Graco 3A0233J, Air-Powered Ram Instructions

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Instructions-Parts

Air-Powered Ram

3A0233J

EN

For transferring or dispensing a non-heated bulk supply of sealants, adhesives, or other medium to high viscosity fluids. Replaces rams for Hydra-Mate

, Precision Dose, 8900

Proportioner, 1:1 Extruders, and robotic interface rams. For professional use only.

Not for use in explosive atmospheres.

D200 3 inch dual post

257435 Model Shown

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

See page 4 for model information and maximum work ing pressure.

r_257435_3a0233_1c

2

Table of Contents

Table of Contents

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

Ram Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Pump Mounting Chart . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Component Identification . . . . . . . . . . . . . . . . . . . . 6

D200 Rams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Integrated Air Controls . . . . . . . . . . . . . . . . . . . . 7

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . . 7

Platen Component Identification . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Attach Drum Stops . . . . . . . . . . . . . . . . . . . . . . . 9

Mount Check-Mate 450, 800, 1000, and 2100

Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mount Power-Flo, Check-Mate 200, Fire-Ball 300 and Fire-Ball 400 Pumps . . . . . . . . . . . . . . 11

3:1 Bulldog Pump . . . . . . . . . . . . . . . . . . . . . . . 12

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

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

Flush Before Using Equipment . . . . . . . . . . . . . 13

Start and Adjust Ram . . . . . . . . . . . . . . . . . . . . 13

Start and Adjust Pump . . . . . . . . . . . . . . . . . . . 14

Change Drums . . . . . . . . . . . . . . . . . . . . . . . . . 14

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Platen Maintenance . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

200 Liter (55 Gallon) Platen . . . . . . . . . . . . . . . . 23

Drum Position Clamp Set for D200 Ram, 206537

23

55 Gallon Platen Cover Kit, 255691 . . . . . . . . . 23

Pump Mounting Kit 224829 . . . . . . . . . . . . . . . 23

Platen Mounting Kit 222776 . . . . . . . . . . . . . . . 24

Platen Mounting Kit 247335 . . . . . . . . . . . . . . . 24

Platen Mounting Kit 247336 . . . . . . . . . . . . . . . 24

Platen Mounting Kit 247337 . . . . . . . . . . . . . . . 24

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

California Proposition 65 . . . . . . . . . . . . . . . . . . 27

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 28

3A0233J

Related Manuals

Component Manuals in U.S. English :

Manual Description

310726 1:1 Extruder, Operation

308930 Hydra-Mate ™ Variable Ratio Proportioner

309790 8900 Proportioner

307982 Power-Flo ® Displacement Pump

307049 Bulldog ® Air Motor

309348 King ® Air Motor

307043 Monark ® Air Motor

312374 Air Controls Instructions-Parts

406681 Platen Cover Kit

Related Manuals

3A0233J 3

4

Ram Models

Ram Models

This table lists ram models that replace rams included with Graco bulk supply systems that have older style rams.

Ram models without integrated air controls utilize the air controls of the compatible system.

Ram

Model Size

257435 3 in.

257452 3 in.

Style

D200

D200

Compatible System

Not specified

Hydra-Mate systems

Replaces

Ram

207279

196079

Platen

NA

Air Controls

Integrated air controls with pump regulator

NA

257453

24C769

257461

3 in.

3 in.

3 in.

D200

D200

D200

Hydra-Mate systems

8900 Proportioner

1:1 Extruder

196708

232110

954419

55 gallon

EPDM

55 gallon neoprene

55 gallon

EPDM

NA

NA

Integrated air controls without pump regulator

NA

Pump Mounting Chart

This table lists the parts necessary to mount various Graco pumps on the ram. Refer to pages 10-11 for mounting

instructions. See Accessories on page 23 for parts.

For pump mounting and application information, contact your Graco distributor.

Pump Type

Monark ® and President ® Check-Mate ™ 450 Pumps

Bulldog ® and Senator ® Check-Mate ™ 450 Pumps

King ™ , Bulldog ® , and Senator ® Check-Mate ™ 800 Pumps

King ™ Check-Mate ™ 1000 Pumps

King ™ , Bulldog ® , and Viscount ® Check-Mate ™ 2100 Pumps

King ™ , Bulldog ® , and Senator ® Power-Flo ® Pumps

Monark ® and President ® Check-Mate ™ 200 Pumps

Bulldog and King Pumps with intake housing mounting flange

Fire-Ball 300, 50:1

Fire-Ball 425, 10:1, 50:1, 75:1

Ram Mounting Kit

224829

247335 and 247336

247335 and 247337

Platen Mounting Kit

222776

3A0233J

Warnings

Warnings

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

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from gun, 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 gun 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 Pressure Relief Procedure in this manual, 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.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. 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 arc).

• 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.

• Ground all equipment in the work area. See

Grounding

instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately.

Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec tric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on power and extension cords.

• Do not expose to rain. Store indoors.

3A0233J 5

Component Identification

Component Identification

D200 Rams

257435 & 25R470 Model Shown

Lift Locations

A

H

K

J

G

C

F

D

B

F IG . 1: Typical Installation

Key:

A Ram Assembly

B Platen (see F IG . 3)

C Integrated Air Controls (see F IG . 2)

D Platen Bleed Port

E Blowoff Air Supply Line (see F IG . 15)

F Platen Lift Rod

G Main Air Line (not supplied)

H Air Line Drain Valve (not supplied)

J Air Filter (not supplied)

K Bleed Type Air Shutoff Valve (not supplied)

6 3A0233J

Component Identification

Integrated Air Controls

The integrated air controls include:

• Main air slider valve (AA): turns air on and off to the system. When closed, the valve relieves pres sure 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)

• Air motor regulator (AE): controls air pressure to motor.

• Air motor slider valve (AF): turns air on and off to the air motor. When closed, the valve relieves air trapped between it and the air motor. Push the valve in to shutoff.

• Blowoff button (AG): turns air on and off to push the platen out of an empty drum.

Air Line Accessories

See F IG . 1.

• Air line drain valve (H)

• Air line filter (J): removes harmful dirt and moisture from compressed air supply.

• Second bleed-type air valve (K): isolates air line accessories and ram for servicing. Locate upstream from all other air line accessories.

• Air relief valve (attached to ram air regulator, not visible): automatically relieves excessive pressure.

Platen Component Identification

255663 and 255664, 200 liter (55 gallon)

EK

EA EL

EM

EH

EJ not included with

24C824

{

AF

AE

AD

AC

TI10518A

AG

AA

F IG . 2. Integrated Air Controls ti10438a

AB

EB

F IG . 3. Platen

Key:

EA Plate

EB Wipers

EG Spacer

EH Cap Screws

EJ Clamps

EK Bleed Handle

EL Bleed Valve

EM Air Assist Body Check Valve

EN Wiper Plate (under wiper)

EP O-ring Seal

3A0233J 7

8

Installation

Installation

NOTE: Reference numbers and letters in parenthe ses in the text refer to the callouts in the figures.

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

F IG . 1 is the only guide for selecting and installing sys

tem components and accessories. Contact your Graco distributor for assistance in designing a system to suit your particular needs.

Location

NOTICE

Always lift ram at proper lift locations (see F IG . 1).

Do not lift in any other way. Lifting at these loca tions allows the ram to be lifted straight up and pre vents the ram from bumping into objects nearby.

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

Position the ram so the air controls are easily accessi ble. Ensure that there is enough space overhead for the

ram to raise fully. (See Dimensions, page 25.)

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 nec essary, 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.

Grounding

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

Pump: use a ground wire and clamp. Loosen grounding lug locknut and washer. Insert one end of supplied ground wire into slot in lug and tighten locknut securely .

Connect other end of wire to a true earth ground. See

F IG . 4.

ti8250a

F

IG

. 4

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 electrical resistance of hoses. If total resistance to ground exceeds 29 megohms, replace hose immedi ately.

Air compressor: follow manufacturer’s recommenda tions.

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

Fluid supply container: follow local code.

Object being sprayed: follow local code.

Solvent pails used when flushing: follow local code.

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

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

The equipment must be grounded. Grounding reduces the risk of static and electric shock by pro viding an escape wire for the electrical current due to static build up or in the event of a short circuit.

3A0233J

Installation

Attach Drum Stops

Rams 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

(FA), lock washers (not shown), and drum stops (FB).

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

2. Using the capscrews (FA) and lock washers (not shown), attach the drum stops (FB) to the ram base.

D200 and D200s Base

F IG . 5

FB FA ti10917a

F

IG

. 6

3A0233J 9

Installation

Mount Check-Mate 450, 800,

1000, and 2100 Pumps

NOTE:

The Pump Mounting Chart on page x lists the parts necessary to mount Check-Mate 450, 800, 1000, and

2100 Pumps on this ram. Installing other pumps on the ram may require alternate parts. For informa tion, contact your Graco distributor.

This installation requires Mounting Kit 222776 and

224829 which must be ordered separately. See

Accessories on page 23.

1. Position the mounting brackets (42) so that the top of the pump will clear the support beam (4).

2. For President and Monark Check-Mate 450 Pumps only, install the mounting plate (CA) from kit 224829 onto the mounting brackets (42) using four screws

(CB) and lockwashers (CC). See F IG . 7.

NOTE: The plate (CA) is oriented differently for the

President than for the Monark.

For President Pumps

3. Attach the motor to the mounting brackets (57) or mounting plate (CA) with the fasteners supplied (‡), as applicable.

4. Place the gasket (CK) from Mounting Kit 222776 on

the ram plate (114). See F IG . 8. Loosen the mount

ing bracket setscrews (43), and carefully lower the pump onto the gasket and plate. Secure the pump’s intake flange (CN) to the plate with the screws (CL) and lugs (CM) included in the mounting kit.

CL

CM

CN

CK

114

02938

F IG . 8

CB

CC

CJ

CL

CA

For Monark Pumps

CB

CC

CA

F IG . 7

10 3A0233J

Installation

Mount Power-Flo, Check-Mate

200, Fire-Ball 300 and Fire-Ball

400 Pumps

NOTE:

The Pump Mounting Chart on page 4 lists the parts

necessary to mount Power-Flo, Check-Mate 200,

Fire-Ball 300 and Fire-Ball 425 pumps on this ram.

Installing other pumps on the ram may require alter nate parts. For information, contact your Graco dis tributor.

1. Position the mounting brackets (42) so that the top of the pump will clear the support beam (4).

2. For President, Monark Check-Mate 200, and

Fire–Ball Pumps only, install the mounting plate

(CA) onto the mounting brackets (42) using four

screws (CB) and lockwashers (CC). See F IG . 9.

NOTE: The plate (CA) is oriented differently for the

President and Fire–Ball 425 than for the Monark and

Fire–Ball 300.

For President and Fire-Ball 425 Pumps

3. Attach the motor to the mounting brackets (42) or mounting plate (CA) with the fasteners supplied, as applicable.

NOTE: Before proceeding to step 4, install Adapter

Kit 224267 for the Fire–Ball 300 pump. Install

Adapter Kit 224266 for Fire–Ball 425, 50:1 and 75:1

Pump.

4. Slide the top seal plate (CG) up over the pump intake valve and push the seal (CF) onto the pump intake housing. Leave the bottom seal plate (CG) and gasket

(CH) in place. See F IG . 10.

5. Loosen the mounting bracket setscrews (35), and carefully lower the pump until the intake valve is below the gasket (CH), then tighten the setscrews.

6. Push the seal (CF) down firmly against the bottom seal plate (CG).

7. Align the holes in the top seal plate with the holes in the ram plate (114). Secure tightly to the ram plate with the four screws (CD) and washers (CC).

CF CD, CC

CG

CB

CC

CA

For Monark and Fire-Ball 300 Pumps r_257435_3a0233_2c

CB

CC

CA

114

F IG . 10 r_257435_3a0233_3c

F IG . 9

3A0233J

CG CH

02938

11

Installation

3:1 Bulldog Pump

1. Remove four nuts (1) from the lower part of the

pump as shown in F IG . 11.

F

IG

. 11

2. Slide gasket (Part No. 162788) over pump intake cylinder (2). Align holes with cylinder mounting col -

lars (3) and pump (F

IG

. 11).

3. Lower pump onto platen and align so the bolts from

the pump can be attached to the platen (F

IG

. 12).

F IG . 13: Model 257435 shown

F IG . 12

4. Tight bolts to secure pump.

12 3A0233J

Operation

Operation

Start and Adjust Ram

Pressure Relief Procedure

1. Lock the gun/valve trigger.

2.

For D200 Air Controls: See F IG . 2, page 7. a. Close the air motor slider valve (AF) and the main air slider valve (AA).

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

c. Jog the director valve up and down to bleed air from ram cylinders.

3. Unlock the gun/valve trigger.

4. Hold a metal part of the gun/valve firmly to the side of a grounded metal pail, and trigger the gun/valve to relieve pressure.

5. Lock the gun/valve trigger.

6. Open the fluid line drain valve and the pump bleeder valve (P). Have a container ready to catch the drainage.

7. Leave the pump bleeder valve (P) open until ready to spray again.

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

Now clear the tip/nozzle or hose.

Flush Before Using Equipment

The pump was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contam inating fluid with oil, flush the pump with a compatible solvent before use. See pump manual for flushing directions.

Moving parts can pinch or amputate fingers. When the pump is operating and when raising or lowering the ram, keep fingers and hands away from the pump intake, platen, and lip of the drum.

1. Refer to F IG . 1. Close all air regulators and air

valves.

2. Open main air slider valve (AA) and set ram air reg ulator (AB) to 40 psi (0.28 MPa, 2.8 bar). Set direc tor valve handle (AC) to UP and let the ram rise to its full height. See F IG . 2 on page 7.

3. Lubricate the platen seals (B) with grease or other lubricant compatible with the fluid you will pump.

4. Remove the drum cover and smooth the surface of the fluid with a straightedge.

5. Put a full drum of fluid on the ram base, slide it back against the drum stops, and center it under the platen (B). An optional drum roller kit is available for

D200 and D200s rams to make it easier to load the drum on the base. Order Kit 255627.

NOTICE

To avoid damage to the platen seals, do not use a drum that is dented or damaged.

3A0233J 13

Operation

6. Remove bleed stick from platen bleed port (D).

7. If drum has a plastic liner, pull it over edge of drum.

Secure liner with tape wrapped around circumfer ence of drum.

Change Drums

D

B

F IG . 14 ti10543a

8. Set the director valve (AC) to DOWN and lower the ram until fluid appears at the top of the platen bleed port (D). Adjust ram air regulator (AB) as needed.

Set the director valve (AC) to neutral and close the platen bleed port (D). 2-Button Interlock: If system has this feature, press and hold both buttons to start lowering the ram. See F IG . 2, page 7.

Start and Adjust Pump

1. Connect pump outlet fittings and hose (not sup plied).

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

2. Be sure the pump air valve is closed. Then set the ram air regulator (AB) to about 50 psi (0.35 MPa,

3.5 bar). Set the director valve (AC) to DOWN. Start the pump as explained in the separate pump instruction manual.

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

NOTE: Increase air pressure to the ram if the pump does not prime properly with heavier fluids.

Decrease air pressure if fluid is forced out around the top seal or platen.

1. Stop the pump.

a. Push in the air motor slider valve (AF) to stop the pump.

2. Raise the platen out of the drum.

a. Set ram director valve (AC) to UP to raise the platen (B) and immediately press and hold the blowoff air button (AG) until the platen (B) is completely out of drum. Use minimum amount of air pressure necessary to push the platen out of the drum.

3. Follow steps 4-8.

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.

4. Release the blowoff air button and allow the ram to rise to its full height.

5. Remove empty drum.

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

7. Place full drum on ram base.

8. Lower the ram and adjust the position of the drum relative to the platen. See Start and Adjust Ram

on page 13.

14 3A0233J

Maintenance

Maintenance

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pres sure Relief procedure.

Platen Maintenance

See F IG . 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. Relieve pressure. Refer to parts illustration on page

23 and disassemble air assist valve as shown.

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

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

F

EG

Remove 55 Gallon Platen Wipers

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

Wipe fluid off of platen.

2. Cut top and bottom wipers with knife and remove from platen. See F IG . 16.

EB

TI10613A

F IG . 16

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.

2.

Working from the bottom , angle one wiper (EB) over back of platen. See F IG . 17.

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 compati ble with material being pumped. Check with mate rial supplier.

r_255319_3a0233_1b

F IG . 15

EB

TI10614A

F IG . 17

3A0233J 15

Troubleshooting

Troubleshooting

Problem

Ram will not raise or lower.

Ram raises and lowers too fast.

Air leaks around cylinder rod.

Fluid squeezes past ram plate wip ers.

Pump will not prime properly or pumps air.

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

Cause Solution

Closed air valve or clogged air line.

Open, clear.

Not enough air pressure.

Increase.

Worn or damaged piston.

Hand valve closed or clogged.

Replace. See Repair on page 17.

Open, clear.

Air pressure is too high.

Worn rod seal.

Air pressure too high.

Worn or damaged wipers.

Decrease.

Replace. See Repair on page 17.

Decrease.

Replace. See Remove 55 Gallon

Platen Wipers on page 15.

Closed air valve or clogged air line.

Open, clear.

Not enough air pressure.

Increase.

Worn or damaged piston.

Hand valve closed or clogged.

Replace. See pump manual.

Open, clear. See Platen Mainte nance on page 15.

-

Hand valve is dirty, worn, or dam aged.

Clean, service.

Closed air valve or clogged air line.

Open, clear. See Platen Mainte nance on page 15.

Not enough air pressure.

Valve passage clogged.

Increase.

Clean. See

Platen Maintenance

on

page 15.

16 3A0233J

Repair

Repair

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pres sure Relief procedure. Do not use pressurized air to remove the guide sleeve or the piston.

D200 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. Relieve pressure.

2. Access piston rod seal and bearing.

a. Remove nuts (6) and lockwashers (5) holding the tie bar (4) to the piston rods (2n). Refer to

parts illustration on page 19 or page 21.

b. Remove tie bar (4).

3. Remove retaining ring (3).

4. Remove piston rod seal and bearing.

a. Slide end cap (2a), pin (2b), o-ring (2c), and spring (2m) up off of the piston rod (2n). b. Remove retaining ring (2k) and bearing (2j) from end cap (2a) and remove o-ring (2d).

5. Inspect parts for wear or damage. Replace as nec essary.

NOTE: Do not reinstall end cap assembly if the ram piston (2e) needs to be removed from the piston

rod. See Assemble Piston Rod Seal and Bearing

instructions.

2c

2a

2j

2m

2n

TI10520A

3

2d

2b

2k

F

IG

. 18: 3 in. Piston Rod Seal

Assemble Piston Rod Seal and Bearing

See F

IG

. 18.

1. Lubricate o-ring (2d) and bottom bearing (2j). a. Install o-ring (2d), bottom bearing (2j), and retaining ring (2k) into end cap (2a). b. Install new o-ring (2c) and pin (2b) on end cap

(2a). Lubricate o-ring (2c) and end cap (2a).

c. Slide spring (2m) and end cap (2a) on piston rod (2n).

2. Install retaining ring (3).

3. Install tie bar (4), washers (5), and nuts (6).

3A0233J 17

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 (2e) and rod (2n) down so piston rod will not be bent. Remove nut (2f), washer (2g), piston (2e), outer o-ring (2c), and inner o-ring (2h).

3. Inspect parts for wear or damage. Replace as nec essary.

Assemble Ram Piston

1. Install new o-rings (2h, 2c) and lubricate piston (2e) and o-rings.

2. Apply medium strength thread sealant. Install pis ton (2e), washer (2g), and nut (2f) on piston rod (2n).

3. Carefully insert piston (2e) into cylinder and push piston rod (2n) straight down into cylinder.

4. Slide spring (2m) and end cap (2a) onto piston rod

(2n).

5. Install retaining ring (3), tie bar (4), washers (5), and nuts (6).

2n

2c

2h

2e

2g

2f

TI10521A

F IG . 19: 3 in. Ram Piston

18 3A0233J

Parts

Parts

3 in. Ram with EPDM 55 Gallon Platen, 257452

3 in. Ram with Neoprene 55 Gallon Platen, 257453

3 in. Ram, 257461

8

6

5

2j

2k

2m

3

2c

2d

2a

2b

4

2n

31

40

18

(9 ft) 20

41

31

17

See Detail A

53, 54, 55 2c

2h

2e

2g

2f

1

WLD

20 (6 ft)

17

Detail A

63 67

64 66, 65

63

02938

3A0233J 19

Parts

3 in. Ram with EPDM 55 Gallon Platen, 257452

3 in. Ram with Neoprene 55 Gallon Platen, 257453

3 in. Ram, 257461

Ref.

No. Part No. Description

1 ‡ 255286 RAM, 3 in.

2 ‡ 255328 PISTON, assembly 3 in. ram;

2a includes 2a-2n

BEARING, ram end cap

2b 107092 PIN, spring, straight

2c*

2d*

2f*

O-RING

O-RING

2e 183943 PISTON

NUT, jam

WASHER, split

O-RING

BEARING, ram end cap

2g*

2h*

2j*

2k*

2m*

RETAINER, retaining ring

SPRING, compression

2n 167651 ROD, piston, ram

3* ‡ 127510 RING, retaining, 3.06 dia

4

5

6

8

621386 BEAM, support

101533 WASHER, spring lock

101535 NUT, full hex

189559 CAP, end

17 ‡ 128863 FITTING, elbow

18 C19407 FITTING, connector, male

20 ‡ C12509 TUBE, nylon, rnd; 18 ft

31 ▲ 15J074 LABEL, safety

40 167652 ROD, tie ram

41 255663 PLATE, wiper 55gal EPDM; 257452 only

255664 PLATE, wiper 55gal neoprene;

257453 only

53 C19853 SCREW, cap, socket hd

54 C38185 WASHER, lock

55 C32467 STOP, drum

63 162789 PLATE, seal

64 161452 SEAL, follow plate

65 100133 WASHER, lock

66 100004 SCREW, cap, hex hd

67 162788 GASKET

Qty.

1

2

1

4

1

1

4

2

2

2

2

4

4

2

1

2

2

2

2

2

2

2

2

4

2

2

2

4

2

1

1

1

2

2

Replacement Danger and Warning labels, tags, and cards are available at no cost.

* Parts included in repair kit 255687 (purchase sepa rately).

‡ Parts used with 257461 3 in. ram.

20 3A0233J

2g

2f

2h

2c

2e

2j

2k

2m

3

2c

2d

2a

3 in. Ram with Integrated Air Controls, 24C769

3 in. Ram with Integrated Air Controls and 55 Gallon EPDM Platen, 257435 & 25R470

11

12

Detail A

8

6

5

36

Not included with 24C264

}

2b

4

11

12

9

12

11

43

42

15

13 ti10767a 36

31

2n

Detail A

40

17

16

20

Parts

41

53, 54, 55 ti11078a

1

20

17 r_257435_3a0233_4c

3A0233J 21

Parts

3 in. Ram with Integrated Air Controls, 24C769

3 in. Ram with Integrated Air Controls and 55 Gallon EPDM Platen, 257435 & 25R470

Ref.

No.

1

2

5

6

3*

4

2j*

2k*

2m*

2n

2a

2b

2c*

2d*

2e

2f*

2g*

2h*

Part No. Description

RAM, 3 in.

255328 PISTON, assembly 3 in. ram; includes 2a-2n

BEARING, ram end cap

107092 PIN, spring, straight

O-RING

O-RING

183943 PISTON

NUT, jam

WASHER, split

O-RING

BEARING, ram end cap

RETAINER, retaining ring

SPRING, compression

167651 ROD, piston, ram

7

8

9

11

127510 RING, retaining, 3.06 dia

167646 BEAM, tie

101533 WASHER, spring lock

101535 NUT, full hex

15M663 LABEL

189559 CAP, end

255296 BRACKET, mounted

101682 SCREW, cap, sch

12 100016 WASHER, lock

13

24C264 CONTROL, air, ram, hyd driver

✿ 289105 CONRTOL, air

119835 GAUGE, press, air 15

16

17

20

132848 FITTING, elbow, plug in

128863 FITTING, elbow

C12509 TUBE, nylon, rnd; 15 in.

31

15J074 LABEL, safety

36 ▲ 15V954 LABEL, valve, shutoff, air control

40

167652 ROD, tie ram

41 ✿ 255663 PLATE, wiper 55 gal EPDM

25R468 PLATE, wiper 55 gal NITRILE

42 ✿ 161822 PLATE, mounting

43

100672 SCREW, set

53

54

55

C19853 SCREW, cap, socket hd

C38185 WASHER, lock

C32467 STOP, drum

Replacement Danger and Warning labels, tags, and cards are available at no cost.

Only used with 24C769.

Only used with 257435.

* Parts included in repair kit 255687 (purchase sepa rately).

Qty.

1

2

1

1

1

2

1

4

2

2

2

2

2

4

2

1

1

8

1

1

8

1

2

2

2

2

1

2

2

2

2

2

2

2

2

4

2

2

2

22 3A0233J

Accessories

Accessories

200 Liter (55 Gallon) Platen

Platen with EPDM Seals, 255663

Platen with Neoprene Seals, 255664

103

121

119

*126

*127

118

124

*128

117

114

108

TI10655B

200 Liter (55 Gallon) Platen Parts

Ref.

No. Part No. Description

103 255232 HANDLE, bleed assy

108 255652 SEAL, wiper, drum, 55 gal., neo prene; for 255664 only.

255653 SEAL, wiper, drum, 55 gal., EPDM; for 255663 only.

PLATE, ram 55 gal.

114

116 114243 VALVE, check

117 114153 FITTING, TUBE, quick disconnect

118 100505 BUSHING, pipe

119 119992 NIPPLE, 3/4 x 3/4 npt

121 166466 TEE, pipe, female

124 156849 NIPPLE

126* 102637 SCREW, cap

127* 276025 CLAMP

128* 109495 O-RING

Qty.

1

2

2

1

4

1

1

4

1

1

1

1

1

*Parts included in 255392 Kit (purchase separately).

Drum Position Clamp Set for

D200 Ram, 206537

(Includes two clamps) Attach to ram cylinders to center drum in place and prevent drum from moving.

55 Gallon Platen Cover Kit,

255691

See 406681 for more information.

Pump Mounting Kit 224829

See pages 10 for mounting instructions. Required for

mounting President and Monark Check-Mate 450 pumps.

Ref.

No. Part No. Description

CA 184140 PLATE, mounting

CB 100101 SCREW, hex hd, cap;

3/8-16 x 1 in. (25.4 mm)

CC 100133 LOCKWASHER, spring, 3/8 in.

CD 100004 SCREW, hex hd, cap;

3/8-16 x 1-1/4 in. (31 mm)

CF 161452 SEAL, ram plate, standard

CG 162789 PLATE, seal, standard

CH 162788 GASKET; cork

CJ 100016 WASHER, lock

CK 102025 NUT, hex, regular

CL 100270 SCREW, cap, hex

CM 15B588 SCREW, cap, socket

Qty.

1

4

8

4

2

2

2

1

2

1

2

3A0233J 23

Accessories

Platen Mounting Kit 222776

See page 10 for mounting instructions. Required for

mounting Check-Mate 450, 800, 1000, and 2100 pumps on the ram.

See manual 405952 for parts.

Platen Mounting Kit 247335

See pages 11 for mounting instructions. Required for

mounting Fire-Ball 300 and Fire-Ball 425 pumps.

C Ref.

No. Part No. Description

CC 100133 LOCKWASHER, spring, 3/8 in.

CD 100004 SCREW, hex hd, cap;

3/8-16 x 1-1/4 in. (31 mm)

CF 160098 SEAL, ram plate

CG 162789 PLATE, seal, standard

CH 162788 GASKET; cork

Platen Mounting Kit 247336

See pages 11 for mounting instructions. Required for

mounting Fire-Ball 300, 50:1 pumps.

Qty.

4

4

1

2

1

Ref.

No. Part No. Description

CA 184140 PLATE, mounting

CB 100101 SCREW, hex hd, cap;

3/8-16 x 1 in. (25.4 mm)

CC 100133 LOCKWASHER, spring, 3/8 in.

‡ 100022 SCREW, hex hd, cap;

1/4-20 x 3/4 in.

100016 WASHER, lock

100015 NUT, hex, 1/4-20

‡ Mounting hardware for pump to plate (CA).

Qty.

1

4

2

2

8

2

Platen Mounting Kit 247337

See pages 11 for mounting instructions. Required for

mounting Fire-Ball 425, 10:1, 50:1, and 75:1 pumps.

Ref.

No. Part No. Description

CA 162225 PLATE, mounting

CB 100101 SCREW, hex hd, cap;

3/8-16 x 1 in. (25.4 mm)

CC 100133 LOCKWASHER, spring, 3/8 in.

100022 SCREW, hex hd, cap;

1/4-20 x 3/4 in.

100016 WASHER, lock

‡ Mounting hardware for pump to plate (CA).

Qty.

1

4

8

2

2

24 3A0233J

Dimensions

Dimensions

A

F

E

C

D r_257435_3a0233_1c

Ram Model

D200

Weight

Platen Size

Gallons (Liters)

55 (200)

102.3 (2599) 64.8 (1646)

Maximum Weight

51 (23)

21.0 (533) 25.0 (635) 38.0 (965) 42.0 (1067)

3A0233J 25

Dimensions

26 3A0233J

Technical Data

Technical Data

Max air input pressure (ram) / Air inlet size

D200 - 3 in. dual post, 55 gal. (200 L), 30 gal. (115 L) 150 psi (1.0 MPa, 10 bar) / 3/4 npt(f)

Max fluid, air working pressure, and weight

(displacement pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Check-Mate pump packages, see manual 312376.

For Dura-Flo pump packages, see manuals 311826,

311828, 311833.

Wetted Parts

Displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Check-Mate displacement pumps, see manual

312375.

For Dura-Flo displacement pumps, see manuals

311717, 311825, 311827.

Platens

255663, 55 gal. (200 L) . . . . . . . . . . . . . . . . . . . . . . .

EPDM, aluminum, zinc plated carbon steel, 316 sst

255664, 55 gal. (200 L) . . . . . . . . . . . . . . . . . . . . . . .

PTFE, neoprene, aluminum, zinc plated carbon steel,

316 sst

25R468, 55 gal. (200 L) . . . . . . . . . . . . . . . . . . . . . . .

NITRILE, aluminum, zinc plated steel, 316 sst

Ambient operating temperature range (ram) 32-120 °F (0- 49°C)

California Proposition 65

CALIFORNIA RESIDENTS

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

3A0233J 27

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by

Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT

LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés,

à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com

.

For patent information, see www.graco.com/patents .

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211, Fax: 612-378-3505

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

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

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 3A0233

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

Copyright 2009, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision J, December 2021

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Key Features

  • Replaces outdated rams for Graco bulk supply systems
  • Not for use in explosive atmospheres
  • Transfers or dispenses high viscosity fluids
  • Integrated Air Controls
  • 3 inch Dual Post
  • 200 Liter (55 Gallon) Capacity
  • 150 psi (1.0 MPa, 10 bar) Maximum Air Inlet Pressure

Related manuals

Frequently Answers and Questions

What is the Graco 3A0233J Air-Powered Ram used for?
The Graco 3A0233J Air-Powered Ram is used for transferring or dispensing a non-heated bulk supply of sealants, adhesives, or other medium to high viscosity fluids.
What is the maximum air inlet pressure for the Graco 3A0233J Air-Powered Ram?
The maximum air inlet pressure for the Graco 3A0233J Air-Powered Ram is 150 psi (1.0 MPa, 10 bar).
What is the capacity of the Graco 3A0233J Air-Powered Ram?
The Graco 3A0233J Air-Powered Ram has a capacity of 200 liters (55 gallons).
What are the dimensions of the Graco 3A0233J Air-Powered Ram?
The dimensions of the Graco 3A0233J Air-Powered Ram are not specified in the provided manual.
What is the weight of the Graco 3A0233J Air-Powered Ram?
The weight of the Graco 3A0233J Air-Powered Ram is not specified in the provided manual.
Does the Graco 3A0233J Air-Powered Ram come with a warranty?
The warranty information for the Graco 3A0233J Air-Powered Ram is not specified in the provided manual.