a pump runaway
valve, order Part No. 224040.
5. Install an air regulator (D) to control air inlet pressure.
WARNING
A bleed-type master air valve (C) is required in
your system to relieve air trapped between this
valve and the pump after the air regulator is closed.
Trapped air can cause the pump to cycle unexpectedly, which could result in serious bodily injury,
including splashing in the eyes, injury from moving
parts, or contamination from hazardous fluids.
6. Install one bleed-type master air valve (C) downstream from the air regulator and use it to relieve
trapped air. Locate the other master air valve upstream from all air line accessories and use it to
isolate the accessories during cleaning and repair.
7. Install an air line filter (A) to remove harmful dirt
and moisture from your compressed air supply.
8. Install a grounded air supply line (P) with a minimum 1/2 in. ID. See Fig. 4.
Ventilate the Air Exhaust
WARNING
Improper handling of hazardous fluids or inhaling
their vapors can cause serious bodily injury, even
death. For your safety, it is imperative that you read
all product warning labels and Material Safety Data
Sheets (MSDS) for the fluids you are using. An
MSDS can be obtained from your fluid suppliers. It
is also important that you read and understand the
warnings and precautions regarding HAZARDOUS
FLUID HAZARD on page 5 before you operate.
All systems using hazardous fluid in enclosed
areas or within buildings should have a properly
designed and installed ventilation system. Consult
your local building code and other industrial and
governmental standards for proper design criteria.
K
C
KEY
A Air line filter
B Air line lubricator
C Bleed-type master air valve
D Air regulator
E Fluid drain valve
F Fluid filter
G Pump air inlet
H Grounded fluid line
J Outlet manifold
Fig. 4
T
D
AB
K Main air line
L Ground wire
M Intake manifold
N Glutton pump
P Grounded air line
R Fluid supply
S Fluid suction hose
T Runaway valve
L
G
C
P
N
JF
M
E
S
R
H
0232
307843 9
Operation
Pressure Relief Procedure
WARNING
The system pressure must be manually relieved to
prevent the system from starting or spraying accidentally. To reduce the risk of an injury from accidental spray from the gun, splashing fluid, or
moving parts, always follow the Pressure Relief
Procedure whenever you
D are instructed to relieve the pressure
D Stop spraying
D Check or service any of the system equipment
D install or clean the spray nozzle.
1. * Engage the spray gun or dispensing valve safety
latch.
2. Shut off the air supply.
3. * Disengage the gun or dispensing valve safety
latch.
4. * Hold a metal part of the gun or valve firmly to a
grounded metal waste container and trigger it to
relieve the fluid pressure.
5. * Engage the safety latch again.
6. Open the pump drain valve (required in system),
and have a container ready to catch the drainage.
7. Leave the drain valve open until you are ready to
spray again.
* Applies only when using a spray gun or dispensing
valve.
Start and Adjust the Pump
NOTE: Check all fittings to be sure they are tight. Be
sure to use a thread sealant compatible with the fluid
being pumped on all male pipe threads.
1. Place the suction hose (S) in the fluid to be
pumped. See Fig. 5.
2. Close the fluid drain valve (E).
3. With the air regulator (D) closed, open both bleedtype master air valves (C).
4. Open the fluid control device while continuing with
the following steps.
5. Slowly open the air regulator (D). Adjust it until the
pump runs smoothly.
6. Allow the pump to cycle slowly until all air is
pushed out of the lines (the fluid will be flowing in a
steady stream from the fluid outlet) and the pump
is primed.
WARNING
To reduce the risk of component rupture, which
could cause serious bodily injury, never exceed
100 psi (0.7 MPa, 7 bar) air supply pressure to the
pump. Read the warning section EQUIPMENT
MISUSE HAZARD on page 4.
If you suspect that the spray tip, nozzle, or hose is
clogged or that pressure has not been fully relieved
after following the steps above, very slowly loosen the
hose end coupling and relieve pressure gradually, then
loosen completely, then clear the tip, nozzle, or hose
obstruction.
Flush the Pump Before First Use
WARNING
To reduce the risk of fluid injection injury, static
sparking and splashing, read and follow Flushing
Safety under FIRE OR EXPLOSION HAZARD on
page 5.
The pump was tested with lightweight oil, which is left
in to protect the pump parts. If this solution could contaminate the fluid you are pumping, flush it thoroughly
with a compatible solvent. To start the pump, follow the
procedure in Start and Adjust the Pump, below.
10 307843
Operation
3
7. If you are flushing:
a. Run the pump long enough to thoroughly clean
the pump and hoses.
b. Close the fluid control device and air regulator
(D).
c. Remove the suction hose (S) from the solvent
and place it in the fluid to be pumped.
8. If you are going to use the pump:
a. Start the pump. Be sure the suction hose is in
the supply container.
b. If you are using this pump to spray fluid, re-
lieve the pressure, then install a spray tip in
the gun. Trigger the gun into a grounded metal
waste container to prime the hose. Adjust the
pump pressure just enough to completely atomize the fluid. Higher pressures cause premature spray tip and pump wear.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of a serious injury whenever you
are instructed to relieve pressure, follow the Pres-
sure Relief Procedure on page 10.
c. In a direct supply system, the pump will start
and stop as the spray gun, dispensing valve,
or fluid outlet valve is opened and closed.
d. In a circulating system, the pump runs continu-
ously and speeds up or slows down as supply
demands until the air supply is shut off.
CAUTION
Never allow the pump to run dry of fluid. A dry pump
will accelerate to a high speed, possibly damaging
itself. If your pump accelerates quickly, or is running
too fast, stop it immediately and check the fluid
supply. If the supply is empty and air has been
pumped into the lines, refill the container and prime
the pump and lines with fluid, or flush and leave filled
with compatible solvent. Be sure to eliminate all air
from the system. A Pump Runaway Valve, Part No.
224040, is available.
9. If you are shutting down the pump:
a. Flush the pump before shutting down, espe-
cially if pumping a material that will set up.
b. Remove the suction hose from the fluid con-
tainer and run the pump until the fluid is forced
out of the system, then shut off the air supply
immediately.
c. Relieve the pressure.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of a serious injury whenever you
are instructed to relieve pressure, follow the Pres-
sure Relief Procedure on page 10.
d. Refer to the Maintenance instructions on
page 14.
Fig. 5
C
D
C
E
S
0232
307843 11
Troubleshooting
Relieve the pressure, and check all probable causes
before disassembling the pump.
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of a serious injury whenever you
are instructed to relieve pressure, follow the Pres-
sure Relief Procedure on page 10.
SYMPTOM PROBABLE CAUSE TEST PROCEDURE REMEDY
1. Pump will not
prime
Air is getting into the intake
housing:
a. Defective o-ring (19) on in-
take manifold or accumulator
WARNING
a. Replace o-ring.
See page 15.
2. Pump will not
run
b. Suction hose/tube not
sealed
a. Air supply turned off
b. Fluid valve turned off
c. Air pressure regulator
set too low
d Pilot valve assemblies
worn
e. Air control valve
defective
f. Air piston quad ring (28)
worn
c. Minimum air pressure
on regulator 25 psi (175
kPa, 1.95 bar), depending on fluid being
pumped
d. Remove tube ends from
hose studs. With air
supply on, alternately
plug tube ends. If pump
runs, remove pilot
valves, inspect
e. Check for air coming
from exhaust when
pump is not running
b. Tighten, or add
sealant to threads
a. Turn air supply on
b. Turn fluid supply
valve on
c. Increase air pressure
regulator adjustment
d. Repair or replace pilot
valve assembly. See
page 22.
e. Repair or replace air
control valve. See page
20.
f. Replace quad ring. See
page 18.
12 307843
Troubleshooting
SYMPTOM PROBABLE CAUSE TEST PROCEDURE REMEDY
3. Pump runs but
does not maintain constant
pressure
a. Air in fluid line
b. Air line too small
a. Check for spitting at
fluid line outlet
a. Bleed fluid line until con-
stant flow is
obtained
b. Install larger air line,
minimum size 1/2 in.
4. Paint dripping
externally
around piston
rod
c. Obstructed or worn ball
(57) and seat (49)
d. Worn fluid piston (17)
and/or piston seal (13)
e. Air control valve
mufflers (38) plugged
f. Air control valve dirty or
worn
g. Lack of lubrication
h. Dirty air passages
a. Ruptured bellows seal
(14)
c. Pump fast cycles on
one end of stroke
indicates that side is bypassing
d. Pump fast cycles on
one end of stroke
indicates that side is bypassing
e. Check for slow air flow
at muffler
g. Pump reacts slowly
h. Check for sluggish air
control valve operation
a. Check for presence of
paint around piston
shaft (15)
c. Remove, clean, and in-
spect seat, ball, and ball
guide (56). Replace if
worn. See page 15.
d. Replace piston and/or
seal. See page 16.
e. Remove and clean muf-
flers
f. Repair or replace air
control valve. See page
20.
g. Adjust lubricator
h. Clean air passages; do
not enlarge orifices.
Empty air line filter and/
or control valve filter
(40q). See step 5 in Disassembly on page 20.
a. Replace bellows seal.
See page 16. Be sure
to suction feed, not
pressure feed, pump.
Maximum fluid inlet
pressure is 15 psi (104
kPa, 1.04 bar)
307843 13
Maintenance
Flush the Pump With Compatible Solvent
WARNING
To reduce the risk of fluid injection injury, static
sparking and splashing, read and follow Flushing
Safety under FIRE OR EXPLOSION HAZARD on
page 5.
1. Flush often enough to prevent fluid from drying in
the pump and damaging it.
2. Always flush before storing.
a. If you are pumping water-based fluid, first flush
the pump with water, then with mineral spirits
or a compatible oil-based solvent.
b. Leave the mineral spirits or oil-based solvent
in the pump to protect the pump parts from
corrosion.
3. Be sure to eliminate all air from the system.
Tighten Threaded Connections
1. Before each use, check all hoses for wear or damage and replace as necessary. Be sure all
threaded connections are tight, and leak-free.
2. At least every six months, check and tighten all
threaded connections, including manifold screws,
clamps, plugs, and valve screws.
Check and Service the Lubricator, Regulator, and Filter
Check and service according to the instructions supplied with them. See Manual 308169 for oil recommendations.
14 307843
Service
Repairing the Ball Check Valves
NOTE: Parts marked with an asterisk are included in a
repair kit, for example, (54*). See pages 38 and 39 for
repair kit part numbers. Use all the parts in the kit for
the best results.
Disassembly
1. Relieve the pressure.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of a serious injury whenever you
are instructed to relieve pressure, follow the Pres-
sure Relief Procedure on page 10.
2. Disconnect the air and fluid lines, remove the
pump from its mounting, and place it on a bench.
3. Remove the cap (53) from each side of the outlet
housing (33). See Fig. 6.
4. Remove the ball guide (56), ball (57), valve seat
(49), and o-ring (48*) on each side of the outlet
housing.
Disassembly
1. Relieve the pressure.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of a serious injury whenever you
are instructed to relieve pressure, follow the Pres-
sure Relief Procedure on page 10.
2. Loosen the tube nuts (A) and remove the outlet
manifold (50). Unscrew the connectors (51). Remove the o–ring (52). See Fig. 6.
3. Remove the screws (34), washers (35), outlet
housing (33), piston seal (13*) and retaining plate
(12). Remove the o–ring (18). Repeat on the other
side of the pump.
5. Inspect the ball stop (55) inside the cap (53) for
wear. Remove o–ring (54). Replace if necessary.
6. Clean all parts and inspect for wear or damage.
Replace as needed.
Assembly
1. Lubricate the o-rings (48*) and place one in the
groove on each valve seat (49).
2. Install the valve seat (49) with the o-ring (48) facing down, ball (57), and ball guide (56) into each
outlet housing (33).
NOTE: Stainless steel seats are reversible.
3. Lubricate the o-rings (54*) and the cap (53)
threads. Place one o-ring on each cap. Screw the
caps into the housing and torque them to 55 to 85
ft-lb (75 to 115 NSm).
NOTE: On stainless steel pumps (Models 220666
through 220668 and Models 237011 to 237013), apply
anti-seize lubricant to the threads of the cap (53).
Repairing the Fluid Piston and Seal
4. Holding the screw (16) on one side of the pump,
loosen the screw three or four turns on the opposite side of the pump, using a socket and breaker
bar.
5. Remove the piston (17) by grasping it with your
hand and and hit screw (16) with a plastic mallet to
drive piston loose from shaft. Remove screw (16)
and piston (17).
6. Remove the screws (32), washers (46 or 61), and
inlet manifold (47). Remove o–rings (19).
7. Remove the intake housing (36), bellows (14*),
and retaining plate (20).
8. Holding the piston shaft (15) flats with a wrench,
remove the remaining screw (16).
NOTE: Parts marked with an asterisk are included in a
repair kit, for example, (52*). See pages 38 and 39 for
repair kit part numbers. Use all the parts in the kit for
the best results.
9. Repeat steps 6 and 7 on the opposite end of the
pump. Clean all parts and inspect for wear or damage. Replace as needed.
307843 15
Loading...