Graco 239140, 223596 User Manual

Page 1
Instructions–Parts List
HYDRA–SPRAY
R
Monarkr and Presidentr Pumps
For airless and air–assisted spraying of finishing materials. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
See page 2 for Table of Contents
Part No. 223596, Series B 23:1 Ratio Monarkr Pump
with Part No. 223595 carbon steel severe–duty displacement pump* with stainless steel glands, intake housing, piston valve, and ball stop
2760 psi (19 MPa, 190 bar) Maximum Fluid Working Pressure 120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
307619ZAA
ENG
II 1/2 G T3
ITS03ATEX11228
Part No. 237958, Series B 23:1 Ratio Monarkr Pump
with Part No. 239145 stainless steel severe–duty displacement pump*
3450 psi (24 MPa, 238 bar) Maximum Fluid Working Pressure 150 psi (1.0 MPa, 10.4 bar) Maximum Air Input Pressure
II 1/2 G T3
ITS03ATEX11228
Part No. 239140, Series A 46:1 Ratio Presidentr Pump
with Part No. 239145 stainless steel severe–duty displacement pump*
4600 psi (32 MPa, 317 bar) Maximum Fluid Working Pressure 100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure
II 2 G T6
* Severe–duty displacement pumps have abrasion–resistant
displacement rods and sleeves. Refer to Technical Data on page 20 for information on the wetted parts.
Model 223596
06936
Model 239140
02097
Page 2
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service
Disconnecting the Displacement Pump 11. . . . . . . .
Reconnecting the Displacement Pump 11. . . . . . . .
Displacement Pump Service 12. . . . . . . . . . . . . . . . .
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.
Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conversion Kits 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 19. . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 24. . . . . . . . . . . . . . . . . . . . . .
Graco Information 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 on page 20 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 180_F (82_C) or below –40_F (–40_C).
D Wear hearing protection when operating this equipment.
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
2 307619
Page 3
WARNING
SKIN INJECTION HAZARD
Spray from the gun, 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 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.
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 8 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, 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 air motor piston, can pinch or amputate your fingers.
D Keep clear of all moving parts when starting or operating the pump.
D Before servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the
equipment from starting unexpectedly.
307619 3
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 5.
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.
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.
4 307619
Page 5
Installation
NOTES:
D Reference numbers and letters in parentheses in
the text refer to the callouts in the figures and drawings.
D Always use Genuine Graco Parts and Accessories,
available from your Graco distributor. If you supply your own accessories, be sure they are adequately sized and pressure-rated to meet the system’s requirements.
D 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.
Prepare the Operator
All persons who operate the equipment must be trained in the safe, efficient operation of all system components as well as the proper handling of all fluids. All operators must thoroughly read all instruction manuals, tags, and labels before operating the equipment.
Prepare the Site
Ensure that you have an adequate compressed air supply. Refer to the performance charts on pages 21 and 23 to find the air consumption of your sprayer.
Mount the pump (A) to suit the type of installation planned. The pump dimensions and mounting hole layout are shown on page 19.
Keep the site clear of any obstacles or debris that could interfere with the operator’s movement.
Have a grounded, metal pail available for use when flushing the system.
Grounding
D Pump: Use a ground wire and clamp. See Fig.1.
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 in lug (Z) and tighten the locknut securely. Connect the other end of the wire to a true earth ground. For a ground wire and clamp, order Part No. 237569.
Z
Y
X
W
0720
Fig. 1
D Air and fluid hoses: Use only electrically conductive
hoses with 500 ft (150 m) maximum combined hose length to ensure grounding continuity.
D Air compressor: Follow manufacturer’s
recommendations.
D Spray gun or dispensing valve: Connect to a
properly grounded fluid hose and pump.
D Object being sprayed: Follow your local code.
D Fluid supply container: Follow your local code.
D 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.
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the system as explained below. Also read the section FIRE AND EXPLOSION HAZARD on page 4.
D To maintain proper grounding continuity when
flushing or relieving pressure, always hold the metal
part of the spray gun firmly to the side of a grounded metal pail, then trigger the gun.
307619 5
Page 6
Typical Installation
Installation
KEY A Pump
B Wall bracket C Air line lubricator D Bleed-type master air valve (required for pump)
See Warning on page 7 for part number.
E Pump air regulator F Air line filter G Bleed-type master air valve (for accessories) H Electrically conductive air supply hose J Fluid drain valve (required)
See Warning on page 7 for part numbers.
K Fluid filter L Electrically conductive fluid supply hose M Spray gun N Fluid suction hose P Air Line Moisture Trap and Drain Valve Y Ground wire (required)
Part No. 237569. See page 5 for installation instructions.
FG
H
CDE
A
Y
M
B
P
K
Fig. 2
J
N
L
02098
6 307619
Page 7
Installation
System Accessories
WARNING
A bleed-type master air valve (D) and a fluid drain valve (J) are required in your system. These accessories help 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.
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. Order Part No. 113333.
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. Order one of the following:
Part No. Description 238635 1/4 npt (mbe), carbon steel
210657 1/4 npt (mbe), carbon steel 210658 3/8 npt (mbe), carbon steel 210659 1/4 npt x 3/8 npt (mbe), carbon steel 239018 1/4 npt (mbe), stainless steel 235992 1/4 npt x 3/8 npt (mbe), stainless steel
Air and Fluid Hoses
Be sure all air and fluid hoses are properly sized and pressure-rated for your system. Use only electrically conductive air and fluid hoses. Use a 1/2 in. (13 mm) I.D. (minimum) air hose (H) to supply air to the pump.
Fluid hoses must have spring guards on both ends. Connect a fluid hose (L) to the pump’s 3/8 npt(f) fluid outlet. Use of a short whip hose between the main fluid hose and the gun (M) allows freer gun movement. Connect a fluid suction hose or tube (N) to the pump’s 3/4 npt(m) fluid intake.
Air Line Accessories
Install the following accessories in the order shown in Fig. 2, using adapters as necessary:
D Air line lubricator (C)
Provides automatic air motor lubrication.
D Bleed-type master air valve (D)
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 downstream from the air regulator (E).
D Air regulator (E)
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).
D Air line filter (F)
Install an air line filter (F) and a moisture trap and drain valve (P) to help remove moisture and contaminants from the compressed air supply.
D Second bleed-type air valve (G)
Isolates the air line accessories for servicing. Locate upstream from all other air line accessories.
Fluid Line Accessories
Install the following accessories in the positions shown in Fig. 2, using adapters as necessary:
D Fluid drain valve (J)
Required in your system to relieve fluid pressure in the hose and gun (see the WARNING at left). Install the drain valve so that it points down and the handle points up when it is opened.
D Fluid filter (K)
Filters harmful particles from the fluid.
D Spray gun (M)
Dispenses the fluid. The gun shown in Fig. 2 is an airless spray gun.
307619 7
Page 8
Operation
Pressure Relief Procedure
WARNING
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:
D are instructed to relieve the pressure, D stop spraying, D check or service any of the system equipment, D or install or clean the spray tip.
1. Lock the gun trigger safety.
2. Shut off the air supply to the pump.
3. Close the bleed-type master air valve (required in your system).
4. Unlock the gun trigger safety.
Packing Nut/Wet-Cup
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure at left.
Keep the packing nut/wet-cup (104) filled with Graco Throat Seal Liquid (TSL) or compatible solvent to help prolong the packing life. Ensure weekly that the packing nut is torqued to 18 to 20 ft-lb (24 to 27 N.m); do not overtighten it. See Fig. 3 on page 11. Relieve the pressure before adjusting the packing nut or adding TSL.
Starting and Adjusting the Pump
Begin these steps before you install the spray tip.
1. Ensure that the air regulator (E) and bleed-type master air valve (D) are closed. See Fig. 2 on page 6.
2. Connect a suction hose (N) to the pump’s fluid inlet, or lower the pump into a fluid supply container.
5. Hold a metal part of the gun firmly to the side of a grounded metal pail, and trigger the gun to relieve pressure.
6. Lock the gun trigger safety.
7. Open the drain valve (required in your system), and have a container ready to catch the drainage.
8. Leave the drain valve open until you are ready to spray again.
If you suspect that the spray tip 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 it completely. Then clear the tip or hose.
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 before using the pump. If the pump is being used to supply a circulating system, allow the solvent to circulate until the pump is thoroughly flushed. See Flushing the Pump on page 9.
3. Hold a metal part of the spray gun (M) firmly to the side of a grounded metal pail and hold the trigger open.
4. Open the pump’s bleed-type master air valve (D).
5. Slowly open the air regulator (E) until the pump starts (approximately 40 psi [0.28 MPa, 2.8 bar]).
6. Cycle the pump slowly until all the air is pushed out and the pump and hoses are fully primed.
7. Release the spray gun trigger and lock the trigger safety. The pump should stall against pressure when you release the trigger.
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure at left.
8. Relieve the pressure.
9. Install the spray tip in the gun.
Continued on page 9.
8 307619
Page 9
WARNING
Operation
Flushing the Pump
COMPONENT RUPTURE HAZARD
To reduce the risk of overpressurizing your system, which could cause component rupture and serious injury,
never exceed the specified maximum air input pressure to the pump (see Technical Data on
page 20).
10. Control the pump speed and fluid pressure with the air regulator (E). Always use the lowest air pressure necessary to get the desired results. Higher pressure causes premature spray tip and pump wear.
11. With the pump and lines primed, and with adequate air pressure and volume supplied, the pump starts and stops as the spray gun is opened and closed. In a circulating system, the pump runs continuously and speeds up or slows down as supply increases or decreases until the air supply is shut off.
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 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.
Shutdown and Care of the 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.
WARNING
FIRE AND EXPLOSION HAZARD Before flushing, read the section FIRE AND EXPLOSION HAZARD on page
4. Be sure the entire system and flushing pails are properly grounded. Refer to Grounding on page 5.
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.
CAUTION
Never leave water or water-base fluid in the pump overnight. If you are pumping water-base fluid, flush with water first, then with a rust inhibitor such as mineral spirits. Relieve the pressure, but leave the rust inhibitor in the pump to protect the parts from corrosion.
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. Remove the spray tip from the gun.
3. Hold a metal part of the gun 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.
For overnight shutdown, relieve the pressure, and always stop the pump at the bottom of the stroke to prevent the fluid from drying on the exposed displacement rod and damaging the throat packings.
Always flush the pump before the fluid dries on the displacement rod. See Flushing the Pump.
6. Flush the system until clear solvent flows from the gun.
7. Relieve the pressure.
307619 9
Page 10
Troubleshooting
1. Relieve the pressure.
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
Problem Cause Solution
Pump fails to operate. Restricted line or inadequate air
supply.
2. Check all possible problems and solutions before disassembling pump.
Clear; increase air supply.
Pump operates but output is low on both strokes.
Pump operates but output is low on downstroke.
Insufficient air pressure; closed or clogged air valves, etc.
Exhausted fluid supply. Refill; purge all air from pump and
Damaged air valve; stalling. Service air motor (see air motor
Dried fluid seizure of displacement rod (103).
Restricted line or inadequate air supply.
Insufficient air pressure; closed or clogged air valves, etc.
Exhausted fluid supply. Refill; purge all air from pump and
Clogged fluid line, valves, etc. Clear* (be sure to use fluid filter). Packing nut (104) is too tight. Loosen (see page 8). Loose packing nut (104) or worn
throat packings (114, 123). Held open or worn intake valve. Clear; service. See page 12.
Open; clean (be sure to use air filter).
fluid lines.
manual, supplied). Clean, check or replace throat pack-
ings (114, 123); always stop pump at bottom of stroke and keep wet-cup filled with compatible solvent.
Clear; increase air supply.
Open; clean (be sure to use air filter).
fluid lines.
Tighten packing nut (see page 8); replace throat packings.
Pump operates but output is low on upstroke.
Erratic or accelerated operation. Exhausted fluid supply. Refill; purge all air from pump and
* To determine if the fluid hose or gun is obstructed, relieve the pressure and 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 to 40 psi [0.14 to 0.28 MPa, 1.4 to 2.8 bar]). If the pump starts when the air is turned on, the obstruction is in the fluid hose or gun.
10 307619
Held open or worn fluid piston valve or packings (115, 124).
Held open or worn intake valve. Clear; service. See page 12. Held open or worn fluid piston valve
or packings (115, 124).
Clear; service. See page 12.
fluid lines.
Clear; service. See page 12.
Page 11
Service
Disconnecting 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.
1. Flush the pump if possible. Stop the pump at the bottom of its stroke. Relieve the pressure.
2. Disconnect the air and fluid hoses. Remove the pump from its mounting. Note the relative position of the fluid outlet (R) to the air inlet (S). See Fig. 3.
3. Unscrew the tie rod locknuts (4) from the tie rods (10). Remove the cotter pin (3). Carefully pull the displacement pump (13) off the air motor (12). Unscrew the displacement rod (103) from the air motor (12) or adapter (5, President Pump only). Inspect the o-ring (6).
4. Refer to page 12 for displacement pump service. To service the air motor, refer to the separate air motor manual, which is supplied.
Reconnecting the Displacement Pump
1. Lubricate the o-ring (6) and check that it is in place on the displacement rod (103).
2. Orient the fluid outlet (R) to the air inlet (S) as noted in step 2 under Disconnecting the Displacement Pump. Position the displacement pump (13) on the tie rods (10). See Fig. 3.
3. Screw the displacement rod (103) into the shaft of the air motor (12) or the adapter (5, President Pump only) until the pin holes are aligned. Screw the locknuts (4) onto the tie rods (10) loosely. Install the cotter pin (3).
4. Mount the pump and reconnect all hoses. Reconnect the ground wire if it was disconnected during repair. Torque the packing nut (104) to 18 to 20 ft-lb (24 to 27 N.m). Fill the wet-cup with Graco Throat Seal Liquid or compatible solvent.
5. Tighten the tie rod locknuts (4) evenly, and torque as specified in Fig. 3. Start the pump and run it at about 40 psi (0.28 MPa, 2.8 bar) air pressure, to check that it is operating properly.
Monark Models 223596 (shown) and 237958
1
6
103
4
104
R
1
Lubricate.
2
Torque to 10 to15 ft-lb (14 to 20 N.m).
3 Torque to 20 to 30 ft-lb (27 to 41 N.m). 4 Torque to 18 to 20 ft-lb (24 to 27 N.m).
S
President Model 239140 (shown)
12
10
2
3
4
2
13
S
12
5
10
3
3
1
6
103
104
4
4
3
R
13
Fig. 3
02099
06938
307619 11
Page 12
Service
Displacement Pump Service
Disassembling
When disassembling the pump, lay out all removed parts in sequence to make reassembling easier. Refer to Fig. 4.
NOTE: Repair Kits and Conversion Kits are available. Refer to the parts list for your pump (pages 14 to 17). For the best results, use all the new parts in the kit. Parts included in the kit are marked with one asterisk (for example, 3*).
Clean all the parts thoroughly when disassembling. Check them carefully for damage or wear, and replace parts as needed.
1. Remove the displacement pump from the air motor as explained on page 11.
2. Unscrew the intake valve housing (105) from the outlet housing (107). If it is difficult to remove, squirt penetrating oil around the threads and gently tap around the valve housing with a plastic hammer to loosen it.
3. Remove the ball stop pin (113), o-ring retainer (108), o-ring (109), ball guide (101), and ball (112).
4. Loosen the packing nut (104). Push the displacement rod (103) down as far as possible, and pull it out of the outlet housing (107), being careful not to scratch the sleeve (106).
5. Secure the flats of the piston stud (102) in a vise. Screw the displacement rod (103) off the piston stud. Remove the ball (110), retainer (122), packings (124, 115), and glands (117, 121).
Reassembling
1. Lubricate the throat packings (114*, 123*). Install the throat packing parts in the outlet housing (107) one at a time, in the order shown in Detail A of Fig.
4. Be sure the lips of the v-packings face down,
lubricate the packing nut threads, and install the packing nut finger tight.
2. If you removed the sleeve (106), reinstall it in the outlet housing (107), making sure to replace the gasket (120). To install the gasket, lay it flat in the outlet housing (107) and use the sleeve to seat the gasket against the shoulder of the outlet housing.
Be sure the tapered end of the sleeve faces down, toward the pump intake.
3. Lubricate the piston packings (115*, 124*). Install the piston packing parts on the piston stud (102) one at a time, in the order shown in Detail B of Fig.
4. Be sure the lips of the v-packings face up,
toward the threads of the piston stud.
4. Place the flats of the piston stud in a vise. Install the piston ball (110*) on the piston and screw the displacement rod (103) onto the piston valve assembly. Torque to 35 to 40 ft-lb (47 to 54 N.m).
5. Insert the displacement rod (103) into the bottom of the outlet housing (107), being careful not to scratch the sleeve (106). Push the rod straight up until it protrudes from the packing nut (104).
6. Install the ball (112*), guide (101), o-ring (109*), retainer (108), and ball stop pin (113) in the intake valve housing (105). Lubricate the intake valve housing threads, and screw the intake valve housing into the outlet housing (107). Torque to 55 to 65 ft-lb (75 to 88 N.m).
6. Remove the packing nut (104), throat packings (123, 114), glands (116, 118), and washer (119) from the outlet housing (107).
7. Inspect all parts for damage. Clean all parts and threads with a compatible solvent before reassembling. Inspect the polished surfaces of the displacement rod (103) and sleeve (106) for scratches, scoring, or other damage, which can cause premature packing wear and leaking. To check, run a finger over the surface or hold the part up to the light at an angle. Replace any worn or damaged parts.
NOTE: If the sleeve (106) needs replacement and is hard to remove, contact your Graco distributor.
12 307619
7. Reconnect the displacement pump to the air motor as explained on page 11.
Page 13
Service
Lubricate.
1
Install the throat packings in the following order, with the
2
lips of the v-packings facing down: washer (119), male gland (118*), four leather v-packings (114*), one PTFE v-packing (123*), female gland (116*), and the packing nut (104), install finger tight.
3
Tapered end of sleeve (106) must face down toward pump intake.
103
1
104
Install the piston packings in the following order, with the
4
lips of the v-packings facing up: female gland (121*), one PTFE v-packing (124*), four leather v-packings (115*), male gland (117*), and packing retainer (122*).
Torque to 35 to 40 ft-lb (47 to 54 N.m).
6
Torque to 55 to 65 ft-lb (75 to 88 N.m).
7
See Reconnecting the Displacement Pump on page
8
11 for instructions on when to torque the packing nut to 18 to 20 ft-lb (24 to 27 N.m).
8
1 8
Detail A: Throat Packings
104
2
(Ref)
116*
107 (Ref)
See Detail A
102
6
See Detail B
108
120
106
107
113
*123
1
*114
1
1
118*
119
3
Detail B: Piston Packings
4
103 (Ref)
*110
6
102 (Ref)
*122
*117
*115
1
1
Fig. 4
101
*124
1
*121
105
7
*112
109*
1
06937
307619 13
Page 14
12
13, 14
Parts
Model 223596, Series B, 23:1 Ratio CST Monarkr Pump (shown)
includes items 3, 4, 6, 10, 12, and 13
Model 237958, Series B, 23:1 Ratio SST Monarkr Pump
includes items 3, 4, 6, 10, 12, and 14
Ref Part No. No. Description Qty
3* 101946 PIN, cotter, stainless steel,
0.12 in. (3.2 mm) x 1.5 in. (38 mm) 1
4 101566 NUT, lock, 3/8–16 3
6
10
3*
4
6 154771 SEAL, o-ring, buna-N 1 10 164722 ROD, tie, carbon steel,
4.375 in. (112 mm) shoulder-to-shoulder 3
12 222791 AIR MOTOR
see 307043 for parts 1
13 223595 DISPLACEMENT PUMP ASSY,
carbon steel, for pump Model 223596 see page 15 for parts.1
14 239145 DISPLACEMENT PUMP ASSY,
stainless steel, for pump Model 237958 (not shown) see page 17 for parts. 1
02099
* This part is included in Repair Kit 239328, which may be
purchased separately. See pages 15 and 17 for additional kit parts.
14 307619
Page 15
Parts
Model 223595, Series D
Carbon steel severe-duty displacement pump with stainless steel glands, intake housing, piston valve, and ball stop
104 *116 *123 *114
*114 *114 *114
*118
119
107
120
103
122* 117* 115* 115* 115* 115*
124* 121* 110*
102 113
108 101
106
Ref Part No. No. Description Qty
101 186187 GUIDE, ball, intake, stainless steel 1 102 223591 STUD, piston, stainless steel with
tungsten carbide seat 1 103 24C508 ROD, displacement, stainless steel 1 104 206269 PACKING NUT/WET-CUP, CST 1 105 223593 HOUSING, valve, intake, SST
with tungsten carbide seat 1 106 24C499 SLEEVE, housing, stainless steel 1 107 207011 HOUSING, outlet, carbon steel 1 108 186183 RETAINER, o-ring, stainless steel 1 109* 165052 O-RING, PTFE 1 110* 105444 BALL, 440C stainless steel,
0.31 in. (7.9 mm) dia. 1
112* 105445 BALL, 440C stainless steel,
0.5 in. (13 mm) dia. 1
113 186179 PIN, ball stop, intake, stainless steel 1
109*
112* 105
02101A
Ref Part No. No. Description Qty
114* 164397 V-PACKING, throat, leather 4 115* 184300 V-PACKING, piston, leather 4 116* 186194 GLAND, throat, female, stainless steel 1 117* 186195 GLAND, piston, male, stainless steel 1 118* 186196 GLAND, throat, male, stainless steel 1 119 186197 WASHER, flat, stainless steel 1 120 164480 GASKET, flat, PTFE 1 121* 186198 GLAND, piston, female, stainless steel 1 122* 186199 RETAINER, packing, stainless steel 1 123* 164913 V-PACKING, throat, PTFE 1 124* 164912 V-PACKING, piston, PTFE 1 125 Y 172479 TAG, warning (not shown) 1
* These parts are included in Repair Kit 239328, which may be purchased separately. See page 14 for additional parts. Y Replacement danger and warning labels, tags, and cards are available for free.
307619 15
Page 16
Parts
Model 239140, Series A, 46:1 Ratio SST Presidentr Pump
includes items 3, 4, 5, 6, 10, 12, and 13
12
*3
Ref Part No. No. Description Qty
3* 101946 PIN, cotter, stainless steel,
0.12 in. (3.2 mm) x 1.5 in. (38 mm) 2 4 101566 NUT, lock, 3/8–16 3 5 191995 ADAPTER 1
5
10
6
4
6 154771 SEAL, o-ring, buna-N 1 10 191996 ROD, tie, carbon steel,
6 in. (152 mm) shoulder-to-shoulder 3
12 207352 AIR MOTOR
See 306982 for parts 1
13 239145 DISPLACEMENT PUMP ASSY,
stainless steel, see page 17 for parts.1
* This part is included in Repair Kit 239328, which may be
purchased separately. See page 17 for additional kit parts.
13
06938A
16 307619
Page 17
Model 239145, Series A
Stainless steel severe-duty displacement pump
104
*116
Parts
*123
*114 *118
119
107
120
106
*123
124*
103
110* 122* 117*
115* 124*
121* 102
113 108
101
109*
112*
105
Ref Part No. No. Description Qty
101 186187 GUIDE, ball, intake, stainless steel 1 102 223591 STUD, piston, stainless steel with
tungsten carbide seat 1 103 24C508 ROD, displacement, stainless steel 1 104 223590 PACKING NUT/WET-CUP,
stainless steel 1 105 223593 HOUSING, valve, intake, stainless
steel with tungsten carbide seat 1 106 24C499 SLEEVE, housing, stainless steel 1 107 239137 HOUSING, outlet, stainless steel 1 108 186183 RETAINER, o-ring, stainless steel 1 109* 165052 O-RING, PTFE 1 110* 105444 BALL, 440C SST, 0.31 in. (7.9 mm) dia. 1 112* 105445 BALL, 440C SST, 0.5 in. (13 mm) dia. 1
* These parts are included in Repair Kit 235636, which may be purchased separately. See page 16 for additional parts. Y Replacement danger and warning labels, tags, and cards are available for free.
Ref Part No. No. Description Qty
113 186179 PIN, ball stop, intake, stainless steel 1 114* 164397 V-PACKING, throat, leather 2 115* 164715 V-PACKING, piston, leather 2 116* 186194 GLAND, throat, female, stainless steel 1 117* 186195 GLAND, piston, male, stainless steel 1 118* 186196 GLAND, throat, male, stainless steel 1 119 186197 WASHER, flat, stainless steel 1 120 164480 GASKET, flat, PTFE 1 121* 186198 GLAND, piston, female, stainless steel 1 122* 186199 RETAINER, packing, stainless steel 1 123* 164913 V-PACKING, throat, PTFE 2 124* 164912 V-PACKING, piston, PTFE 2 125 Y 172479 TAG, warning (not shown) 1
06935
307619 17
Page 18
Conversion Kits
PTFE Conversion Kit 236724
For converting pumps to all PTFE packings. Must be purchased separately.
Part No. Description Qty
101946 PIN, cotter, stainless steel 1 101545 PIN, cotter (for old-style ball checks) 1 165052 O-RING, PTFE 1 105444 BALL, 440C stainless steel,
0.31 in. (7.9 mm) dia. 1
105445 BALL, 440C stainless steel,
0.5 in. (13 mm) dia. 1 186194 GLAND, throat, female, stainless steel 1 186195 GLAND, piston, male, stainless steel 1 186196 GLAND, throat, male, stainless steel 1 186198 GLAND, piston, female, stainless steel 1 186199 RETAINER, packing, stainless steel 1 164912 V-PACKING, piston, PTFE 4 164913 V-PACKING, throat, PTFE 4
PTFE/Leather Conversion Kit 235636
For converting pumps to PTFE and leather packings. This is the standard repair kit for Model 223595 Displacement Pump, Series C and earlier. Must be purchased separately.
Part No. Description Qty
101946 PIN, cotter, stainless steel 1 101545 PIN, cotter (for old-style ball checks) 1 165052 O-RING, PTFE 1 105444 BALL, 440C stainless steel,
0.31 in. (7.9 mm) dia. 1 105445 BALL, 440C stainless steel,
0.5 in. (13 mm) dia. 1 164397 V-PACKING, throat, leather 2 164715 V-PACKING, piston, leather 2 186194 GLAND, throat, female, stainless steel 1 186195 GLAND, piston, male, stainless steel 1 186196 GLAND, throat, male, stainless steel 1 186198 GLAND, piston, female, stainless steel 1 186199 RETAINER, packing, stainless steel 1 164912 V-PACKING, piston, PTFE 2 164913 V-PACKING, throat, PTFE 2
UHMWPE/Leather Conversion Kit 223674
For converting pumps to UHMWPE and leather packings. Must be purchased separately.
Part No. Description Qty
101946 PIN, cotter, stainless steel 1 101545 PIN, cotter (for old-style ball checks) 1 165052 O-RING, PTFE 1 105444 BALL, 440C stainless steel,
0.31 in. (7.9 mm) dia. 1
105445 BALL, 440C stainless steel,
0.5 in. (13 mm) dia. 1 164397 V-PACKING, throat, leather 2 164715 V-PACKING, piston, leather 2 186194 GLAND, throat, female, stainless steel 1 186195 GLAND, piston, male, stainless steel 1 186196 GLAND, throat, male, stainless steel 1 186198 GLAND, piston, female, stainless steel 1 186199 RETAINER, packing, stainless steel 1 108455 V-PACKING, throat, UHMWPE 2 108456 V-PACKING, piston, UHMWPE 2
PTFE/Leather Conversion Kit 239328
For converting pumps to leather packings. Must be purchased separately.
Part No. Description Qty
101946 PIN, cotter, stainless steel 1 101545 PIN, cotter (for old-style ball checks) 1 165052 O-RING, PTFE 1 105444 BALL, 440C stainless steel,
0.31 in. (7.9 mm) dia. 1 105445 BALL, 440C stainless steel,
0.5 in. (13 mm) dia. 1 164397 V-PACKING, throat, leather 4 184300 V-PACKING, piston, leather 4 186194 GLAND, throat, female, stainless steel 1 186195 GLAND, piston, male, stainless steel 1 186196 GLAND, throat, male, stainless steel 1 186198 GLAND, piston, female, stainless steel 1 186199 RETAINER, packing, stainless steel 1 164912 V-PACKING, piston, PTFE 1 164913 V-PACKING, throat, PTFE 1
18 307619
Page 19
Dimensions
Mounting Hole
Model 223596 shown
D
(air inlet)
Layout
A 4.38 in. (111.3 mm) diameter B 2.5 in. (64 mm) C 5.0 in. (127 mm) D 0.28 in. (7.1 mm) diameter
Use Gasket 161023 (order separately)
C
A
B
D
C
E
(fluid outlet)
F
(fluid intake)
Model
Dimension
A 10.8 in.
B 15.2 in.
C 28.8 in.
D 3/8 npt(f) 3/8 npt(f) 1/2 npt(f) E 3/8 npt(f) 3/8 npt(f) 3/8 npt(f) F 3/4 npt(m) 3/4 npt(m) 3/4 npt(m)
223596
(274 mm)
(386 mm)
(732 mm)
Model 237958
10.9 in. (277 mm)
15.2 in. (386 mm)
28.8 in. (732 mm)
B
A
02097
Model 239140
10.8 in. (274 mm)
16.8 in. (426 mm)
31.6 in. (802 mm)
307619 19
Page 20
Technical Data
Category Model 239140 SST Pres-
ident
Ratio 46:1 23:1 23:1
Maximum fluid working pressure
Maximum air input pressure
Fluid flow at 60 cycles per minute
Maximum pump operating temperature
Weight approx. 24 lb (11 kg) approx. 24 lb (11 kg) approx. 24 lb (11 kg) Wetted parts AISI 304, 316, 440C, and
4600 psi (32 MPa, 317 bar)
100 psi (0.7 MPa, 7 bar)
0.55 gpm (2.1 liters/min)
180_F (82_C) 180_F (82_C) 180_F (82_C)
17–4 PH grades of stain­less steel; tungsten carbide; PTFE; leather
Model 223596 CST
Monark
2760 psi (19 MPa, 190 bar)
120 psi (0.8 MPa, 8 bar)
0.4 gpm (1.5 liters/min)
carbon steel; AISI 304, 316, 420, 440C, and 17–4 PH grades of stainless steel; chrome; chrome and zinc plating; tungsten carbide; PTFE; leather
Model 237958 SST
Monark
3450 psi (24 MPa, 238 bar)
150 psi (1.0 MPa, 10 bar)
0.4 gpm (1.5 liters/min)
AISI 304, 316, 440C, and 17–4 PH grades of stain­less steel; tungsten carbide; PTFE; leather
Sound Pressure Levels (dBa)
(measured at 1 meter from unit)
Input Air Pressures at 15 cycles per minute
Air Motor 40 psi (0.28 MPa, 2.8 bar) 70 psi (0.48 MPa, 4.8 bar) 100 psi (0.7 MPa, 7 bar)
President 73.6 dB(A) 78.3 dB(A) 80.9 dB(A) Monark 62.6 dB(A) 62.5 dB(A) 63.9 dB(A)
Sound Power Levels (dBa)
(tested in accordance with ISO 9614–2)
Input Air Pressures at 15 cycles per minute
Air Motor 40 psi (0.28 MPa, 2.8 bar) 70 psi (0.48 MPa, 4.8 bar) 100 psi (0.7 MPa, 7 bar)
President 87.4 dB(A) 92.1 dB(A) 94.6 dB(A) Monark 69.5 dB(A) 70.7 dB(A) 71.0 dB(A)
20 307619
Page 21
Technical Data
Model 223596 23:1 Ratio CST Monark Performance Chart
To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow
(lpm/gpm) and operating air pressure (psi/MPa/bar):
1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with selected fluid outlet pressure curve (black). Follow left to scale to read fluid outlet pressure.
A 120 psi (0.8 MPa, 8 bar) air pressure B 70 psi (0.49 MPa, 4.9 bar) air pressure C 40 psi (0.28 MPa, 2.8 bar) air pressure
Monark 23:1 Fluid Outlet Pressure
psi
MPa, bar
3000
21, 210
2250
15.8, 158
1500
10.4,104
750
FLUID PRESSURE
5.1, 51
0
0.0 0.1 0.2 0.3 0.4 0.5
gpm
liters/minute
FLUID FLOW (TEST FLUID: NO. 10 WEIGHT OIL)
A
B
C
cycles per minute
15 30 45 7560
0.4 0.8 1.2 1.5 1.9
To find Pump Air Consumption (m#/min or scfm) at a specific fluid flow (lpm/gpm) and air pressure (psi/MPa/bar):
1. Locate desired flow along bottom of chart.
2. Read vertical line up to intersection with selected air consumption curve (dashes). Follow left to scale to read air consumption.
Monark 23:1 Air Consumption
scfm
m#/min
16
0.45
12
0.34
0.22
AIR CONSUMPTION
.011
gpm
liters/minute
8
4
0
0.0 0.1 0.2 0.3 0.4 0.5
FLUID FLOW (TEST FLUID: NO. 10 WEIGHT OIL)
cycles per minute
15 30 45 7560
A
B
C
0.4 0.8 1.2 1.5 1.9
Model 237958 23:1 Ratio SST Monark Performance Chart
To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow
(lpm/gpm) and operating air pressure (psi/MPa/bar):
1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with selected fluid outlet pressure curve (black). Follow left to scale to read fluid outlet pressure.
A 150 psi (1.0 MPa, 10 bar) air pressure B 70 psi (0.49 MPa, 4.9 bar) air pressure C 40 psi (0.28 MPa, 2.8 bar) air pressure
Monark 23:1 Fluid Outlet Pressure
psi
MPa, bar
3500
24.5, 245
3000
21, 210
2500
17.5, 175
2000
14, 140
1500
10.5, 105
1000
7,70
FLUID PRESSURE
500
3.5, 35
0
0.0 0.1 0.2 0.3 0.4 0.5
gpm
liters/minute
FLUID FLOW (TEST FLUID: NO. 10 WEIGHT OIL)
A
C
cycles per minute
15 30 45 7560
B
0.4 0.8 1.2 1.5 1.9
To find Pump Air Consumption (m#/min or scfm) at a specific fluid flow (lpm/gpm) and air pressure (psi/MPa/bar):
1. Locate desired flow along bottom of chart.
2. Read vertical line up to intersection with selected air consumption curve (dashes). Follow left to scale to read air consumption.
Monark 23:1 Air Consumption
scfm
m#/min
16
0.45
12
0.34
0.22
AIR CONSUMPTION
.011
gpm
liters/minute
8
4
0
0.0 0.1 0.2 0.3 0.4 0.5
FLUID FLOW (TEST FLUID: NO. 10 WEIGHT OIL)
cycles per minute
15 30 45 7560
A
B
C
0.4 0.8 1.2 1.5 1.9
307619 21
Page 22
Notes
22 307619
Page 23
Technical Data
Models 239140 46:1 Ratio SST President Performance Chart
To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow
(lpm/gpm) and operating air pressure (psi/MPa/bar):
1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with selected fluid outlet pressure curve (black). Follow left to scale to read fluid outlet pressure.
A 100 psi (0.7 MPa, 7 bar) air pressure B 70 psi (0.49 MPa, 4.9 bar) air pressure C 40 psi (0.28 MPa, 2.8 bar) air pressure
President 46:1 Fluid Outlet Pressure
psi
MPa, bar
5000
35, 350
4000
28, 280
3000
21, 210
2000
14, 140
1000
FLUID PRESSURE
7,70
0
0.0 0.2 0.4 0.6 0.8
gpm
liters/minute
FLUID FLOW (TEST FLUID: NO. 10 WEIGHT OIL)
A
C
cycles per minute
21 41 8262
B
0.8 2.31.5 3.0
To find Pump Air Consumption (m#/min or scfm) at a specific fluid flow (lpm/gpm) and air pressure (psi/MPa/bar):
1. Locate desired flow along bottom of chart.
2. Read vertical line up to intersection with selected air consumption curve (dashes). Follow left to scale to read air consumption.
President 46:1 Air Consumption
scfm
m#/min
40
1.12
30
0.84
20
0.56
10
AIR CONSUMPTION
0.28
gpm
liters/minute
0
0.0 0.2 0.4 0.6 0.8
FLUID FLOW (TEST FLUID: NO. 10 WEIGHT OIL)
cycles per minute
21
0.8 2.31.5 3.0
41
8262
A
B
C
307619 23
Page 24
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 Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the distributor closest to you: Phone: 612–623–6921 or Toll Free: 1–800–328–0211 Fax: 612–378–3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
24 307619
Original instructions. This manual contains English. MM 307619
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 1983, Graco Inc. is registered to ISO 9001
www.graco.com
Revised 02/2011
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