Graco 311882Y, 295616 Instructions manual

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Page 1

Instructions

311882Y

2:1 Ratio Transfer Pump

For use with polyurethane foam, polyurea, and similar non-flammable materials. For professional use only.

Not approved for use in European explosive atmosphere locations.

Model 295616 (55-gallon drum)

180 psi (1.2 MPa, 12 bar) Maximum Air Working Pressure 405 psi (2.7 MPa, 27 bar) Maximum Fluid Working Pressure

Important Safety Instructions

Read all warnings and instructions in this manual before using the equipment. Save these instructions.

WLD

Page 2

Contents

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

Important Isocyanate (ISO) Information . . . . . . . . . 5

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 5

Material Self-Ignition . . . . . . . . . . . . . . . . . . . . . . 6

Keep Components A and B Separate . . . . . . . . . 6

Moisture Sensitivity of Isocyanates . . . . . . . . . . . 6

Foam Resins with 245 fa Blowing Agents . . . . . . 6

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 6

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Typical Installation, without Circulation . . . . . . . . 7

Typical Installation, with Circulation . . . . . . . . . . . 8

Typical Installation for Lubrication Applications . . 9

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

System Accessories. . . . . . . . . . . . . . . . . . . . . . 10

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 10

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . . 10

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Grounding the System . . . . . . . . . . . . . . . . . . . . 12

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Pressure Relief Procedure . . . . . . . . . . . . . . . . . 13

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Daily Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Daily Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . 14

Repair the Air Motor . . . . . . . . . . . . . . . . . . . . . . . . 15

Repair the Pump Lower . . . . . . . . . . . . . . . . . . . . . 17

Reassemble the Air Motor and the Pump

Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Parts - Model 295616 . . . . . . . . . . . . . . . . . . . . . . . 22

Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Performance Chart . . . . . . . . . . . . . . . . . . . . . . . . . 26

Calculate Fluid Outlet Pressure

(black curves). . . . . . . . . . . . . . . . . . . . . . . . 26

Calculate Pump Air Consumption

(gray curves) . . . . . . . . . . . . . . . . . . . . . . . . 26

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Technical Specifications . . . . . . . . . . . . . . . . . . . . 29

California Proposition 65 . . . . . . . . . . . . . . . . . . . . 29

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 30

Graco Information. . . . . . . . . . . . . . . . . . . . . . . . . . 30

2 311882Y

Page 3

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or swallowed.

• Read Safety Data Sheets (SDSs) for handling instructions and to know the specific hazards of the fluids you are using, including the effects of long-term exposure.

• When spraying, servicing equipment, or when in the work area, always keep work area well-ventilated and always wear appropriate personal protective equipment. See Personal Protective Equipment warnings in this manual.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

Always wear appropriate personal protective equipment and cover all skin when spraying, servicing equipment, or when in the work area. Protective equipment helps prevent serious injury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and hearing loss. This protective equipment includes but is not limited to:

• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.

• Protective eyewear and hearing protection.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Specifications in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

311882Y 3

Page 4

Warnings

WARNING

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

BURN HAZARD

Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply

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Page 5

Important Isocyanate (ISO) Information

Isocyanates (ISO) are catalysts used in two component materials.

Isocyanate Conditions

Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates.

• Read and understand the fluid manufacturer’s warnings and Safety Data Sheets (SDSs) to know specific hazards and precautions related to isocyanates.

• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you are trained, qualified, and have read and understood the information in this manual and in the fluid manufacturer’s application instructions and SDSs.

• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material, which could cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted according to instructions in the manual.

• To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work area must wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDSs.

• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.

• Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personal protective equipment must stay out of the work area during application and after application for the time period specified by the fluid manufacturer. Generally this time period is at least 24 hours.

• Warn others who may enter work area of hazard from exposure to isocyanates. Follow the recommendations of the fluid manufacturer and local regulatory authority. Posting a placard such as the following outside the work area is recommended:

TOXIC FUMES

HAZARD

DO NOT ENTER DURING

SPRAY FOAM APPLICATION OR FOR ___ HOURS AFTER

APPLICATION IS COMPLETE

DO NOT ENTER UNTIL:

DATE: TIME:

311882Y 5

____________ ____________

Page 6

Important Isocyanate (ISO) Information

Material Self-Ignition

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and Safety Data Sheets (SDSs).

Keep Components A and B Separate

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination:

• Never interchange component A and component B wetted parts.

• Never use solvent on one side if it has been contaminated from the other side.

NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

Foam Resins with 245 fa Blowing Agents

Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.

Changing Materials

NOTICE

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystal that become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity.

NOTICE

Partially cured ISO will reduce performance and the life of all wetted parts.

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Keep the ISO pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.

• Use only moisture-proof hoses compatible with ISO.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Always lubricate threaded parts with an appropriate lubricant when reassembling.

• Check with your material manufacturer for chemical compatibility.

• When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.

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Page 7

Typical Installation

Typical Installation, without Circulation

Typical Installation

FIG. 1: Typical Installation, without Circulation

Key:

A Reactor Proportioner B Heated Hose C Fluid Temperature Sensor (FTS) D Heated Whip Hose E Fusion Spray Gun F Proportioner and Gun Air Supply Hose G Feed Pump Air Supply Lines (3/8 in. (76 mm) ID min.

ti11572a

* Shown exposed for clarity. Wrap with tape during operation.

H Waste Containers J Fluid Supply Lines (217382) K Feed Pumps L Agitator M Desiccant Dryer N Bleed Lines/Over Pressure Relief P Gun Fluid Manifold

311882Y 7

Page 8

Typical Installation

Typical Installation, with Circulation

ti11571a

* Shown exposed for clarity. Wrap with tape during operation.

FIG. 2: Typical Installation, with Circulation

Key:

A Reactor Proportioner B Heated Hose C Fluid Temperature Sensor (FTS) D Heated Whip Hose E Fusion Spray Gun F Proportioner and Gun Air Supply Hose

8 311882Y

G Feed Pump Air Supply Lines (3/8 in. (76 mm) ID min) J Fluid Supply Lines K Feed Pumps L Agitator M Desiccant Dryer N Recirculation/Over Pressure Relief Return Hoses P Gun Fluid Manifold

Page 9

Typical Installation for Lubrication Applications

AA AB

Typical Installation

01349

FIG. 3: Typical Installation for Lubrication Applications

Key:

AA Pump Air Regulator AB Air Line Lubricator AC Air Line Filter AD Bleed-Type Master Air Valve (required, for pump) AE Fluid Drain Valve (required) AF Bung Adapter

311882Y 9

AG Grounded Air Hose AH Grounded Fluid Hose AJ Pump Fluid Inlet AK 1/4 npt(f) Pump Air Inlet AL 3/4 npt(f) Pump Fluid Outlet

Page 10

Installation

A bleed-type master air valve (D) and a fluid drain valve (E) are required in your system, to help reduce the risk of serious injury, including splashing fluid in the eyes or on the skin, and injury from moving parts when you are adjusting or repairing the pump.

• The bleed-type master air valve (D) relives air trapped between this valve and the pump after the pump is shut off. Trapped air can cause the pump to cycle unexpectedly and result in serious injury, including amputation. Install the valve close to the pump.

• The fluid drain valve (E) helps relieve pressure in the displacement pump, hose, and dispensing valve when shutting off the pump. Actuating the dispensing valve to relieve pressure may not be sufficient, especially if there is a clog in the hose or the spray gun or dispensing valve.

System Accessories

Air Line Accessories

Install the following accessories in the order shown in the Gun Fluid Manifold, page 8, using adapters as necessary:

An air line lubricator (AB) provides automatic air motor lubrication.

A bleed-type master air valve (AD) is required in your system to relieve air trapped between it and the air motor when the valve is closed (see the WARNING on left). Be sure the bleed valve is easily accessible from the pump, and is located downstream from the air regulator.

An air line filter (AC) to remove harmful dirt and moisture from the compressed air supply.

A second bleed-type air valve (AD) isolates the air line accessories for servicing. Locate upstream from all other air line accessories.

To ensure maximum pump performance, be sure that all accessories used are properly sized to meet your system’s requirements. See Accessories, page 24.

Fluid Line Accessories

A fluid drain valve (BA) is required in your system to

relieve fluid pressure in the hose and gun (see the WARNING on left). Install the drain valve so that it points down and the handle points up when the valve is opened.

10 311882Y

Page 11

Setup

1. Apply thread sealant to the male threads of the air needle valve (48) and the quick disconnect fitting (49) and install. See FIG. 4

Apply thread sealant

WLD

FIG. 4

2. Apply thread sealant to the male outlet fitting (not supplied) and insert into the outlet port. See FIG. 5.

3. Use labels (70) provided to identify the appropriate pump for your material. See FIG. 5.

FIG. 6

4. Lubricate the bung adapter inside diameter and mounting threads. Install supplied handles and tighten the jam nuts. Install supplied handles and tighten the jam nuts. Ensure the gasket is in place and screw the bung adapter (51) securely into the bunghole of the drum. Insert the pump through the adapter and lock it in place. See FIG. 7.

Lubricate threads

Apply thread sealant

WLD

FIG. 5

WLE

FIG. 7

311882Y 11

Page 12

Setup

5. Install air line (3/8 in. (76 mm) ID minimum) with quick disconnect air coupler (52) provided. See FIG.

WLD

FIG. 8

Grounding the System

Pump: Connect Ground Wire (Y) to grounding screw

(72) and tighten the screw securely. See FIG. 9. Connect the other end of the wire to a true earth ground. Make certain to comply with all National, State, and Local Electrical Codes.

WLD

FIG. 9

Air compressor: Follow manufacturer’s

recommendations.

Fluid hoses: Use only grounded hoses with a maximum of 300 ft (91 m) combined hose length to ensure grounding continuity. Refer to Hose Grounding Continuity.

The equipment must be grounded to reduce the risk of static sparking. Static sparking can cause fumes to ignite or explode. Grounding provides an escape wire for the electric current.

To reduce the risk of static sparking, ground the pump and all other equipment used or located in the pumping area. Check your local electrical code for detailed grounding instructions for your area and type of equipment. Ground all of this equipment.

Dispensing valve: Ground through connection to a properly grounded fluid hose and pump.

Object being sprayed: Follow local code.

Fluid supply container: Follow local code.

Solvent pails used when flushing: Follow local code.

Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

To maintain grounding continuity when flushing or relieving pressure: Hold metal part of the spray

gun/dispense valve firmly to the side of a grounded metal pail, then trigger the gun/valve.

12 311882Y

Page 13

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Shut off the air to the pump.

2. Close the bleed-type master air valve (D).

3. Hold a metal part of the dispense valve firmly to a grounded metal pail. Trigger the valve to relieve pressure.

4. Open all fluid drain valves in the system, having a waste container ready to catch drainage. Leave drain valve(s) open until you are ready to dispense again.

5. If you suspect the nozzle or hose is clogged or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen the hose end coupling to relieve pressure gradually, then loosen completely. Clear hose or nozzle obstruction.

Flushing

To avoid fire and explosion, always ground equipment and waste container. To avoid static sparking and injury from splashing, always flush at the lowest possible pressure. Hot solvent may ignite. To avoid fire and explosion:

• Flush equipment only in a well-ventilated area

• Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary.

• Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts.

1. Follow Pressure Relief Procedure, page 13.

2. Allow the fluid in the system to cool.

3. Remove spray tip and soak in solvent.

4. Place pump fluid inlet in grounded metal pail containing cleaning fluid.

5. Set pump to lowest possible fluid pressure, and start pump.

6. Hold a metal part of the gun or dispense valve firmly to a grounded metal pail. Trigger the gun or dispense valve until clean solvent dispenses.

7. Remove gun or dispense valve from hose. See gun manual to further clean gun or dispense valve.

8. Follow Pressure Relief Procedure, page 13, and Remove fluid filter and soak in solvent. Replace filter cap.

311882Y 13

Page 14

Operation

Daily Startup

1. Verify that the air needle valve is closed.

2. Connect the air line quick disconnect coupler to the transfer pump

3. Turn on the main air supply.

4. Slowly open the air needle valve until the transfer pump runs slowly.

5. Use the air needle valve to control the pump speed.

NOTICE

Never allow the pump to run dry of the fluid being pumped. A dry pump will quickly accelerate to a high speed and could cause damage to the pump. If the pump accelerates quickly or starts running too fast, stop it immediately and check the fluid supply. If the supply container is empty or 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.

Daily Shutdown

1. Disconnect air line coupler.

2. When air pressure is bled off, close the air line needle valve.

Do not attempt to operate pump unless it is securely mounted in a drum.

14 311882Y

Page 15

Repair the Air Motor

NOTE: Air valve assembly has changed to series B for

improved performance. Parts are not interchangeable between series A and B air motor. Series A air valves can be upgraded to series B with kit 262042.

1. Relieve the pressure. Follow Pressure Relief Procedure, page 13.

2. Remove cap (1), cylinder (4), and square gaskets (3*). Inspect all parts, including spring under cap (not shown in FIG. 10) for damage and replace if necessary. See FIG. 10. Unscrew by hand or use a chain wrench to prevent distortion of the cylinder’s shape.

Repair the Air Motor

3. Series A air motors only: Loosen set screw (18) and unscrew air valve (5). If necessary to assist turning, wedge a screwdriver blade between the screw heads and the hex cap of air valve (5). Discard items 5, 13, 15, and 18. See FIG. 11.

*15

*13

ti9897b

WLD

FIG. 10

NOTE: Cap (1) was replaced with a spring stop

assembly for improved spring life. Existing pumps can be upgraded with Kit 24T043.

NOTE: Series A air motors have thin, flat, white seals in air valve. Series B (and later) air motors have thicker black seals in the air valve.

FIG. 11: Series A Air Valve

4. Series B (and later Air Motors): Unscrew air valve (5). If necessary to assist turning, wedge a screwdriver blade between the screw heads and the hex cap of the air valve (5). Inspect o-rings (13* and 15*) for damage and replace if necessary. Ensure o-ring (13*) is correctly positioned and not pinched. See FIG. 12.

*15

*13

WLD

FIG. 12 Series B Air Valve

311882Y 15

Page 16

Repair the Air Motor

5. Align slot of shield (75) with piston hole and place pin tool (69) in piston hole to prevent piston from turning. Use second pin tool (69) to unscrew piston cap (17) and separate from piston (21) to expose dowel pin (19). See FIG. 13.

WLD

FIG. 13

7. Slide air piston (21) out the top of the air motor base (23). Remove o-ring (24*) from air motor base. Inspect all parts, including the spring (22) in the air motor base, for damage. See FIG. 15.

*24

WLD

FIG. 15

6. Remove dowel pin (19) and take piston cap (17) off transfer shaft (20). Remove o-ring (50*) from piston cap. Inspect all parts for damage. See FIG. 14.

*50

WLD

FIG. 14

16 311882Y

Page 17

Repair the Pump Lower

1. Relieve the pressure. Follow Pressure Relief Procedure, page 13.

1. Allow the fluid in the system to cool.

2. Use a chain wrench near the top of the suction tube at the point indicated in FIG. 16, and a wrench on the flats of the foot valve (45) to loosen the foot valve from the suction tube (44). To prevent damage to the suction tube, do not remove the foot valve until instructed to do so in step 4.

Apply chain wrench approximately here

ti9976a

FIG. 16

3. With the foot valve still in place to support the suction tube, use a chain wrench near the bottom of the suction tube at the point indicated in FIG. 17, to loosen the suction tube (44) from the pump body (34).

4. Remove the foot valve assembly from the suction tube (44).

5. Remove retaining ring (46), snap ring (47), ball (71), and o-ring (38*) from foot valve (45). Inspect all parts for damage. See FIG. 17.

6. Remove suction tube (44) from pump body (34). See FIG. 18.

7. Inspect o-ring (38) on pump body and suction tube for damage. See FIG. 18.

Apply chain wrench approximately here

ti9976

NOTICE

When removing the suction tube, be very careful not to bend, dent, or damage it. To avoid damage, use the chain wrench only at the top and bottom of the suction tube as indicated in FIG. 16 and FIG. 17. Do not apply the wrench to the middle of the suction tube.

*38

ti9903

Apply chain wrench approximately here

FIG. 18

FIG. 17

311882Y 17

Page 18

Repair the Pump Lower

8. Pull transfer shaft (20) out the bottom of pump body (34). See FIG. 19.

ti9905

FIG. 19

10. Remove pins (55). See FIG. 21.

r_311880_14e_fig21

FIG. 21

NOTE: Series A and B pumps were equipped with

springs pins. In Series C pumps, these pins were replaced with a solid clevis pin (55, 56).

9. Remove pin (56). Remove piston valve assembly. Unscrew piston valve (43) from piston housing (53). Remove wear ring (41*), u-cup (40*) and ball (42). Inspect all parts for damage. See FIG. 20.

*40

Lip up

*41

ti9904b

FIG. 20

11. Loosen set screw (37) from collar (36). Remove collar from piston housing (54). Remove u-cup (35*). Inspect all parts for damage. See FIG. 22.

*35

Lip down

r_311882_14e_fig22

FIG. 22

18 311882Y

Page 19

Repair the Pump Lower

12. Unscrew mounting flange (26) from pump body (34). Remove o-ring (32*) and PTFE gasket (33*) from pump body (34). Inspect all parts for damage. See FIG. 23.

NOTE: Align a bottom slot of the shield (75) and use pin tool (69) to loosen the hex nut/packings from the pump shaft.

*32

*33

WLD

14. Unscrew three fasteners (60) to remove the flange (26) and tie-rods (25). Slide the guard (75) out. Unscrew the tie rods (25) using the wrench flats at the bottom.

FIG. 23

13. Remove hex nut (27) from mounting flange (26). Remove female gland (30*), 2 PTFE packings (29*), male gland (28*) and wiper (31*). Inspect all parts for damage. See FIG. 25.

*30

*29

*28

*31

FIG. 24

WLD

WLD

Seal stack enlarged to show detail.

FIG. 25

311882Y 19

Page 20

Reassemble the Air Motor and the Pump Lower

To reassemble the pump lower and air motor, reverse the steps on the preceding pages. Follow the torque requirements listed in the drawing on page 21.

NOTE: See Repair the Air Motor, page 15, step 4 and step 5 (FIG. 12) for special notes on reassembly.

20 311882Y

Page 21

Troubleshooting

1. Follow Pressure Relief Procedure, page 13, before checking or repairing pump.

2. Check all possible problems and causes before disassembling pump.

Problem Cause Solution

The pump fails to operate Dirty or worn air motor. Clean, service

Troubleshooting

Inadequate air supply or restricted lines.

Closed or clogged air valves. Open or clear the valves.

Clogged fluid hose or valve. Clear the hose or valves

Worn or damaged valves or seals. Service the valves or seals.

The pump operates, but the output is low on both strokes.

The pump operates, but the output is low on the downstroke.

The pump operates, but the output is low on the upstroke.

Erratic or accelerated operation. Exhausted fluid supply. Refill the fluid supply and reprime

Pump slowly moves after fluid shutoff in downstroke.

Clogged fluid hose or valve. Clear the hose or valves.

Exhausted fluid supply. Refill the fluid supply and reprime

Worn or damaged valves or seals. Service the valves or seals.

Held open or worn intake valve. Clear or service the valve.

Worn or damaged valves or seals. Service the valves or seals.

Held open or worn piston valve. Clear or service the valve.

Worn or damaged valves or seals. Service the valves or seals.

Broken air motor compression spring.

Clogged or dirty intake valve check ball.

Clean lines or increase the air supply (see Technical Data).

the pump.

Replace the spring.

Clean ball and seat.

Worn or damaged valves or seats. Install repair kit.

Pump slowly moves after fluid shutoff in upstroke.

311882Y 21

Clogged or dirty lower piston ball or seat.

Worn or damaged valves or seats. Install repair kit.

Clean ball and seat.

Page 22

Parts - Model 295616

24*

74

56

40

41

42

38

5a*

5

5b*

5h*

*30

*29

*28

5j*

19

*50



*32

*33

WLF

Lubricate all o-rings and seals before and after assembly

Torque to 45-55 ft-lb (61-74.5 N•m)

Torque to 30-40 ft-lb (40.6-54.2 N•m)

Torque to 15-20 ft-lb (20.3-27.1 N•m)

Torque to 10-12 ft-lb (13.5-16.3 N•m)

Torque to 110-120 in-lb (12.3-13.4 N•m)

31*

20

55

Bung Adapter

Torque to 20-30 in-lb (2.2-3.3 N•m)

Torque to 50-60 in-lb (5.6-6.7 N•m)

Tighten 1/8 to 1/4 turn past finger-tight

73

35

54

51c

51h

51b

51a

38

51j

71

22 311882Y

Page 23

Parts - Model 295616

Ref Part Description Qty

1‡ 16V524 CAP, air cylinder 2‡ 157630 SPRING, tapered 3‡* 120212 PACKING, square 4 24J528 CYLINDER, air motor 5 262035 VALVE, air 5a* 15J539 GASKET, upper 5b* 121889 O-RING 5c 15J544 SPACER 5d 121610 SCREW 5e 16U730 CAP, air, valve 5f 15V554 HEAD, air valve 5g 15J546 DISK, air valve 5h* 160258 O-RING 5j* 722834 O-RING 17 CAP, air piston 19 15J548 PIN, dowel 20 SHAFT, transfer 21 24J535 PISTON, air 22 15J551 SPRING, compression 23 24J529 BASE, air motor 24* 159846 O-RING (green) 25 15J553 ROD, tie 26 24J530 FLANGE, mounting 27 15J555 NUT, hex 28* 15J556 GLAND, packing, (male) 29* 15J557 V-PACKING, PTFE 30* 15J558 GLAND, packing, (female) 31* 15J559 WIPER, ROD 32* 15C638 O-RING, PTFE, encapsulated 33* 15J560 GASKET, PTFE 34 24J536 BODY, pump, 2:1 35 15J562 PACKING, piston cup 36 15J563 COLLAR, retaining 37 101194 SCREW, set, socket head,

10-32 x .25 in. (6 mm)

38 106258 O-RING 39 24J534 CYLINDER, fluid 40 15J565 PACKING, u-cup, PTFE 41 42 103462 BALL, outlet, sst, 3/4 in. (19 mm) 43 24J531 VALVE, piston 44 24J532 TUBE, suction 45 24J533 VALVE 46 120734 RING, retaining, internal 47 120735 RING, snap, e series 48† 206264 VALVE, needle 49† 169969 FITTING, air line 50* 108832 O-RING 51 25B395 ADAPTER, bung 51a 120998 O-RING, fluoroelastomer 51b ----------- ADAPTER

15J566 RING, wear

Ref Part Description Qty

51c 234188 CLAMP, hopper

51h 120207 O-RING; inner (brown)

51j 25N940 HANDELS with jam nut

52† 114558 COUPLER, air line

53 15J570 HOUSING, piston

54 PISTON, upper

55 120294 PIN, clevis, 3/16 in. x 3/4 in.

56 120295 PIN, clevis, 3/16 in. x 1-1/4 in.

60 120348 SCREW, cap, socket head

69† 15H197 TOOL, pin

70† 15K008 LABEL, material identification.

71 107167 BALL, intake, sst, 1 in. (25 mm)

72 116343 SCREW, ground

73 113944 O-RING

74 SHAFT, transfer, lower

75 24V858 GUARD

76‡ 111819 O-RING

77‡ 16V523 PIN, spring stop

1 1

* Parts included in Upper Seal Repair Kit 262034 (not sold

1 3 1 1 1 2 1 1 1 1 1 1 1 1

2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

separately).

 Parts included in Lower Seal Repair Kit 247883.

NOTE: Seal Repair Kit 24X056 includes all parts in kit 262034 and kit 247883. The spring pins (55, 56) originally supplied in series A and B pumps have been upgraded to a solid clevis pin for improved reliability.

 Parts included in repair kit 256560

NOTE: The pump shaft originally supplied in series A pumps has been upgraded to a multi-piece assembly for better sealing and serviceability. Pumps can be upgraded with repair kit 256560.

 Parts included in repair kit 262042

The air valve originally supplied in series A pumps

NOTE:

can be upgraded with kit 262042.

† Indicates parts not shown, 48, 49, 52, 69, 70

(shipped loose)

 O-rings included in Tube Extension Kit 24N451.

‡ Parts included in air cap 24T043.

NOTE: The cylinder cap has been upgraded with spring stop for improved reliability. Existing pumps can be upgraded with Kit 24T043.

The T2 can be adapted for use in 250 gallon (946 liter) totes. Tube Extension 24N451 increases the length by

6.25 in. (165 mm) to reach material in the bottom of

larger totes.

1/4-20 x 1 in. (25 mm)

1 1

1 1 1 2 1 3

2 1 1 1 1 1 1 1 1

311882Y 23

Page 24

Accessories

Grounding Clamp

Part Description Qty.

103538 CLAMP, ground

Bleed-Type Master Air Valve

300 psi (2.1 MPa, 21 bar) Maximum Working Pressure

Part Description Qty.

107142 VALVE, ball, vented; 1/2 npt(m) inlet x

1/2 npt(f) outlet

Air Line Filter

250 psi (1.7 MPa, 17.5 bar) Maximum Working Pressure

Air Line Lubricator

250 psi (1.7 MPa, 17.5 bar) Maximum Working Pressure

Part Description Qty.

214848 LUBRICATOR, air line; 8 oz (0.24 liter)

bowl capacity; 1/2 npt(f) inlet and outlet

Air Line Filter and Regulator

180 psi (1.3 MPa, 13 bar) Maximum Working Pressure

Part Description Qty.

202660 FILTER, air; includes gauge and two 1/4

npt(m) outlet valves, 50 micron filter element with 100 mesh inlet strainer; 1/2 npt(f) inlet; flow rate is over 50 scfm (1.4

m3/min).

Part Description Qty.

106149 FILTER, air line; 1/2 npt(f) inlet and

outlet

24 311882Y

01355

Page 25

Accessories

Air Regulator and Gauge

300 psi (2.1 MPa, 21 bar) Maximum Working Pressure

Part Description Qty.

202156 REGULATOR, air; 0-200 psi (0-14 bar)

regulated pressure range; 3/8 npt(f) inlet and outlet

Fluid Drain Valve

500 psi (3.5 MPa, 35 bar) Maximum Working Pressure

Part Description Qty.

208630 VALVE, ball; 1/2 npt(m) x 3/8 npt(f); for

non-corrosive fluids; carbon steel and PTFE

237534 VALVE, ball; 3/8 npt(m) x 3/8 npt(f); for

corrosive fluids; SST and PTFE

311882Y 25

Page 26

Performance Chart

Calculate Fluid Outlet Pressure (black curves)

To calculate fluid outlet pressure (MPa/bar/psi) at a specific fluid flow (lpm/gpm) and operating air pressure (MPa/bar/psi), use the following instructions and pump data chart.

1. Locate desired fluid flow along bottom of chart.

2. Follow vertical line up to intersection with selected air pressure curve (black). Follow horizontally left to read fluid outlet pressure.

Key: Air Pressure

A 180 psi (1.2 MPa, 12.4 bar) B 100 psi (0.7 MPa, 7 bar) C 70 psi (0.5 MPa, 4.8 bar) D 40 psi (0.3 MPa, 2.8 bar)

Outlet Pressure in PSI (MPa, bar)

500

(3.5, 34.5)

400

(2.8, 28)

300

(2.1, 21)

200

(1.4,14)

100

(0.7, 7)

0.0

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

Calculate Pump Air Consumption (gray curves)

To calculate pump air consumption (m3/min or scfm) at a specific fluid flow (lpm/gpm) and air pressure (MPa/bar/psi), use the following instructions and pump data chart.

1. Locate desired fluid flow along bottom of chart.

2. Follow vertical line up to intersection with selected air pressure curve (gray). Follow horizontally right to read air consumption.

40.00 (1.1)

35.00 (1.0)

30.00 (0.8)

25.00 (0.7)

20.00 (0.6)

15.00 (0.4)

10.00 (0.3)

5.00 (0.1)

0.00

(17.1)(15.2)(13.3)(9.5)(5.7)(1.9) (11.4)(7.6)(3.8)

Air Consumption in SCFM (m

/min)

Fluid Flow in gpm (lpm)

26 311882Y

Page 27

Dimensions

1/4 npt inlet

33.7 in. (85.6 cm)

3/4 npt outlet

54 in. (137.2 cm)

WLD

311882Y 27

Page 28

Dimensions

28 311882Y

Page 29

Technical Specifications

T2, 2:1 Ratio Transfer Pump

US Metric

Pressure ratio 2.25:1 Maximum fluid working pressure 405 psi 2.8 MPa, 28 bar Maximum air inlet pressure 180 psi 1.2 MPa, 12 bar Maximum continuous outlet flow 5 gpm 20 lpm Maximum intermittent outlet flow 7.5 gpm 28 lpm Pump cycles per 1 gallon (3.8 liters) 15.9 Maximum recommended pump speed for con-

tinuous operation Gallons (liters) per pump cycle 0.063 gal 0.24 l Maximum ambient operating temperature 120°F 49°C Maximum fluid temperature 190°F 88°C

Inlet/Outlet Sizes

Air inlet size

Fluid outlet size 3/4 npt (f)

Materials of Construction

Wetted materials Stainless steel, PTFE

Weight

All models 21 lb. 9.5 kg

Noise (dBa)

Maximum sound pressure*

Maximum sound power**

*Sound pressure measured 3.28 feet (1 meter) from equipment. **Sound power measured per ISO-9614-2.

100 cpm (150 cpm intermittent)

1/4 npt(f)

88.7 dB(A) at 80 psi (.55 MPa, 5.5 bar)

96.8 dB(A) at 80 psi (.55 MPa, 5.5 bar)

California Proposition 65

CALIFORNIA RESIDENTS

WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov.

311882Y 29

Page 30

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is 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 procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents. TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. 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.

Original instructions. This manual contains English. MM 311882

International Offices: Belgium, China, Japan, Korea

Graco Headquarters: Minneapolis

www.graco.com

Revision Y,

April 2021