Graco PDW8200, PDW9200, PDW8400, PDW9700, PDW8700 User Manual
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Instructions–Parts List
321 MM (12.625 IN.)
Premier™ Air Motor
100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure
Part No. 222800, Series C
Standard Motor
United States Patent Nos. 5,189,943; Des. 345,138; 2,032,617; 5,363,739
Taiwan Patent No. 050264
Canada Patent No. D75390
Korea Patent No. 152224
Other US and Foreign Patents Pending
308213V
EN
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Table of Contents.
06818C
Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation/Operation 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting the Air Motor 8. . . . . . . . . . . . . . . . . . . .
Preventive Maintenance Schedule 8. . . . . . . . . . . .
Checking for Leaks or Damaged Parts 8. . . . . . . . .
Check Chart 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 10. . . . . . . . . . . . . . . . . .
Required Service Tools 10. . . . . . . . . . . . . . . . . . . . .
Air Motor Shroud 11. . . . . . . . . . . . . . . . . . . . . . . . . .
Air Valve Replacement 11. . . . . . . . . . . . . . . . . . . . .
Air Valve Service 13. . . . . . . . . . . . . . . . . . . . . . . . . .
Subplate and Rocker Assemblies 17. . . . . . . . . . . .
Piston and Piston Rod Seals 19. . . . . . . . . . . . . . . .
Parts Drawings and Parts Lists 21. . . . . . . . . . . . . . . . . .
Air Motor 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Valve 222799 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 28. . . . . . . . . . . . . . . . . . . . . .
Graco Information 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 308213
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
D Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 26 for the maximum working pressure of this equipment.
D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
D Do not kink or overbend hoses or use hoses to pull equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 180_F (82_C) or below –40_F (–40_C).
D Wear hearing protection when operating this equipment.
D Do not lift pressurized equipment.
D Do not lift the equipment by the Premier air motor lift ring if the total weight of the equipment ex-
ceeds 550 lb (250 kg).
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
308213 3
WARNING
SKIN INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause
extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause serious injury.
D Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
surgical treatment.
D Do not point the gun at anyone or at any part of the body.
D Do not put your hand or fingers over the spray tip.
D Do not stop or deflect leaks with your hand, body, glove or rag.
D Do not “blow back” fluid; this is not an air spray system.
D Always have the tip guard and the trigger guard on the gun when spraying.
D Check the gun diffuser operation weekly. Refer to the gun manual.
D Be sure the gun trigger safety operates before spraying.
D Lock the gun trigger safety when you stop spraying.
D Follow the Pressure Relief Procedure on page 10 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
D Tighten all fluid connections before operating the equipment.
D Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
D Use only Graco approved hoses. Do not remove the spring guard that is used to help protect the
hose from rupture caused by kinks or bends near the couplings.
MOVING PARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
D Keep clear of all moving parts when starting or operating the pump.
D Before servicing the equipment, follow the Pressure Relief Procedure on page 10 to prevent the
equipment from starting unexpectedly.
4 308213
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
D Ground the equipment and the object being sprayed. Refer to Grounding on page 7.
D If there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing immediately. Do not use the equipment until you identify and correct the problem.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
D Keep the spray area free of debris, including solvent, rags, and gasoline.
D Electrically disconnect all equipment in the spray area.
D Extinguish all open flames or pilot lights in the spray area.
D Do not smoke in the spray area.
D Do not turn on or off any light switch in the spray area while operating or if fumes are present.
D Do not operate a gasoline engine in the spray area.
D Keep a fire extinguisher in the work area.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
308213 5
Installation/Operation
CAUTION
The Premier air motor is designed for intermittent
duty cycle applications, such as spraying of corrosion
control materials, or adhesive and sealant applications. It is not recommended for continuous duty
circulating systems. Contact your Graco distributor
for further application information.
Mounting Accessories
Mount the motor to suit the type of installation planned.
Motor dimensions and the mounting hole layout are
shown on page 27.
If you are mounting the motor on an elevator or a cart,
refer to the separate manuals supplied with those
components for installation and operation instructions.
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawings.
NOTE: Always use Genuine Graco Parts and Accessories, available from your Graco distributor. If you
supply your own accessories, be sure they are adequately sized and pressure rated for your system.
System Accessories
WARNING
A bleed-type master air valve and a fluid drain
valve are required in your system. These accessories help reduce the risk of serious injury, including
fluid injection and splashing of fluid in the eyes or
on the skin, and injury from moving parts if you are
adjusting or repairing the pump.
The bleed-type master air valve relieves air trapped
between this valve and the pump after the air is
shut off. Trapped air can cause the pump to cycle
unexpectedly. Locate the valve close to the pump.
The fluid drain valve assists in relieving fluid pressure in the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may not be
sufficient.
Air Line Accessories
The following air line accessories are available from
Graco. Contact your Graco distributor for help in
designing a system to suit your particular needs.
D A bleed-type master air valve is required in your
system to relieve air trapped between it and the air
motor when the valve is closed (see the WARNING
at left). Be sure the bleed valve is easily accessible
from the motor, and is located downstream from
the air regulator. Order Part No. 113163.
D An air regulator controls pump speed and outlet
pressure by adjusting the air pressure to the motor.
Locate the regulator close to the motor, but up-
stream from the bleed-type master air valve.
D An air line filter removes harmful dirt and moisture
from the compressed air supply.
D An air line lubricator adds oil to the compressed
air supply at an adjustable rate, to automatically
lubricate the air motor.
D A pump runaway valve senses when the pump is
running too fast and automatically shuts off the air
to the motor. A pump which runs too fast can be
seriously damaged. Install closest to the motor air
inlet.
6 308213
Installation/Operation
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE AND EXPLOSION
HAZARD on page 5.
1. Pump: use a ground wire and clamp (supplied).
See Fig. 1. Loosen the grounding lug locknut (W)
and washer (X). Insert one end of a 1.5 mm@ (12
ga) minimum ground wire (Y) into the slot in lug (Z)
and tighten the locknut securely. Connect the other
end of the wire to a true earth ground. Order Part
No. 237569 Ground Wire and Clamp.
W
X
Y
Z
2. Air and fluid hoses: use only electrically conductive
hoses.
3. Air compressor: follow manufacturer’s recommen-
dations.
4. Spray gun: ground through connection to a prop-
erly grounded fluid hose and pump.
5. Fluid supply container: follow your local code.
6. Object being sprayed: follow your local code.
7. Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continuity.
Fig. 1
0864
8. To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray
gun firmly to the side of a grounded metal pail,
then trigger the gun.
308213 7
Troubleshooting the Air Motor
Preventive Maintenance Schedule
The operating conditions of your particular system
determine how often maintenance is required. Establish a preventive maintenance schedule by recording
when and what kind of maintenance is needed, and
then determine a regular schedule for checking your
system.
Air Motor Cylinder
Premier motors require lubrication and continuous
maintenance including the replacement of the air motor
cylinder casting at least every 15,000,000 cycles of
use. Use Premier cylinder repair kit 16P239.
Repair or replace the Air Valve assembly (222799)
whenever motor stalling or hesitation occurs. This
ensures the motor does not overtravel and cause
added stress to the cylinder casting.
WARNING
EXPLOSION HAZARD
Without proper maintenance, the cylinder casting (120026) may fracture
unexpectedly due to metal fatigue. This
is a potentially hazardous condition and
may result in serious injury. The precise
life of this casting is difficult to predict
and is affected by the operating pressure, number
of cycles, lubrication and air valve maintenance.
Checking the Air Motor for Leaks
or Damaged Parts
If the pump is not performing well, the problem could
be in the air motor. To check the air motor, perform the
following steps.
1. Close the bleed-type master air valve. Disconnect
the air line.
2. Remove the shroud. Refer to page 11.
3. Reinstall the air inlet fitting (22). Reconnect the air
line.
4. Open the bleed-type master air valve and set the
air regulator to about 0.1 MPa, 1 bar (14 psi).
Observe the rocker arms and trip rods for smooth
operation. Check at points A through E in Fig. 2 by
listening or feeling for escaping air, or squirting a
small amount of oil around the suspected leak.
The oil will bubble if air is leaking. Refer to the
sections noted in the Check Chart for detailed
service procedures.
Check Chart
NOTE: Service the air valve every 3 million cycles. If
the air motor stalls, service the air valve immediately.
Ref.
Letter
A Rocker assemblies
B Air escaping around
C Air escaping around
D Air escaping around
E Air escaping around
F Air motor stalls. Service air valve (see
Problem Refer to:
Service rocker arms
(29) not operating.
trip rod or push rods.
air valve (25).
or out of exhaust
manifold (45).
piston rod (4).
(see pages 17 and
18).
Service trip rod
and air valve
(see pages 11–16).
Service push rod
seals (see pages 17
and 18).
Service air valve
and air valve gaskets
(see pages 11–16).
Service slide blocks
and air valve seals
(see pages 11–16).
Service piston and
rod seals (see pages
19 and 20).
the NOTE above, and
refer to pages 11–16).
Install the detent, trip
rod, and air valve kits
(see pages 21–24).
8 308213
22
29 (under the cover)
Fig. 2
A, B
(4) E
(45) D
A, B
C (25), F
29
06547A
308213 9
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