GRACO D60, D200, D200S Instruction manual

Installation - Parts

E-Flo

3A6331G

Supply Systems

For transferring or dispensing sealants, adhesives, or other medium to high viscosity fluids. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

D60 3 inch dual post

20 liter (5 gallon), 30 liter (8 gallon), 60 liter (16 gallon) sizes

150 psi (1.0 MPa, 10 bar) Maximum Air Inlet Pressure

D200 3 inch dual post

200 liter (55 gallon) size

150 psi (1.0 MPa, 10 bar) Maximum Air Inlet Pressure

D200S 6.5 inch dual post

200 liter (55 gallon) size

125 psi (0.9 MPa, 9 bar) Maximum Air Inlet Pressure

See page 4 for model information, including maximum working pressure and approvals.

The Graco Control Architecture Electric Components are Listed in Intertek’s Directory of Listed Products.

Important Safety Instructions

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

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 6

Tandem Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Component Identification . . . . . . . . . . . . . . . . . . . 11

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 11

Integrated Air Control Module . . . . . . . . . . . . . . 12

Integrated Air Line Accessories . . . . . . . . . . . . . 12

Advanced Display Module (ADM) . . . . . . . . . . . 13

Platen Component Identification . . . . . . . . . . . . 14

Junction Box Connections . . . . . . . . . . . . . . . . . 15

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Power Requirements . . . . . . . . . . . . . . . . . . . . . 17

Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . 17

Attach Drum Stops. . . . . . . . . . . . . . . . . . . . . . . 18

Fluid Hose and Air Line Connections. . . . . . . . . 18

Install Vented Oil Cap Before Using Equipment. 18

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Flush the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 20

Start and Adjust the Ram. . . . . . . . . . . . . . . . . . 21

Start and Adjust the Pump . . . . . . . . . . . . . . . . . 21

Pressure Relief Procedure. . . . . . . . . . . . . . . . . . . 22

Shutdown and Care of the Pump . . . . . . . . . . . . . 23

Change Drums. . . . . . . . . . . . . . . . . . . . . . . . . . 23

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Driver Maintenance . . . . . . . . . . . . . . . . . . . . . . 24

Platen Maintenance . . . . . . . . . . . . . . . . . . . . . . 25

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Disconnect Pump from Platen . . . . . . . . . . . . . . 30

Connect Platen . . . . . . . . . . . . . . . . . . . . . . . . . 31

Remove Wipers . . . . . . . . . . . . . . . . . . . . . . . . . 31

Install Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Remove Displacement Pump. . . . . . . . . . . . . . . 31

Install Displacement Pump . . . . . . . . . . . . . . . . 32

Remove Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Install Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Supply Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 34

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

D200s 6.5 in. Supply Units . . . . . . . . . . . . . . . . . 38

D200 3 in. Supply Units . . . . . . . . . . . . . . . . . . . 40

D60 3 in. Supply Units . . . . . . . . . . . . . . . . . . . . 42

D200s and D200 Pump Mounts for 55 Gallon (200

Liter) Platen . . . . . . . . . . . . . . . . . . . . . . . . . 44

D60 Pump Mount 257624 for 5 Gallon (20 Liter)

Platen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Cable Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

55 Gallon Platen . . . . . . . . . . . . . . . . . . . . . . . . . 49

20 Liter (5 Gallon), 30 Liter (8 Gallon), and 60 Liter

(16 Gallon) Platens . . . . . . . . . . . . . . . . . . . 50

Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . 55

Drum Roller Kits for D200 and D200S Supply Units,

255627 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Drum Position Clamp Set for D200 Supply Units,

206537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Drum Position Clamp for D200S Supply Units . . 55

Enclosed Wet Cup Recirculation Kit. . . . . . . . . . 55

200 Liter (55 Gallon) Platen Cover Kits, 255691 55

Light Tower Kit, 255468 . . . . . . . . . . . . . . . . . . . 55

ADM Kit, 25E437 . . . . . . . . . . . . . . . . . . . . . . . . 55

CAN Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

I/O Cable, 122029 . . . . . . . . . . . . . . . . . . . . . . . 55

Communication Gateway Module (CGM) Kits . . 56

Low Level Sensor Kit, 25E447 . . . . . . . . . . . . . . 58

Tandem Connection Kit, 25E595 . . . . . . . . . . . . 59

Tandem Depressurization/Recirculation Kit, 25E618

(carbon steel), 25E619 (stainless steel). . . . 60

Tandem Fluid Filter Kit, 25E620 . . . . . . . . . . . . . 64

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Pump Performance . . . . . . . . . . . . . . . . . . . . . . . . . 69

E-Flo SP Performance Charts . . . . . . . . . . . . . . 70

Technical Specifications . . . . . . . . . . . . . . . . . . . . 76

California Proposition 65 . . . . . . . . . . . . . . . . . . . . 77

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 78

Graco Information 78

2 3A6331G

Related Manuals

Manual Description

3A6586

3A6724 E-Flo SP Software Instructions

313526 Supply Systems Operation

E-Flo SP Electric Pump Instructions Parts

Related Manuals

312375

311827

311825

311717

312889

312467

312468

312469

312470

312374 Air Controls Instructions-Parts

312491 Pump Fluid Purge Kit Instructions - Parts

312492 Drum Roller Kit Instructions

312493 Light Tower Kit Instructions

312494

406681 Platen Cover Kit

Check-Mate® Displacement Pumps Instructions-Parts

™

Dura-Flo 180cc, 220cc, 290cc) Instructions-Parts

Dura-Flo 580cc) Instructions-Parts

Carbon Steel Displacement Pump (1000cc) Instructions-Parts

60 cc Check-Mate Displacement Pump Repair Parts

100 cc Check-Mate Displacement Pump Repair Parts

200 cc Check-Mate Displacement Pump Repair Parts

250 cc Check-Mate Displacement Pump Repair Parts

500 cc Check-Mate Displacement Pump Repair Parts

Enclosed Wetcup Recirculation Kit Instructions - Parts

Displacement Pumps (145cc,

™

Displacement Pumps (430cc,

334048 EPDM Hose Wiper Kit Instructions - Parts

3A6321

3A6482

3A6331G 3

ADM Token In-System Programming Instructions

APD20 Advanced Precision Driver Instructions

Models

Check the identification plate (ID) for the 7-digit part number of the supply system. Use the following matrix to define the construction of the supply system, based on the seven digits. For example, Part No. EMC1121 represents an electric supply system (EM), a carbon steel Check-Mate 100 Severe Duty displacement pump with an electric driver (C1), a 3 in. dual post ram with integrated air controls (1), a 5-gallon platen with a nitrile seal (2), and 240 VAC power

(1).

NOTICE

To prevent damage to DataTrak soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

NOTE: Systems with the EMD as the first and second digits are Dura-Flo supply systems.

The digits in the matrix on the next page do not correspond to the Ref. Nos. in the Parts drawings and lists.

4 3A6331G

Models

EM C1 1

First

and

Second

Digit

(Electric

Supply

System)

Third and

Fourth

Digit Fifth Digit

Ram Options

Pump

Code

(See Table 1: for 2-digit Check-Mate

Pump

Code)

(See Table 1: for 2-digit

Dura-Flo

Pump

Code)

Size Style

1 3 in. D60

2 3 in. D200

3 6.5 in. D200s

Sixth Digit Seventh Digit

Platen and Seal Options

Drum

Size

20 L

(5 Gal) INT 1 No Platen 1 None 240 VAC

200 L

(55 Gal) INT 2

200 L

(55 Gal) INT 3

Air

Controls

Platen

(5 Gal) F, SW CS Nitrile D60 2 None 480 VAC

(5 Gal) F, SW CS

(5 Gal) F, DW CS Nitrile D60 4 ADM 480 VAC

(5 Gal) F, DW CS

(5 Gal) F, SW SS

200 L

(55 Gal) DR

200 L

(55 Gal) DR AL EPDM

200 L

(55 Gal) DR AL Neoprene

200 L

(55 Gal) DR AL

Size

20 L

Platen

Style

Platen

Material

PTFE

Coated

AL EPDM

Seal

Material

Polyure-

thane D60 3 ADM 240 VAC

Polyure-

thane D60 PTFE

coated D60

EPDM

Hose

Ram

Compati-

bility Interface Power

D200,

D200s

D200,

D200s

D200,

D200s

D200,

D200s

Interface and Power

Options

KEY: INT = Integrated air controls SW = Single wiper CS = Carbon Steel Severe Duty

F = Flat DW = Double wiper SS = Stainless Steel Severe Duty SM = Stainless Steel MaxLife DR = Dual o-ring AL = Aluminum

CM = Carbon Steel MaxLife

Table 1: Pump Code Index

Pump

Code Part No. Pump Type

Pump

Size

Pump

Material

C1 EC100CS1 Check-Mate 100cc CS C2 EC100CM1 Check-Mate 100cc CM C3 EC100SS1 Check-Mate 100cc SS C4 EC100SM1 Check-Mate 100cc SM C5 EC200CS1 Check-Mate 200cc CS C6 EC200CM1 Check-Mate 200cc CM C7 EC200SS1 Check-Mate 200cc SS C8 EC200SM1 Check-Mate 200cc SM

C9 EC250CS1 Check-Mate 250cc CS CA EC250CM1 Check-Mate 250cc CM CB EC250SS1 Check-Mate 250cc SS CC EC250SM1 Check-Mate 250cc SM CD EC500CS1 Check-Mate 500cc CS CE EC500CM1 Check-Mate 500cc CM

CF EC500SS1 Check-Mate 500cc SS

Pump

Code Part No. Pump Type

CG EC500SM1 Check-Mate 500cc SM

D1 ED115CS1 Dura-Flo 115cc CS D2 ED145CS1 Dura-Flo 145cc CS D3 ED145SS1 Dura-Flo 145cc SS D4 ED180CS1 Dura-Flo 180cc CS D5 ED180SS1 Dura-Flo 180cc SS D6 ED220CS1 Dura-Flo 220cc CS D7 ED220SS1 Dura-Flo 220cc SS D8 ED290CS1 Dura-Flo 290cc CS

D9 ED290SS1 Dura-Flo 290cc SS DA ED430CS1 Dura-Flo 430cc CS DB ED430SS1 Dura-Flo 430cc SS DC ED430SM1 Dura-Flo 430cc SM

NOTE: See the E-Flo SP Electric Pump Instructions-Parts

manual for a complete parts list.

Pump

Size

Pump

Material

3A6331G 5

Models

System Pressure

Due to factors such as the dispensing system design, the material being pumped, and the flow rate, the dynamic pressure will not reach the rated working (stall) pressure of the system.

Pump Working (Stall) Pressure Max Dynamic (Run) Pressure

Lower Size psi bar MPa psi bar MPa

100CS/CM/SS/SM 200CS/CM/SS/SM 250CS/CM/SS/SM 500CS/CM/SS/SM

Check-Mate

145SS 180SS 220SS 290SS 430CS/SS/SM 115CS

Dura-Flow

145CS 180CS 220CS 290CS

6,000 414 41.4 6,000 414 41.4 4,200 290 29.0 3,905 269 26.9 3,400 234 23.4 3,122 215 21.5 1,600 110 11.0 1,487 103 10.3 5,600 386 38.6 5,204 359 35.9 4,500 310 31.0 4,164 287 28.7 3,700 255 25.5 3,470 239 23.9 2,800 193 19.3 2,602 179 17.9 1,900 131 13.1 1,735 120 12.0 6,000 414 41.4 6,000 414 41.4 5,600 386 38.6 5,204 359 35.9 4,500 310 31.0 4,164 287 28.7 3,700 255 25.5 3,472 239 23.9 2,800 193 19.3 2,602 179 17.9

Flow Rate Table

Lower Size

100CS/CM/SS/SM 200CS/CM/SS/SM 250CS/CM/SS/SM 500CS/CM/SS/SM

Check-Mate

145SS 180SS 220SS 290SS 430CS/SS/SM 115CS

Dura-Flow

145CS 180CS 220CS 290CS

Flow Rate

(cc/min)

2,500 0.66 1 in. NPT female 5,000 1.32 1 in. NPT female 6,250 1.65 1 in. NPT female

12,500 3.30 1-1/2 in. NPT female

3,625 0.96 1 in. NPT female 4,500 1.19 1 in. NPT female 5,500 1.45 1 in. NPT female 7,250 1.92 1 in. NPT female

10,750 2.84 1-1/2 in. NPT female

2,875 0.76 1 in. NPT female 3,625 0.96 1 in. NPT female 4,500 1.19 1 in. NPT female 5,500 1.45 1 in. NPT female 7,250 1.92 1 in. NPT female

Flow Rate

(gpm) Outlet Fitting Size

6 3A6331G

Tandem Ram

Models

How to Buy

1. Configure Tandem Ram “A” - E-Flo SP Ram with an ADM (Quantity 1 per Tandem System).

- Example: EMC1283 – D200 Ram, Electric

Pump with Check-Mate 100 CS Lower, 200L EPDM Platen, 240V, with ADM.

2. Configure Tandem Ram “B” - E-Flo SP Ram without an ADM (Quantity 1 per Tandem System).

- Example: EMC1281 – D200 Ram, Electric

Pump with Check-Mate 100 CS Lower, 200L EPDM Platen, 240V, without ADM.

3. Purchase Tandem Connection Kit, 25E595 (Quantity 1 per Tandem System).

4. Purchase Accessories.

- Depressurization/Recirculation Kit (Quantity 1

per Ram)

25E618: for Carbon Steel Pump Lowers 25E619: for Stainless Steel Pump Lowers

5. Purchase hoses for the system.

- For Check-Mate Pumps:

Pump Lower

Size

100cc 6000 psi 200cc 4200 psi 250cc 3400 psi 500cc 1600 psi

- For Dura-Flo Pumps:

Pump Lower

Size

115cc 6000 psi 145cc 5600 psi 180cc 4500 psi 220cc 3700 psi 290cc 2800 psi 430cc 1900 psi

Max. Pressure

Rating

Max. Pressure

Rating

- Fluid Filter Kit, 25E620 (Quantity 1 per Tandem

System)

- Extension Cables for Fluid Filter Monitoring

Pressure Transducers (Quantity 1 per Ram)

124943: 1 meter 122497: 2 meters 124409: 3 meters 17H363: 7.5 meters 17H364: 16 meters

- Low Level Sensor Kit, 25E447 (Quantity 1 per

Ram)

NOTE: Rams come with Empty Level Sensors already installed.

3A6331G 7

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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this

manual where applicable.

DANGER

SEVERE ELECTRIC SHOCK HAZARD

This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• This equipment must be grounded. Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

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

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or

servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

MOVING PARTS HAZARD

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

• Keep clear of moving parts.

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

• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the

Pressure Relief Procedure and disconnect all power sources.

8 3A6331G

Warnings

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:

• Use equipment only in well-ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static sparking).

• Ground all equipment in the work area. See Grounding instructions.

• Never spray or flush solvent at high pressure.

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are anti-static or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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 Safety Data Sheets (SDSs) from distributor or retailer.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

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

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• 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.

SPLATTER HAZARD

Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of platen, splatter may occur.

• Use minimum air pressure when removing platen from drum.

3A6331G 9

Warnings

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) to know the specific hazards of the fluids you are using.

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

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

10 3A6331G

Component Identification

Typical Installation

D200 3 in. and D200s 6.5 in. Dual Post

EMC1223 Model Shown

Lift Locations

NOTICE

Always lift the supply system at the proper lift locations (see FIG. 1). Do not lift in any other way. Failure to lift at the proper lift locations can result in damage to the supply system.

NOTE: The Outlet Pressure Relief Valve is used on Check-Mate 100cc pumps only. See the E-Flo SP Electric Pump Instructions-Parts manual for a complete parts list.

FIG. 1: Typical Installation

Key:

A Ram Assembly B Electric Driver C Displacement Pump D Platen E Cable Track F Advanced Display Module (ADM) G Integrated Air Controls (see F J Platen Bleed Port K Power Junction Box M Disconnect Switch

IG. 2)

N Platen Lift Rod P Pump Bleed Valve R Enclosed Wet Cup S Fluid Line (not supplied) T Air Line (not supplied) U Air Line Drain Valve (not supplied) V Air Filter (not supplied) W Bleed Type Air Shutoff Valve (required) (not supplied) X Level Sensors Y Outlet Pressure Transducer Z Outlet Pressure Relief Valve (Check-Mate 100 only)

3A6331G 11

Component Identification

Integrated Air Control Module

D200, D200s, and D60 Models

The integrated air controls include:

• Main air slider valve (AA): turns air on and off to

the system. When closed, the valve relieves pressure downstream.

• Ram air regulator (AB): controls ram up and down

pressure and blowoff pressure.

• Ram director valve (AC): controls ram direction.

• Exhaust port with muffler (AD)

• Blowoff button (AE): turns air on and off to push

the platen out of an empty drum.

Integrated Air Line Accessories

See FIG. 1.

• Air line drain valve (U).

• Air line filter (V): removes harmful dirt and mois-

ture from compressed air supply.

• Second bleed-type air valve (W) (required): iso-

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

• Air relief valve (required) (not visible):

automatically relieves excessive pressure.

FIG. 2. Integrated Air Control Module

12 3A6331G

Advanced Display Module (ADM)

Front and Rear Views

Component Identification

FIG. 3: ADM Component Identification

Key: BA Pump Enable

Enables the pump. Toggles between Active and System Off.

BB Pump Status Indicator Light BC Pump Soft Stop

Stops all pump processes and disables the pump.

BD Soft Keys

Defined by the icon on the screen next to the soft key.

BE Cancel

Cancel a selection or number entry while in the process of entering a number or making a selection. Cancels the pump processes.

BF Enter

Accept change, acknowledge error, select item, and toggle selected item.

BG Lock/Setup

Toggle between run and setup screens.

BH Directional Keypad

Navigate within a screen or to a new screen.

BJ Numeric Keypad BK Part Number Identification Label BL USB Interface BM CAN Cable Connection

Power and communication.

BN Module Status LEDs

Visual indicators to show the status of the ADM.

BP Token Access Cover

Access cover for software token.

BR Battery Access Cover

3A6331G 13

Component Identification

Platen Component Identification

Model 255319, 200 liter (55 gallon)

FIG. 4

Model 256742 and 256745, 20 liter (5 gallon)

Key:

EA Plate EB Wipers EC Spacer ED Cap Screws EE Clamps (not shown) EF Bleed Stick EG Bleed Port EH Air Assist Body Check Valve EJ Wiper Plate (under wiper) EK O-ring Seal (not shown)

14 3A6331G

Junction Box Connections

Component Identification

FIG. 5

Key:

C1 CGA CAN Port C2 GCA CAN Port C3 Low and Empty Level Sensor Input C4 Fluid Filter Solenoid Input

NOTE: See the E-Flo SP Software Instructions manual for all I/O descriptions.

3A6331G 15

Installation

All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

Location

To properly locate and anchor the supply system, refer to Dimensions on page 67.

NOTICE

Always lift the supply system at the proper lift locations (see FIG. 1). Do not lift in any other way. Failure to lift at the proper lift locations can result in damage to the supply system.

Attach a lifting sling at the proper lift locations. Lift off the pallet using a crane or a forklift.

NOTE: The lift ring on the driver is only to be used for replacing the driver. Do not use it to lift the entire system.

Grounding

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

Electric pump: the pump is grounded through the power cord.

Ram: the ram is grounded through the power cord.

Air and fluid hoses: use only electrically conductive

hoses with a maximum of 500 ft. (150 m) combined hose length to ensure grounding continuity. Check the electrical resistance of the hoses. If the total resistance to ground exceeds 29 megaohms, replace the hose immediately.

Air compressor: follow manufacturer’s recommendations.

Dispense valve: ground through connection to a prop-

erly grounded fluid hose and pump.

Position the ram so the driver, disconnect switch, air controls, and ADM are easily accessible. Ensure that there is enough space overhead for the ram to raise fully.

Using the holes in the ram base as a guide, drill holes for 1/2 in. (13 mm) anchors.

Ensure that the ram base is level in all directions. If necessary, level the base using metal shims. Secure the base to the floor using 1/2 in. (13 mm) anchors that are long enough to prevent the ram from tipping.

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 non-conductive surface, such as paper or cardboard, which interrupts the grounding continuity.

To maintain grounding continuity when flushing or relieving pressure: hold a metal part of the dispense

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

16 3A6331G

Installation

Power Requirements

The system requires a dedicated circuit protected with a circuit breaker.

Voltage Phase Hz Current

200-240 VAC 1 50/60 20 A 400-480 VAC 1 50/60 10 A

Connect Power

NOTICE

To avoid equipment damage, route and secure a power cord that is long enough to allow the full range of movement for the ram.

6. Cut power cord wires to the following lengths:

• Ground wire - 6.5 inches (16.5 cm)

• Power wires - 3.0 inches (7.6 cm)

• Add ferrules as necessary. See FIG. 6.

8. Insert the power cord through the cord grip and into the junction box (K).

Ground Stud

Disconnect Switch Terminal Block

Cord Grip

FIG. 8: Power Connection

9. Attach the ground wire to the ground stud inside the junction box (K).

10. Refer to FIG. 9 and connect the wires from the power cord into terminals 4T2 and 6T3 on the disconnect switch terminal block.

LQ

LQ

FIG. 6: Power Cord

7. Remove the six screws holding the cover of the junction box (K), then remove the junction box cover.

Screws

1L1

3L2

5L2

2T1

4T2

6T3

FIG. 9: Disconnect Switch Terminal Block

11. Tighten the cord grip to securely hold the power cord to the junction box (K).

12. Replace the junction box cover and secure it with the six screws that were removed in step 2.

FIG. 7: Remove the Junction Box Cover

3A6331G 17

Installation

Attach Drum Stops

The electric supply systems are shipped with drum stops in place to help position the drum on the ram. For replacement parts, order Kit 255477. The kit includes 2 each of capscrews, lock washers (not shown), and drum stops.

Capscrews

Drum Stops

FIG. 10: Drum Stop Installation

Install Vented Oil Cap Before Using Equipment.

The driver gear-box is shipped from the factory pre-filled with oil. The temporary unvented cap prevents oil leaks during shipment. This temporary cap must be replaced with the vented oil cap supplied with the equipment, before use.

NOTE: Prior to use, check oil level. Oil level should be half way up the sight glass.

Vented Cap

Unvented Cap

1. Locate the correct set of mounting holes on the ram base.

2. Using the capscrews and lock washers, attach the drum stops to the ram base.

Fluid Hose and Air Line Connections

Refer to FIG. 1 on page 11 for a typical installation.

Attach the fluid hose (not supplied) to the Outlet Check Valve (E) connection.

Attach the air line (not supplied) to the bottom of the Integrated Air Control (G) at the 3/4 in. NPT connection.

NOTE: Be sure all components are adequately sized and pressure rated to meet the system’s requirements.

FIG. 11: Unvented and Vented Oil Caps

18 3A6331G

Setup

Wet Cup

Before starting, fill the wet cup (L) 1/3 full with Graco Throat Seal Liquid (TSL) or a compatible solvent.

Torque the Wet Cup

The wet cup is torqued at the factory; however, throat packing seals on Severe Duty pumps may relax over time. Check wet cup torque frequently after initial start-up and periodically after the first week of production. Maintaining proper wet cup torque is important to

extending seal life.

Setup

FIG. 12: Wet Cup

NOTE: MaxLife pumps use a special u-cup throat seal

that is non-adjustable and does not require periodic torquing.

1. Follow the Pressure Relief Procedure on page 22.

2. Torque the wet cup (R) 95-115 ft-lbs (128-155 N•m) using the packing nut wrench (supplied) whenever necessary. Do not overtighten the wet cup. See the table below for torque values.

3A6331G 19

Startup

Letters in parenthesis are used in this section for reference to callouts in the Component Identification section starting on page 11.

Flush the Pump

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

NOTE: 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.

Always 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.

3. Turn the disconnect switch (M) ON.

4. At the ADM (F), use the ADM’s arrow keys to select the pump you want to flush from the Menu Bar.

NOTE: If multiple pumps are connected together, there can be up to six pumps listed in the Menu Bar.

5. Enter the Edit screen for that pump by pressing the

soft key next to the icon.

6. Press the soft key next to the Pressure Mode icon.

7. Enter 100 psi (0.69 MPa, 6.9 bar) as the pressure.

8. Press the soft key next to the Pump On/Off icon to turn on the pump.

9. Adjust pressure as necessary.

10. Hold a metal part of the dispense valve firmly to the side of a grounded metal pail.

11. Open the dispense valve and flush the system until clear solvent flows from the gun/valve.

NOTE: Check with your fluid manufacturer or supplier for recommended flushing fluids and flushing frequency.

NOTICE

To prevent damage to the pump from rust, never leave water or water-based fluid in a carbon steel pump overnight. If you are pumping a water-based fluid, flush with water first. Then flush with a rust inhibitor, such as mineral spirits. Relieve pressure, but leave the rust inhibitor in the pump to protect parts from corrosion.

NOTE: Refer to the E-Flo SP Software Instructions manual for additional information about using the software features of the ADM. See Related Manuals on page 3.

1. Follow the Pressure Relief Procedure on page 22.

2. Place a pail of compatible solvent in the ram. See

Grounding instructions for solvent pails on page

16.

12. Exit the Edit screen by pressing the soft key next to

the icon.

13. Repeat steps 3 through 11 for each pump you want to flush.

14. Follow the Pressure Relief Procedure on page 22.

15. Remove the solvent pail from the ram.

20 3A6331G

Startup

Start and Adjust the Ram

1. Turn the disconnect switch (M) OFF.

2. Raise the Ram by opening the main air slider valve (AA) and setting the ram air regulator (AB) to 40 psi (0.28 MPa, 2.8 bar).

3. Set the ram director valve handle (AC) to UP and let the ram rise to its full height.

4. Set the ram director valve handle (AC) to neutral.

5. Lubricate the platen wiper (EB) with grease or other lubricant compatible with the fluid you will pump.

6. Put a full drum/pail on the ram base and center it under the platen (D).

7. Remove the drum/pail cover and smooth the surface of the fluid with a straightedge. To prevent air from being trapped under the platen, scoop fluid from the center of the pail to the sides, to make the surface concave.

8. Adjust the drum/pail to be sure it is aligned with the platen, and remove the platen bleed stick to open the platen bleed port.

9. With hands away from the drum/pail and the platen, push down on the ram director valve (AC) handle, and lower the ram until the platen rests on the lip of the drum/pail. Move the ram director valve handle to the horizontal position (neutral).

10. Lower the ram:

a. Set the ram director valve (AC) to DOWN and

continue to lower the ram until fluid appears at the platen bleed port.

b. Set the ram director valve to neutral, replace the

platen bleed stick, and tighten it securely.

Start and Adjust the Pump

1. With the disconnect switch (M) OFF, set the ram air regulator (AB) to about 50 psi (0.35 MPa, 3.5 bar). Set the ram director valve (AC) to DOWN.

2. Turn the driver disconnect switch (M) ON.

3. Start the pump. See the E-Flo SP Software Instructions manual for instructions on operating the system.

D60

Platen Bleed Stick

4. Keep the ram director valve (AC) set to DOWN while the pump is operating.

NOTE: Increase air pressure to the ram if the pump does not prime properly with more viscous fluids. Decrease air pressure if fluid is forced out around the top seal or platen.

D200

Platen Bleed Stick

3A6331G 21

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. At the ADM, enter manual mode by pressing the

soft key next to the icon.

2. Press the soft key next to the icon to stop the pump.

7. Hold a metal part of the dispense valve firmly to the side of a grounded metal pail, and open the dispense valve to relieve pressure.

8. Open your system’s fluid line drain valve and open the pump bleed valve (P). Have a container ready to catch the drainage.

9. Leave the pump bleed valve (P) open until ready to dispense again.

3. Turn the disconnect switch (M) OFF.

FIG. 13: Air Control for Pressure Relief

4. Close the main air slider valve (AA).

5. Set the ram director valve (AC) to DOWN. The ram will slowly drop.

6. Once the ram is completely down, jog the ram director valve up and down to bleed air from the ram cylinders.

22 3A6331G

Shutdown and Care of the Pump

Change Drums

NOTICE

1. Set the ram director valve (AC) to DOWN, and lower the ram to the desired position for shutdown.

2. Set the ram director valve (AC) to neutral.

1. Stop the pump.

2. Set the ram director valve (AC) to UP to raise the platen, and immediately press and hold the blowoff air button (AE) until the platen is completely out of the drum. Use the minimum amount of air pressure

necessary to push the platen out of the drum.

Shutdown and Care of the Pump

3. Stop the pump at the bottom of the stroke to prevent fluid from drying on the exposed displacement rod and damaging the throat packings. See the E-Flo SP Software Instructions manual for information about jogging the pump. See Related Manuals on page 3.

4. Always flush the pump before the fluid dries on the displacement rod. Follow steps to Flush the Pump on page 20.

Excessive air pressure in the material drum could cause the drum to rupture, causing serious injury. The platen must be free to move out of the drum. Never use drum blowoff air with a damaged drum.

3. Release the blowoff air button (AE) and allow the ram to rise to its full height.

4. Remove the empty drum.

5. Inspect the platen and, if necessary, remove any remaining material or material build–up.

3A6331G 23

Maintenance

Driver Maintenance

NOTICE

Do not open/remove the gear cover. The gear side is not intended to be serviced. Opening the gear cover may alter the factory set bearing pre-load and may reduce the product life.

Preventative Maintenance Schedule

The operating conditions of your particular system determine how often maintenance is required. Establish a preventative maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your system.

Change the Oil

NOTE: Change the oil after a break-in period of 200,000

to 300,000 cycles. After the break-in period, change the oil once per year.

Check Oil Level

Refer to FIG. 14 below. Check the oil level in the sight glass on a regular basis. The oil level should be near the halfway point of the sight glass when the driver is not running. If the oil is low, open the fill cap and add Graco Part No. 16W645 ISO 220 silicone-free synthetic EP gear oil.

The oil capacity is approximately 1.0 - 1.2 quarts (0.9 -

1.1 liters). Do not overfill.

NOTICE

Only use oil with Graco part number 16W645. Any other oil may not lubricate properly and can cause damage to the drive train.

Fill Cap

1. Follow the Pressure Relief Procedure on page 22.

2. Place a minimum 2 quart (1.9 liter) container under the oil drain port.

3. Remove the oil drain plug. See FIG. 14 for the loca- tion of the drain plug. Allow all oil to drain from the driver.

4. Reinstall the oil drain plug. Torque to 18-23 ft-lb (25-30 N•m).

5. Open the fill cap and add Graco Part 16W645 ISO 220 silicone-free synthetic EP gear oil. Check the oil level in the sight glass. Fill until the oil level is near the halfway point of the sight glass. The oil capacity is approximately 1.0 - 1.2 quarts (0.9 - 1.1 liters). Do

not overfill.

6. Reinstall the fill cap.

Bearing Pre-loads

Sight Glass

Oil Drain Plug

FIG. 14: Sight Glass and Oil Fill Cap

Bearing Pre-Load

The bearing pre-loads are factory set and are not user adjustable. Do not adjust the bearing pre-loads. See APD20 Advanced Precision Driver Instructions-Parts manual for maintenance information.

24 3A6331G

Maintenance

Platen Maintenance

See FIG. 15. If the platen does not come out of the pail easily when the pump is being raised, the air assist tube (F) or check valve may be plugged. A plugged valve prevents air from reaching the underside of the plate to assist in raising it from the pail.

1. Follow the Pressure Relief Procedure on page 22.

2. Refer to parts illustration on page 50 and disassemble air assist valve as shown.

3. Clear air assist tube (AT) in platen. Clean all parts of valve and reassemble.

4. Remove bleed stick (EF) from platen. Push bleed stick through bleed relieve ports to remove material residue.

Adjust Spacers

Tapered and Straight Sided Pails

The platen is supplied for use with 20 liter (5 gallon), 30 liter (8 gallon), and 60 liter (16 gallon) straight sided pails, but only single wiper platens can be easily modified for use with tapered pails.

Platen with Tapered Pails

1. Follow the Pressure Relief Procedure on page 22.

2. Working from the bottom, use screwdriver to pry

spacer (EC) loose. Work spacer upward completely above the flange of the platen. See FIG. 16.

3. By hand, angle spacer (EC) and work it off the plate, pulling it down over the flange and bottom wipers (EB). See FIG. 17.

4. Save spacer (EC), as it is required for other applications.

FIG. 15

To use Model 255745 platens with tapered pails, the spacer (EC) must be removed.

r_255468_313527_33a

FIG. 16

r_255468_313527_30a

3A6331G 25

Maintenance

Platen with straight sided pail

1. Follow the Pressure Relief Procedure on page 22.

2. Ensure large diameter of spacer (EC) is facing

down. Work spacer (EC) up over the platen by hand completely above the flange of the platen. See FIG. 17.

3. Working from the top, use screwdriver to position

spacer (EC) between flange and wipers (EB). See FIG. 18.

r_255468_313527_30a

FIG. 17: Sliding spacer

Remove and Reinstall Wipers

Disassemble 20, 30, and 60 Liter Wiper Assemblies

1. Follow the Pressure Relief Procedure on page 22.

2. Remove wiper assembly; see FIG. 35 on page 50:

a. For all single wiper platens: Remove two clips

(470) with needle nose pliers and remove platen cover (469).

b. Remove eight nuts (459) that hold wiper assem-

bly to platen casting (451) and remove wiper assembly.

c. See Reassemble 20, 30, and 60 Liter Wiper

Assemblies to change wiper sizes, styles, or a complete wiper assembly.

3. Remove eight nuts (459) on wiper assembly.

4. Separate top plate (457), spacer (452), wiper(s) (453), wiper support (454), and bottom plate (455).

5. Clean, inspect, and replace worn components.

Reassemble 20, 30, and 60 Liter Wiper Assemblies

FIG. 18: Installing Spacer

r_255468_313527_32a

1. Assemble wiper assembly; see FIG. 35 on page 50:

a. For single wiper assemblies with carbon steel

platens: Place bottom plate (455) on flat surface. Place wiper support (454), wiper (453), spacer (452), and top plate (457) on bottom plate (455).

b. For single wiper assemblies with SST platens:

Place bottom plate (455) on flat surface. Place wiper support (454), wiper (453), flowered wiper support (460), PTFE spacer (452), and top plate (457) on bottom plate (455).

c. For double wiper assemblies: Place bottom

plate (455) on flat surface. Place wiper support (454), wiper (453), spacer (452), wiper (453) and top plate (457) on bottom plate (455).

2. Install eight nuts (459) on outer ring. Torque to 45 in-lbs (61 N•m).

3. Replace o-ring (456), or install new o-ring under platen casting (451). Use lubricant to hold in place.

26 3A6331G

4. Install platen casting (451). Tighten with four nuts (459).

Remove 55 Gallon Platen Wipers

Maintenance

1. Follow the Pressure Relief Procedure on page 22.

2. Turn the disconnect switch (M) to OFF.

3. To replace worn or damaged wipers (EB), raise platen up out of drum. Remove drum from base. Wipe fluid off of platen.

4. Cut top and bottom wipers with knife and remove from platen. See FIG. 19.

TI10613A

FIG. 19

Reinstall 55 Gallon Platen Wipers

1. Using a wooden or plastic tool to prevent damage to the wiper (EB), clean all material from seal grooves.

TI10614A

FIG. 20

Remove 55 Gallon Platen Hose Wipers

1. Follow the Pressure Relief Procedure on page 22.

2. Turn the disconnect switch (M) to OFF.

3. To replace worn or damaged wipers (EB), raise platen up out of drum. Remove drum from base. Wipe fluid off of platen.

4. Loosen ends of banding (410) with jack screw. See FIG. 21.

2. Working from the bottom, angle one wiper (EB) over

back of platen. See FIG. 20.

3. Insert wiper (EB) in top groove and run front of wiper into groove.

4. Insert second wiper (EB) in lower groove and run front of wiper into groove.

5. Lubricate outside of wiper with lubricant compatible with material being pumped. Check with material supplier.

410

WLD

FIG. 21

3A6331G 27

Maintenance

Reinstall 55 Gallon Plate Hose Wipers

1. Clean all material from the seal grooves. Lubricate ram plate grooves before assembly.

2. Assemble two bands (410) together. Align one end of band about 9 in. from jack screw and tape attached band. Install screw jack in slot.



410

3. Insert jack screw end of band (410) into hose (408 or 409) and push completely through hose.



WLD

410

408, 409

NOTE: To prevent material from potentially leaking past both hoses, ensure hose (408,409) seams are 90°-180° apart, and not on top of each other.

408



409



410 (x2)

WLD

WLD

4. Lubricate outside of hoses (408,409) and place on upper or lower groove on plate. Adjust hose and band so that the angled ends of hose press against each other. Tighten two ends of banding (410) together with jack screw.

410

WLD

5. Work hose to completely close gap at the ends.

28 3A6331G

Troubleshooting

2. Check all possible problems and causes before disassembling the ram, pump, or platen.

NOTE: Refer to Supply Unit Operation manual for descriptions of DataTrak diagnostic codes.

NOTE: Refer to your pump package manual for pump

1. Follow Pressure Relief Procedure, page 22,

before checking or repairing the ram, pump, or platen.

Problem Cause Solution

Ram will not raise or lower. Closed air valve or clogged air line. Open, clear.

Not enough air pressure. Increase.

Worn or damaged piston. Replace. See Supply Unit Repair on

Hand valve closed or clogged. Open, clear.

Ram raises and lowers too fast. Air pressure is too high. Decrease.

Air leaks around cylinder rod. Worn rod seal. Replace. See Supply Unit Repair on

Fluid squeezes past ram plate wipers.

Pump will not prime properly or pumps air.

Air assist valve will not hold drum down or push plate up.

Air pressure too high. Decrease.

Worn or damaged wipers. Replace. See Remove and Rein-

Not enough pressure. Increase pressure setting.

Worn or damaged piston. Replace. See pump manual.

Hand valve closed or clogged. Open, clear. See Platen Mainte-

Hand valve is dirty, worn, or damaged.

Closed air valve or clogged air line. Open, clear. See Platen Mainte-

Not enough air pressure. Increase.

Valve passage clogged. Clean. See Platen Maintenance on

troubleshooting.

page 34.

stall Wipers on page 26.

nance on page 25.

Clean, service.

nance on page 25.

page 25.

3A6331G 29

Repair

Disconnect Pump from Platen

4. Carefully pull pump away to prevent damage to pump inlet and remove o-ring (428).

20, 30, and 60 Liter Platen

1. Follow the Pressure Relief Procedure on page 22.

The pump is mounted to the platens by different mounting kits. See the Repair Kits on page 55.

55 Gallon Platen

1. Follow the Pressure Relief Procedure on page 22.

2. Turn the disconnect switch (M) to OFF.

3. Remove four hex screws (426), four clamps (427), and washers (425).

428

426

425

427

428

2. Turn the disconnect switch (M) to OFF.

3. Loosen two 5/16 in. screws (462) from platen.

4. Carefully pull pump away to prevent damage to pump inlet. If using a pump with intake adapter, remove screws (472), adapter (471), and o-rings (463) from pump inlet.

428

426

425

427

426

425

427

TI10422A

Check-Mate Mounting

FIG. 22: 55 Gallon Mounting Kit

463

462

r_255648_313527_35a

Check-Mate Mounting

FIG. 23: 20, 30, and 60 liter mounting kit

30 3A6331G

Dura-Flo SS Mounting

471

462

Dura-Flo SS Mounting

472

463

Dura-Flo CS Mounting

471

462

Dura-Flo CS Mounting

472

463

Repair

Connect Platen

55 Gallon Platen

1. Place o-ring (428) from mounting kit on the platen. If attached to plate, place displacement pump onto platen. See FIG. 22.

2. Secure pump’s intake flange to plate with screws (426), washers (425), and clamps (427) included in mounting kit 255392.

20, 30, and 60 Liter Platen

NOTE: Before installing the 20, 30, or 60 liter platen to a

pump with an intake adapter, install adapter and o-ring from mounting kit using the two set screws. See FIG. 23.

1. Place o-ring (463) from mounting kit on pump intake. Loosen the pump intake flange screws (462) and carefully lower pump onto o-ring (463) and platen.

2. Secure pump’s intake flange to plate with screws (462).

Remove Displacement Pump

The procedure for removing your displacement pump depends on which driver and platen your unit uses. Find your ram unit, driver, and platen below to remove the displacement pump. Refer to your displacement pump manual to repair the displacement pump.

If the driver does not require servicing, leave it attached to its mounting. If the driver does need to be removed, see Remove Driver on page 33.

D200 3 in. and D200s 6.5 in. Supply Units

1. Follow the Pressure Relief Procedure on page 22.

2. Turn the disconnect switch (M) to OFF.

3. See Disconnect Displacement Pump in your

pump package manual.

4. Open the main air slider valve (AA).

Remove Wipers

See Remove and Reinstall Wipers on page 26.

Install Wipers

See Remove and Reinstall Wipers on page 26.

5. Raise the driver:

a. Loosen nut (105a) under ram bar and thread it

down the threaded rod (106) to the lift ring adapter (107) holding the driver. Use wrench on nut (105) on top of ram bar to raise driver.

106

105

105a

107

FIG. 24

3A6331G 31

Repair

b. For driver with smaller platens and all supply

units: See procedure for D60 3 in. Dual Post Supply Units on page 32.

6. See Disconnect Pump from Platen on page 30 to

disconnect the platen from the displacement pump.

7. Use two people to lift out the displacement pump.

Install Displacement Pump

D200 3 in. and D200s 6.5 in. Supply Units

1. Insert displacement pump on platen. Follow Connect Platen steps on page 31.

2. See Reconnect Displacement Pump in your pump package manual.

3. Connect driver:

a. Use wrench on nut (105) on top of ram bar to

lower driver onto displacement pump. See FIG. 24 on page 31. Thread nut (105) up and tighten it under ram bar. Tighten nut (105) below the crossbar to 25 ft-lb (34 N•m) maximum.

D60 3 in. Dual Post Supply Units

1. Raise ram to install displacement pump to platen.

2. Insert displacement pump on platen. Follow Con-

nect Platen steps on page 31.

FIG. 25

D60 3 in. Dual Post Supply Units

1. Follow the Pressure Relief Procedure on page 22.

2. Turn the disconnect switch (M) to OFF.

3. See Disconnect Displacement Pump in your

pump packages manual.

4. See Disconnect Pump from Platen on page 30 to

disconnect the platen from the displacement pump.

5. Open the main air slider valve (AA).

6. Raise the ram assembly to lift the driver away from the displacement pump.

3. See Reconnect Displacement Pump in your pump

packages manual.

7. Remove displacement pump and service as needed.

32 3A6331G

Remove Driver

To avoid serious injury when installing and removing the driver, make sure the driver is supported at all times.

Repair

1. Follow the Pressure Relief Procedure on page 22.

2. Turn the disconnect switch (M) OFF.

3. See Disconnect Displacement Pump in your

pump package manual.

4. Disconnect power from the driver:

a. Remove the driver housing cover (HC).

b. Disconnect the wires inside the driver housing.

c. Loosen the cord grip (CG).

d. Remove wires from driver housing by pulling

them through the cord grip (CG).

e. Disconnect the cables connected to ports 1-6

on the side of the driver, shown in FIG. 27.

FIG. 27

5. Disconnect driver:

a. D200 3 in. and D200s 6.5 in. supply units:

Loosen nut (125) below crossbar. Use wrench to hold lift ring adapter (127) in place and loosen threaded rod (126) above crossbar with another

wrench. See FIG. 28.

126

125

127

FIG. 28: 55 Gallon Platen

b. D60 3 in. supply units: Remove screws (255)

FIG. 26

FIG. 29: D60 with Ram

3A6331G 33

and washers (256) from mounting plate (259). Using a secure hoist, lift the driver from the mounting plate (259). See FIG. 29.

259

256

255

Repair

Install Driver

To avoid serious injury when installing and removing the driver, make sure the driver is supported at all times.

D200 3 in. and D200s 6.5 in. Supply Units

55 gallon platen:

1. Using a capable hoist, insert tie rods into displacement pump and secure driver to pump.

a. See Reconnect Displacement Pump in your

pump package manual.

b. Install threaded rod (126) through center hole in

the crossbar. Install lock washers (124) and nuts (125) onto threaded rod (126), both above and below crossbar. Use wrench to hold lift ring adapter (127) and tighten threaded rod (106) into lift ring adapter (127) using another wrench. See FIG. 30.

c. Tighten nut (125) below crossbar to 25 ft-lb (34

N•m) maximum.

2. Connect power to the driver. Follow a-e of step 4 on page 33 in reverse.

3. Turn the disconnect switch (M) ON.

D60 3 in. Dual Post Supply Unit

1. Using a secure hoist, attach driver to mounting plate (259) with screws (255) and washers (256). See FIG. 29 on page 33.

2. See Reconnect Displacement Pump in your pump package manual.

3. Connect power to the driver. Follow a-e of step 4 on page 33 in reverse.

Supply Unit Repair

To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 22. Do not use pressurized air to remove the guide sleeve or the piston.

D200s 6.5 in. Ram Piston Rods

d. Tighten nut (125) above crossbar to lock driver

in place.

126

125

124

125

FIG. 30

Always service both cylinders at the same time. When you service the lift rod always install new o-rings in the piston rod seal and ram piston.

Disassemble Piston Rod Seal

1. Follow the Pressure Relief Procedure on page 22.

2. Turn the disconnect switch (M) OFF.

3. Remove the nuts (123) and lockwashers (122) holding the tie bar (219) to the piston rods (132). See parts illustration on page 38.

4. Remove nuts (303, 305) and washers (302, 304). See parts illustration on page 44.

127

5. Lift tie bar (219) off of rods.

6. Remove retaining ring (136) by gripping the ring tab with a pair of pliers and rotating the ring out of its groove.

7. Remove snap ring (134) and rod wiper (133).

8. Remove guide sleeve (135) by sliding it off of rod (132). Four 1/4 in -20 holes are provided to ease removal of the guide sleeve.

34 3A6331G

Repair

9. Inspect parts for wear or damage.

134

136

137

133

142

135

132

TI10784A

FIG. 31: 6.5 in. Piston Rod Seal

Assemble Piston Rod Seal

1. Install new o-rings (137,142), rod wiper (133), and snap ring (134). Lubricate packings with o-ring lubricant.

2. Slide guide sleeve (135) onto rod (132) and push it into cylinder. Replace retaining ring (136) by feeding it around the guide sleeve groove.

7. Remove guide sleeve (135) and slide it off piston rod (132).

NOTICE

Do not tilt the piston rod to one side when removing it from the base or when installing it. Such movement can damage the piston or inside surface of the base cylinder.

8. Carefully lay piston (141) and rod (132) down so rod will not be bent. Remove bottom retaining ring (138) and o-ring (139). Remove piston guide band (140). Slide piston (141) off piston rod (132).

132

139

138

137

141

140

3. Reinstall tie bar (219) using nuts (123) and lockwashers (122). Torque to 40 ft-lb (54 N•m).

4. Reinstall washers (302, 304) and nuts (303, 305).

Disassemble Ram Piston

1. Follow the Pressure Relief Procedure on page 22.

2. Turn the disconnect switch (M) OFF.

3. Remove nuts (123) and lockwashers (122) holding the tie bar (219) to the piston rods (132). See page

38.

4. Remove nuts (303, 305) and washers (302, 304). See parts illustration on page 44.

5. Lift tie bar (219) off rods.

6. Remove retaining ring (136) by gripping the ring tab with a pair of pliers and rotating the ring out of its groove.

TI10785A

FIG. 32: 6.5 in. Ram Piston

Assemble Ram Piston

1. Install new o-rings (139, 137) on piston rod (132) and piston (141). Lubricate the piston (141) and o-rings (139, 137). Reinstall piston (141) and lower retaining ring (138) onto piston rod (132). Install piston guide band (140) onto piston (141).

2. Carefully insert piston (141) into cylinder and push rod (132) straight down into cylinder. Add three ounces of lubricant to each cylinder after inserting the piston (141).

3. Slide guide sleeve (135) onto piston rod (132).

4. Install retaining ring (134) and tie bar (219). Perform steps to Disassemble Ram Piston in reverse order.

3A6331G 35

Repair

D200 and D60 3 in. Ram Piston Rods

Always service both cylinders at the same time. When you service the piston rod always install new o-rings in the piston rod seal and ram piston.

Disassemble Piston Rod Seal and Bearing

1. Follow the Pressure Relief Procedure on page 22.

2. Access piston rod seal and bearing.

a. For D200 3 in. Ram: Remove nuts (125) and

lockwashers (124) holding the tie bar (219) to the piston rods (246). Remove nuts (305) and washers (304). Remove tie bar (219). Refer to parts illustration on page 40.

b. For D60 3 in. Ram: Ensure ram is in lowest

position. Remove nuts (125) and lockwashers (254) from piston rods (261). Remove entire pump package, including the mounting plate (259) off of the piston rods (261). Secure pump package so pump and platen will not fall. See page 45.

D200 and D60 3 in. Rams

245

241

238

243

244

261, 246

WLD

FIG. 33: 3 in. Piston Rod Seal

Assemble Piston Rod Seal and Bearing

218

240

242

3. Remove retaining ring (218).

4. Remove piston rod seal and bearing.

a. Slide end cap (241), pin (238), o-ring (245), and

spring (244) up off of the piston rod (261, 246). Remove retaining ring (242) and bearing (243) from end cap (241) and remove o-ring (240).

5. Inspect parts for wear or damage. Replace as necessary.

NOTE: Do not reinstall end cap assembly if the ram piston (247) needs to be removed from the piston rod. See the next page for ram piston repair instructions.

See FIG. 33 on page 36.

1. Lubricate o-ring (240) and bottom bearing (243).

a. Install o-ring (240), bottom bearing (243), and

retaining ring (242) into end cap (241).

b. Install new o-ring (245) and pin (238) on end

cap (241). Lubricate o-ring (245) and end cap (241).

c. Slide spring (244) and end cap (241) on piston

rod (261, 246).

2. Install retaining ring (218).

3. For D200 3 in Ram: Install tie bar (219), washers

(124), and nuts (125).

4. For D60 3 in. Ram: Remount mounting plate (259)

and attach nuts (255) and lockwashers (256). Torque to 40 ft-lb (54 N•m).

36 3A6331G

Repair

Disassemble Ram Piston

1. Complete steps 1-4 from Disassemble Piston Rod Seal and Bearing to remove the end cap from the

piston rod.

NOTICE

Do not tilt the piston rod to one side when removing it from the base or when installing it. Such movement can damage the piston or inside surface of the base cylinder.

2. Carefully lay piston (247) and rod (261, 246) down so piston rod will not be bent. Remove nut (125), washer (124), piston (247), outer o-ring (245), and inner o-ring (239).

3. Inspect parts for wear or damage. Replace as necessary.

261, 246

245

Assemble Ram Piston

1. Install new o-rings (245, 239) and lubricate piston (247) and o-rings.

2. Apply medium strength thread sealant. Install piston (247), washer (124), and nut (125) on piston rod (261, 246).

3. Carefully insert piston (247) into cylinder and push piston rod (261, 246) straight down into cylinder.

4. Slide spring (244) and end cap (241) onto piston rod (261, 246).

5. For D200 3 in. Rams: Install retaining ring (218), tie bar (219), washers (124), and nuts (125).

6. For D60 3 in. Rams: Install retaining ring (218) and install mounting plate (259) with nuts (255) and washers (256) with pump package and platen.

239

FIG. 34: 3 in. Ram Piston

247

124

125

TI10521A

3A6331G 37

Parts

D200s 6.5 in. Supply Units

Model 25E201 Shown

141

145

146

148

150

149

147

134

142

105

125

126

124

123

121

122

108

107

143

108

107

115

101

131

110

104

Detail A

114

112

144

149

116

135

152

153 152

136

111

155

154

117

119

118

136

106

160

106

134

132

107,108

Detail B

106

103, 113

102, 109

133

130

131

38 3A6331G

D200s 6.5 in. Supply Units, 25E201

Parts

Ref. Part Description Qty.

101 102040 NUT, lock, hex 1 102 110755 WASHER, plain 1 103 117017 WASHER 1 104 15V954 LABEL, valve, shutoff, air control 1 105 16W583 LABEL, cross bar 1 106 C12509 TUBE, nylon, rnd 15 107 100016 WASHER, lock 15 108 121112 SCREW, cap, socket head 15 109 121250 SCREW, shch 1 110 255375 BRACKET, mounting, painted 1 111 255438 RAM, 6.5 in. 1 112 255633 BRACKET, pendant pivot, painted 1 113 121253 KNOB, display adj., ram pkgs 1 114 255639 BRACKET, mounting, assembly 1 115 24C264 CONTROL, air, ram, hyd driver 1 116 25E207 JUNCTION BOX, ram mounted,

e-drive 117 C19853 SCREW, cap, socket hd 2 118 C32467 STOP, drum 2 119 C38185 WASHER, lock 2 120 070408 SEALANT, pipe, sst 1 121 15M531 ROD, follower 2 122 101015 WASHER, lock 2 123 C19187 NUT, nex 2 124 101533 WASHER, spring lock 2 125 101535 NUT, full hex 2 126 15J992 ROD, threaded 1 127 15J991 ADAPTER, lift ring 1 128 15J993 RING, lift, plate 1 129 073028 LUBRICANT, anti-seize 1 130 130787

PKG

131 123656 CABLE, spin, male/female 1

SENSOR, barrel, m18 x 1, pnp, nc 1

Ref. Part Description Qty.

132 24D006 ACTUATOR, sensor, low/empty,

wmmlt, pt

133 17Y704

PKG

134 114958 STRAP, tie 7 135 196548 LABEL, caution (Junction Box) 1 136 15J074 LABEL, safety, crush & pinch 4 141 113939 NUT, jam, hex 2 142 113933 WASHER, lock, helical 2 143 15M538 BEAM, tie, 6.5 in. ram 1 144 C32401 ROD 2 145* C03043 RING, snap 2 146* C31001 WIPER, rod 2 147 25T845 SLEEVE, guide 2 148* C32409 RING, retaining 2

149* C38132 PACKING, o-ring 4 150* C02073 PACKING, quad ring 2 152* C20417 RING, retaining 4 153* 158776 PACKING, o-ring 2 154* C32408 BAND, guide 2 155 C32405 PISTON, elevator air 2 157 100040 PLUG, pipe 2 160 114153 FITTING, elbow, male, swivel 2

 Replacement safety labels, tags, and cards are

available at no cost.

* Parts included in Supply Units Repair Kit 918432

(purchase separately).

 Not shown.

BRACKET, lvl sensor, dual, d200s. pnt

3A6331G 39

Parts

D200 3 in. Supply Units

Model 25E200 Shown

108

107

115

218

245

246

116

245

240

243

242

238

241

244

225

135

224

220

125

124

201, 213, 107

219

107, 108

205, 217

226

105

125

124

126

252

108

107

208

101

106

107,108

136

112

133

104

Detail A

114

102, 109

103,113

107,108

221

106

Detail B

132

247

239

124

125

40 3A6331G

117

119

118

106

223

131

130

134

D200 3 in. Supply Units, 25E200

Parts

Ref. Part Description Qty.

101 102040 NUT, lock, hex 1 102 110755 WASHER, plain 1 103 117017 WASHER 1 104 15V954 LABEL, valve, shutoff, air control 1 105 16W583 LABEL, cross bar 1 106 C12509 TUBE, nylon, rnd 15 107 100016 WASHER, lock 16 108 121112 SCREW, cap, socket head 12 109 121250 SCREW, shcs 1 112 255633 BRACKET, pendant pivot, painted 1 113 121253 KNOB, display adj., ram pkgs 1 114 255639 BRACKET, mounting, assembly 1 115 24C264 CONTROL, air, ram, hyd driver 1 116 25E207 JUNCTION BOX, ram mounted,

e-drive 117 C19853 SCREW, cap, socket hd 2 118 C32467 STOP, drum 2 119 C38185 WASHER, lock 2 120 070408 SEALANT, pipe, sst 1 124* 101533 WASHER, spring lock 6 125* 101535 NUT, full hex 6 126 15J992 ROD, threaded 1 127 15J991 ADAPTER, lift ring 1 128 15J993 RING, lift, plate 1 129 073028 LUBRICANT, anti-seize 1 130 130787

PKG 131 123656 CABLE, spin, male/female 1 132 255381 ACTUATOR, sensor, low/empty,

133 17Y702

PKG 134 114958 STRAP, tie 7 135 196548 LABEL, caution (Junction Box) 1 136 15J074 LABEL, safety, crush & pinch 4

SENSOR, barrel, m18 x 1, pnp, nc 1

painted BRACKET, lvl sensor, dual, d200,

pnt

Ref. Part Description Qty.

201 100014 SCREW, cap, hex hd 4 205 108050 WASHER, lock, spring 6 208 189559 CAP, end 2 213 100015 NUT, hex mscr 4 217 121518 SCREW, cap, shc 6 218* 127510 RING, retaining, internal 2 219 167646 BEAM, tie 1 220 255286 RAM, weldment, 3” 1 221 255296 BRACKET, mounted, painted 1 223 128863 FITTING, elbow 2 224 15W703 BRACKET, mounting, btm 1 225 16A314 BRACKET, mounting, acc. box 1 226 16A566 BRACKET, mounting, ram 1

234 070303 LUBRICANT, grease 1 235 073021 LUBRICANT, oil 1 237 070615 SEALANT, thread, med strength 1 238* 121259 BEARING, ram end cap 1 239* 156401 PACKING, o-ring 1 240* 156698 PACKING, o-ring 1 241* 15F453 RETAINER, retaining ring 1 242 15M295 BEARING, ram end cap 1 243 15U979 PIN, spring, straight 1 244* 160138 SPRING, compression 1 245* 160258 PACKING, o-ring, buna-n 2 246 167651 ROD, piston ram 1 247 183943 PISTON 1 251 C20987 PACKING, o-ring 1 252 167652 ROD, tie ram 2

 Replacement safety labels, tags, and cards are

available at no cost.

* Parts included in Supply Units Repair Kit 255687 (pur-

chase separately).

 Not shown.

3A6331G 41

Parts

D60 3 in. Supply Units

Model 25E199 Shown

218

245

240

243

242

260

238

241

244

107,108

225

256

255

108

125

254

259

114

107

101

106

112

136

Detail A

254,125

108

107

221

115

104

102, 109

261

245

116

247

239

125

205, 217

124

135

224

201,107,

213

257

226

117

119

118

258

106

223

107,108

106

132

223

Detail B

133

103,113

107,108

134

130

131

134

107,108

42 3A6331G

D60 3 in. Supply Units, 25E199

Parts

Ref. Part Description Qty.

101 102040 NUT, lock, hex 1 102 110755 WASHER, plain 1 103 117017 WASHER 1 104 15V954 LABEL, valve, shutoff, air control 1 106 C12509 TUBE, nylon, rnd 2 107 100016 WASHER, lock 18 108 121112 SCREW, cap, socket head 14 109 121250 SCREW, shch 1 112 255633 BRACKET, pendant pivot, painted 1 113 121253 KNOB, display adj., ram pkgs 1 114 255639 BRACKET, mounting, assembly 1 115 24C264 CONTROL, air, ram, hyd driver 1 116 25E207 JUNCTION BOX, ram mounted,

E-drive 117 C19853 SCREW, cap, socket hd 2 118 C32467 STOP, drum 2 119 C38185 WASHER, lock 2 120 070408 SEALANT, pipe, sst 1 124* 101533 WASHER, spring lock 1 125* 101535 NUT, full hex 3 130 130787

SENSOR, barrel, m18 x 1, pnp, nc 1

PKG 1313 123673 HARNESS 1 132 255381 ACTUATOR, sensor, low/empty,

painted

133 17Y702

PKG

BRACKET, lvl sensor, dual, D200, pnt

134 114958 STRAP, tie 4 135 196548 LABEL, caution (Junction Box) 1 136 15J074 LABEL, safety, crush & pinch 4

201 100014 SCREW, cap, hex hd 4 205 108050 WASHER, lock, spring 6 213 100015 NUT, hex mscr 4 217 121518 SCREW, cap, shc 6

Ref. Part Description Qty.

218* 127510 RING, retaining, internal 2 221 255296 BRACKET, mounted, painted 1 223 128863 FITTING, elbow 2 224 15W703 BRACKET, mounting, btm 1 225 16A314 BRACKET, mounting, acc. box 1 226 16A566 BRACKET, mounting, ram 1 234 070303 LUBRICANT, grease 1 235 073021 LUBRICANT, oil 1 237 070615 SEALANT, thread, med strength 1 238* 121259 BEARING, ram end cap 1 239* 156401 PACKING, o-ring 1 240* 156698 PACKING, o-ring 1 241* 15F453 RETAINER, retaining ring 1

242 15M295 BEARING, ram end cap 1 243 15U979 PIN, spring, straight 1 244* 160138 SPRING, compression 1 245* 160258 PACKING, o-ring, buna-n 2 247 183943 PISTON 1 254 104395 WASHER, lock, tooth, external 2 255 110141 SCREW, cap, sch 4 256 100133 WASHER, lock, 3/8 4 257 256734 RAM, dp, weldment 1 258 16T421 ADAPTER, pipe hex 1 259 17L703 BRACKET, shelf, D60, 3400/6500 1

17X806

260

PKG

BRACKET, cable track, D60 ram 1

261 15V697 ROD, piston, dp ram 1

 Replacement safety labels, tags, and cards are

available at no cost.

* Parts included in Supply Units Repair Kit 255687

(purchase separately).

 Not shown.

3A6331G 43

Parts

D200s and D200 Pump Mounts for 55 Gallon (200 Liter) Platen

Note: See page 38 for kit configuration table.

305

304

301

304

305

303, 305

302, 304

126

127

128

TI10771A

Ref. Part Description Qty

301 15M531 ROD, platen 2

167652 302 101015 WASHER, lock 2 303 C19187 NUT, hex 2 304 101533 WASHER, spring lock 2 305 101535 NUT, full hex 2 126 15J992 ROD, threaded 1 127 15J991 ADAPTER, lift, ring 1

44 3A6331G

Ref. Part Description Qty

128 15J993 RING, lift, plate 1 324 160327 FITTING, 3/4 nptf x 3/4 npsm, 90° 1 325 C12034 HOSE, coupled; 72 in. 1 326 552071 SLEEVE, protective, 6 ft 1 327 105281 FITTING, 3.4 nptf x 3/4 npsm, 45° 1

 Not shown.

D60 Pump Mount 257624 for 5 Gallon (20 Liter) Platen

Note: See page 38 for kit configuration table.

383

382

381

Parts

384

Ref. Part Description Qty.

381  BRACKET, shelf, NXT3400 and

NXT6500 382 101533 WASHER, spring lock 2 383 101535 NUT, hex 2 384 100133 WASHER, lock 4 385 C38372 SCREW, cap, hex head 4 388 SLEEVE, protective; 72 in. 1 389 STRAP, tie 2 390 HOLDER, cable tie, rotating 2 391 160327 FITTING, 3/4 nptf x 3/4 npsm, 90° 1

 For 257624 only.

 Not shown.

385

3A6331G 45

Parts

Transformer

6.5 in. Ram Transformer Kit 25E202

Tighten u-bolt nuts until lock

washers are flattened. Over-tightening may damage ram cylinder.

511

509

510

508

513

514

517

520

3 in. Ram Transformer Kit 25E203

515

516

513

502

501

514

520

517

516

518

512

507

523

506

515

519

504

521,522

505

525

519

503

524

523

525

46 3A6331G

Transformer Parts

Ref. No. Part No. Description Qty.

501* 16A566 BRACKET, mounting, ram, 3 in. 2 502* 17X839PKG BRACKET, mounting, xformer, 3 in.

ram, painted 503* 100015 NUT, hex mscr 8 504* 100014 SCREW, cap, hex hd 8 505* 100016 WASHER, lock 8 506** 100101 SCREW, cap, hex hd 4 507** C19200 WASHER, plain 4 508** 100131 NUT, full hex 4 509** C32424 BOLT, u, 7 in. 2 510** 617395 CLAMP, saddle 2 511** 100133 WASHER, lock, 3/8 8 512** 17X836 BAR, xformer mounting, 6 in. ram,

painted 513 17D989 CONNECTOR, conduit, liquid-tight 1 514 120800 CONDUIT, 1/2 1 515 17D987 CONNECTOR, conduit, liquid-tight 1 516 129626 TRANSFORMER, 480V 1 517 16K918 LABEL, power in, branch circuit 1 518 196548 LABEL, caution 1 519 107530 SCREW, cap, sch, hex 4 520 25E178 LABEL, safety, danger 1 521 124436 CONNECTOR, splice, wire 2 522 124437 CAP, splice, wire 2 523 065388 WIRE, copper, electric 1 524 124443 TERMINAL, ring, insulated, 1/4 1 525 127667 FERRULE 2

Parts

* Parts only included in kit 25E202.

** Parts only included in kit 25E203.

 Replacement safety labels, tags, and cards are

available at no cost.

3A6331G 47

Parts

Cable Track

809

808

811(x3)

816(x4)

810

807

806

812

814(x4)

805

804

815

813(x4)

811(x3)

Cable Tracks, 25E346, 25E347, and 25E348

Quantity

Ref Part Description 25E346 25E347 25E348

801 C12509 TUBE, nylon, rnd 802 128986 CONNECTOR, 2 conductor, leverlock

131795 CORD, power, d60

803

804 121003 CABLE, can, female / female 3.0 m 805 124415 CABLE, 5pin, mf, 3.0 m, molded

806

807 17X897PKG CABLE, track, igus, d60, e-drive 808 128177 INSERT, rubber, cord grip, 4 x 6 mm 809 128397 INSERT, rubber, cord grip, 9-10 mm 810 131664PKG FRAME, cord grip, 2-position 811 C38321 TIE, cable, 3.62 lg 812 17Y316PKG COVER, disconnect, painted 813 104572 WASHER, lock spring 814 109114 SCREW, cap, sch 815 121171 GRIP, cord, .35-.63, 3/4 816 128670 BOLT, flange hd, serrated, m5, sst

131796 CORD, power, d200 131797 CORD, power, d200s

125183 CABLE, m12, 8 pin, mf, 2.5 m, molded 15Y051 CABLE, m12, 8 pin, mf, 3.0 m, molded

14 ft 15.5 ft 17.5 ft

222 1

1 222 111 11

1 111 111 111 111 666 111 444 444 111 444

803

801

802

48 3A6331G

55 Gallon Platen

Parts

200 Liter (55 Gallon) Platen, 255662, 255663, and 255664

408

*426

*427

*428

416

403

417

421

414

ti20583a

200 Liter (55 Gallon) Platen with EPDM Hose Wipers, 24Y343

*428

*426

*427

414

408

409

403

421

416

417

410

WLD

200 Liter (55 Gallon) Platen Parts

Ref. No.Part No. Description Qty.

403 257697 HANDLE, bleed assy 1 408 255652 SEAL, wiper, drum, 55 gal., neo-

prene; for 255664 only.

255653 SEAL, wiper, drum, 55 gal., EPDM;

for 255663 and 255662 only.

414 PLATE, ram 55 gal., for 255664

and 255663 only. PLATE, ram 55 gal., PTFE 1

416 122056 VALVE, check, 1/4, for 255662 and

255663 only

501867 VALVE, check, 5/8, for 255664 only 1

417 17E556 FITTING, PTC, elbow,1/4 NPT, 1/4

TUBE

421 15W032 ADAPTER, for 255663, 255664,

and 25N344

16W974 ADAPTER, for 255662 only 1

426* 102637 SCREW, cap 4 427* 276025 CLAMP 4 428* 109495 O-RING 1

* Parts included in 255392 Kit (purchase separately).

 Parts not included with 255662, 663, and 664.

200 Liter (55 Gallon) Platen with EPDM Hose Wipers Parts

Ref.

No. Part No. Description Qty.

403 257697 HANDLE, bleed assy 1 408† 17L889 SEAL, wiper, drum, 55 gal., EPDM 1

409† 162230 SEAL, wiper, drum, 55 gal., EPDM 1 410† 17B467 CLAMP, tire 4 414 PLATE, ram 55 gal. 1 416 122056 VALVE, check, 1/4 1

417 17E556 FITTING, PTC, elbow,1/4 NPT, 1/4

TUBE

421 15W032 ADAPTER 1

426* 102637 SCREW, cap 4 427* 276025 CLAMP 4

428* 109495 O-RING 1

* Parts included in 255392 Kit (purchase separately).

† Parts included in 25M210 Kit (purchase separately).

 Parts not included with 24Y343.

 Parts not included with 25N344.

3A6331G 49

Parts

20 Liter (5 Gallon), 30 Liter (8 Gallon), and 60 Liter (16 Gallon) Platens

Double Wiper Platen

461

451

456

457

453

452

453

459

462

464

461

465

459

Single Wiper with

SST Platen

456

459

457

452

460

470

464

451

469

459

465

Single Wiper Platen

470

461

462

451

456

459

457

452

469

459

462

465

464

Single Wiper Platen

PVC

461

456

459

457

453

452

459

462

451

465

464

454

453

454

455

r_255648_313527_25a

r_255648_313527_34a

FIG. 35: Single and Double Wiper Assemblies

453

454

455

r_255648_313527_26a

454

455

50 3A6331G

Platen Descriptions

Parts

Platen Platen Size

257727

257728



257729



257730



257731



25A206

25E110

257732



257733



257734



257735



257736



257737



257740



257738



257739



257741





20 Liter

(see page 52)

30 Liter

(see page 52)

60 Liter

(see page 54)

Platen

Material

CS Nitrile 257639

CS PolyUrethane 257640

SST PTFE-coated

CS Nitrile 257642

CS PolyUrethane 257643

SST Nitrile (FDA

CS PVC 25E111

CS Nitrile 257644

CS PolyUrethane 257645

SST PTFE-coated

CS Nitrile 257647

CS PolyUrethane 257648

CS Nitrile 257649

CS PolyUrethane 257650

SST PTFE-coated

CS Nitrile 257652

CS PolyUrethane 257653

Seal

Material Wiper Assembly Kit

Nitrile

Approved)

Nitrile

257641

25A207

257646

257651

 Single wiper

 Double wiper

See page 52-54 for parts.

3A6331G 51

Parts

Common Parts

The parts listed below are common among all 20, 30, and 60 liter platens. Parts that vary are found in the tables on page 52-54.

Ref. Part Description Qty.

456 121829 O-RING 1 459 555413 NUT, (For SST platens) 12

113504 NUT, keps, hex hd (For CSTL platens) 12 461 257697 HANDLE, bleed, sst 1 463 109482 O-RING; see page 54 1 465 17E556 FITTING, PTC, elbow,1/4 NPT, 1/4

TUBE

Varying Parts - 20 Liter (5 Gallon) Platens

The following table indicates which parts (according to reference number) are included with each platen.

Reference Numbers

Ref. Description

451 BASE 257665 257665 257662 257665 257665 257662 257665

SPACER 276049 276049 276049 257694 257694 276049 17T370

452‡

WIPER, main 257672 257678 257675 257672 (2) 257672 (2) 25A208 15W597

453‡

WIPER, PE support 257681 257681 257681 257681 257681 257681 17T371

454‡

PLATE, bottom 257668 257668 257671 257668 257668 257671 257668

455‡

PLATE, top - clamp retainer 257692 257692 257698 257686 257686 257698 C31154 (2)

457‡

WIPER, support 257689 n/a

460‡

SCREW, cap, hex hd 100057 100057 112894 100057 100057 112894

462‡

464 VALVE, check 122056 122056 501867 122056 122056 501867 122056

TAG, instructions n/a n/a n/a n/a n/a

468‡

COVER 15W184 15W184 15W184 15W184

469‡

PIN, hairpin, cotter (10 pack) 16U740 16U740 16U740 16U740

470‡

Qty:257727 257728 257729 257730 257731 25A206 25E110

1 1

1 (2)

1 1

1 (2)

1 2 1 1 1 2

Parts designated n/a are not available separately. ‡ See page 51 for wiper assembly kits.

Varying Parts - 30 Liter (8 Gallon) Platens

The following table indicates which parts (according to reference number) are included with each platen.

Reference Numbers

Ref.

451 BASE 257665 257665 257662 257665 257665

SPACER 194148 194148 194148 257695 257695

452‡

WIPER, main 257673 257679 257676 257673 (2) 257679 (2)

453‡

WIPER, PE support 257682 257682 257682 257682 257682

454‡

PLATE, bottom n/a n/a n/a n/a n/a

455‡

PLATE, top n/a n/a n/a n/a n/a

457‡

WIPER, support 257690

460‡

SCREW, cap, hex hd 100057 100057 112894 100057 100057

462‡

VALVE, check 122056 122056 501867 122056 122056

464

TAG, instructions n/a n/a n/a

468‡

COVER 15X403 15X403 15X403

469‡

PIN, hairpin, cotter (10 pack) 16U740 16U740 16U740

470‡

Qty:Description 257732 257733 257734 257735 257736

1 1

1 (2)

1 1 1 1 2 1 1 1 2

52 3A6331G

Parts designated n/a are not available separately.

‡ See page 51 for wiper assembly kits.

Parts

3A6331G 53

Parts

Varying Parts - 60 Liter (16 Gallon) Platens

The following tables indicates which parts (according to reference number) are included with each platen.

Reference Numbers

Ref.

451 BASE 257665 257665 257662 257665 257665

SPACER 257684 257684 257684 257696 257696

452‡

WIPER, main 257674 257680 257677 257674 (2) 257680 (2)

453‡

WIPER, PE support 257683 257683 257683 257683 257683

454‡

PLATE, bottom n/a n/a n/a n/a n/a

455‡

PLATE, top n/a n/a n/a n/a n/a

457‡

WIPER, support 257691

460‡

SCREW, cap, hex hd 100057 100057 112894 100057 100057

462‡

464 VALVE, check 122056 122056 501867 122056 122056

TAG, instructions n/a n/a n/a

468‡

COVER 15X404 15X404 15X404

469‡

PIN, hairpin, cotter (10pack) 16U740 16U740 16U740

470‡

 Parts designated n/a are not available separately. ‡ See page 51 for wiper assembly kits.

Platen Mounting Kits

Check-Mate Mounting

Dura-Flo SS Mounting Kit 257630

Dura-Flo CS Mounting

Qty:Description 257737 257740 257738 257739 257741

1 1

1 (2)

1 1 1 1 2 1 1 1 2

471

472

462

463

473

471

472

462

463

r_255648_313527_35a

r_255648_313527_36a

462

473

Ref. Part Description Qty.

463 109482 O-RING 1 471 ADAPTER 1 472 SCREW, socket-hd 2 473 109458 O-RING 1

54 3A6331G

Kits and Accessories

Accessories are available from Graco. Make certain all accessories are adequately sized and pressure-rated to meet the system’s requirements.

Drum Roller Kits for D200 and D200S Supply Units, 255627

See the Drum Roller Kit manual for more information.

Drum Position Clamp Set for D200 Supply Units, 206537

Includes two clamps.

Drum Position Clamp for D200S Supply Units

Order quantity 2 of C32463.

Enclosed Wet Cup Recirculation Kit

See the Enclosed Wetcup Recirculation Kit manual for more information.

200 Liter (55 Gallon) Platen Cover Kits, 255691

ADM Kit, 25E437

Part Description Qty.

24E451 MODULE, gca, adm 124415 CABLE, 5 pin 261105 TIE, cable 15M121 TOKEN, gca, key

CAN Cables

The following CAN cables and splitter are available for use with E-Flow SP electric pumps.

Part Description Length

125306 CABLE, CAN, female/female 123422 CABLE, CAN, female/female 121000 CABLE, CAN, female/female 121227 CABLE, CAN, female/female 121001 CABLE, CAN, female/female 121002 CABLE, CAN, female/female 121003 CABLE, CAN, female/female 120952 CABLE, CAN, female/female 121201 CABLE, CAN, female/female 121004 CABLE, CAN, female/female 121228 CABLE, CAN, female/female 123341 CABLE, CAN, female/female 121807 CONNECTOR, splitter, male/male

0.3 m

0.5 m

0.6 m

1.0 m

1.5 m

3.0 m

4.0 m

6.0 m

8.0 m

15.0 m

40.0 m

See the Platen Cover Kit manual for more information.

I/O Cable, 122029

Light Tower Kit, 255468

For D200s, D200, and D60 single supply systems.

See the Light Tower Kit manual for more information.

3A6331G 55

See the E-Flo SP Software Instructions manual for setup and pin out information.

Part Description Length

122029 CABLE, GCA, M12-8p

15.0 m

Kits and Accessories

Communication Gateway Module (CGM) Kits

4. Drill the mounting holes using the mounting hole

dimensions shown in FIG. 37.

#10-32 UNF

(M5 x 0.8)

2.75 in.

(69.9 mm)

CAN Port 2

CAN Port 1

FIG. 36: CGM CAN Connections

CGM Kits

Part Number Description

25E426 CGM Kit, Ethernetip 25E427 CGM Kit, DeviceNet 25E428 CGM Kit, PROFINET 25E429 CGM Kit, PROFIBUS

Installing a CGM Kit

All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations

3.25 in.

(82.6 mm)

FIG. 37: CGM Mounting Holes

5. Remove the access cover from the CGM (CA).

Loosen the two screws (CB) and remove the CGM (CC) from the base (CD) as shown in FIG. 38.

1. Follow the Pressure Relief Procedure on page 22.

2. Verify the power is off to the system.

3. Mount the CGM near the pump or near the integration point.

56 3A6331G

FIG. 38: Disassembling the CGM

6. Using the four 10-32 mounting screws included with the kit, mount the base (CD) in the holes you drilled.

7. Reattach the CGM (CC) on the base (CD) with the two screws (CB) that were removed in step 5.

8. Reattach the access cover (CA).

Kits and Accessories

9. Connect the CAN cable included in the kit to either port 1 or port 2 (whichever is available) on the driver. See FIG. 39.

Port 1

Port 2

Port 6

FIG. 39: Driver Port Locations

10. Connect the other end of the CAN cable to either CAN port 1 or 2 on the CGM. See FIG. 36. It can be connected to either port.

NOTE: Longer CAN cables, if required, are available from Graco. See CAN Cables on page 55.

11. Connect the Ethernet, DeviceNet, or PROFIBUS cable to the fieldbus connection on the CGM as applicable. See FIG. 40.

Fieldbus Connection

FIG. 40: CGM Fieldbus Connection

12. Connect the other end of the cable to the fieldbus device.

13. Refer to the Graco Control Architecture Module Programming manual for step-by-step instructions on how to update the software version of GCA modules. See Related Manuals on page 3.

14. Refer to the E-Flo SP Software Instructions manual for details regarding the fieldbus pinout setup and to perform the setup procedure to configure the fieldbus. See Related Manuals on page 3.

3A6331G 57

Kits and Accessories

Low Level Sensor Kit, 25E447

To install the Low Level Sensor:

1. Turn the disconnect switch (M) OFF.

2. Disconnect cable from the empty level sensor (EL).

3. Mount the low level sensor (LL) on the mounting bracket.

4. Connect the shorter cable to the low level sensor (LL).

5. Connect the other shorter cable to the empty level sensor (EL).

6. Connect the low level sensor cable to the A port on the splitter (SP).

7. Connect the empty level sensor cable to the B port on the splitter (SP).

8. Connect the original cable to the last port on the splitter (SP).

9. Raise/lower the low level sensor (LL) to the desired position to activate the sensor.

10. See the E-Flo SP Software Instructions manual to set up the low level sensor.

58 3A6331G

Kits and Accessories

Tandem Connection Kit, 25E595

Ref. Part Description Qty.

501 121226 CABLE, can, 0.4 m 1 502 124003 CABLE, can, 5.0 m 1 503 121003 CABLE, can, 3.0 m 1 504 121807 CONNECTOR, splitter 1 505 114958 STRAP, tie 3 506 117329 STRAP, tie 6

To install the Tandem Connection Kit:

1. On the primary tandem unit (Ram 1), connect the cable (501) from port C1 to the splitter (504).

Ram 1

Ram 2

2. Connect the other cable (503) from the splitter to the ADM. Run the cable along the back of the ram using wire ties (505) to secure to the tubing.

Ram 1

504

503

505

3. Connect the cable (502) from the splitter to port C2 on the secondary tandem unit (Ram 2) junction box.

Ram 1

504

Ram 1

501

502

Ram 2

Port C1

502

4. See the E-Flo SP Software Instructions manual for system setup.

3A6331G 59

Kits and Accessories

Tandem Depressurization/Recirculation Kit, 25E618 (carbon steel), 25E619 (stainless steel)

To assemble the Tandem

Ref. Part Description Qty.

601 C20487 FITTING, nipple, hex (25E618 only) 1

190724 NIPPLE, sst (25E619 only)

602 132019 FITTING, tee, 3/4 npt (25E618

only)

15M862 FITTING, tee, pipe (25E619 only) 604 15B556 FITTING, adapter, 1/4 npt x 3/4 npt 1 605 114582 ADAPTER, swivel, straight

(25E618 only)

15M859 FITTING, adapter, male, swivel

(25E619 only) 606 054753 TUBE, nylon, black 22.5 ft 607 25R844 VALVE, 25, npt/b,000rm,amb,5k 1 609 255722 HOSE, coupled, hp (25E618 only) 1

255725 HOSE, coupled, hp, sst (25E619

only) 610 517434 FITTING, tee, 1/2 npt 1 613 15M574 VALVE, solenoid 1 614 117820 SCREW, cap, socket hd 2 615 198178 FITTING, elbow 3 616 17Z412 BRACKET, valve, solenoid 1 617 107100 SCREW, cap 2 618 18A098

PKG 619 116504 FITTING, tee 1 620 070408 SEALANT, pipe, sst 1 621 114958 STRAP, tie 4 624 114151 FITTING, elbow, male, swivel 2

HARNESS, solenoid, tandem 1

Depressurization/Recirculation Kit:

1. Disconnect the air line from the air assist body check

valve (EH)

2. Remove the bleed stick (EF) and bleed port (EG). Save all parts for later.

3. Assemble the fittings and valve onto the platen as shown below.

624

605

607

60 3A6331G

604

602

601

Kits and Accessories

4. Assemble the bleed port (EG) and bleed stick (EF) to the cross fitting (602).

602

5. Mount the solenoid mounting plate (616) to the side of the driver using the supplied screws (617).

7. Connect the cable (618) from the solenoid (613) to Port 4 on the driver.

Port 4

613

618

8. Remove the adapter and pressure transducer from the bottom of the check valve block.

Check Valve Block

617

616

6. Mount the solenoid (613) to the solenoid mounting plate (616) with the supplied screws (614).

616

613

614

Pressure Transducer

9. Connect the tee fitting (614) to replace the adapter and pressure transducer removed in the previous step.

614

3A6331G 61

Kits and Accessories

10. Looking at the valve check block from the front, connect the adapter and pressure transducer that were removed in step 8 to the connection on the right side of the tee fitting (610). Connect a union adapter fitting (605) to the other side of the tee fitting.

11. Connect the hose (609) between the fitting (605) above to the fitting (605) in the valve.

605

610

609

Adapter and Pressure Transducer

605

13. Install the air line (606) from the integrated air control module (G), along the back of the ram, through the cable track and to the solenoid (613).

606

12. Install the fittings (611, 615) on the back of the integrated air control module (G).

606

619

613

615

606

62 3A6331G

14. Install the air line (606) from the lower solenoid outlet to the valve close fitting (615). Cut any excess air line.

15. Install the air line (606) from the upper solenoid outlet to the valve open fitting (615). Cut any excess air line.

Kits and Accessories

Upper Solenoid Outlet

Lower Solenoid Outlet

606

624, Valve Open

624, Valve Close

16. See the E-Flo SP Software Instructions manual for Depressurization/Recirculation setup.

3A6331G 63

Kits and Accessories

Tandem Fluid Filter Kit, 25E620

Fluid Inlet from Tandem A

714

708

712

713

722

723

706

725

Fluid Inlet from Tandem B

715, 716, 717

724

718, 719, 720

703

702

Fluid Outlet

704

710

709

711

707

Ref. Part Description Qty.

701 247498 SUPPORT, stand 1 702 410178 CAP PLUG, vinyl 1 703 147499 BASE, mounting 1 704 C30021 BOLT, u 2 705 210658 VALVE, ball 1 706 515216 HOUSING, filter 1 707 C19652 FITTING, bushing, reducing 2 708 121189 FITTING, elbow, 1” 2 709 521477 VALVE, ball, 1” 3 710 121182 ADAPTER, pipe, female 2 711 102814 GAUGE, press, fluid 2 712 C19488 FITTING, tee 1 713 121163 FITTING, cross, 1” npt 2 714 131526 FITTING, nipple, 1” npt, cs 6 715 101044 WASHER, plain 4 716 100018 WASHER, lock, spring 4 717 C19853 SCREW, cap, socket hd 4 718 100023 WASHER, flat 4 719 100133 WASHER, lock, 3/8 4 720 100131 NUT, full hex 4 721 070408 SEALANT, pipe, sst 1 722 158586 FITTING, bushing 2 723 16U440 ADAPTER, fitting, pressure sensor 2 724 15M669 SENSOR, pressure, fluid outlet 2 725 515222 ELEMENT, filter 1 726 15Y048 CABLE, M12 2

705

701

To assemble the Tandem Fluid Filter Kit:

1. Ensure the base of the fluid filter stand (701) is level in all directions. If necessary, use metal shims to level the base.

2. Secure the base to the floor using anchors that are long enough to prevent the filter stand from tipping.

3. Install the material hose from tandem A to fluid inlet A.

4. Install the material hose from tandem B to fluid inlet B.

5. Install the material hose from the fluid filter outlet to the dispense valve.

6. Connect the inlet fluid filter pressure transducer to Port 6 on the tandem A driver for fluid filter monitoring.

64 3A6331G

Kits and Accessories

7. Connect the inlet fluid filter pressure transducer to port 6 on the tandem B driver for fluid filter monitoring.

a. Available extension cables are shown in the

table below.

Part Description

122497 CABLE, M12, 5 pin, 2 m 124409 CABLE, M12, 5 pin, 3 m 124943 CABLE, M12, 5 pin, 1 m 17H363 CABLE, M12, 5 pin, 7.5 m 17H364 CABLE, M12, 5 pin, 16 m

8. See the E-Flo SP Software Instructions manual to set up fluid filter monitoring on the ADM.

Fluid Filter Kit Dimensions

Key

A 52.25 in. (1327 mm) B 11 in. (279 mm) C 14 in. (356 mm) D 17 in. (432 mm) E 14 in. (356 mm) F 1 in. npt(f) G 1 in. npt(f)

Filter Element Mesh Sizes

Part No. Mesh

515219 60 515220 50 515221 40 515222 30 (standard)

TI11158A

3A6331G 65

Kits and Accessories

Notes:

66 3A6331G

Dimensions

D200

D200s

D60

3A6331G 67

Dimensions

Ram Size

in. (mm)

D60 D200 D200s

Total Height (A) 70 (1778) 88 (2235) 96 (2438)

Ram Height (B) 57 (1448) 70 (1778) 69 (1753)

Extended Ram

Height (C)

Base Depth (D) 20 (508) 25 (635) 25 (635)

Machine Width (E) 45 (1143) 52 (1321) 45 (1143)

Mounting Hole

Depth (F)

Mounting Hole

Width (G)

89 (2261) 118 (2997) 125 (3175)

14 (356) 21 (533) 23 (584)

24 (610) 38 (965) 45 (1143)

Weight

Use the table below to identify the maximum weight for each available platen size.

Platen Size

Gallons (Liters) Maximum Weight

55 (200)

30 (115)

16 (60)

8 (30)

5 (20)

See the identification plate (ID) for the weight of your supply system.

51 (23)

44 (20)

25 (11.3)

21 (9.5)

19 (8.7)

68 3A6331G

Pump Performance

Calculate Fluid Outlet Pressure

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

1. Refer to the desired flow along the bottom of the chart.

2. Follow the vertical line up to the intersection with the selected fluid outlet pressure curve. Follow left to the scale to read the fluid out pressure.

Calculate Electrical Power

To calculate electrical power (W) at a specific fluid flow (gpm/lpm), use the following instructions and pump data chart.

1. Refer to the desired flow along the bottom of the chart.

2. Follow the vertical line up to the intersection with the selected electrical power curve. Follow right to the scale to read the fluid out pressure.

NOTE: Performance is measured using 10 weight oil. System design and material being pumped may produce different results.

3A6331G 69

Pump Performance

E-Flo SP Performance Charts

&'MP41%SJWFSXJUI%VSB'MP-PXFS

6000

(41.4, 414)

5000

(34.5, 345)

4000

(27.6, 276)

3000

(20.7, 207)

2000

1SFTTVSFQTJ.1BCBS

(13.8, 138)

1000

(6.9, 69)

0 (0, 0)

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

(0.0) (3.0)(2.6)(2.3)(1.9)(1.1)(0.8)(0.4)

3000

Pressure WŽǁĞƌ

2500

2000

1500

1PXFS8BUUT

1000

500

(1.ϱ)

'MPXHQNMQN

&'MPX41XJUI%VSB'MP-PXFS

6000

(41.4, 414)

5000

(34.5, 345)

4000

(27.6, 276)

3000

(20.7, 207)

2000

1SFTTVSF QTJ.1BCBS

(13.8, 138)

1000

(6.9, 69)

0 (0, 0)

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

(0.0) (0.4) (0.8) (1.1) (1.5) (1.9) (2.3) (2.6) (3.0) (3.8)(3.4)

3000

Pressure WŽǁĞƌ

2500

2000

1500

1PXFS8BUUT

1000

500

'MPXHQNMQN

70 3A6331G

Pump Performance

NOTE: Performance is measured using 10 weight oil. System design and material being pumped may produce different results.

3A6331G 71

Pump Performance

&'MPX41XJUI%VSB'MP-PXFS

5000

(34.5, 345)

4000

(27.6, 276)

3000

(20.7, 207)

2000

(13.8, 138)

1SFTTVSF QTJ.1BCBS

1000

(6.9, 69)

0 (0, 0)

0.0 0.2 0.4 0.6 0.8 1.0 1.2

(0.0) (0.8) (1.5) (2.3) (3.0) (3.8) (4.5)

Pressure WŽǁĞƌ

'MPXHQNMQN

3500

2800

2100

1400

700

1PXFS8BUUT

&'MPX41XJUI%VSB'MP-PXFS

4000

(27.6, 276)

3500

(24.1, 241)

3000

(20.7, 207)

2500

(17.2, 172)

2000

(13.8, 138)

1500

(10.3, 103)

1SFTTVSF QTJ.1BCBS

1000

(6.9, 69)

500

(3.4, 34)

0 (0, 0)

0.0 0.2 0.4 0.6 0.8 1.0 1.2

(0.0) (0.8) (1.5) (3.0) (3.8) (4.5)

Pressure WŽǁĞƌ

(Ϯϯ)

'MPXHQNMQN

3000

2625

2250

1875

1500

1PXFS8BUUT

1125

750

375

NOTE: Performance is measured using 10 weight oil. System design and material being pumped may produce different results.

72 3A6331G

&'MPX41XJUI%VSB'MP-PXFS

Pump Performance

3000

(20.7, 207)

2500

(17.2, 172)

2000

(13.8, 138)

1500

(10.3, 103)

1SFTTVSF QTJ.1BCBS

1000

(6.9, 69)

500

(3.4, 34)

0 (0, 0)

0.0 0.5 1.0 1.5 2.0

(0.0) (1.9) (5.7) (7.6)

4500

Pressure WŽǁĞƌ

3750

3000

2250

1PXFS8BUUT

1500

750

(ϯϴ)

'MPXHQNMQN

&'MPX41XJUI%VSB'MP-PXFS

2000

(13.8, 138)

1750

(12.1, 121)

1500

(10.3, 103)

1250

(8.6, 86)

1000

(6.9, 69)

750

(5.2, 52)

1SFTTVSF QTJ.1BCBS

500

(3.4, 34)

250

(1.7, 17)

0 (0, 0)

0.0 0.5 1.0 1.5 2.0 2.5

(0.0) (1.9) (3.8) (7.6) (9.5)

Pressure WŽǁĞƌ

(5.7)

'MPXHQNMQN

NOTE: Performance is measured using 10 weight oil. System design and material being pumped may produce different results.

3000

2625

2250

1875

1500

1PXFS8BUUT

1125

750

375

3A6331G 73

Pump Performance

&'MPX41XJUI$IFDLNBUF-PXFS

6000

(41.4, 414)

5000

(34.5, 345)

4000

(27.6, 276)

3000

(20.7, 207)

2000

1SFTTVSFQTJ.1BCBS

(13.8, 138)

1000

(6.9, 69)

0 (0, 0)

0.0 0.1 0.2 0.3 0.5 0.6 0.7 0.8

Pressure WŽǁĞƌ

0.4

(1.ϱ)

'MPXHQNMQN

2400

2000

1600

1200

1PXFS8BUUT

800

400

(3.0)(2.6)(2.3)(1.9)(1.1)(0.8)(0.4)(0.0)

4500

(31.0, 310)

3750

(25.9, 259)

3000

(20.7, 207)

2250

(15.5, 155)

1500

1SFTTVSFQTJ.1BCBS

(10.3, 103)

750

(5.2, 52)

0 (0, 0)

0.0 0.2 0.4 0.6 0.8 1.0 1.2

(0.0) (0.8) (1.5) (3.0) (3.8) (4.5)

&'MPX41XJUI$IFDLNBUF-PXFS

3000

Pressure WŽǁĞƌ

2500

2000

1500

1PXFS8BUUT

1000

500

(2.3)

'MPXHQNMQN

NOTE: Performance is measured using 10 weight oil. System design and material being pumped may produce different results.

74 3A6331G

&'MPX41XJUI$IFDLNBUF-PXFS

Pump Performance

3500

(24.1, 241)

3000

(20.7, 207)

2500

(17.2, 172)

2000

(13.8, 138)

1500

(10.3, 103)

1SFTTVSFQTJ.1BCBS

1000

(6.9, 69)

500

(3.4, 34)

0 (0, 0)

0.0 0.2 0.4 0.6 1.0 1.2 1.4 1.6

(0.0) (0.8) (1.5) (2.3) (3.8) (4.5) (5.3) (6.1)

Pressure WŽǁĞƌ

0.8

(3.Ϭ)

'MPXHQNMQN

2625

2250

1875

1500

1125

750

375

1PXFS8BUUT

1800

(12.4, 124)

1500

(10.3, 103)

1200

(8.3, 83)

900

(6.2, 62)

600

1SFTTVSF QTJ.1BCBS

(4.1, 41)

300

(2.1, 21)

0 (0, 0)

0.0 0.5 1.0 1.5 2.0 2.5 3.0

(0.0) (1.9) (3.8) (7.6) (9.5) (11.4)

&'MPX41XJUI$IFDLNBUF-PXFS

3000

Pressure WŽǁĞƌ

2500

2000

1500

1PXFS8BUUT

1000

500

(ϱϳ)

'MPXHQNMQN

NOTE: Performance is measured using 10 weight oil. System design and material being pumped may produce different results.

3A6331G 75

Technical Specifications

E-Flo SP Supply Systems

US Metric

Driver thrust 4,840 lbs 2,195 kg Stroke length 4.75 in. 120.65 mm Maximum fluid operating temperature 180°F 82.3°C Maximum driver cycle rate 25 cycles per minute

Line voltage rating

Air inlet size (supply system) 3/4 npt(f) Ambient operating temperature range (supply

system) Displacement pump effective area See pump manual. Wetted parts See pump manual.

Sound pressure, measured per EN ISO 11202:2010

Normal operation (dispensing) < 70 dBA Drum change 77 dBA

Full load amperage

240V systems 20A 480V systems 10A

Maximum fluid working pressure

100cc Check-Mate - All 6000 psi 414 bar, 41.4 MPa 200cc Check-Mate - All 4200 psi 290.5 bar, 29.0 MPa 250cc Check-Mate - All 2700 psi 186.1 bar, 18.6 MPa 500cc Check-Mate - All 1600 psi 89.6 bar, 8.9 MPa 145cc Dura-Flow - SS 5600 psi 386 bar, 38.6 MPa 180cc Dura-Flow - SS 4500 psi 310 bar, 31.0 MPa 220cc Dura-Flow - SS 3700 psi 255 bar, 25.5 MPa 290cc Dura-Flow - SS 2800 psi 193 bar, 19.3 MPa 430cc Dura-Flow - SS 1900 psi 131 bar, 13.1 MPa 115cc Dura-Flow - CS 6000 psi 414 bar, 41.4 MPa 145cc Dura-Flow - CS 5600 psi 386 bar, 38.6 MPa 180cc Dura-Flow - CS 4500 psi 319 bar, 31.0 MPa 220cc Dura-Flow - CS 3700 psi 255 bar, 25.5 MPa 290cc Dura-Flow - CS 2800 psi 193 bar, 19.3 MPa

Fluid outlet size

Check-Mate 100, 200, 250 1” NPT female Check-Mate 500 1-1/2” NPT female Dura-Flow 115, 145, 180, 220, 290 1” NPT female Dura-Flow 430 1-1/2” NPT female

Maximum air input pressure (supply system)

D60 - 3 in. dual post, 5 gal. (20 L) 150 psi 1.0 MPa, 10 bar D200 - 3 in. dual post, 55 gal. (200 L) 150 psi 1.0 MPa, 10 bar D200s - 6.5 in. dual post, 55 gal. (200 L) 125 psi 0.9 MPa, 9 bar

200-240V, 1ps, 50/60 Hz 400-480V, 1ps, 50/60 Hz

32-120°F 0-49°C

76 3A6331G

California Proposition 65

E-Flo SP Supply Systems

US Metric

Platen wetted materials

257727, 5 gal. (20 L) Electroless nickel, polyurethane, nitrile, carbon steel, 257732, 8 gal. (30 L) 257737, 16gal. (60 L) 257728, 5 gal. (20 L) Electroless nickel, polyurethane, carbon steel, polyethylene, 257733, 8 gal. (30 L) 257740, 16gal. (60 L) 257729, 5 gal. (20 L) Stainless steel, polyurethane, PTFE coated nitrile, 257734, 8 gal. (30 L) 257738, 16gal. (60 L) 257730, 5 gal. (20 L) Electroless nickel, aramind reinforced elastomer, 257735, 8 gal. (30 L) 257739, 16gal. (60 L) 257731, 5 gal. (20 L) Electroless nickel, aramind reinforced elastomer, 257736, 8 gal. (30 L)

257741, 16gal. (60 L)

25E110, 5 gal. (20 L)

25A206, 5 gal. (20 L)

polyethylene, zinc plated carbon steel, buna, 316 sst, 17-4PH sst

nitrile, zinc plated carbon steel, buna, 316 sst 17-4PH sst

polyethylene, nitrile, PTFE, 303 sst, 304 sst, 316 sst, 17-4PH sst

rubber-based PSA, nitrile, polyethylene, zinc plated carbon steel, buna, 1018 carbon steel, 304 sst, 316 sst, 17-4PH sst

rubber-based PSA, polyurethane, polyethylene, nitrile, zinc plated carbon steel, buna, 1018 carbon steel, 304 sst, 316 sst, 17-4PH sst

Electroless nickel, nitrile, carbon steel, zinc plated carbon steel, buna, 316 sst, 17-4PH sst, aluminum, PVC

Stainless steel, polyurethane, nitrile (FDA approved), polyethylene

California Proposition 65

CALIFORNIA RESIDENTS

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

3A6331G 77

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

Sealant and Adhesive Dispensing Equipment

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, go to www.graco.com, or call to identify the nearest

distributor.

If calling from the USA: 1-800-746-1334

If calling from outside the USA: 0-1-330-966-3000

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 3A6331

International Offices: Belgium, China, Japan, Korea

Graco Headquarters: Minneapolis

www.graco.com

Revision

G, February 2021

GRACO D60, D200, D200S Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Models

System Pressure

Tandem Ram

Warnings

Component Identification

Typical Installation

Integrated Air Control Module

Integrated Air Line Accessories

Advanced Display Module (ADM)

Platen Component Identification

Junction Box Connections

Installation

Location

Grounding

Power Requirements

Connect Power

Attach Drum Stops

Install Vented Oil Cap Before Using Equipment.

Fluid Hose and Air Line Connections

Setup

Wet Cup

Startup

Flush the Pump

Start and Adjust the Ram

Start and Adjust the Pump

Pressure Relief Procedure

Shutdown and Care of the Pump

Change Drums

Maintenance

Driver Maintenance

Platen Maintenance

Troubleshooting

Repair

Disconnect Pump from Platen

Connect Platen

Remove Displacement Pump

Remove Wipers

Install Wipers

Install Displacement Pump

Remove Driver

Install Driver

Supply Unit Repair

Parts

D200s 6.5 in. Supply Units

D200 3 in. Supply Units

D60 3 in. Supply Units

D200s and D200 Pump Mounts for 55 Gallon (200 Liter) Platen

D60 Pump Mount 257624 for 5 Gallon (20 Liter) Platen

Transformer

Cable Track

55 Gallon Platen

20 Liter (5 Gallon), 30 Liter (8 Gallon), and 60 Liter (16 Gallon) Platens

Kits and Accessories

Drum Roller Kits for D200 and D200S Supply Units, 255627

Drum Position Clamp Set for D200 Supply Units, 206537

Drum Position Clamp for D200S Supply Units

Enclosed Wet Cup Recirculation Kit

200 Liter (55 Gallon) Platen Cover Kits, 255691

ADM Kit, 25E437

CAN Cables

I/O Cable, 122029

Light Tower Kit, 255468

Communication Gateway Module (CGM) Kits

Low Level Sensor Kit, 25E447

Tandem Connection Kit, 25E595

Tandem Depressurization/Recirculation Kit, 25E618 (carbon steel), 25E619 (stainless steel)

Tandem Fluid Filter Kit, 25E620

Dimensions

Dimensions

Pump Performance

E-Flo SP Performance Charts

Technical Specifications

California Proposition 65

Graco Standard Warranty