Graco 308351K User Manual

Instructions

Parts

CARBON STEEL

Check–Mate™ 800 Pumps

With Priming Piston and Severe–Duty Rod and Cylinder

Refer to page 2 for Table of Contents.

US Patent Nos. 5,147,188 and 5,154,532. Other patents pending.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions. See page 2 for model

numbers and maximum working pressures.

Models 237265,

246940 and 246941

Models 198466

and 246938

Models 236471

and 246942

308351K

04995

4990B

ti1447a

GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441

Table of Contents

List of Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation/Maintenance 12. . . . . . . . . . . . . . . . . . . . . . . .

Service

Troubleshooting 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required Tools 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disconnecting the Displacement Pump 18. . . . . . . .

Reconnecting the Displacement Pump 19. . . . . . . .

Displacement Pump Service 20. . . . . . . . . . . . . . . . .

Parts 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data and Performance Chart 38. . . . . . . . . . .

Dimensions 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Hole Layout 49. . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Standard Warranty 50. . . . . . . . . . . . . . . . . . . . . .

Graco Information 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Models

Maximum Fluid

Part No. Series Pump Model Ratio

236471 B Kingt 65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)

237265 B Reduced Icing

Quiet Kingt

240945 B Quiet Kingt 65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)

65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)

Working Pressure

Maximum Air (or Hydraulic*) Input Pressure

253376 B Quiet Kingt 65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)

237261 A Bulldogr 31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)

241901 A Bulldogr

(55 Gallon/200 Liter Size)

237274 A Reduced Icing

Quiet Bulldogr

237264 A Senatorr 19:1 15 MPa, 157 bar (2280 psi) 0.8 MPa, 8.4 bar (120 psi)

198475 A Quiet Kingt 65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)

198466 A Viscountr II 40 MPa, 403 bar (5850 psi) 10.3 MPa*, 103 bar* (1500 psi*)

246942 A Kingt 65:1 48 MPa, 483 bar (7000 psi) 0.7 MPa, 7 bar (100 psi)

246940 A Bulldogr 31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)

246941 A Senatorr 19:1 15 MPa, 157 bar (2280 psi) 0.8 MPa, 8.4 bar (120 psi)

246938 A Viscountr II 40 MPa, 403 bar (5850 psi) 10.3 MPa*, 103 bar* (1500 psi*)

31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)

2 308351

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

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 not sure, call your Graco distributor.

D Do not alter or modify this equipment.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

D Check equipment daily. Repair or replace worn or damaged parts immediately.

D Do not exceed the maximum working pressure stated on the equipment or in the Technical Data

for your equipment. Do not exceed the maximum working pressure of the lowest rated component in your system.

D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-

nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

D Do not use hoses to pull equipment.

D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose

Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).

D Wear hearing protection when operating this equipment.

D Do not lift pressurized equipment.

D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

308351 3

WARNING

SKIN INJECTION HAZARD

Spray from the spray gun/dispense valve, 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 surgi-

cal treatment.

D Do not point the gun/valve at anyone or at any part of the body.

D Do not put your hand or fingers over the spray tip/nozzle.

D Do not stop or deflect leaks with your hand, body, glove or rag.

D Do not “blow back” fluid; this is not an air spray system.

D Always have the tip guard and the trigger guard on the gun when spraying.

D Check the gun diffuser operation weekly. Refer to the gun manual.

D Be sure the gun/valve trigger safety operates before spraying.

D Lock the gun/valve trigger safety when you stop spraying.

D Follow the Pressure Relief Procedure on page 12 if the spray tip/nozzle clogs and before clean-

ing, checking or servicing the equipment.

D Tighten all fluid connections before operating the equipment.

D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not

repair high pressure couplings; you must replace the entire hose.

D Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by

kinks or bends near the couplings.

MOVING PARTS HAZARD

Moving parts, such as the priming piston, can pinch or amputate your fingers.

D Keep clear of all moving parts when starting or operating the pump.

D Before servicing the equipment, follow the Pressure Relief Procedure on page 12 to prevent the

equipment from starting unexpectedly.

4 308351

WARNING

FIRE AND EXPLOSION HAZARD

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury.

D Ground the equipment and the object being sprayed. Refer to Grounding on page 6.

D If there is any static sparking or you feel an electric shock while using this equipment, stop spray-

ing/dispensing immediately. Do not use the equipment until you identify and correct the problem.

D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid

being sprayed/dispensed.

D Keep the spray/dispense area free of debris, including solvent, rags, and gasoline.

D Electrically disconnect all equipment in the spray/dispense area.

D Extinguish all open flames or pilot lights in the spray/dispense area.

D Do not smoke in the spray/dispense area.

D Do not turn on or off any light switch in the spray/dispense area while operating or if fumes are

present.

D Do not operate a gasoline engine in the spray/dispense area.

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed.

D Know the specific hazards of the fluid you are using.

D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,

state and national guidelines.

D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and

solvent manufacturer.

308351 5

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 mm2 (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. 222011 Ground Wire and Clamp.

0864

Fig. 2

2. Air and fluid hoses: use only electrically conductive hoses.

3. Air compressor: follow manufacturer’s recommendations.

4. Spray gun/dispense valve: ground through connection to a properly grounded fluid hose and pump.

5. Fluid supply container: follow your local code.

6. Object being sprayed: follow your local code.

Fig. 1

7. All solvent pails used when flushing: follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not

TI1052

place the pail on a nonconductive surface, such as paper or cardboard, which interrupts the grounding continuity.

8. To maintain grounding continuity when flushing or relieving pressure, always hold a metal part of the gun/valve firmly to the side of a grounded metal pail, then trigger the gun/valve.

6 308351

Installation

All Systems

NOTE: Reference numbers and letters in parentheses

in the text refer to the callouts in the figures and parts drawings.

The Typical Installations shown in Figs. 3 and 4 are only guides for selecting and installing system components and accessories. Contact your Graco distributor for assistance in designing a system to suit your particular needs.

Accessories are available from Graco. If you supply your own accessories, be sure they are adequately sized and pressure–rated to meet the system’s requirements.

System Accessories

Air and Fluid Hoses

Be sure all air hoses and fluid hoses are properly sized and pressure-rated for your system. Use only electrically conductive hoses. Fluid hoses must have spring guards on both ends.

Mounting Accessories (Except 198466, 198475 and

246938)

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 page 49.

If you are mounting the pump on a ram, refer to the separate ram manual for installation and operation instructions. Mounting Kit 222776 is available to mount the pump on a 55 gallon (200 liter) ram.

308351 7

Installation (Air–Powered Pumps)

KEY

A Pump B 200 Liter (55 Gallon) Air-Powered Ram C Main Air Bleed Valve (required, for pump and ram) D Air Line Lubricator (position only) E Pump Air Bleed Valve (required, for pump) F Pump Air Regulator G Air Manifold H Electrically Conductive Air Supply Hose J Air Line Filter K Air Shutoff 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 U Ram Director Valve V Pump Runaway Valve (position only) W Air LIne Drain Valve Y Ground Wire (required, see page 6 for

installation instructions)

MAIN AIR LINE

FLUID HEADER PIPE (3 in. Diameter)

Fig. 3

05097

8 308351

Installation (Air–Powered Pumps)

WARNING

A main air bleed valve (C), pump air bleed valve (E), and fluid drain valve (M) are required. 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 main air bleed valve (C) shuts off the air to the pump and ram. The pump air bleed valve (E) 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. 107141.

D A pump runaway valve (V) 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. Locate in the position shown.

D 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) and ram director valve (U).

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

moisture from the compressed air supply. Also, install a drain valve (W) at the bottom of each air line drop, to drain off moisture.

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 Part No. 210658.

Air Line Accessories

Install the following accessories in the order shown in Fig. 3, using adapters as necessary:

D An air line lubricator (D) provides automatic air

motor lubrication. Locate in the position shown.

D A main air bleed valve (C) is required in your

system to shut off the air supply to the pump and ram (see the WARNING above). When closed, the valve will bleed off all air in the ram and pump, and the ram will slowly lower. Be sure the valve is easily accessible from the pump, and is located upstream from the air manifold (G).

D A pump air bleed 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 at left). Be sure the bleed valve is easily accessible from the pump, and is located downstream from the air regulator.

D 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 pump air bleed valve.

D An air shutoff valve (K) isolates the air line acces-

sories for servicing. Locate upstream from all other air line accessories.

Fluid Line Accessories

Install the following accessories in the positions shown in Figs. 3 and 4, using adapters as necessary:

D Install a fluid shutoff valve (P) at each gun/valve

drop, to isolate the gun/valve and fluid accessories for servicing.

D Install a fluid drain valve (M) near the pump fluid

outlet, and at each gun/valve station. The drain valves are required in your system to relieve fluid pressure in the displacement pump, hose and gun/valve (see the WARNING at left). Drain valves at the gun/valve stations may be mounted in the base of a fluid regulator (L), using an adapter.

D A fluid regulator (L) controls fluid pressure to the

gun/valve, and dampens pressure surges.

D A gun or dispense valve (S) dispenses the fluid.

The gun shown in Fig. 3 is a high pressure dispensing gun for highly viscous fluids.

D A gun/valve swivel (R) allows freer gun/valve

movement.

308351 9

Installation (Hydraulic–Powered Pumps)

KEY

A Accessory Pump Stand

(P/N 218742)

B Surge Tank (P/N 218509 or

238983) C 50 mm (2 in.) Diameter Pipe D Full Flow, Non-Restrictive

Fluid Shutoff Valve E Fluid Supply Line F Mix Tank G Hydraulic Supply Line

Shutoff Valve

H Hydraulic Pressure Gauge J Flow Control Valve K Pressure Reducing Valve L Drain Line M Hydraulic Return Line

Shutoff Valve N Accumulator P Hydraulic Supply Line Q Hydraulic Return Line Y Ground Wire (required,

see page 6)

Fig. 4

01408

10 308351

Installation (Hydraulic–Powered Pumps)

NOTE: Hydraulic fluid is exhausted from differential

CAUTION

The Hydraulic Power Supply must be kept clean at all times to avoid damage to the motor and hydraulic power supply.

1. Blow out hydraulic lines with air and flush thoroughly before connection to the motor.

2. Plug hydraulic inlets, outlets, and line ends when disconnecting them for any reason.

Always plug the hydraulic inlets, outlets and lines when disconnecting them for any reason to avoid introducing dirt and other contaminants into the system.

Be sure that your hydraulic power supply is equipped with a suction filter to the hydraulic pump and a system return line filter of 10 micron size. Carefully follow the manufacturer’s recommendations on reservoir and filter cleaning and periodic changes of hydraulic fluid.

hydraulic motors only on the upstroke of the operating cycle. The oil return line must have at least twice the flow capacity as the oil supply line. Otherwise, back pressure on the hydraulic motor piston will slow down the motor and the fluid displacement pump, resulting in a loss of pump performance.

On the hydraulic oil supply line (P), install a shutoff valve (G) to isolate the system for servicing; a fluid pressure gauge (H) to monitor hydraulic oil pressure to the motor and avoid overpressurizing the motor or displacement pump; a pressure- and temperaturecompensated flow control valve (J) to prevent the motor from running too fast; a pressure reducing valve (K) with a drain line (L) running directly into the hydraulic return line (Q); and an accumulator (N) to reduce the hammering effect caused by the motor reversing direction.

On the hydraulic return line (Q), install a shutoff valve (M) for isolating the motor for servicing.

308351 11

Pressure Relief Procedure

Operation

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/dispensing, D check or service any of the system equipment, D or install or clean the spray tip/nozzle.

1. Lock the gun/valve trigger safety.

2. Shut off the power to the pump.

3. In an air-powered system, close the air regulator and close the bleed-type master air valve.

4. In a hydraulic-powered system, close the hydraulic supply line shutoff valve first, then the return line shutoff valve.

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure at left.

The packing nut is torqued at the factory and is ready for operation. If it becomes loose and there is leaking from the throat packings, relieve pressure, then torque the nut to 128–156 N.m (95–115 ft-lb) using the supplied wrench (109). Do this whenever necessary. Do not overtighten the packing nut.

109

5. Unlock the gun/valve trigger safety.

6. 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.

7. Lock the gun/valve trigger safety.

8. In an air–powered system, open the drain valve (required in your system), having a container ready to catch the drainage. Leave the drain valve open until you are ready to spray/dispense again.

If you suspect that the spray tip/nozzle or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip/nozzle or hose.

Packing Nut/Wet-Cup

Before starting, fill the packing nut (2) 1/3 full with Graco Throat Seal Liquid (TSL) or compatible solvent. See Fig. 5.

Fig. 5

129

Bleed hole must

face down.

Torque to 128–156 N.m

(95–115 ft-lb).

04995

12 308351

Flush the Pump Before First Use

Operation

WARNING

The pump is tested with lightweight oil, which is left in to protect the pump parts. If the fluid you are using may be contaminated by the oil, flush it out with a compatible solvent. See Flushing on page 16.

Starting and Adjusting the Pump

WARNING

MOVING PARTS HAZARD

Keep hands and fingers away from the priming piston (21) during operation and

whenever the pump is charged with air. The priming piston extends beyond the intake housing (19) to pull material into the pump and can amputate a hand or finger caught between it and the intake housing. Follow the Pressure Relief Procedure on page 12, before checking, clearing, or cleaning the priming piston.

COMPONENT RUPTURE HAZARD

To reduce the risk of overpressurizing your system, which could cause component rupture and serious injury, never

exceed the Maximum Input Pressure to the pump

(see the Technical Data on pages 38–46).

Air–Powered Systems

1. Supply fluid to the pump, per the requirements of your system.

2. See Fig. 3. Close the air regulator (F).

3. Open all air bleed valves (C, E).

4. Hold a metal part of the gun/valve (S) firmly to the side of a grounded metal pail and hold the trigger open.

5. Slowly open the air regulator until the pump starts.

6. Cycle the pump slowly until all air is pushed out and the pump and hoses are fully primed.

7. Release the gun/valve trigger and lock the trigger safety. The pump should stall against pressure.

WARNING

SKIN INJECTION HAZARD

To reduce the risk of fluid injection, do not use your hand or fingers to cover the bleed hole on the underside of the bleeder valve body (29) when priming the pump. Use a crescent wrench to open and close the bleeder plug (20). Keep your hands away from the bleed hole.

CAUTION

Do not allow the pump to run dry. It will quickly accelerate to a high speed, causing damage. If your pump is running too fast, stop it immediately and check the fluid supply. If the container is empty and air has been pumped into the lines, refill the container and prime the pump and the lines, or flush and leave it filled with a compatible solvent. Eliminate all air from the fluid system.

8. If the pump fails to prime properly, open the bleeder valve plug (20) slightly. Use the bleed hole, on the underside of the valve body (29), as a priming valve until the fluid appears at the hole. See Fig. 5. Close the plug.

NOTE: When changing fluid containers with the hose and gun/valve already primed, open the bleeder valve plug (20), to help prime the pump and vent air before it enters the hose. Close the plug when all air is eliminated.

9. With the pump and lines primed, and with adequate air pressure and volume supplied, the pump will start and stop as you open and close the gun/valve. In a circulating system, the pump will speed up or slow down on demand, until the air supply is shut off.

10. Use the air regulator (F) to control the pump speed and the fluid pressure. Always use the lowest air pressure necessary to get the desired results. Higher pressures cause premature tip/nozzle and pump wear.

308351 13

Operation

Hydraulic–Powered Systems

Refer to the warnings on page 13.

1. Supply fluid to the pump, per the requirements of your system.

2. Open the shutoff valves between the pump and supply tanks.

3. Open the dispensing valve(s) or spray gun(s).

4. To adjust the system, perform the following procedure:

a. Turn on the hydraulic power supply.

b. Open the flow control valve all the way.

c. Adjust the pressure–reducing valve until you

get the desired fluid pressure. Run the pump until all air is purged from the fluid lines.

d. Count the cycle rate of the pump.

e. Close the flow control valve until the cycle rate

and fluid pressure start to drop.

f. Open the flow control valve slightly until the

cycle rate and fluid pressure return to the desired level. This method of setting the hydraulic controls ensures proper pump operation and will prevent pump runaway and damage if the fluid supply runs out.

g. Close the gun or valve.

14 308351

Notes

308351 15

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