Graco 308-017 User Manual

INSTRUCTIONS–P

This

manual contains IMPORT

WARNINGS AND INSTRUCTIONS

READ AND RETAIN FOR REFERENCE

ANT

ARTS LIST

308-017

Check-Mate 450 Pumps

With Priming Piston, and Severe-Duty Rod and Cylinder

Model

222-770, Series A, 10:1 Ratio Monark Pump

125 bar (1800 psi) MAXIMUM FLUID WORKING PRESSURE

12.5 bar (180 psi) MAXIMUM AIR INPUT PRESSURE

Model 222-768, Series A, 20:1 Ratio President Pump

250 bar (3600 psi) MAXIMUM FLUID WORKING PRESSURE

12.5 bar (180 psi) MAXIMUM AIR INPUT PRESSURE

Model 222-769, Series A, 34:1 Ratio Senator Pump

238 bar (3400 psi) MAXIMUM FLUID WORKING PRESSURE 7 bar (100 psi) MAXIMUM AIR INPUT PRESSURE

Model 224-660, Series A, 34:1 Ratio Quiet Senator Pump

238 bar (3400 psi) MAXIMUM FLUID WORKING PRESSURE 7 bar (100 psi) MAXIMUM AIR INPUT PRESSURE

Model 222-778, Series A, 55:1 Ratio Bulldog Pump

347 bar (4950 psi) MAXIMUM FLUID WORKING PRESSURE

6.3 bar (90 psi) MAXIMUM AIR INPUT PRESSURE

Rev D

Supersedes C

Model 222-813, Series A, 55:1 Ratio Quiet Bulldog Pump

347 bar (4950 psi) MAXIMUM FLUID WORKING PRESSURE

6.3 bar (90 psi) MAXIMUM AIR INPUT PRESSURE

ABLE OF CONTENTS

Warnings 2, Typical Installation 5 Operation/Maintenance 6, Service

Parts

Accessories 22, Technical

Dimensional Mounting Warranty Back Cover. Toll-Free

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Required Tools 9. Disconnecting Reconnecting Displacement

Drawings and Lists Model 222-770 Monark Pump Model

222-768 President Pump

Model

222-769 & 224-660 Senator Pump

Model

222-778 & 222-813 Bulldog Pump

Displacement

Data and Performance Charts Model 222-770 Monark Pump Model

222-768 President Pump

Model

222-769 Senator Pump

Model

224-660 Quiet Senator Pump

Model

222-778 Bulldog Pump

Model

222-813 Quiet Bulldog Pump

Hole Layouts

Graco Phone Numbers

the Displacement Pump9. . . . . . . . . . . . . . .

Pump Service

Pump

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drawing

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. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chart8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

the Displacement Pump9. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . . . . . .

Back Cover.

10-13.

16.

17.

18.

19.

20, 21

24.

25.

26.

27.

28.

29.

30.

31.

Model

222-768

Shown

0423

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441



OBSER

SAFETY

HIGH

PRESSURE FLUID CAN CAUSE SERIOUS INJURY. FOR PROFESSIONAL USE ONL

VE ALL W

ARNINGS. Read And Understand All Instruction Manuals Before Operating Equipment.

MOVING PARTS HAZARD

KEEP

HANDS AND FINGERS AWAY FROM THE PRIMING PIST DURING OPERA WITH

AIR to reduce the risk of injury!

priming

piston extends beyond the intake cylinder

the

pump. The priming

and whenever the pump is charged with air

tion severely

injure or amputate a hand or finger

it and the intake cylinder

tween

below

cedure, any

part of the pump.

TION AND WHENEVER THE PUMP IS CHARGED

piston works under extreme force. During opera

. Always

, before checking, clearing, cleaning, flushing or

On the pump downstroke the

to pull the material into

, the priming piston can

, or break a tool, caught be

follow the

Pressure Relief Pro

servicing

FLUID INJECTION HAZARD

General

This gun/dispensing valve, leaks or ruptured components can inject fluid through injury, into

NEVER the

ALWA

ALWAYS or

removing the spray tip/nozzle or servicing any system equipment.

NEVER try to stop or deflect leaks with your hand or body

Be use.

Medical

any fluid appears

CARE AT

exactly

Note portant

delay otic plastic

Spray

Be sure all spray gun/dispensing valve safety devices are operating properly valve;

Safety

Whenever the tion, result

Trigger

Never moved. tally

Diffuser

The tion Follow the Pressure Relief Procedure, to the right, then remove the spray gun firmly to the pail. Using the lowest possible pressure, trigger the spray place

Safety

equipment

including the need for amputation. Also, fluid injected or splashed

the eyes or on the skin can cause serious damage.

body

YS have the tip guard in place on

sure all equipment safety devices are operating properly before each

coatings injected directly into the blood stream. Consultation with a

this can cause a malfunction and result in serious bodily injury

generates very high fluid pressure. Spray from the spray

your skin and into your body and cause extremely serious bodily

point

the spray gun/dispensing valve at anyone or at any part of

. NEVER put hand or fingers over the spray tip/nozzle.

the spray gun when spraying.

follow the

Alert––Airless Spray W

ONCE. DO NOT TREA

what fluid was injected.

to Physician:

to treat the injury surgically as soon as possible

treatment to research toxicity

surgeon or reconstructive hand surgeon may be advisable.

Gun/Dispensing V

before each use. Do not remove or modify any part of the

Pressure Relief Procedure

ounds

to penetrate your skin, get

Injection in the skin

T AS A SIMPLE CUT

is a traumatic injury

. T

oxicity is a concern with some ex

alve Safety Devices

, right, before

EMERGENCY MEDICAL

cleaning

. T

ell the doctor

It is im

. Do

not

gun/

Latch

you stop spraying/dispensing, even for a moment, always

spray gun/dispensing valve safety latch in the closed

making the gun/valve inoperative. Failure to set the safety latch can

in accidental triggering of the gun/valve.

or “safe” posi

set

Guard (if present)

operate the spray

This guard

if it is dropped or bumped.

gun/dispensing valve with the trigger guard re

helps prevent the gun/valve from triggering acciden

(only on spray guns)

spray gun dif

when the tip is not installed. Check the dif

tip. Aim the spray gun into a grounded metal pail, holding the spray

gun. If the dif

fuser breaks up spray and reduces the risk of fluid injec

the fluid emitted is not dif fuser immediately

fuser operation regularly

fused into an irregular stream, re

ARNINGS

The

air motor piston (located behind the air motor plates or shield ) also

moves

when air is supplied to the motor

the

air motor plates or shield removed.

the

Pressure Relief Procedure

accidentally.

Tip

Guard (only on spray guns)

ALWAYS tip

does

Spray T

Use spray dispensing

Relief

NEVER wipe off build-up around the spray tip/nozzle until pressure is fully

have the tip guard in place on the spray gun while spraying. The

guard alerts you to the fluid injection hazard and

not prevent,

your body close to the spray tip.

the risk of accidentally placing your fingers or any part

ip/Nozzle Safety

extreme caution when cleaning or

tip/nozzle clogs while

valve safety latch immediately

Procedure

relieved and the

Pressure

reduce the risk of serious bodily injury splashing always follow this procedure whenever you shut of f the pump,

checking or servicing any part of the spray/dispensing sys

when

when installing, cleaning

tem, whenever

Engage the spray gun/dispensing valve safety latch.

Shut of

3. Close

tem). Disengage the gun/valve safety latch.

5. Hold a metal part of the gun/valve firmly to the side of a

grounded sure.

6. Engage

7. Open the drain valve (required in your system) and/or the

pump bleeder valve, having a container ready to catch the drainage.

8. Leave

pense

If you suspect that the spray tip/nozzle or hose is completely clogged, the

steps above,

hose end coupling and relieve pressure gradually

completely.

and then remove the spray tip/nozzle to clean it.

Relief Procedure

in the eyes or on the skin, or injury from moving parts,

you stop spraying/dispensing.

f the air to the pump.

the bleed-type master air valve (required in your sys

metal pail,

the gun/valve safety latch.

the drain valve open until you are ready to again.

or that pressure has not been fully relieved after following

Now clear the tip/nozzle or hose.

spraying/dispensing, engage the spray gun/

spray gun/dispensing valve safety latch is engaged.

and trigger the gun/valve to relieve pres

VER

Y SLOWL

. NEVER operate the pump with

Before servicing the pump, follow

below to prevent the pump from

helps reduce,

changing spray tips/nozzles. If the

. ALWAYS follow the

, including fluid injection,

or changing spray tips/nozzles, and

Y loosen the tip guard retaining nut

starting

Pressure

spray/dis

, then loosen

but

 

EQUIPMENT MISUSE HAZARD

General

Any overpressurizing, ids, or using worn or damaged parts, can cause them to rupture and result in

fluid injection, splashing in the eyes or on the skin, or other serious bod

ily

injury

NEVER to

malfunction.

CHECK worn

Always ommended

Safety

misuse of

or damaged parts immediately

the spray/dispensing equipment or accessories, such as

modifying parts, using incompatible chemicals and flu

, or fire, explosion or property damage.

alter or modify any part of this equipment; doing so

all spray/dispensing equipment

wear protective eyewear

by the fluid and solvent manufacturer

regularly and repair or replace

, gloves, clothing and

could cause it

respirator as rec

HOSE SAFETY

High

pressure fluid

ops

a leak,

high

pressure spray emitted from it can cause a fluid injection injury or

other

serious bodily injury or property damage.

ALL FLUID HOSES MUST HA VE SPRING GUARDS ON BOTH

The spring guards help protect the hose from kinks or bends at or

ENDS!

to the coupling which can result in hose rupture.

TIGHTEN fluid can dislodge a loose coupling or allow high pressure spray to be emitted

from the coupling.

NEVER

use a damaged hose. Before each use, check the entire hose cuts, leaks, couplings.

NOT try to recouple high pressure hose or mend it with tape or any

DO other

device.

fluid.

in the hoses can be very dangerous. If the hose devel

split or rupture due to any kind of wear

all fluid connections securely before each use. High pressure

abrasion,

If any of

bulging cover

these conditions exist, replace the hose immediately

A repaired hose cannot safely contain the high pressure

, or damage or movement of the hose

, damage or misuse, the

for

System

NEVER inlet pressure stated on your pump or in the TECHNICAL DATA on pages

Be withstand the the

Fluid

BE the ways this

HANDLE

move ner peratures

Pressure

exceed the recommended working pressure or the maximum air

24-29.

sure that all

maximum system.

spray/dispensing equipment and accessories are rated to

the maximum working pressure of the pump. DO NOT

working pressure of any component or accessory used in

exceed

Compatibility

SURE that all fluids and solvents used are chemically compatible with wetted parts shown in the

read the manufacturer’s literature before using fluid or solvent

pump.

AND ROUTE HOSES CAREFULLY. Do not pull on hoses to

equipment. Do not use fluids which are not compatible

tube and cover of the hose. DO NOT expose Graco hoses to tem

above 82C (180F) or below –40C (–40

TECHNICAL DATA on pages 24-29. Al

with the in

F).

Hose Grounding Continuity

Proper

hose grounding continuity is essential to maintaining a grounded spray/dispensing fluid

hoses at least once a week. If your hose does not

which

specifies the plier 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

ungrounded or poorly grounded hose can make your system hazard

Also, read

ous.

system. Check the electrical resistance of your air and

maximum electrical resistance, contact the hose sup

FIRE OR EXPLOSION HAZARD

have a tag on it

, below

FIRE OR EXPLOSION HAZARD

Static

electricity is created by the high velocity flow of fluid through the pump and hose. If every part of the spray/dispensing equipment is not properly

grounded, sparking may occur hazardous. power being sprayed/dispensed, dust particles and other flammable substances, can age. pensing area when there is any chance of igniting fumes still

you experience any static sparking or even a slight shock while using this equipment, STOP SPRA YING/DISPENSING IMMEDIATELY. Check the entire system for proper grounding. Do not use the system again

Sparking may also occur when plugging in or unplugging a

supply cord. Sparks can ignite fumes from solvents and the fluid

whether

cause a fire or explosion

Do not plug in or unplug any power supply cords in the spray/dis

until the problem has been identified and corrected.

you are spraying/dispensing indoors or outdoors, and

and serious bodily injury and property dam

Grounding

To reduce the risk of static sparking, ground the pump, object being sprayed, spray/dispensing area. CHECK your local electrical code for detailed grounding ground

and all other spray/dispensing equipment used or located in the

instructions for your area and type of equipment. BE SURE to

all of this spray/dispensing equipment:

Pump:

use a ground wire and clamp. See Fig 1.

Air hoses:

Fluid hoses:

Air compressor:

Spray

nection

Fluid supply container:

Object being sprayed:

All

Use only metal pails, which are conductive, placed on a grounded surface. paper

use only grounded air hoses.

use only grounded fluid hoses.

follow manufacturer’s recommendations.

gun or dispensing valve:

to a properly grounded fluid hose and pump.

according to your local code.

solvent pails used when flushing,

Do not place the pail on a nonconductive

or cardboard, which interrupts the grounding continuity

, and the system may become

in the air

grounding is obtained through con

according to your local

surface, such as

code.

o maintain grounding continuity when flushing

, always

sure

firmly

hold a metal part of the spray gun/dispensing valve

to the side of a grounded

metal

pail, then trigger the gun/valve.

To ground the pump:

To ground the pump, loosen the grounding lug locknut (W) and

(X). Insert one end of a 1.5 mm (12 ga) minimum ground

washer wire

(Y) into the slot in lug (Z) and tighten the locknut securely Fig 1. Connect the other end of the wire to a true earth ground. See the

ACCESSORIES section to order a ground wire and clamp.

Fig

Flushing Safety

Before

flushing, be sure the

grounded. Refer to Grounding, above. Follow the Pressure Relief

Procedure

gun/dispensing maintain during and

on page 2, and remove the spray tip/nozzle from the spray

valve. Always use the

firm metal-to-metal contact between the gun/valve and the pail

flushing to reduce the risk of fluid injection injury

splashing.

entire system and flushing pails are properly

lowest possible fluid pressure, and

or relieving pres

. See

, static sparking

IMPORTANT

United

States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards – particularly the Gen

eral

Standards, Part 1910, and the Construction Standards, Part 1926 – should be consulted.

 3

TYPICAL INSTALLATION

KEY

MAIN AIR LINE

PUMP AIR SUPPL

Y HOSE

A Pump B 19 C D E F G Bleed-T

H J K Bleed-T L M N P Gun/V Y

Liter (5 Gal.) Pail Ram Wiper Plate Air Manifold Pump Runaway V Air Line Lubricator

(required, for pump) Pump Air Regulator Air Line Filter

Fluid Drain V Fluid Pressure Regulator Gun or Dispensing V

Ground Wire (required; see page 3 for installation instructions)

alve

ype Master Air V

alve (required)

alve Swivel

alve

alve (for accessories)

alve

RAM AIR

SUPPL

RAM AIR REGULA

PUMP FLUID OUTLET

19 LITER (5 GAL.) P

Y HOSE

MAIN FLUID HOSE

TOR

AIL

4 

FLUID WHIP HOSE

0218

INSTALLATION

NOTE: Reference numbers and letters in parentheses

the text refer to the callouts in the figures and

the

parts drawing.

See pages 22 and 23 for accessories available from

Graco. If

sure they

rated

to meet the system’

The Typical Installation shown on page 4 is for selecting and installing system components and accessories. Contact your Graco representative or Graco Technical Assistance (see back page) for assistance in designing

SYSTEM ACCESSORIES

Refer to the T

A valve sories help reduce the risk of serious bodily injury including injury from moving parts if you are adjusting or re pairing the pump.

The between this valve and the pump after the air is shut off. Trapped air can cause the pump to cycle unex pectedly.

The fluid drain valve assists in relieving fluid pres sure in the displacement pump, hose, and gun. Triggering the gun to relieve pressure may not be sufficient.

Air and Fluid Hoses

Be sure all air and fluid hoses are properly sized and pressure-rated for your system. Use only grounded air and both ends. Use of a short whip hose between the main fluid

Mounting Accessories

Mount the pump (A) to suit the type of installation planned. The pump dimensions and mounting hole layouts

If you are mounting the pump on a ram (B), refer to the manual eration instructions. The ram shown in the T lation is a 222-781 19 liter (5 gal.) pail ram, used with a wiper

also requires an air supply hose and an air manifold

It which divides the main air supply into separate lines for the pump and the ram.

By using Pump Mounting Kit 222-776, you can also mount the pump on Floor Stand 222-780, 200 liter (55 gal.) Ram 223-634, or Inductor 222-635. See Accessories

a system to suit your particular needs.

ypical Installation drawing on page 4.

bleed-type master air valve (G) and a fluid drain

(L) are required in your system. These

splashing in the eyes or on the skin, and

bleed-type master air valve relieves air trapped

Locate the valve close to the pump.

fluid hoses. Fluid hoses must have

hose and the gun allows freer gun movement.

are shown on pages 30 and 31.

supplied with the ram unit for

plate (C).

for further information.

you supply your own accessories,

are adequately sized and pressure-

s requirements.

only a guide

WARNING

acces

spring guards on

installation and op

ypical Instal

The ram shown includes an air regulator

(D),

Air Line Accessories

Install

the following

Typical

Fluid Line Accessories

Install the T

Installation, using adapters as necessary:

A pump runaway valve (E

running the ly

An air line lubricator (F)

tor

system to relieve air trapped between it and the air motor left). the pump, and is located downstream from the air regulator.

pressure by adjusting the air pressure to the pump. Locate from

An air line filter (J) removes harmful dirt and moisture

A second bleed-type air valve (K) isolates the air line all other air line accessories.

A fluid drain valve (L) 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 the up

A fluid regulator (M) controls fluid pressure to the gun/valve,

A gun or valve (N) dispenses the fluid. The gun shown in the Typical Installation is a dispensing gun for

A gun swivel (P)

Before operating the pump, ground the system as explained under FIRE OR EXPLOSION HAZARD and

too fast and automatically shuts off the air to

motor

damaged. Install closest to the pump air inlet.

lubrication.

bleed-type master air valve (G)

when the valve is closed (see

Be sure the bleed valve is

air

regulator (H)

the regulator close

the bleed-type master air valve.

from the compressed air supply

accessories

the following accessories in the positions shown in

ypical Installation, using adapters as necessary:

branch of a tee mounted

drain valve pointing down, but so the handle points

when the valve is opened.

highly viscous fluids.

Grounding

accessories in the order shown in the

) senses when the pump is

. A pump which runs too fast can be serious

provides automatic air mo

is required in your

the

WARNING

easily accessible from

controls pump speed and outlet

to the pump, but

for servicing. Locate upstream from

in the fluid line. Install

and dampens pressure surges.

allows freer gun movement.

upstream

GROUNDING

WARNING

on page 3.

 5

OPERATION/MAINTENANCE

WARNING

Pressure Relief Procedure

o reduce the risk of serious bodily injury

fluid

injection, splashing in the eyes or on the skin, or

injury from moving parts, always follow this proce-

whenever you shut of

dure ing

or servicing any tem, when installing, cleaning or changing spray tips/nozzles, and whenever you stop spraying/dispensing.

1. Engage the spray gun/dispensing valve safety

latch.

2. Shut

3. Close

your

Disengage the gun/valve safety latch.

5. Hold a metal part of the gun/valve firmly to the

side valve

Engage the gun/valve safety latch.

7. Open the drain valve (required in your system)

and/or the pump bleeder valve, having a container

8. Leave

spray/dispense

f the air to the pump.

the bleed-type master air valve (required in

system).

of a grounded metal pail, and trigger the gun/

to relieve pressure.

ready to catch the drainage.

the drain valve open until you are ready

part of the spray/dispensing sys

again.

f the pump, when check

, including

If you suspect that the spray tip/nozzle or hose is completely clogged, or that pressure has not been fully

relieved after following the

SLOWLY end coupling and relieve pressure gradually , then loosen

Packing Nut/W

Fill

the packing nut/wet-cup (2)

Seal

Liquid (TSL) or compatible solvent. See Fig. 2. Ad

the packing nut weekly so it is just snug; do not over

just tighten. Follow the Pressure Relief Procedure W arn-

ing

above before adjusting the packing nut.

Flushing the Pump

pump is tested with lightweight oil, which is left in to

The protect the pump parts. If the fluid you are using may be contaminated

before using the pump.

vent

For your safety , read the warning section, FIRE OR

ing,

loosen the tip guard retaining nut or hose

completely

EXPLOSION HAZARD

and follow all recommendations given there.

. Now clear the tip or hose.

et–Cup

by the oil, flush it out with a compatible sol

WARNING

steps above,

1/3 full with Graco Throat

on page 3 before flush

VER

WARNING

Moving other body parts. When the pump is operating, the priming the air motor piston (located behind the air motor plates or shield) move. See Fig. 2. Therefore, NEVER or away

Before attempting to clear an obstruction from the priming piston (25) or service the pump, follow the

Pressure

vent

Cycle the gun/dispensing The is

released.

the pump fails to prime properly (35) the hole.

NOTE: When changing fluid containers with the hose

To reduce the risk of fluid injection, DO NOT use your hand or fingers to cover the bleeder hole (R) when

With the pump and lines primed, and with adequate air

pressure and volume supplied, the pump will start and

stop

Use the the fluid pressure. Always use the lowest air pressure necessary to get the desired results. Higher pressures cause

To which could result in component rupture and cause serious

MAXIMUM INCOMING AIR PRESSURE to the pump

parts can pinch or amputate your fingers or

piston (25) (located at the

operate the pump with the air motor

shield removed, and keep your fingers and hands

from the priming piston.

Relief Procedure W

the pump from starting accidentally

the pump slowly until all the air is pushed out

pump and hoses are fully primed. Release the spray

valve trigger and engage the safety

pump should stall against pressure when the

slightly

valve, as a priming valve until the fluid appears at the

as the gun/valve is opened and closed.

. Use the bleed hole (R), on the underside of

See Fig 2. Close the bleeder valve.

and

gun already

(35),

to assist in priming the pump and venting air before it enters the hose. Close the bleeder valve when

all air has been eliminated.

priming the pump.

air regulator (H) to control the pump speed and

premature tip/nozzle and pump wear

reduce the risk of overpressurizing your system,

bodily

injury, NEVER exceed the specified

(see the T

primed, open the bleeder valve

WARNING

echnical Data on pages 24-29).

pump intake) and

arning

, open the bleeder valve

at left to

plates

pre

latch.

trigger

and

Starting and Adjusting the Pump

the

See using arate instructions for those components for set-up and operation

Lower the pump into a fluid container . Be sure the air regulator are part of the spray gun/dispensing valve (N) firmly to the side Now slowly open the air regulator until the pump starts.

6 

TYPICAL INST

a ram or wiper plate with the pump, refer to the sep

instructions.

(H)

and pump’

closed. Then open the bleed

a grounded metal pail and hold the trigger open.

ALLATION

s bleed-type master air valve (G)

on page 4.

valve (G). Hold a metal

If you are

Never allow the pump to run dry of the fluid being pumped. A dry pump will quickly accelerate to a high speed,

possibly damaging itself. A pump runaway valve

(E),

which shuts of accelerates the Typical Installation on page 4 and ACCESSORIES

pages 22 and 23. If your pump accelerates quickly

on is

running too fast, stop it immediately and check the fluid supply. pumped into the lines, refill the container and prime the pump and the lines with fluid, or flush and leave it filled with the

If the supply container is empty and air has been

a compatible solvent. Be sure to eliminate all air from

fluid system.

f the air supply to the pump if the pump

beyond the pre-set speed, is available. See

, or

Shutdown and Care of the Pump

For

overnight shutdown, follow the Pressure Relief Pro

cedure

bottom

Warning

of the stroke to prevent the fluid from

on page 6. Always

stop the pump at the

drying on the exposed displacement rod and damaging the throat packings.

Always flush the pump before the fluid dries on the displacement

rod. Never leave water or water-based fluid in the pump overnight. First, flush with water or a compatible solvent, then with mineral spirits. Relieve the pressure,

but leave the

the

parts from corrosion.

mineral spirits in the pump to protect

AIR MOT

OR PLA

Fig 2

0423

 7

TROUBLESHOOTING

CHART

PROBLEM CAUSE SOLUTION

Pump

fails to operate

Restricted line or inadequate air supply

Clear; see

TECHNICAL DATA

on pages 24-29.

Pump operates, but out-

low on both strokes

put

Pump operates, but out-

low on downstroke

put

Pump operates, but out-

low on upstroke

put

Erratic or accelerated

speed

pump

Obstructed fluid hose or gun/valve; fluid hose ID is too small

Fluid dried on the displacement rod

Dirty

, worn, or damaged motor parts

Restricted line or inadequate air supply

Obstructed fluid hose or gun/valve; fluid hose ID is too small

Bleeder valve open

Air leaking into supply container

Fluid too heavy for pump priming

orn packings in displacement pump

Fluid too heavy for pump priming

Held open or worn intake valve or seals

Held open or worn piston valve or seals

Exhausted fluid supply

Fluid too heavy for pump priming

Open, clear*; use hose with larger ID.

Clean; always stop pump at bottom of stroke; keep wet-cup 1/3 filled with compatible solvent.

Clean or repair; see air motor manual, supplied.

Clear; see

TECHNICAL DATA

on pages 24-29.

Open, clear*; use hose with larger ID.

Close.

Check wiper plate or ram plate seal.

Use bleeder valve (see page 6). Use inductor or ram. Remove piston spacer (33).**

Replace packings.

Use bleeder valve (see page 6). Use inductor or ram. Remove piston spacer (33).**

Clear valve; replace seals.

Refill and prime.

Use bleeder valve (see page 6). Use inductor or ram. Remove piston spacer (33).**

Held open or worn piston valve or seals

Held open or worn priming piston

orn packings in displacement pump

*To

determine if the fluid hose or gun is obstructed, follow the container when

Remove the piston spacer (33) only as a last resort, as the pump may not perform well without it.

NOTE:

at the pump fluid outlet to catch any fluid. T

the air is turned on, the obstruction is in the fluid hose or gun.

If you experience air motor icing, call Graco T

Pressure Relief Procedure W

urn on

the air just enough to start the pump (about 1.4-2.8 bar [20-40 psi]).. If the pump starts

echnical Assistance

Clear valve; replace seals.

Clear; service.

Replace packings.

(1-800-543-0339).

WARNING

Pressure

To tion, ing the dispensing system, when installing, cleaning or changing spray tips/nozzles, and whenever you stop spraying/dispensing.

1. Engage

3. Close the bleed-type master air valve (required in your

4. Disengage

Relief Procedure

reduce the risk of serious bodily injury

, including fluid injec

splashing in the eyes or on the skin, or injury from mov

parts, always follow this

pump, when checking or servicing

procedure whenever you shut of

any part of the spray/

the spray gun/dispensing valve safety latch.

Shut of

f the air to the pump.

system).

the gun/valve safety latch.

Hold a metal part of the gun/valve firmly to the side of a grounded pressure.

6. Engage

7. Open

the gun/valve safety latch.

the drain valve (required

pump bleeder valve, having a container ready to catch

drainage.

the

8. Leave

you suspect that the spray tip/nozzle or hose is completely

clogged, lowing

the drain valve open until

dispense

again.

or that pressure has not been fully relieved after fol

the steps above,

retaining nut or hose end coupling and relieve pressure gradually,

then loosen completely

arning

below

. Disconnect the fluid hose

metal

pail, and trigger the gun/valve to relieve

in your system) and/or the

you are ready to spray/

VER

Y SLOWL

Y loosen the tip guard

. Now clear the tip or hose.

and place a

8 

SERVICE

REQUIRED TOOLS

 T

orque wrench



Bench vise, with soft jaws

 Hammer 

Rubber mallet

 13 mm (1/2”) dia. brass rod

O-ring pick

  11

mm, 12 mm, 19 mm, 22 mm, 26 mm, and 28 mm

open-end



17 mm box or socket wrench



32 mm crow’s-foot wrench



400 mm adjustable wrench



Set of adjustable wrenches



Thread lubricant



Anaerobic thread sealant

wrenches

DISCONNECTING THE DISPLACEMENT PUMP

WARNING

KEEP HANDS AND FINGERS AWAY FROM

THE PRIMING PISTON DURING OPERA TION AND WHENEVER

THE PUMP IS CHARGED WITH AIR

to reduce the risk of injury! On the pump down-

stroke

the priming piston extends beyond the intake cylinder ing tion

to pull the material into the pump. The prim

piston works under extreme

force. During opera

and whenever the pump is charged with air

, the

priming piston can severely injure or amputate a

or finger

hand the

intake cylinder

, or

break a tool, caught between it and

. Always follow the

Pressure Re

lief Procedure Warning on page 8, before check-

ing,

clearing, cleaning, flushing or

the pump.

servicing any part

The air motor piston (located behind the air motor

or shield) also moves when air is supplied to

plates the motor. NEVER operate the pump with the air motor plates or shield removed. Before servicing the pump, follow the Pressure Relief Procedure

Warning

ing

1. Flush tom

dure

on page 8, to prevent the

accidentally

pump from start

the pump if possible. Stop the pump at the bot

of its stroke.

arning

Follow the

on page 8.

Pressure Relief Proce

2. Disconnect the air hose. Hold the fluid outlet fitting (8)

with a 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 motor’s air inlet.

3. Using an adjustable wrench, unscrew the coupling nut

(104) from the connecting rod (103). Remove the

coupling

4. Hold turning. 17 locknuts the

5. Refer service manual,

collars (105). See Fig 3.

the tie rod flats with a wrench to keep them from

Use the wrench provided with the

pump (or a

mm box or socket wrench) to unscrew the tie rod

(106) from the tie rods (102). Carefully

displacement

pump (107) of

f the air motor (101).

pull

to page 10 for displacement pump service. T

the air motor

, refer to the

separate air motor

supplied.

RECONNECTING THE DISPLACEMENT PUMP

1. Orient

the pump’

as was noted in step 2 under

let

s fluid outlet to the air motor’s air in

Disconnecting the

Displacement Pump. Position the displacement

pump

(107) on the tie rods (102). See Fig 3.

NOTE: If

you removed the tie rods (102) from the air tor (101) or air motor adapter plate, reinstall them

using an 1

1 mm wrench. T

orque 20-25 N.m (15-18 ft-lb) on President pumps, and 36-45

N.m (27-33 ft-lb) on all other pumps.

2. Screw

the locknuts

(106) onto the tie rods (102) and torque to 27-34 N.m (20-25 ft-lb), using the wrench provided

(or a 17 mm box or socket wrench).

3. Place the coupling nut (104) on the displacement then place the coupling collars (105) in the nut.

rod, Screw

the coupling nut onto the connecting rod (103) loosely. Hold the connecting rod flats to keep it from turning. With an adjustable wrench,

the coupling nut to 50-61 N.m (37-45 ft-lb).

torque

4. Using a torque wrench in the square hole of the supplied

wrench (1

10), torque the packing

45-53 N.m (33-39 ft-lb).

5. Mount

the pump and reconnect all hoses. Reconnect

the

ground wire if it was

on the air and run the pump slowly

Turn

disconnected during repair

6. Fill the packing nut/wet-cup 1/3 full of Graco Throat Seal

Liquid or compatible solvent.

101

103

111

102

104

TORQUE TO

50-61 N.m

(37-45 ft-lb)

105

TORQUE TO 20-25 N.m (15-18 ft-lb) ON PRESIDENT PUMPS; 36-45 N.m (27-33 ft-lb) ON ALL OTHER PUMPS

110

107

TORQUE TO 45-53 N.m (33-39 ft-lb)

106

TORQUE TO 27-34 N.m (20-25 ft-lb)

MODEL 222-768 PRESIDENT PUMP SHOWN

Fig 3

 9

the rods to

with a wrench

nut (2) to

0424

DISPLACEMENT

PUMP SER

VICE

Disassembly

When

disassembling the pump, lay out all removed parts

sequence, to ease reassembly

NOTE: Repair

Kit 222-773 is available to replace the pis

ton

and intake valve seals. For

. Refer to Fig 6.

the best results, use all the new parts in the kit. Kit parts are marked

with one asterisk, for example (1

1*).

Repair Kit 222-774 is available to replace the throat

packings. For the best results, use all the

new

parts in the kit. Kit parts are marked with two

asterisks,

for example (3**).

1. Remove the displacement pump from the air motor as explained on page 9. Place the pump in a vise,

the jaws on the outlet housing (10).

with

2. Hold

the flats of the priming piston rod (24) with a 12 mm wrench. Using a 22 mm wrench, unscrew the priming and of other

piston nut (30). Slide the priming piston (25)

piston guide (31) of

f the rod.

Inspect the surfaces

the guide (31) and piston (25) for scoring, wear

damage.

, or

10. Inspect the outer surfaces of the displacement rod (1) and priming piston rod (24) for wear , scoring or other damage by holding them up to the light at an angle

or running a finger over the surface.

11. Use

a vise with soft jaws

(1)

by its flats.

Place a 19 mm wrench on the flats of

to hold the displacement rod

the piston and unscrew the piston (13) and priming piston rod (24) from the displacement rod (1). Remove

the spacer (33). Disassemble the piston guide

(14)

from the piston (13).

12.

It is not necessary to remove the priming piston rod (24) from the piston (13) unless your inspection reveals scoring, wear, or other damage to either part. To disassemble, place the piston flats in a vise and unscrew

13. Place a

13 mm (1/2 in.) dia. brass rod,

the rod, using a 12 mm wrench on the flats.

the flats of the piston seat (16) in a vise. Using

unscrew the piston

guide (14) from the piston seat (16). See Fig 4. Re-

the piston seal (15); always replace with a new

move one. Inspect the mating surfaces of the piston (13) and

piston seat (16) for nicks, scoring or wear

BRASS ROD

3. Loosen the packing nut (2) using the wrench (1 10) supplied, take

4. Unscrew der

or a hammer and brass rod. Remove the in

cylinder (23), using an adjustable wrench.

the intake valve housing (17) from the

(12),

using an adjustable wrench. Pull the hous

cylin

ing off the pump. The intake check valve assembly (S)

should slide down the priming piston rod (24)

as you remove the housing; if it does not slide easily , firmly

tap on

the top of the housing (17) with a rubber

mallet

to loosen.

5. Use an o-ring pick to remove the seal (21) from the intake valve housing (17). Discard the seal; use a new one for reassembly. Pull the intake valve seat (22)

out the bottom of

the housing (17). If the seat is difficult to remove, insert a hammer and brass rod through the top of the housing and drive the seat out.Take (S) as it comes free, and set it aside for later

6. Push

care not to drop the check valve assembly

the displacement

rod (1) down as far as possi

ble, then pull it and the priming piston rod (24) out of the

outlet housing (10) and cylinder (12).

7. Remove the packing nut (2), throat packings (3, 5) and glands (4, 6) from the outlet housing (10). DO

NOT

remove the

from

the housing unless they need replacement.

fluid outlet nipple (8) and o-ring (9)

Fig 4

14. To

disassemble the intake check valve (S), place the

nut

(18) in a vise and unscrew the intake valve body

(19),

using a 28 mm wrench. See Fig 5. Remove the

seals

(42, 20) from the nut and from the valve body;

always

replace them with new ones. Inspect the mat ing surfaces of the intake valve body (19) and seat (22)

for wear

NOTE: The

require

, scoring, or other damage.

seal (42) is press-fit in the nut

cutting to ease removal.

(18) and may

0205

8. Unscrew housing.

the handle of the bleeder valve (35) from

Clean the threads and the bleed hole in the

valve housing. It is not necessary to remove the

housing from the outlet housing (10).

valve

9. Use

a 400 mm adjustable wrench on the flats of the

pump

cylinder

outlet

housing (10). Remove the

the

inside surface of the cylinder for wear

other

damage by holding it up to the light at an angle

running a finger over the surface.

(12) and unscrew the cylinder from the

o-rings (1

10 

its

1). Inspect

, scoring or

0206

Fig 5

15. Inspect all parts for damage and clean with a compatible

solvent. T

o reassemble, refer to page 12.

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