Graco 308149P User Manual
Instructions – Parts List
Parts
CARBON STEEL
Check–Matet2100 Pumps
With Priming Piston, and Severe–Duty Rod and Cylinder
Part No. 222828 Pump, Series A
Part No. 246935 Pump, Series A
12:1 Ratio, with Bulldogr Air Motor
8.3 MPa, 83 bar (1200 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure
Part No. 222829 Pump, Series A
12:1 Ratio, with Quiet Bulldogr Air Motor
8.3 MPa, 83 bar (1200 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure
Part No. 222835 Pump, Series A
Part No. 246936 Pump, Series A
24:1 Ratio, with Kingt Air Motor
16.6 MPa, 166 bar (2400 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure
Part No. 222901 Pump, Series B
24:1 Ratio, with Quiet Kingt Air Motor
16.6 MPa, 166 bar (2400 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure
308149P
Part No. 222940 Pump, Series A
39:1 Ratio, with Premiert Air Motor
26.9 MPa, 269 bar (3900 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure
Part No. 222902 Pump, Series B
Part No. 246937 Pump, Series A
with Viscountr Hydraulic Motor
15.9 MPa, 159 bar (2300 psi) Maximum Fluid Working Pressure
10 MPa, 103 bar (1500 psi) Maximum Hydraulic Input Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Table of Contents.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
Part No.
222835
Shown
Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation (Air-Powered Pumps) 8. . . . . . . . . . . . . . . . .
Installation (Hydraulic-Powered Pumps) 10. . . . . . . . . .
Operation/Maintenance
All Models 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air-Powered Models 12. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic-Powered Models 14. . . . . . . . . . . . . . . . . .
Service
Troubleshooting Chart 15. . . . . . . . . . . . . . . . . . . . . . .
Required Tools 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting the Displacement Pump 16. . . . . . . .
Reconnecting the Displacement Pump 18. . . . . . . .
Displacement Pump Service 19. . . . . . . . . . . . . . . . .
Parts Drawings and Lists
Pump Assemblies 25. . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 28. . . . . . . . . . . . . . . . . . . . . . . .
Technical Data and Performance Charts 30. . . . . . . . . .
Dimensions 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 37. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 38. . . . . . . . . . . . . . . . . . . . . .
Graco Information 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 308149
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on pages 30–35 for the maximum working pressure of this equipment.
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.
Do not kink or overbend hoses or use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
Wear hearing protection when operating this equipment.
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
308149 3
WARNING
SKIN INJECTION HAZARD
Spray from the gun/valve, hose leaks, or ruptured components can inject fluid into your body and
cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the
skin can also cause serious injury.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi-
cal treatment.
Do not point the gun/valve at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip/nozzle.
Do not stop or deflect leaks with your hand, body, glove or rag.
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the gun/valve when spraying.
Be sure the gun/valve trigger safety operates before spraying.
Lock the gun/valve trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 12 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip/
nozzle.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
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.
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the Pressure Relief Procedure on page 12 to prevent the
equipment from starting unexpectedly.
4 308149
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
Ground the equipment and the object being sprayed. Refer to Grounding on page 7.
If there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not operate a gasoline engine in the spray area.
Keep a fire extinguisher in the work area.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
308149 5
Notes
6 308149
Installation
Grounding
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 5.
1. King Pumps: use a ground wire and clamp. See
Fig. 1. Remove the ground screw (Z) and insert
through eye of ring terminal at the end of ground
wire (Y). Fasten ground screw back onto pump
and tighten securely. Connect the other end of the
wire to a true earth ground. Order Part No. 222011
Ground Wire and Clamp.
All Other Pumps: use a ground wire and clamp.
See Fig. 2. Loosen the grounding lug locknut (W)
and washer (X). Insert one end of a 1.5 mm (12
ga) minimum ground wire (Y) into the slot in lug (Z)
and tighten the locknut securely. Connect the other
end of the wire to a true earth ground. Order Part
No. 237569 Ground Wire and Clamp.
7. Object being sprayed: according to your local
code.
8. All solvent pails used when flushing, according to
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.
9. To maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
spray gun/dispensing valve firmly to the side of a
grounded metal pail, then trigger the gun/valve.
Z
Y
2. Air and hydraulic hoses: use only electrically
conductive hoses.
3. Fluid hoses: use only electrically conductive fluid
hoses.
4. Air compressor or hydraulic power supply: follow
manufacturer’s recommendations.
5. Spray gun/dispensing valve: grounding is obtained
through connection to a properly grounded fluid
hose and pump.
6. Fluid supply container: according to your local
code.
Fig. 1
Fig. 2
TI1052
W
X
Y
Z
0864
308149 7
Installation
(AIR-POWERED PUMPS)
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawings.
Accessories are 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.
KEY
A Pump
B 200 Liter (55 Gallon) Air-Powered Ram
C Pump Runaway Valve
D Air Line Lubricator
E Bleed-Type Master Air Valve
(required, for pump)
F Pump Air Regulator
G Air Manifold
H Electrically Conductive Air Supply Hose
J Air Line Filter
JK
The Typical Installation shown in Fig. 3 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.
K Bleed-Type Master Air Valve (for accessories)
L Fluid Regulator
M Fluid Drain Valve (required)
N Electrically Conductive Fluid Supply Hose
P Fluid Shutoff Valve
R Gun/Valve Swivel
S Airless Spray Gun or Dispensing Valve
T Ram Air Regulator
Y Ground Wire (required, see page 7 for
installation instructions)
FLUID HEADER PIPE
(3 in. Diameter)
MAIN AIR LINE
Y
B
A
D
L
E
F
T
P
LP
C
H
G
S
R
M
N
M
N
M
R
S
Fig. 3
8 308149
01177A
Installation
(AIR-POWERED PUMPS)
SYSTEM ACCESSORIES
WARNING
A bleed-type master air valve (E) and a fluid drain
valve (M) are required in your system. These
accessories help reduce the risk of serious injury,
including fluid injection and splashing of fluid in the
eyes or on the skin, and injury from moving parts if
you are adjusting or repairing the pump.
The bleed-type master air valve relieves air trapped
between this valve and the pump after the air is
shut off. Trapped air can cause the pump to cycle
unexpectedly. Locate the valve close to the pump.
The fluid drain valve assists in relieving fluid pressure in the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may not be
sufficient.
Air and Fluid Hoses
Be sure all air hoses (H) and fluid hoses (N) are properly sized and pressure-rated for your system. Use
only electrically conductive hoses. Fluid hoses must
have spring guards on both ends.
A bleed-type master air valve (E) is required in
your system to relieve air trapped between it and
the air motor when the valve is closed (see the
WARNING above). Be sure the bleed valve is
easily accessible from the pump, and is located
downstream from the air regulator.
An air regulator (F) 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.
A pump runaway valve (C) senses when the
pump is running too fast and automatically shuts off
the air to the motor. A pump which runs too fast can
be seriously damaged.
An air manifold (G) has a swivel air inlet. It
mounts to a ram, and has ports for connecting lines
to air accessories, such as the ram air regulator
(T).
An air line filter (J) removes harmful dirt and
moisture from the compressed air supply.
A second bleed-type air valve (K) isolates the air
line accessories for servicing. Locate upstream
from all other air line accessories.
Mounting Accessories
WARNING
For Model 222940 Premier Pump, do not lift the
pump by the lift ring when the total weight exceeds
550 lb (250 kg).
Mount the pump (A) to suit the type of installation
planned. Fig. 3 on page 8 illustrates a ram-mounted
pump in a multi-gun header system. Pump dimensions
and the mounting hole layout are shown on pages 36
and 37.
If you are mounting the pump on a ram, refer to the
separate ram manual for installation and operation
instructions.
Air Line Accessories
Install the following accessories in the order shown in
Fig. 3, using adapters as necessary:
An air line lubricator (D) provides automatic air
motor lubrication.
Fluid Line Accessories
Install the following accessories in the positions shown
in Fig. 3, using adapters as necessary:
Install a fluid shutoff valve (P) at each gun drop,
to isolate the gun and fluid accessories for servicing.
Install a fluid drain valve (M) near the pump fluid
outlet, and at each gun station. The drain valves
are required in your system to relieve fluid pressure
in the displacement pump, hose and gun (see the
WARNING at left). Drain valves at the gun stations
may be mounted in the base of a fluid regulator
(L), using an adapter.
A fluid regulator (L) controls fluid pressure to the
gun/valve, and dampens pressure surges.
A gun or valve (S) dispenses the fluid. The gun
shown in Fig. 3 is a high pressure dispensing gun
for highly viscous fluids.
A gun swivel (R) allows freer gun movement.
308149 9
Installation
(HYDRAULIC-POWERED PUMPS)
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
Accessories are available from your Graco . If you
supply your own accessories, be sure they are adequately sized and pressure-rated to meet the system’s
requirements.
The Typical Installation shown in Fig. 4 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.
KEY
A Pump
B 200 Liter (55 Gallon) Air-Powered Ram
C Hydraulic Supply Line
D Hydraulic Return Line
E Drain Line (from pressure reducing valve)
F Pressure Gauge
G Flow Control Valve
H Pressure Reducing Valve
J Accumulator
K Drain Line (from motor drip pan)
L Fluid Regulator
M Fluid Drain Valve (required)
N Electrically Conductive Fluid
Supply Hose
P Fluid Shutoff Valve
R Gun/Valve Swivel
S Airless Spray Gun
or Dispensing Valve
T Ram Air Regulator
H
J
U Hydraulic Supply Line Shutoff Valve
V Hydraulic Return Line Shutoff Valve
Y Ground Wire (required, see page 7 for
installation instructions)
AA Hydraulic Return Line Filter
AIR FILTER FOR RAM
MAIN AIR LINE
F
UCV
CAUTION
It is very important to keep the hydraulic supply
system clean at all times. Be sure that all hydraulic
fluid lines are absolutely clean. Blow out the lines
with air and flush thoroughly with solvent before
connecting to the hydraulic motor, to avoid introducing harmful contaminants into the motor. Plug the
hydraulic lines immediately when they are disconnected.
Do not exceed 37.8 liter/min (10 gpm) hydraulic oil
volume to the motor, to avoid pump stalling.
For optimum pump performance, keep the temperature of the hydraulic oil below 54 C (130 F)
AIR SHUTOFF VALVE FOR RAM
FLUID HEADER PIPE
(3 in. Diameter)
A
B
Y
P
L
L
P
HYDRAULIC
POWER SUPPLY
DRAINAGE
CONTAINER
Fig. 4
10 308149
G
D
E
AA
T
S
R
M
K
MM
N
R
S
N
01178
Installation
(HYDRAULIC-POWERED PUMPS)
SYSTEM ACCESSORIES
WARNING
A fluid drain valve (M) is required in your system to
help reduce the risk of serious injury, including fluid
injection and splashing of fluid in the eyes or on the
skin if you are adjusting or repairing the pump.
The fluid drain valve assists in relieving fluid pressure in the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may not be
sufficient.
Mounting Accessories
Mount the pump (A) to suit the type of installation
planned. Fig. 4 on page 10 illustrates a ram-mounted
pump in a multi-gun header system. Pump dimensions
and the mounting hole layout are shown on pages 36
and 37.
If you are mounting the pump on a air-powered ram,
refer to the separate ram manual for installation and
operation instructions, and recommended air accessories.
A pressure reducing valve (H), with a drain line
(E) running into the hydraulic return line (D).
An accumulator (J) to reduce the hammering
effect caused by the motor reversing direction.
On the hydraulic return line (D), install the following
accessories in the order shown in Fig. 4, using adapters as necessary:
A shutoff valve (V) to isolate the pump for servic-
ing.
A filter (AA) of 10 micron size.
Hydraulic Motor Drip Pan
The hydraulic motor has a drip pan to collect any
leakage that may occur. Connect a 6 mm (1/4 in.) ID
drain line (K) to the barbed hose fitting on the drip pan,
and place the free end in a suitable container to receive the drainage.
Fluid Supply Hoses
Filters
Be sure your hydraulic power supply is equipped with a
suction filter to the hydraulic pump and a system return
line filter (AA) of 10 micron size.
Carefully follow the manufacturer’s recommendations
on reservoir and filter cleaning, and periodic changes
of hydraulic fluid. Use only Graco-approved hydraulic
oil. Order Part No. 169236, 5 gal. (19 liter) or 207428,
1 gal. (3.8 liter). Do not substitute a lower grade oil or
one with a lower flash point.
Hydraulic Lines
The motor has a 3/4 npt(f) hydraulic oil supply fitting,
and a 1” npt(f) hydraulic oil return fitting. Use a minimum 13 mm (1/2 in.) ID hydraulic supply line, and a
minimum 16 mm (5/8 in.) ID return line.
On the hydraulic supply line (C), install the following
accessories in the order shown in Fig. 4, using adapters as necessary:
A shutoff valve (U) to isolate the pump for servic-
ing.
Be sure the fluid supply hose (N) is properly sized and
pressure-rated for your system. Use only electrically
conductive hoses. Fluid hoses must have spring
guards on both ends.
Fluid Line Accessories
Install the following accessories in the positions shown
in Fig. 4, using adapters as necessary:
Install a fluid shutoff valve (P) at each gun drop,
to isolate the gun and fluid accessories for servicing.
Install a fluid drain valve (M) near the pump fluid
outlet, and at each gun station. The drain valves
are required in your system to relieve fluid pressure
in the displacement pump, hose and gun (see the
WARNING at left). Drain valves at the gun stations
may be mounted in the base of a fluid regulator
(L), using an adapter.
A fluid regulator (L) controls fluid pressure to the
gun/valve, and dampens pressure surges.
A fluid pressure gauge (F) to monitor hydraulic oil
pressure to the motor and to avoid overpressurizing
the motor or displacement pump, and a pressure-
and temperature-compensated flow control
valve (G) to prevent the motor from running too
fast and possibly damaging itself.
A gun or valve (S) dispenses the fluid. The gun
shown in Fig. 4 is a high pressure dispensing gun
for highly viscous fluids.
A gun swivel (R) allows freer gun movement.
308149 11
Operation
(ALL MODELS)
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
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:
are instructed to relieve the pressure,
stop spraying/dispensing,
check or service any of the system equipment,
or install or clean the spray tip/nozzle.
1. Engage the gun/valve trigger safety.
2. Shut off the air or hydraulic supply to the pump.
3. In air-powered systems, close the bleed-type
master air valve (required in your system). In
hydraulic-powered systems, close the hydraulic
supply line valve first, then the return line valve.
4. Unlock the gun/valve safety latch.
5. Hold a metal part of the gun/valve firmly to the side
of a grounded metal pail, and trigger the gun/valve
to relieve pressure.
6. Lock the gun/valve safety latch.
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 the drain valve open until you are ready to
spray/dispense again.
If you suspect that the spray tip/nozzle or hose is
completely clogged, or that pressure has not been fully
relieved after following the steps above, very slowly
loosen the tip guard retaining nut, nozzle, or hose end
coupling and relieve pressure gradually, then loosen
completely. Now clear the tip/nozzle or hose.
Packing Nut/Wet-Cup
Flushing the Pump
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.
WARNING
Before operating the pump, ground the system as
explained under FIRE AND EXPLOSION HAZARD
and Grounding on page 5.
(AIR-POWERED MODELS)
Starting and Adjusting the Pump
Supply fluid to the pump, per the requirements of your
system.
Refer to Fig. 3 on page 8. Be sure the air regulator
(F) is closed. Then open the pump’s bleed-type master
air valve (E). Hold a metal part of the spray gun/dispensing valve (S) firmly to the side of a grounded
metal pail and hold the trigger open. Now slowly open
the air regulator until the pump starts.
Cycle the pump slowly until all the air is pushed out
and the pump and hoses are fully primed. Release the
spray gun/dispensing valve trigger and engage the
safety latch. The pump should stall against pressure
when the trigger is released.
If the pump fails to prime properly, open the bleeder
valve plug (35) slightly. Use the bleed hole, on the
underside of the valve body (34), as a priming valve
until the fluid appears at the hole. See Fig. 5. Close the
plug (35).
NOTE: When changing fluid containers with the hose
and gun already primed, open the bleeder valve plug
(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.
Fill the packing nut/wet-cup (2) 1/3 full with Graco
Throat Seal Liquid (TSL) or compatible solvent. See
Fig. 5. Using the supplied wrench (104), adjust the
packing nut weekly so it is just snug; do not overtighten. Follow the Pressure Relief Procedure above
before adjusting the packing nut.
12 308149
WARNING
To reduce the risk of fluid injection, do not use your
hand or fingers to cover the bleed hole when
priming the pump.
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