Hitachi 206700, 206405, SERIES K, SERIES J, 206699 User Manual

Instructions – Parts List

15:1 Fire-BallR 300 Pumps

For pumping petroleum–based undercoating material.

2700 psi (18.6 MPa, 186 bar) Maximum Working Pressure 180 psi (1.2 Ma, 12 bar) Maximum Air Input Pressure

Model No. 206405, Series K

35 lb. pail size

Model No. 206699, Series J

120 lb. drum size

Model No. 206700, Series J

400 lb. drum size

306531AD

Important Safety instructions

Read all warnings and instructions in this manual. Save these instructions.

WARNING

This product is designed to be used for pumping non-corrosive and non-abrasive fluids only. Any other use can cause unsafe operating conditions and result in component rupture, fire, or explosion, which can cause serious injury, including skin injection.

Table of Contents

Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Guide 12. . . . . . . . . . . . . . . . . . .

Air Motor Service 13. . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pump Service 16. . . . . . . . . . . . . .

Parts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Hole Layout 23. . . . . . . . . . . . . . . . . . . .

Dimensional Drawings 23. . . . . . . . . . . . . . . . . . .

Technical Data 23. . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Warranty 24. . . . . . . . . . . . . . . . . . . . . . . . .

Graco Phone Numbers 24. . . . . . . . . . . . . . . . . . .

Model 206405 Shown

04208B

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

Symbols

Caution Symbol

CAUTION

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

WARNING

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

INSTRUCTIONS

D This equipment is for professional use only.

D Read all instruction manuals, tags, and labels before operating the equipment.

D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

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

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

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

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

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

D Handle hoses carefully. Do not use hoses to pull equipment.

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

Graco hoses to temperatures above 66_C (150_F) or below –40_C (–40_F).

D Wear hearing protection when operating this equipment.

D Do not lift pressurized equipment.

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

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WARNING

SKIN INJECTION HAZARD

Spray from the gun, 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 Close the gun ball valves when you stop spraying.

D Lock the gun trigger safety when you stop spraying.

D Follow the Pressure Relief Procedure on page 8 if the spray tip clogs and before cleaning,

checking or servicing the equipment.

D Tighten all fluid connections before operating the equipment.

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

Do not repair high pressure couplings; you must replace the entire hose.

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

kinks or bends near the couplings.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

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

D Before checking or servicing the equipment, follow the Pressure Relief Procedure on page 8 to

prevent the equipment from starting unexpectedly.

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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 Before operating this equipment, electrically disconnect all equipment in the spray area.

D Before operating this equipment, 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.

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.

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Notes

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Fig. 1

KEY A Electrically Conductive Air Hose

B Female Quick Disconnect Coupler C Male Quick Disconnect Fitting D Air Line Filter E Air Regulator and Gauge F Bleed-Type Master Air Valve G Air Line Lubricator H Pump Runaway Valve J Pump Air Inlet K Ground Wire L Pressure Drain Valve M Electrically Conductive Fluid Hose N Spray Gun

Installation

1/2 in. (13 mm)

04209

NOTE: Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawings.

Figure 1 is only a guide to selecting and installing optional and required accessories. For help in designing a system to suit your needs, contact your Graco distributor.

Mount the pump to suit the type of installation planned. See page 23 for dimensions and mounting hole layout.

System Accessories

WARNING

To reduce the risk of serious injury including skin injection, splashing in the eyes or on the skin, and injury from moving parts, if you are adjusting or repairing the pump, two accessories are required in your system: a bleed-type master air valve (F) and a pressure drain valve (L).

The bleed-type master air valve (F) relieves air trapped between it and the air motor after the air supply is shut off. Trapped air can cause the air motor to cycle unexpectedly if you are adjusting or repairing the pump. Install the valve near the pump air inlet, within easy reach of the pump.

The pressure drain valve (L) assists in relieving fluid pressure in the displacement pump, hoses and gun. Triggering the spray gun to relieve pressure may not be sufficient.

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CAUTION

Installation

D Pump: use a ground wire and clamp as shown

below.

Provide a bracket for mounting the air accessories. The fittings are not strong enough to support the accessories and may cause one or more to break.

NOTE: Install the accessories in the order shown in Figure 1.

D A pump runaway valve (H) shuts off the air to the

pump if the pump accelerates beyond the pre-adjusted setting. A pump which runs too fast can be seriously damaged.

D An air line lubricator (G) provides automatic air

motor lubrication.

D A bleed-type master air valve (F) relieves air

trapped between it and the motor when the valve is closed. Order Part No. 107142.

D The air regulator (E) controls pump speed and

pressure.

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

contaminants from your compressed air supply.

D A drain valve (L) is required near the pump fluid

outlet to relieve fluid pressure in the pump, hose and gun. Order Part No. 210657.

D Truck bed or platform: according to your local code.

D Fluid hoses: use only electrically conductive hoses.

D Air compressor: follow manufacturer’s recommen-

dations.

D Spray gun: grounding is obtained through connec-

tion to a properly grounded fluid hose and pump.

D Object being sprayed: according to local code.

D Fluid supply container: according to local code.

D All solvent pails used when flushing or relieving

pressure, always hold a metal part of the gun firmly to the side of a grounded metal pail, then trigger the gun.

To ground the pump:

To ground the pump, use a ground wire and clamp as shown below. Remove the ground screw (Z) and insert through the eye of ring terminal at end of ground wire (Y). Fasten the ground screw back onto the pump and tighten securely. Connect the other end of the ground wire to a true earth ground. See Fig. 2. To order a

ground wire and clamp, order Part No. 222011.

D Install an electrically conductive fluid hose (M) and

spray gun (N).

Grounding

Proper grounding is an essential part of maintaining a safe system.

To reduce the risk of static sparking, ground the pump. Check your local electrical code for detailed grounding instructions for your area and type of equipment. Be sure to ground all of this equipment:

Fig. 2

TI1052

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Pressure Relief Procedure

Operation

WARNING

SKIN INJECTION HAZARD

The system pressure must be manually relieved to prevent the system from

starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:

D are instructed to relieve the pressure, D stop spraying, D check or service any of the system equipment, D or install or clean the spray tips.

1. Lock the spray gun trigger safety.

2. Close the pump air regulator. Close the bleed-type master air valve (required in your system).

3. Unlock the gun trigger safety.

4. Hold a metal part of the spray gun firmly to a grounded metal waste container and trigger the gun to relieve the fluid pressure.

5. Lock the gun trigger safety.

Never operate the pump with the warning plate (20) or the identification plate (40) removed. These plates protect your fingers from pinching or amputation by moving parts in the air motor.

Starting and Adjusting the Pump

1. With the air regulator (E) closed, open the bleedtype master air valve (F).

2. Connect the air hose.

3. Trigger the spray gun (N) into a grounded metal pail, making firm metal-to-metal contact.

4. Open the pump air regulator (E) slowly, just until the pump is running. When the pump is primed and all air has been pushed out of the lines, release the spray gun trigger. With sufficient air supplied, the pump starts when the spray gun is triggered and shuts off when the trigger is released.

6. Open the pump drain valve (required with your system) and leave it open until you are ready to spray again.

If you suspect that the spray tip or hose is clogged or that fluid pressure is not fully relieved after following the steps above, very slowly loosen the tip guard

retaining nut or hose end coupling and relieve pressure gradually. Clear the tip or hose obstruction.

WARNING

COMPONENT RUPTURE HAZARD

Overpressurizing any component can result in rupture, fire, explosion, property

damage, and serious injury. To reduce the risk of overpressurizing, know the Maximum Working Pressure of the lowest rated component in your system, and limit the air to the pump so that you never exceed that pressure.

To determine the fluid output pressure using the air regulator reading, multiply the pump ratio by the air pressure you set on the regulator gauge. Example:

15 (:1) ratio x 100 psi air = 1500 psi fluid output

[15 (:1) ratio x 7 bar air = 105 bar fluid output]

5. Adjust the air regulator just until you get adequate flow from the spray gun. Always run the pump at the lowest speed necessary.

CAUTION

Never allow the pump to run dry of the fluid being pumped. A dry pump will quickly accelerate to a high speed, possibly damaging itself. If your pump accelerates quickly, or is running too fast, stop it immediately and check the fluid supply. If the supply container is empty and air has been pumped into the lines, prime the pump and lines with fluid, or flush it and leave it filled with a compatible solvent. Be sure to eliminate all air from the fluid lines. Use a pump runaway valve (K) to automatically shut off the pump if it starts to run too fast.

6. Read and follow the instructions supplied with each component in your system.

7. If the pump will be unattended for any period of time, or to shut off the system at the end of the work shift, always follow the Pressure Relief

Procedure, at the left.

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