Graco 308675B Pro-Wash Gun Washer Owner's Manual

INSTRUCTIONS-PARTS LIST

This manual contains important warnings and information.

READ AND KEEP FOR REFERENCE.

308–675

First choice when quality counts.

Rev. B

Supersedes Rev. A

INSTRUCTIONS

PRO-WASH Gun Washer

With Husky 307 Pump

100 psi (0.7 MPa, 7 bar) Maximum Working Pressure

Model 112–636

Table of Contents

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

Introduction and Description . . . . . . . . . . . . . . . . . . . . . 4

Controls and Indicators

Installation

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

6

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Shutdown and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 18

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Drawings and Lists

19

Gun Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 32

Graco Phone Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 32 03299

GRACO INC.

P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

http://www.graco.com

COPYRIGHT 1996, GRACO INC.

Graco Inc. is registered to I.S. EN ISO 9001

Symbols

Caution Symbol Warning Symbol

WARNING

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

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

INSTRUCTIONS

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

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 the equipment daily. Repair or replace worn or damaged parts immediately.

D Do not exceed the maximum working pressure of the lowest rated system component. This equipment has a 100 psi (0.7 MPa, 7 bar) maximum fluid working pressure at 100 psi (0.7 MPa,

7 bar) maximum incoming air pressure.

D

Do not operate the gun washer at a pressure above the maximum working pressure rating of the gun(s) being cleaned.

D Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 150 _ F (65 _ C) or below –40 _ F (–40 _ C).

D

Do not use the hoses to pull the equipment.

D

Do not move pressurized equipment.

D Use fluids or solvents that are compatible with the equipment wetted parts. See the Technical

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

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

PRESSURIZED EQUIPMENT HAZARD

Spray from hose leaks, ruptured components, or from operating the gun washer with an open lid can splash fluid in the eyes or on the skin and cause serious injury.

D A safety device has been installed to shut off the pump when the gun washer lid is opened. Do not tamper with or alter this device.

D

Open the gun washer lid slowly.

D

Do not prop the gun washer lid open with an object or by any other means.

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

D Follow the Pressure Relief Procedure on page 9 whenever you: are instructed to relieve the pressure; stop operating the gun washer; and clean, check, or service the equipment.

D

Tighten all the 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.

2 308–675

WARNING

FIRE AND EXPLOSION HAZARD

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in fire or explosion and serious injury.

Ground the equipment. See Grounding on page 6.

Provide fresh air ventilation to avoid the buildup of flammable fumes from the solvent.

Extinguish all the open flames or pilot lights in the gun washer area.

Electrically disconnect all the equipment in the gun washer area.

Keep the gun washer area free of debris, including solvent, rags, and gasoline.

Do not turn on or off any light switch in the gun washer area while operating or if fumes are present.

Do not smoke in the gun washer area.

Do not operate a gasoline engine in the gun washer area.

Follow the gun manufacturers solvent and other cleaning recommendations.

Use solvent with the highest possible flash point.

Use non-conductive solvent when cleaning electrostatic guns.

Do not allow solvent to enter the air passage of an electrostatic gun.

Do not flush an electrostatic gun with the electrostatics ON-OFF lever in the ON position.

If there is any static sparking while using the equipment, stop operation immediately. Identify and correct the problem.

Drain the solvent into a proper storage container when the gun washer(s) is not in use.

TOXIC FLUID HAZARD

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

Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.

Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.

Wear the appropriate protective clothing, gloves, eyewear and respirator.

Pipe and dispose of the exhaust air safely. If the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 7.

308–675 3

Introduction and Description

Introduction

This manual provides operation and maintenance instructions with illustrated parts breakdown for the Graco Model

112–636 Pro-Wash Gun Washer, hereafter referred to as the gun washer.

Description

The gun washer is used to clean spray paint guns, pressure cups, hoses and other paint containers.

The gun washer consists of a stainless steel tank with 5 gallon (19 liter) capacity and a double diaphragm pump.

The pump circulates solvent at a maximum working pressure of 100 psi (0.7 MPa, 7 bar) .

4 308–675

Controls and Indicators

B

A

Fig. 1

Switch/ Indicator

A GUN CLEAN/OFF/HOSE

CLEAN 3-way valve

B PUSH TO START reset valve block

Explanation

GUN CLEAN position directs solvent flow through the gun supports and spray nozzles to clean guns. OFF stops cleaning operation. HOSE

CLEAN position directs solvent flow through hose clean bulkhead fitting

(Fig. 6) to clean hoses.

Pushing the button on the reset valve block starts the spray cycles when the GUN CLEAN/OFF/HOSE CLEAN 3-way valve is in either the

GUN CLEAN or HOSE CLEAN position.

308–675 5

Install the Gun Washer

Installation

2.

Install a bleed-type master air valve (E) upstream and within easy reach of the gun washer to relieve air trapped between this valve and the pump after the air is shut off.

WARNING

FIRE HAZARD

To prevent hazardous concentrations of flammable and/or toxic vapors, the gun washer must be installed in a properly ventilated paint mixing room or spray booth. Never operate the gun washer unless ventilation fans are operating.

Check and follow all the National, State and Local codes regarding ventilation requirements.

WARNING


The bleed-type master air valve (E) is required in your system to relieve air trapped between this valve and the pump after the air is shut off.

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury, including splashing in the eyes or on the skin.

Make sure the gun washer is standing on a level, solid surface.

Grounding

3.

Install a 1/4 in. npt male coupler (F), that is compatible with the quick disconnect of your air supply line, into the air inlet adapter (G). See Fig.

2.

4.

Connect the air line (H) to the coupler (F).

WARNING


Improper grounding can cause a hazardous condition and result in fire or explosion and serious injury. Ground the gun washer and all other equipment used or located in the gun washer area.

Check your local electrical code for detailed grounding instructions for your area and type of equipment. Also read the section FIRE

AND EXPLOSION HAZARD, on page 3.

G

F

1.

Ground the gun washer and its pump by connecting the clamp end (A) of the gun washer’s

15 ft. (4.6 m) ground wire (B) to a true earth ground (C). See Fig. 4.

2.

Use only electrically conductive air and fluid hoses with a maximum of 500 ft. (150 m) combined hose length to ensure grounding continuity.

3.

Ground the air compressor according to manufacturer’s recommendations.

4.

Ground all solvent pails used when flushing and draining according to local code. Use only metal pails, which are conductive. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts the grounding continuity.

Connect the Air Line

1.

Install an air pressure regulator (D) on the gun washer air supply line to control air pressure to the gun washer. See Fig. 4.

Fig. 2 03302

6 308–675

Air Exhaust Ventilation

Installation

To exhaust to a remote location:

1.

Remove the muffler (11) from the pump air exhaust port.

WARNING

FIRE, EXPLOSION, AND TOXIC FLUID

HAZARD

Diaphragm failure will cause the fluid being pumped to exhaust with the air.

Place an appropriate container at the end of the air exhaust line to catch the fluid. See Fig. 3.

Vent the exhaust to a safe place outside the work area.

WARNING


To reduce the risk of eye injury from ice particles, never operate the pump with the air exhaust port open. Ice may form during pump operation and ice be ejected from the port with the exhaust air. If the muffler (11) is removed, always connect an air exhaust hose to the exhaust port.

The air exhaust port is 3/8 npt(f). Do not restrict the air exhaust port. Excessive exhaust restriction can cause erratic pump operation.

2.

Install an electrically conductive air exhaust hose

(X) and connect the muffler to the other end of the hose. The minimum size for the air exhaust hose is 3/8 in. (10 mm) ID. If a hose longer than 15 ft

(4.57 m) is required, use a larger diameter hose.

Avoid sharp bends or kinks in the hose.

3.

Place a container (Z) at the end of the air exhaust line to catch fluid in case a diaphragm ruptures. If the fluid is flammable, ground the container. See

Fig. 3.

VENTING EXHAUST AIR

X

Z

11

06271

Fig. 3

308–675 7

Installation

Typical Installation and Grounding

D

E

H

B

A

C

06269

Fig. 4

F

8 308–675

Operation

Pressure Relief Procedure

WARNING

TOXIC FLUID HAZARD

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

Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.

Wear the appropriate protective clothing, gloves, eyewear and respirator.

WARNING


The system pressure must be manually relieved to prevent the system from starting accidentally. To reduce the risk of an injury from accidental spray, splashing fluid, or moving parts, follow the Pres-

sure Relief Procedure whenever you: are instructed to relieve the pressure, shut down the gun washer, check, clean, or service any of the system equipment.

WARNING


To avoid igniting flammable liquid solvent vapors and reduce the risk of serious injury, fire, or explosion:

Keep all ignition sources, such as static electricity, sparks, arcs, open flames, and hot objects, away from the gun washer.

Cleanup solvent leaks or spills immediately.

Repair leaking components before operating the gun washer again.

Use solvent with the highest possible flashpoint.

Follow the FIRE AND EXPLOSION HAZARD warnings on page 3.

1.

Disconnect the air supply.

2.

Drain the solvent into a proper solvent container.

Place the container under the fluid drain valve on the bottom of the tank and open the fluid drain valve.

Filling the Gun Washer Fluid Tank

1.

Make sure the fluid drain valve is in the closed position.

2.

Carefully pour solvent into the fluid tank until the fluid level is just below the bottom of the manifold assembly.

NOTE: Do not pour more than 5 gallons (18.9 liters) of a compatible solvent into the fluid tank.

CAUTION

Use only non-conductive solvents when cleaning electrostatic guns. Conductive solvents can cause the gun to malfunction.

Follow the gun manufacturers solvent and other cleaning recommendations.

308–675 9

Operation

Preparing Guns/Cups for the Gun Washer

1.

Remove the pressure cup or fluid line and the air line from the spray gun.

2.

Drain any excess fluid in the gun or cup into a fluid container. The solvent in the gun washer will last longer if pressure cups are thoroughly emptied before placing them in the gun washer.

WARNING


To reduce the risk of electrostatic shock, fire, or explosion; which could result in serious injury and property damage, be sure to follow these precautions.

CAUTION

All pressure gauges must be removed before placing the equipment in the gun washer to avoid damaging the gauges.

D

Only use non-conductive solvents when cleaning electrostatic guns.

D

Make sure the ES ON-OFF valve lever (electrostatics) is turned to OFF before cleaning the gun.

D Never allow solvent to enter the air passage of any electrostatic gun.

D Never place the gun air inlet over a gun support.

D

Only use the fluid inlet adapter provided with the gun washer. Install it on the gun fluid inlet as instructed below.

3.

To lock the gun trigger in the open position, install the wire trigger lock around the gun handle and trigger as shown in Fig. 5.

If the wire trigger lock does not fit on your electrostatic gun, wrap the chain around the trigger and handle to hold the trigger in an open position.

Placing Guns in the Gun Washer

(See Fig. 5, page 11)

The following are guns typically cleaned with the gun washer and how to position them in the gun washer for cleaning. To clean guns not mentioned here, use the fluid inlet adapter and long or short gun supports as needed. Follow the procedure on page 13 to operate the gun washer.

Siphon Feed Guns

Set the gun siphon stem over the short gun support.

Pressure Feed Guns with Cup Lid

(2 Qt. Capacity Cups)

Set the cup cover stem over the short gun support as shown in Fig. 5.

Pressure Feed Guns

Set the gun fluid inlet over the long gun support as shown in Fig. 5.

Gravity Feed Guns

Set the gun fluid inlet over the long gun support as shown in Fig. 5.

Electrostatic Guns

The PRO-Wash t

gun washer is approved to clean the

Graco PRO 3500, PRO 4500, and PRO AA4500 electrostatic guns. Consult the manufacturer of any other electrostatic gun before using the PRO-Wash.

A kit, part no. 236–659 or 236–681, is required to clean Graco electrostatic PRO t

guns.

The following is a general procedure for cleaning electrostatic guns. See the manual supplied with kit

236–659 (Manual 308–411) or kit 236–681 (Manual

308–412) for specific cleaning instructions.

1.

Install the electrostatic gun cleaning parts as instructed in the manual supplied with the kit.

2.

Make sure the ES ON-OFF lever (electrostatics) is turned to OFF. Refer to your gun manual.

3.

Screw the fluid inlet adapter onto the PRO-gun fluid inlet as shown in Fig. 5.

4.

Place the gun in the gun washer, setting the fluid inlet adapter over the gun support provided in the electrostatic gun cleaning kit.

10 308–675

Operation

Placing Cups and Pots in the Gun Washer

2 Quart Pressure Cups

Set the pressure cup or other paint container over the coupler assembly. Refer to Fig. 5.

Pressure Pots and Other Paint Containers

See the following table to determine the maximum height and width of the container the pressure washer can clean.

Container Dimensions

Maximum Height

14.5 in. (368 mm)

Typical Cleaning Station Use

Maximum Diameter

11 in. (279 mm)

Paint Container

Fig. 5

Wire Trigger Lock

Long Gun Support

Coupler

Assembly

Spray Nozzle

Fluid Inlet Adapter

Cup Cover Stem

Snap Ring

Short Gun Support

03677

308–675 11

Operation

Using the Hose Clean

1.

Place the hose entirely inside the gun washer.

HOSE CLEAN

NOTE: The bulkhead fitting is 1/4–18 npt(f). A 1/4–18 npt(m) to 3/8 npsm adapter nipple is required to clean

3/8 in. fluid hoses. A 1/4–18 npt(m) to 1/4 npsm adapter nipple is required to clean 1/4 in. fluid hoses.

2.

Connect one end of the hose to the hose clean bulkhead fitting. See Fig. 6.

3.

Turn the GUN CLEAN/OFF/HOSE CLEAN (14) selector to HOSE CLEAN .

NOTE: When the selector is set for HOSE CLEAN, the solvent is routed through the hose clean bulkhead fitting instead of the gun supports and spray nozzles.

4.

See the following Operating the Gun Washer instructions to operate the gun washer.

14

Fig. 6

Hose Clean

Bulkhead

Fitting

Husky Pump

Air Filter/Regulator

DO NOT change setting

03305

12 308–675

Operation

Operating the Gun Washer

WARNING


Do not operate the gun washer with the lid open. Serious injury, including blindness, could result.

A safety device has been installed to shut off the pump when the gun washer lid is opened.

Do not tamper with or alter this device.

Open the gun washer lid slowly.

The gun washer lid has been designed to close automatically unless supported by foot. Do not bypass this safety feature by propping the cover open with an object or by any other means.

WARNING


To avoid component rupture, which could result in serious injury or property damage, never use an air supply pressure above the gun washers maximum working pressure of 100 psi (0.7 MPa, 7 bar).

Never operate the gun washer at a pressure above the maximum working pressure rating of the gun(s) being cleaned.

Flush the Gun Washer Pump Before First Use

The pump was tested in water. If the water could contaminate the fluid you are pumping, flush the pump thoroughly with a compatible solvent before normal operation.

Operation

1.

Set the air pressure to the gun washer in the range of 40 to 75 psi (0.28 to 0.52 MPa, 2.8 to 5.2 bar), using an air regulator on the gun washer air supply line.

NOTE: The gun washer includes a pump air filter/regulator that has been preset at the factory; do not readjust it. See Fig. 6, page 12.

2.

Make sure all adapter chains and cables are inside the gun washer tank.

3.

If one or more of the gun mounts is not being used, place a stream blocking device, such as a pint-size can, over the stem supports and the cup spray nozzle not being used to prevent those jets of solvent from hitting the underside of the gun washer lid.

4.

Close the gun washer lid.

5.

Press the start button on the reset valve block to start the gun washer. Guns, cups, or other paint containers will be cleaned in about 30 to 60 seconds.

NOTE: The cleaning operation should not exceed

60 seconds. Longer operation will not improve the cleaning process and will cause unnecessary wear on the pump.

If the lid is opened while the gun washer is operating, the air supply will automatically shut off and spraying will stop. To restart the pump, close the lid and press the start button.

6.

Remove the gun from the gun washer and blow or wipe any solvent remaining on the gun exterior.

7.

Hang up the gun until it is used again.

CAUTION

Always hang the gun with its nozzle pointing down to avoid having solvent run into the gun air passages.

Solvent in the gun air passages can cause poor atomization and can damage the gun.

CAUTION

Do not change the setting on the pump air filter/regulator as this will damage the regulator.

308–675 13

Shutdown and Care

Gun Washer Shutdown and Care

WARNING


To reduce the risk of an injury from accidental spray, splashing fluid, or moving parts, follow the

Pressure Relief Procedure, covered in steps 1 and 2 below, when you shut down the gun washer and before you check, clean, or service any of the system equipment.

Air Filter/Regulator

Drain moisture from filter weekly. Turn small black pin on bottom of filter 1/4 turn clockwise to drain.

Air Cut-off Switch and Reset Block

WARNING


A safety device has been installed to shut off the pump when the gun washer lid is opened. Do not tamper with or alter this device. Serious injury, including blindness, could result.

1.

Disconnect the air supply.

2.

Drain the solvent from the gun washer tank daily, when you shut down the system. Place a proper solvent container under the fluid drain valve on the bottom of the tank and open the fluid drain valve.

The air connections between the air cut-off switch and reset block are color coded. They must always be connected as shown in Fig. 7.

Air Cut-off Switch and Reset Block

WARNING


The PRO-Wash gun washer is classified as a temporary storage container. To reduce the risk of fire or explosion, be sure to drain the solvent into a proper storage container and store it according to the local code for flammable liquids when shutting down your system.

Air Supply

Black Color

Pump

Coupler

Limit

Switch 3.

Wipe the inside of the tank with a cloth or use a brush to remove any built-up paint residue.

4.

Thoroughly clean the gun washer filter (item 12 in the Parts Drawings) with a brush.

Lid Closed Signal

Blue Color

Air Filter/

Regulator

5.

Change the solvent completely when it is no longer thoroughly cleaning the painting equipment. If the gun washer is being filled with old solvent, be sure to filter the solvent before filling the gun washer tank.

NOTE: If the solvent is thoroughly filtered daily to remove paint residue, it can usually be reused for 2 to

8 weeks (depending on gun washer usage).

Start

Switch

Fig. 7

Main

Air

03306

WARNING


To reduce the risk of fire or explosion, always clean-up any solvent leaks or spills immediately. Repair any leaking components before operating the gun washer again.

14 308–675

Shutdown and Care

Check the Gun Washer Electrical

Continuity

Check your local electrical code for detailed grounding instructions for your area and type of equipment.

If electrical continuity is lost, check the grounding connections and reconnect them as needed. See

Fig. 8 for the gun washers grounding circuits.

WARNING


There must be electrical continuity between the gun washer’s fluid tank, divider plate, frame, and main ground wire.

To reduce the risk of static sparking, fire, or explosion, check the electrical continuity between all gun washer metallic parts and true earth ground after servicing the gun washer. Make sure the gun washer is properly grounded before operating it again.

Grounding Circuits

Jumper Wire from Lid to Fluid Manifold

Fig. 8

Jumper Wire from Fluid Drain

Valve to Pump Grounding Bar

Jumper Wire from Pump Inlet to Pump Grounding Bar

Model 1 12–635 shown

Jumper Wire from Pump Outlet to

Pump Grounding Bar

Ground Wire to

True Earth Ground

03307

308–675 15

Pump Maintenance

Lubrication

The air valve is designed to operate unlubricated, however if lubrication is desired, every 500 hours of operation (or monthly) remove the hose from the pump air inlet and add two drops of machine oil to the air inlet.

Tightening the Clamps

When tightening the clamps (111), apply thread lubricant to the bolts and be sure to torque the nuts

(113) to 50 to 60 in-lb (5.6 to 6.8 N-m). See Fig. 9.

Apply thread lube and torque nuts to

50 to 60 In-lb (5.6 to 6.8 N-m)

CAUTION

Do not over-lubricate the pump. Oil is exhausted through the muffler, which could contaminate your fluid supply or other equipment. Excessive lubrication can also cause the pump to malfunction.

111

Flushing and Storage

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page .

Flush the pump when necessary to prevent the fluid you are pumping from drying or freezing in the pump and damaging it. Use a compatible solvent.

Before storing the pump, always flush the pump and relieve the pressure.

Tightening Threaded Connections

Before each use, check all hoses for wear or damage and replace as necessary. Check to be sure all threaded connections are tight and leak-free, but do not overtighten!

At least every six months, check and retorque all threaded connections, including manifold screws, clamps, and valve screws. Do not overtighten!

113

01446

Fig. 9

Preventive Maintenance Schedule

Establish a preventive maintenance schedule, based on the pump’s service history. This is especially important for prevention of spills or leakage due to diaphragm failure.

16 308–675

Notes

308–675 17

Pump Troubleshooting

WARNING


Pressure Relief Procedure on page 9.

1.

Relieve the pressure before checking or servicing the equipment.

2.

Check all possible problems and causes before disassembling the pump.

PROBLEM

The pump will not cycle, or cycles once and stops.

CAUSE

The air valve is stuck or dirty.

SOLUTION

Turn the reset shaft (21).

Disassemble and clean the air valve. See pages 21, 22.

The pump cycles at stall or fails to hold pressure at stall.

There is excessive air leakage from the exhaust port.

The pump operates erratically.

There are air bubbles in the fluid.

The detent link (22) is worn or broken.

The springs (3, 6) and/or valve cup

(5) and plate (13) are broken or damaged.

The check valves or o-rings (108) are leaking.

The check balls (301) or seat (201) are worn.

The check ball (301) is wedged in the seat (201).

The air valve cup (5) or plate (13) is worn.

The shaft seals (403) are worn.

The suction line is clogged.

The check valve balls (301) are sticking or leaking.

The diaphragm (401) is ruptured.

The suction line is loose.


The manifolds (102) are loose or the o-rings (108) are damaged.

The outer diaphragm plates (103) are loose.

Use filtered air.

Replace the detent link (22) and ball

(8). See pages 21, 22.

Replace these parts.

See pages 21, 22.


See page 23.


See page 23.

Replace the ball.

See page 23.


See pages 21, 22.

Replace the seals.

See page 24.

Inspect; clear the line.

Clean or replace the balls.

See page 23.

Replace the diaphragm.

See page 24.

Tighten the suction line.


See page 24.

Tighten the manifold bolts (104) or nuts (106); replace the o-rings

(108). See page 23.

Tighten the plates. See page 24.

18 308–675

Troubleshooting

PROBLEM

There is fluid in the exhaust air.

The pump exhausts air at stall.

The pump exhausts air from the clamps.

The pump exhausts air near the air valve.

CAUSE


SOLUTION


See page 24.

Tighten the plates. See page 24.

The outer diaphragm plates (103) are loose.

The air valve cup (5) or plate (13) is worn.

The shaft seals (403) are worn.


See pages 21, 22.

Replace the seals.

See page 24.

The clamps (111) are loose.

Tighten the clamp nuts (113).

See page 16.

The air valve screws (15) are loose.

Tighten the screws. See page 19.

The pump leaks fluid from the check valves.

The air valve o-ring (19) is damaged.

The o-rings (108) are worn or damaged.

Inspect; replace the o-ring.

See pages 21, 22.

Inspect; replace the o-rings.

See page 23.

Service

Tools Required

D Torque wrench

D Phillips screwdriver

D

O-ring pick

Replacing the Air Valve

NOTE: Air Valve Kit 239–952 is available. Parts included in the kit are marked with a dagger, for example (2

{

). A tube of general purpose grease (26

{

) is supplied in the kit. Install the kit as follows.

WARNING



1.

Relieve the pressure.

2.

Unscrew the six mounting screws (15) and remove the air valve (A) from the pump.

See Fig. 10.

3.

Refer to the Valve Plate Detail in Fig. 10. Remove the two screws (10) holding the valve plate (13) to the pump. Use an o-ring pick to remove the valve plate, seal (12), and bearing (9).

4.

Apply grease (26

{

) to the bearing (9

{

). Install the bearing and the seal (12) in the pump housing (1).

Install the valve plate (13) and secure with the two screws (10

{

), as shown. Torque the screws to

5 to 7 in-lb (0.6 to 0.8 N-m).

5.

Make certain the o-ring (19

{

) is in place on the air valve cover (2

{

).

6.

Apply grease (26

{

) where shown in Fig. 10.

7.

Align the new air valve assembly so the reset shaft

(21

{

) is at the top. Install the valve on the pump, making sure the valve saddle (14

{

) engages the recessed area on the diaphragm shaft (23). Install the six screws (15) and torque oppositely and evenly, to 8 to 14 in-lb (0.9 to 1.6 N-m).

308–675 19

Service

VALVE PLATE DETAIL

12

19

4

21

A

13

2 10

1 15

4 112

01436

1

2

3

Torque oppositely and evenly to 8 to 14 in-lb (0.9 to 1.6 N-m).

Torque to 5 to 7 in-lb (0.6 to 0.8 N-m).

Apply grease (26 ).

3

1

9 3

01458

GREASE APPLICATION

16

3 14

21 3

19

3

03412A

2

Fig. 10

20 308–675

Service

Tools Required

D

Torque wrench

D Phillips screwdriver

D

O-ring pick

D

Rubber mallet

Repairing the Air Valve

Disassembly

WARNING



1.

Relieve the pressure.

2.

Remove the air valve from pump (see page 19).

3.

Remove the screw (15) and shift saddle (14).

See Fig. 11.

4.

Disassemble the link assembly, consisting of the actuator link (16), spacer (17), detent link (22), spring (3), stop (4), and valve cup (5).

5.

Remove the detent ball (8) and spring (6). The detent collar (7) is a press-fit and should not need removal; if it does require replacement, you should also replace the cover (2).

6.

Remove the reset shaft (21), o-ring (20) and washer (18).

7.

Clean all parts and inspect for wear or damage.

Replace as needed. See Reassembly, page 22.

NOTE: ALL PARTS SHOWN ARE INCLUDED

IN AIR VALVE KIT 239–952.

Apply grease (26

{

).

Torque oppositely and evenly to 7 to 9 in-lb (0.8 to 1.0 N-m).

16

17

22

21

18

20

2

15

14

8

6

7

19

3

4

5

Fig. 11

01431A

308–675 21

Service

Reassembly

1.

If the detent collar (7) was removed, carefully install a new collar in a new cover (2), using a rubber mallet. See Fig. 12.

2.

Grease the spring (6) and place it in the collar (7).

Grease the ball (8) and set it on the spring.

3.

Grease the o-ring (20) and install it in the hole (H) in the cover (2). See Fig. 12. Slide the washer (18) onto the blunt end of the reset shaft (21). Insert the shaft through the cover (2) until it seats.

4.

Grease the spring (3). Place the link stop (4) inside the spring.

Apply grease (26).

Bumps face up.

Reset shaft square must engage with square hole.

16

17

22

3

Apply grease (26).

Press fit with rubber mallet.

8

6

5

4

8

21

7

H

18

20

2

01437

Fig. 12

5.

Grease the detent link (22) and link spacer (17).

Assemble the detent link, link spacer, and actuator link (16) as shown in Fig. 13. The raised bumps on the links (22 and 16) must face up.

6.

Squeeze the spring (3) and install it and the stop

(4) in the link assembly. The spring tension will hold all these parts together. Grease the valve cup

(5) and install it in the link assembly as shown.

7.

Install the link assembly on the cover (2) so the pointed end of the reset shaft (21) fits through the holes in the links and the square part of the shaft engages the square hole. Make certain the bumps on the detent link (22) engage the ball (8).

2

7505A

Fig. 13

8.

Grease the inside surfaces of the shift saddle (14) and install it as shown in Fig. 14. Hold the link assembly firmly in place and install the screw (15).

Torque to 7 to 9 in-lb (0.8 to 1.0 N-m). Install the o-ring (19) on the cover (2).

9.

Reinstall the air valve as explained on page 19.

Apply grease (26).

Torque to 7 to 9 in-lb

(0.8 to 1.0 N-m).

14

15

22

5

19

21

2

7506A

Fig. 14

22 308–675

Service

Tools Required

Torque wrench

1/2” (13 mm) socket wrench

O-ring pick

Ball Check Valves (Acetal Pumps)

NOTE: A Fluid Section Repair Kit D03–211 is available. Parts included in the kit are marked with an asterisk, for example (301*). Use all the parts in the kit for the best results. Always replace the o-rings (108) with new ones whenever the old ones are removed.

WARNING



1.

Relieve the pressure. Disconnect all hoses.

Remove the pump from its mounting.

2.

Using a 1/2” socket wrench, remove the bolts

(104) and nuts (106) holding the top manifold (102) to the covers (101). Lift the manifold off the pump.

See Fig. 15.

3.

Remove the outer o-ring (108), ball guide (202), ball (301), seat (201), and inner o-ring (108) from each of the covers.

4.

Turn the pump over and remove the bolts (104), nuts (106), feet (107), and lower manifold (102).

5.

Remove the outer o-ring (108), seat (201), ball

(301), ball guide (202), and inner o-ring (108) from each of the covers (101).

6.


Replace parts as needed.

7.

Reassemble in the reverse order, following all notes in Fig. 15. Be sure the ball checks are assembled exactly as shown.

CAUTION

Do not over-torque the manifold bolts (104). Doing so may cause the nuts (106) to spin in the housings, damaging the cover (101).

1

2

3

4

5

Apply thread lubricant.

Flat side faces ball.

Beveled end up.

Torque to 35 to 55 in-lb

(3.9 to 6.2 N-m).

Do not over-torque.

Fig. 15

106

108*

202* 3

301*

201* 2

108*

102

107

104

1 4 5

102

108*

202* 3

301*

201*

108*

2

101

104

1 4 5

01435

308–675 23

Service

Tools Required

Torque wrench

One 7/16” (11 mm) and two 1/2” (13 mm) socket wrenches

Phillips screwdriver

O-ring pick

13/32” EZY-OUT bearing extractor

Rubber mallet

Vise with soft jaws

Diaphragm Repair

Disassembly

NOTE: A Fluid Section Repair Kit D03–211 is available. Parts included in the kit are marked with an asterisk, for example (401*). Use all the parts in the kit for the best results.

WARNING



1.

Relieve the pressure. Disconnect all hoses.

2.

Remove the air valve from the pump (see page

19).

3.

Remove the manifolds (102) and disassemble the ball check valves as explained on page 23. Always replace the o-rings (108) with new ones.

4.

Using a 7/16” socket wrench, remove the clamp nuts (113) and the grounding strip (112). Loosen the clamps (111) and slip them over the housing

(1). Pull the covers (101) off the pump, then remove the clamps from the housing. See the

Detail in Fig. 16.

5.

Using a 1/2” socket wrench on both outer diaphragm plates (103), unscrew one plate from the diaphragm shaft (23). Remove one diaphragm

(401), inner diaphragm plate (118), and o-ring

(404). Pull the opposite diaphragm assembly and the diaphragm shaft out of the pump housing (1).

See Fig. 16. Clamp the shaft in a vise with soft jaws and unscrew the outer plate (103), then disassemble the remaining diaphragm assembly.

6.

Inspect the diaphragm shaft (23) for wear or scratches. If it is damaged, check the bearings

(402) also. Replace parts as needed. To remove the bearings, place a 13/32 EZY-OUT in a vise.

Position the pump housing (1) over the EZY-OUT

(see Fig. 16). Turn the housing in the direction shown by the arrows to remove the bearing.

7.

Hook the shaft seals (403) with an o-ring pick and pull them out of the housing (1).

8.


Replace parts as needed.

Reassembly

1.

Install the shaft seals (403*) so the lips face into the housing (1). Using a rubber mallet, carefully drive the bearings (402*) flush into the housing so the holes face out. See Fig. 16.

2.

Grease the diaphragm shaft (23) and slide it into the housing (1). Install the o-rings (404*) in the grooves of the housing.

3.

Assemble the inner diaphragm plates (118), diaphragms (401*), and outer diaphragm plates

(103) as shown in Fig. 16. Torque the outer diaphragm plates to 35 to 55 in-lb (3.9 to 6.2 N-m), using a 1/2” socket wrench. Do not over-torque.

These parts must be assembled correctly.

CAUTION

Do not over-torque the outer diaphragm plates

(103). Doing so will damage the hex heads.

4.

When installing the covers (101), slip the clamps

(111) over the housing (1) before positioning the covers. See the Detail in Fig. 16. Engage the notches in the covers with the locator tabs on the housing, then position the clamps over both parts.

The clamp bolts should be on the air valve side of the housing, and pointing down toward the bottom of the pump. Install the grounding strip on the bolts. Apply thread lubricant to the bolts, then install the clamp nuts (113). Using a 7/16” socket wrench, torque the nuts to 50 to 60 in-lb (5.6 to 6.8

N-m).

5.

Reassemble the ball check valves and manifolds as explained on pages 23. Always install new o-rings (108*).

6.

Reinstall the air valve, using the six mounting screws (15). See Fig. 10.

24 308–675

Service

1

2

3

4

7

8

5

6

Grease shaft.

Apply thread lubricant.

Flat side faces ball.

Beveled end up.

Lips face into housing.

Round side must face toward diaphragm.



9 Do not over-torque.

10

Notches must engage tabs.

1

102

*108

101

10

113 8

111

1

2

01440

DETAIL OF CLAMPS AND COVERS

404*

112

23 1 118

*404

*401

2

8

111

113

*108

103 7

Acetal Model Shown

1

FLUID SIDE AIR SIDE

403* 5

402*

103

7

9

*401

Fig. 16

118 6 23 1

CUTAWAY VIEW OF DIAPHRAGM

ASSEMBLIES IN PUMP HOUSING

13/32 IN. EZY-OUT

01443

01442

DETAIL OF BEARING REMOVAL USING EZY-OUT

308–675 25

106

202* 4

301*

201* 3

102

107

104

2 7

9

01441

2

104

7

9

202* 4

301*

201* 3

101

1

403* 5

402*

Parts Drawing for Gun Washer

23

27

Reference

Fluid

Manifold

Detail

F

F

Pump Ground

Bar Detail

Ref. A

33

NOTE: The circled letters indicate the continuation points of illustrations of tubes or wires.

26

5

14

28

13

E

C

D

8

F

A

B

C

F

B

A

12

1

D E

F

4 6

F

F

39

15

16

32

37

2

24

03311

26 308–675

Parts List for Gun Washer

Ref.

No.

Part No.

Description Qty.

Ref.

No.

Part No.

Description

6

8

12

13

4

5

1

2

513–291 OUTLET TUBE, pump

512–803 SWITCH, air cut-off

513–294 INTAKE TUBE, pump

512–804 BLOCK, reset valve

D31–211 PUMP, Husky 307

512–838 REGULATOR, air filter

512–829 FILTER, fluid inlet

112–873 VALVE, fluid drain; brass

14

15

16

17

112–875 VALVE, 3-way

512–871 WIRE, grounding

103–538 CLAMP, grounding

512–799 NOZZLE, spray; plastic

18

19

512–800 GUN SUPPORT, long; brass

112–847 GUN SUPPORT, short; brass

20 512–802 TRIGGER LOCK, wire; stainless steel 3

21 512–835 ADAPTER, gun fluid inlet; brass 3

2

1

1

13

1

1

1

1

1

1

1

1

1

1

Qty.

28

32

33

37

23

24

26

27

39

40

41

42

513–284 GASKET, lid,

512–868 SHOCK ABSORBER

110–567 STAND, gun washer

186–527 LABEL, warning, gun washer

513–049 JUMPER, ground

513–285 ROD, lid opener

112–214 ELBOW, inlet filter

513–305 ROD, trip

512–866 FOOT PEDAL ASSY.

112–695 COUPLER, male;

112–696

112–851

Includes cable & 1 snap ring

COUPLER, female

SNAP RING

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

1

1

1

1

1

1

4

1

1

1

1

1

Fluid Manifold Detail

20

17

21

19

40

41

18

42

18

Ref. A

06270

308–675 27

10

15

Parts Drawing for Pump

1

11

23

12

9

{

13

{

402*

403*

118

*404

27

29

29

28

111

112

113

Y 109

401* 103

{

15

{

14

{ 16

{

17

{ 22

{

21

{

18

{ 20

{

2

5

{

8

{

6 {

19

{

7 {

01431A

{

3

{

4

28 308–675

106

108*

202*

301*

201*

108*

102

107

104

01429A

104

102

108*

202*

301*

201*

108*

101

Ref.

No.

Part No.

Description

Parts List for Pump

Qty.

Ref.

No.

Part No.

Description

1

6 {

7 {

8 {

9

{

2 {

3 {

4 {

5 {

10

192–675

187–728

187–730

111–629

CUP, valve; acetal

SPRING, compression; sst

COLLAR, detent; sst

BALL, detent; carbide

11

12

27

28

111–881

187–719 SEAL, plate, valve; buna-N;

100–179

100–264

1/4–20; 0.375 in. (9.5 mm) long 1

MUFFLER

NUT, hex; 10–24;

SCREW; 10–24;

1

1

13 187–720 PLATE, valve; sst;

14

{

187–718 SADDLE, shift; acetal

15

{

111–630 SCREW, thread-forming;

1

1

10–14 size; 0.75 in. (19 mm) long 7

16 { 187–724 LINK, actuator; sst 1

17 { 188–175 SPACER, link; acetal

18 { 111–750 WASHER, plain; sst

19 { 111–624 O-RING; buna-N

20 { 111–625 O-RING; buna-N

21 { 187–727 SHAFT, reset; sst

22 { 192–526 LINK, detent; sst;

1

1

1

1

1

1

23 187–717 SHAFT, diaphragm; sst;

26 { 111–920 GREASE, general purpose;

1

0.375 oz. (10.5 g); not shown 1

1

29

187–705

187–706

187–722

187–853

HOUSING, center; polypropylene 1

COVER, air valve; polypropylene

SPRING, compression; sst

STOP, link; acetal

187–726 BEARING, link; acetal;

111–631 SCREW, thread-forming;

1

0.31 in. (8 mm) long 1

100–718 LOCKWASHER, int. tooth; no. 10 1

1

1

1

1

1

1

1

Qty.

101 187–701 COVER, fluid; acetal with conductive sst fibers 2

102 235–337 MANIFOLD; acetal; with conductive sst fibers

103 187–711 PLATE, fluid side; acetal

104 111–634 BOLT; 5/16–18;

2

2

2.25 in. (57 mm) long

106 108–946 NUT; 5/16–18

107 187–721 FEET 2

108 111–603 O-RING; PTFE

R

8

109

Y

187–732 LABEL, warning 1

111 187–820 CLAMP 2

8

8

112 187–821 STRIP, grounding

113 112–499 NUT, clamp; 1/4–28

118 186–265 PLATE, air side; sst 2

201* 187–709 SEAT; acetal 4

202* 187–707 GUIDE; acetal 4

301* 111–626 BALL; PTFE R 4

401* 187–716 DIAPHRAGM; PTFE R 2

402* 183–019 BEARING; acetal 2

403* 108–641 PACKING, u-cup; buna-N

404* 166–071 O-RING; buna-N

1

2

2

2

* Pump Repair Kit D03–211 contains these parts. Kit may be purchased separately .

{ Air Valve Kit 239–952 contains these parts. Kit may be purchased separately. The kit includes only one screw

(15), and a tube of grease (26).

Y Replacement Danger and W arning labels, tags and cards are available at no cost.

Use only GENUINE GRACO PARTS AND ACCESSORIES.

308–675 29

Technical Data

Maximum fluid working pressure . . . . . . . . . . . . 100 psi

(0.7 MPa, 7 bar)

Air pressure operating range . . . . . . . . . . 25 to 100 psi

(173 kPa to 0.7 MPa, 1.7 to 7 bar)

Maximum air consumption

Typical noise level (at 70 psi, 1 gpm)

Operating temperature range

Wetted parts

. . . . . . . . . . . . . .

Maximum noise level (100 psi, at full flow)

. . . . . . . . .

. . . . . . . . . .

5.5 SCFM

. . . . 85 dBa

78 dBa

40 to 150 F

(4.4 to 65.5 C)

. . . . . . . . . . . . . . . . . . . . . . . Stainless Steel,

Brass, Acetal, PTFE

Approximate dry weight . . . . . . . . . . . .

Tank, lid, and fluid manifold material

Fluid drain valve

Air inlet

1 in. npt(m)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum tank capacity . . . . . . . . . .

78 lbs. (35.4 kg)

. . . stainless steel

. . . . . . . . . . . . . . . . . . . . . .

1/4 npt(f)

5 gallons (19 liters)

.

E

Dimensions

03299

A

19.25

(489)

Measurements, inches (mm)

B with lid closed

B with lid opened

C D

40.5

(1029)

55.00

(1397)

23.00

(584)

18.00

(457)

E

24.5

(622)

30 308–675

Notes

308–675 31

Manual Change Summary

This manual went from Rev. A to Rev. B to make the following changes:

Air Valve Kit 224–820 is replaced by Air Valve Kit 239–952. See Fig. 11 on page 21.

The torque specification on the air valve screw (15) is changed. See step 8 and Fig. 14 on page 22.

Graco Standard Warranty

Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor 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 procedures concernées.

Graco Phone Number

TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:

1–800–367–4023 Toll Free

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.

32 308–675

Sales Offices: Minneapolis, Detroit, Los Angeles

Foreign Offices: Belgium, Canada, England, Korea, France, Germany, Hong Kong, Japan

GRACO INC.

P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

http://www.graco.com

PRINTED IN U.S.A. 308–675 October 1996, Revised December 1997

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