Graco 307044H DIVORCED DESIGN, 55 GALLON DRUM SIZE, 2Ž npt BUNG MOUNTING 5:1 MONARK PUMP Owner's Manual

INSTRUCTIONS–PARTS LIST
307–044
This manual contains IMPORTANT
WARNINGS AND INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
DIVORCED DESIGN, 55 GALLON DRUM SIZE, 2” npt BUNG MOUNTING
5:1 RATIO MONARK PUMP
900 psi (63 bar) MAXIMUM FLUID WORKING PRESSURE
180 psi (12 bar) MAXIMUM AIR INPUT PRESSURE
Model 218–956, Series B
With PTFE Packings
TABLE OF CONTENTS
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 3
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 6, 7
Service
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . 9
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 11
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
Toll–Free Graco Phone Numbers . . . . . . . . . Back Cover
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Rev H
Supersedes G
SAFETY WARNINGS
HIGH PRESSURE FLUID CAN CAUSE SERIOUS INJURY. FOR PROFESSIONAL USE ONLY.
OBSERVE ALL WARNINGS. Read And Understand All Instruction Manuals Before Operating Equipment.
FLUID INJECTION HAZARD
General Safety
Tip Guard (only on spray guns)
NEVER point the gun/valve at anyone or at any part of the body. NEVER
put hand or fingers over the spray tip/nozzle. NEVER try to “blow back”
paint; this is NOT an air spray system.
Spray Tip/Nozzle Safety
This equipment generates very high fluid pressure. Spray from the gun/
valve, leaks or ruptured components can inject fluid through your skin
and into your body and cause extremely serious bodily injury, including
the need for amputation. Also, fluid injected or splashed into the eyes or
on the skin can cause serious damage.
ALWAYS have the tip guard in place on the spray gun when spraying.
ALWAYS follow the Pressure Relief Procedure, right, before cleaning
or removing the spray tip/nozzle or servicing any system equipment.
NEVER try to stop or deflect leaks with your hand or body.
ALWAYS have the tip guard in place on the spray gun while spraying. The
tip guard alerts you to the fluid injection hazard and helps reduce, but
does not prevent, the risk of accidentally placing your fingers or any part
of your body close to the spray tip.
Use extreme caution when cleaning or changing spray tips/nozzles. If the
spray tip/nozzle clogs while spraying/dispensing, engage the gun/valve
safety latch immediately. ALWAYS follow the Pressure Relief Procedure and then remove the spray tip/nozzle to clean it.
NEVER wipe off build–up around the spray tip/nozzle until pressure is
fully relieved and the gun/valve safety latch is engaged.
Be sure equipment safety devices are operating properly before each
use.
Medical Alert––Airless Spray Wounds
If any fluid appears to penetrate your skin, get EMERGENCY MEDICAL
CARE AT ONCE. DO NOT TREAT AS A SIMPLE CUT. Tell the doctor
exactly what fluid was injected.
Note to Physician: Injection in the skin is a traumatic injury. It is important to treat the injury surgically as soon as possible. Do not
delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the blood stream. Consultation with a
plastic surgeon or reconstructive hand surgeon may be advisable.
Spray Gun/Dispensing Valve Safety Devices
Be sure all gun/valve safety devices are operating properly before each
use. Do not remove or modify any part of the gun/valve; this can cause a
malfunction and result in serious bodily injury.
Safety Latch
Whenever you stop spraying/dispensing, even for a moment, always set
the gun/valve safety latch in the closed or “safe” position, making the gun/
valve inoperative. Failure to set the safety latch can result in accidental
triggering of the gun/valve.
Trigger Guard (only on spray guns)
Never operate the spray gun with the trigger guard removed. This guard
helps prevent the spray gun from triggering accidentally if it is dropped or
bumped.
Diffuser (only on spray guns)
The spray gun diffuser breaks up spray and reduces the risk of fluid injection when the tip is not installed. Check the diffuser operation regularly.
Follow the Pressure Relief Procedure, to the right, then remove the
spray tip. Aim the spray gun into a grounded metal pail, holding the spray
gun firmly to the pail. Using the lowest possible pressure, trigger the
spray gun. If the fluid emitted is not diffused into an irregular stream, replace the diffuser immediately.
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including fluid injection,
splashing in the eyes or on the skin, or injury from moving parts,
always follow this procedure whenever you shut of f the pump,
when checking or servicing any part of the spray/dispensing system, when installing, cleaning or changing spray tips/nozzles, and
whenever you stop spraying/dispensing.
1. Engage the gun/valve safety latch.
2. Close the pump air regulator.
3. Close the bleed–type master air valve (required in
air–powered systems).
4. Disengage the gun/valve safety latch.
5. 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.
6. Engage the gun/valve safety latch.
7. Open the drain valve (required in your system), having a container ready to catch the drainage.
8. Leave the drain valve open until you are ready to spray/dispense again.
If you suspect that the spray tip/nozzle or hose is completely
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.
EQUIPMENT MISUSE HAZARD
General Safety
System Pressure
Any misuse of the spray/dispensing equipment or accessories, such as
overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result
in fluid injection, splashing in the eyes or on the skin, or other serious bodily injury, or fire, explosion or property damage.
The 5:1 ratio Monark Pump develops 900 psi (63 bar) MAXIMUM WORKING PRESSURE at 180 psi (12 bar) MAXIMUM INPUT AIR PRESSURE. NEVER exceed this air pressure to the motor. NEVER exceed the
stated maximum working pressure of the pump or the lowest rated component in your system.
NEVER alter or modify any part of this equipment; doing so could cause it
to malfunction.
Be sure that all accessories you add to the system are properly rated to
withstand the maximum air and fluid working pressures of this system.
CHECK all spray/dispensing equipment regularly and repair or replace
worn or damaged parts immediately.
Fluid Compatibility
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.
307–044
BE SURE that all fluids and solvents used are chemically compatible with
the wetted parts shown in the TECHNICAL DATA on the back cover. Always read the manufacturer’s literature before using fluid or solvent in
this pump.
HOSE SAFETY
High pressure fluid in the hoses can be very dangerous. If the hose develops a leak, split or rupture due to any kind of wear, damage or misuse, the
high pressure spray emitted from it can cause a fluid injection injury or
other serious bodily injury or property damage.
ALL FLUID SPRA Y HOSES MUST HA VE SPRING GUARDS ON
BOTH ENDS! The spring guards help protect the hose from kinks or
bends at or close to the coupling which can result in hose rupture.
TIGHTEN all fluid connections securely before each use. High pressure
fluid can dislodge a loose coupling or allow high pressure spray to be
emitted from the coupling.
NEVER use a damaged hose. Before each use, check the entire hose for
cuts, leaks, abrasion, bulging cover, or damage or movement of the hose
couplings. If any of these conditions exist, replace the hose immediately.
DO NOT try to recouple high pressure hose or mend it with tape or any
other device. A repaired hose cannot safely contain the high pressure
fluid.
HANDLE AND ROUTE HOSES CAREFULLY. Do not pull on hoses to
move equipment. Do not use fluids which are not compatible with the inner tube and cover of the hose. DO NOT expose Graco hoses to temperatures above 82_ C (180_ F) or below –40_ C (–40_ F).
Hose Grounding Continuity
Proper hose grounding continuity is essential to maintaining a grounded
spray system. Check the electrical resistance of your air and fluid hoses
at least once a week. If your hose does not have a tag on it which specifies the maximum electrical resistance, contact the hose supplier or
manufacturer for the maximum resistance limits. Use a resistance meter
in the appropriate range for your hose to check the resistance. If the resistance exceeds the recommended limits, replace it immediately. An ungrounded or poorly grounded hose can make your system hazardous.
Also, read FIRE OR EXPLOSION HAZARD, below.
FIRE OR EXPLOSION HAZARD
Static electricity is created by the flow of fluid through the pump and hose.
If every part of the spray/dispensing equipment is not properly grounded,
sparking may occur, and the system may become hazardous. Sparking
may also occur when plugging in or unplugging a power supply cord.
Sparks can ignite fumes from solvents and the fluid being sprayed, dust
particles and other flammable substances, whether you are spraying/dispensing indoors or outdoors, and can cause a fire or explosion and serious bodily injury and property damage. Do not plug in or unplug any
power supply cords in the spray/dispensing area when there is any
chance of igniting fumes still in the air.
If you experience any static sparking or even a slight shock while using
this equipment, STOP SPRAYING IMMEDIATELY. Check the entire system for proper grounding. Do not use the system again until the problem
has been identified and corrected.
Grounding
9.
To maintain grounding continuity when flushing or relieving pressure, always hold a metal part of the gun/valve firmly to the side of a
grounded metal pail, then trigger the gun/valve.
To ground the pump, loosen the grounding lug locknut (W) and
washer (X). Insert one end of a 12 ga (1.5 mm@) minimum ground
wire (Y) into the slot in lug (Z) and tighten the locknut securely. See
Fig 1. Connect the other end of the wire to a true earth ground. See
the ACCESSORIES section to order a ground wire and clamp.
W
X
Z
To reduce the risk of static sparking, ground the pump, object being
sprayed, and all other spray/dispensing equipment used or located in the
spray/dispensing area. CHECK your local electrical code for detailed
grounding instructions for your area and type of equipment. BE SURE to
ground all of this spray/dispensing equipment:
1.
Pump: use a ground wire and clamp as shown in Fig 1.
2.
Air hoses: use only grounded air hoses.
3.
Fluid hoses: use only grounded fluid hoses.
4.
Air compressor: follow manufacturer’s recommendations.
5.
Spray gun/dispensing valve: grounding is obtained through connection to a properly grounded fluid hose and pump.
Y
Fig 1
6.
Fluid supply container: according to your local code.
7.
Object being sprayed: according to your local code.
8.
All solvent pails used when flushing, according to your local code.
Use only metal pails, which are conductive, placed on a grounded
surface. Do not place the pail on a nonconductive surface, such as
paper or cardboard, which interrupts the grounding continuity.
Flushing Safety
Before flushing, be sure the entire system and flushing pails are properly
grounded. Refer to Grounding, at left. To reduce the risk of fluid injection
injury, static sparking, or splashing, follow the
Pressure Relief
Procedure on page 2, and remove the spray tip/nozzle from the
gun/valve before flushing. Always use the lowest possible fluid pressure,
and maintain firm metal–to–metal contact between the gun/valve and the
pail during flushing to reduce the risk of fluid injection injury, static
sparking and splashing.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers or other body parts. The
air motor piston (located behind the air motor plates) moves when air is
supplied to the motor. Therefore, NEVER operate the pump with the air
motor plates removed. KEEP CLEAR of moving parts when starting or
operating the pump. Before checking or servicing the pump, follow the
Pressure Relief Procedure on page 2 to prevent the pump from starting
accidentally.
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards – particularly the General Standards, Part 1910, and the Construction Standards, Part 1926 – should be consulted.
307–044
3
TYPICAL INSTALLATION
MAIN AIR SUPPLY LINE
Y
G
H
J
C
A
D
E
B
KEY
A
B
C
D
E
F
G
H
J
Y
4
307–044
Bleed–Type Master Air Valve (required, for pump)
Fluid Drain Valve (required)
Air Line Lubricator
Pump Air Regulator
Air Line Filter
Bleed–Type Master Air Valve (for accessories)
Grounded Air Line
Grounded Fluid Line
Pump Runaway Valve
Ground Wire (required)
F
INSTALLATION
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and
the parts drawing.
See page 14 for accessories available from Graco. If you supply your own accessories, be sure
they are adequately sized and pressure–rated to
meet the system’s requirements.
The Typical Installation shown on page 4 is only a guide
for selecting and installing system components and accessories. Contact your Graco representative or Graco
Technical Assistance (see back page) for assistance in
designing a system to suit your particular needs.
SYSTEM ACCESSORIES
Refer to the Typical Installation drawing on page 4.
WARNING
Two accessories are required in your system: a
bleed–type master air valve (A) and a fluid drain
valve (B). These accessories help reduce the risk
of serious bodily injury including fluid injection,
splashing in the eyes or on the skin, and injury from
moving parts if you are adjusting or repairing the
pump.
The bleed–type master air valve relieves air
trapped between this valve and the pump after the
air regulator is shut off. Trapped air can cause the
pump to cycle unexpectedly. Locate the valve close
to the pump.
The fluid drain valve assists in relieving fluid pressure in the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may not be
sufficient.
Mounting Accessories
Mount the pump to suit the type of installation planned.
The pump dimensions and mounting hole layout are
shown on page 15.
The bung adapter has 2” npt threads. Install the pump in
the drum cover until it is 1/2” (13 mm) from the bottom of
the drum, then tighten the bung adapter.
Air and Fluid Hoses
Air Line
Install the following accessories in the order shown in the
Typical Installation, using adapters as necessary:
A pump runaway valve (J) senses when the pump is
running too fast and automatically shuts off the air to
the motor. A pump which runs too fast can be seriously damaged. Install closest to the pump air inlet.
An air line lubricator (C) provides automatic air motor lubrication.
A bleed–type master air valve (A) is required in your
system to relieve air trapped between it and the air
motor when the valve is closed (see the WARNING at
left). Be sure the bleed valve is easily accessible from
the pump, and is located downstream from the air
regulator.
An air regulator (D) controls pump speed and outlet
pressure by adjusting the air pressure to the pump.
Locate the regulator close to the pump, but upstream
from the bleed–type master air valve.
An air line filter (E) removes harmful dirt and moisture from the compressed air supply.
A second bleed–type air valve (F) isolates the air
line accessories for servicing. Locate upstream from
all other air line accessories.
Fluid Line
A fluid drain valve (B) is required in your system to relieve fluid pressure in the hose and gun (see the WARNING at left). Install the drain valve pointing down, but so
the handle points up when opened.
GROUNDING
WARNING
Before operating the pump, ground the system as
explained under FIRE OR EXPLOSION HAZARD
and Grounding on page 3.
Be sure all air and fluid hoses are properly sized and
pressure–rated for your system. Use only grounded air
and fluid hoses. Fluid hoses must have spring guards on
both ends.
Connect a grounded fluid hose (H) to the pump’
npt(f) fluid outlet.
s 3/4
Connect a grounded 3/8 in. I.D. (minimum) air hose (G) to
the pump’s 3/8 npt(f) air inlet.
307–044
5
OPERATION
WARNING
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including
fluid injection, splashing in the eyes or on the skin, or
injury from moving parts, always follow this procedure whenever you shut off the pump, when checking or servicing any part of the spray/dispensing system, when installing, cleaning or changing spray
tips/nozzles, and whenever you stop spraying/dispensing.
1. Engage the spray gun/dispensing valve safety
latch.
2. Close the pump air regulator.
3. Close the bleed–type master air valve (required
in your system).
4. Disengage the gun/valve safety latch.
5. 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.
6. Engage the gun/valve safety latch.
7. Open the drain valve (required in your system),
having a container ready to catch the drainage.
8. Leave the drain valve open until you are ready to
spray/dispense again.
If you suspect that the spray tip/nozzle or hose is
completely 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 the Pump Before Using
The pump is tested with lightweight oil, which is left in to
protect the pump parts. To prevent contamination of fluid,
flush the pump with a compatible solvent before using it.
WARNING
For your safety , read the warning section, FIRE
OR EXPLOSION HAZARD on page 3 before flushing, and follow all the recommendations given there.
Fill the wet–cup 1/2 full with Graco Throat Seal Liquid
(TSL) or a compatible solvent. Keep the cup half–filled at
all times to help prevent the fluid you are pumping from
drying on the exposed displacement rod and damaging
the throat packings.
6
307–044
Starting and Adjusting the Pump
See the TYPICAL INSTALLATION on page 4. Be sure
the air regulator (D) and bleed–type master air valve (A)
are closed. DO NOT INSTALL THE SPRAY TIP YET!
Hold a metal part of the spray gun/dispensing valve firmly
to the side of a grounded metal pail and hold the trigger
open. Then open the pump’s bleed–type master air valve
(A). Now slowly open the air regulator (D) until the pump
starts, about 40 psi (2.8 bar).
Cycle the pump slowly until all the air is pushed out and
the pump and hoses are fully primed. Release the gun/
valve trigger and engage the safety latch. The pump
should stall against pressure when the trigger is released.
Follow the Pressure Relief Procedure Warning at left,
then install the spray tip in the gun.
With the pump and lines primed, and with adequate air
pressure and volume supplied, the pump will start and
stop as the gun/valve is opened and closed. In a circulating system, the pump will run continuously and will speed
up or slow down as the system demands until the air supply is shut off. Always use the lowest air pressure necessary to get the desired results. Higher pressures waste
fluid and cause premature wear of the pump packings
and spray tip/nozzle.
WARNING
NEVER exceed the MAXIMUM WORKING PRESSURE of the lowest rated component in the system,
to reduce the risk of component rupture which can
cause serious bodily injury, including fluid injection
or splashing of fluid in the eyes or on the skin.
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. A pump runaway valve
(J), which shuts off the air supply to the pump if the pump
accelerates beyond the pre–set speed, is available. See
the Typical Installation on page 4 and ACCESSORIES
on page 14. 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, refill the container and prime the
pump and the lines with fluid, or flush and leave it filled
with a compatible solvent. Be sure to eliminate all air from
the fluid system.
MAINTENANCE
Check Valve Adjustment
The piston and intake check valves are set for medium
viscosity fluids. To adjust the valves, first follow the Pressure Relief Procedure Warning on page 6, then disassemble the pump as described in the SERVICE section.
Remove the ball stop pin (17) from the intake valve seat
(30). Move the pin to a higher set of holes to increase the
ball travel for heavier fluids, or to a lower set of holes to
decrease the ball travel for lighter fluids.
To adjust the piston ball travel, loosen the locknut (3) and
turn the piston (11) counterclockwise to increase the ball
travel and clockwise to decrease the ball travel. For medium viscosity fluid, the ball travel should be 0.19” (4.8
mm). See Fig 2.
37
3
FOR MEDIUM
VISCOSITY)
19” (4.8 mm)
Shutdown and Care of the Pump
For overnight shutdown, follow the Pressure Relief Procedure Warning on page 6. Always stop the pump at the
bottom of its stroke to prevent the fluid from drying on the
exposed displacement rod and damaging the throat
packings.
Keep the packing nut/wet–cup 1/2 filled with Graco
Throat Seal Liquid (TSL) or compatible solvent, to help
prolong the packing life. Adjust the packing nut (35)
weekly so it is just tight enough to prevent leakage; do not
overtighten. Follow the Pressure Relief Procedure
Warning on page 6 before adjusting the packing nut.
Then use a spanner wrench or a 0.25” (6.3 mm) diameter
rod to tighten the nut. See Fig. 3.
35
0.25”
(6.3 mm)
DIA. ROD
11
4
Fig 3
If you are pumping fluid which dries, hardens or sets up,
flush the system with a compatible solvent as often as
necessary to prevent a buildup of the fluid in the pump or
hoses.
17
26
PIN (17) IN
MIDDLE HOLES
FOR MEDIUM
VISCOSITY)
19” (4.8 mm)
5
CAUTION
Never leave the pump or hoses filled with water or
air. To help prevent corrosion, flush the water and all
air out of the system and leave it filled with mineral
spirits or an oil–based solvent. Be sure to follow the
Pressure Relief Procedure Warning on page 6 after flushing.
Flushing
To reduce the risk of fluid injection injury, static sparking,
or splashing, follow the Pressure Relief Procedure
Warning on page 6, and remove the spray tip (airless
spray guns or spray valves only) before flushing. Hold a
metal part of the gun/valve firmly to the side of a
grounded metal pail and use the lowest possible fluid
pressure when flushing.
30
Fig 2
15
Lubrication
The accessory air line lubricator (C) provides automatic
air motor lubrication. For daily , manual lubrication, disconnect the regulator, place about 15 drops of light machine oil in the pump air inlet, reconnect the regulator and
turn on the air supply to blow oil into the motor.
307–044
7
NOTES:
8
307–044
TROUBLESHOOTING CHART
WARNING
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including
fluid injection, splashing in the eyes or on the skin, or
injury from moving parts, always follow this procedure
whenever you shut of f the pump, when checking or
servicing any part of the spray/dispensing system,
when installing, cleaning or changing spray tips/
nozzles, and whenever you stop spraying/dispensing.
1. Engage the spray gun/dispensing valve safety
latch.
2. Close the pump air regulator.
3. Close the bleed–type master air valve (required in
your system).
4. Disengage the gun/valve safety latch.
5. 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.
6. Engage the gun/valve safety latch.
7. Open the drain valve (required in your system),
having a container ready to catch the drainage.
8. Leave the drain valve open until you are ready to
spray/dispense again.
If you suspect that the spray tip/nozzle or hose is completely 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.
NOTE: CHECK ALL POSSIBLE PROBLEMS AND SOLUTIONS BEFORE DISASSEMBLING PUMP.
PROBLEM
Pump fails to operate
CAUSE
SOLUTION
Restricted line or inadequate air supply
Clear line; increase air supply.
Insufficient air pressure; closed or
clogged air valves, etc.
Open air valve, clean if necessary.
Exhausted fluid supply
Refill; purge all air from pump and fluid lines.
Damaged air motor
Service air motor (see 307–043).
Restricted line or inadequate air supply
Clear line; increase air supply.
Insufficient air pressure; closed or
clogged air valves, etc.
Open air valve, clean if necessary.
Exhausted fluid supply
Refill; purge all air from pump and fluid lines.
Clogged fluid line, valves, gun, etc.
Clear*.
Fluid check valves need adjustment
Adjust (see page 7).
Loose packing nut or worn throat
packings
Tighten packing nut (see page 7);
replace throat packings.
Damaged cylinder o–rings
Replace.
Pump operates but output
low on down stroke
Held open or worn intake valve
Clear; service.
Damaged cylinder o–rings
Replace.
Pump operates but output
low on up stroke
Held open or worn fluid piston valve
or packings
Clear; service.
Erratic or accelerated
operation
Exhausted fluid supply
Refill; purge all air from pump and fluid lines.
Fluid check valves need adjustment
Adjust (see page 7).
Held open or worn intake valve
Clear; service.
Held open or worn fluid piston valve
or packings
Clear; service.
Pump operates but output
low on both strokes
*
To determine if the fluid hose or gun is obstructed, follow the Pressure Relief Procedure Warning above. Disconnect the fluid
hose and place a container at the pump fluid outlet to catch any fluid. Turn on the air just enough to start the pump (about 20–40
psi [1.4–2.8 bar]). If the pump starts when the air is turned on, the obstruction is in the fluid hose or gun.
307–044
9
SERVICE
Before you repair the pump:
1. Be sure you have all the necessary repair parts on
hand to reduce down time.
2. Packing repair kit 208–520 is available. Refer to the
parts list on page 13. For the best results, use all the
new parts in the kit. Reference numbers with two asterisks, for example (13**), indicate that a part is included in the repair kit.
3. Always be sure to replace the glands when replacing
the packings.
4. Clean all parts as you disassemble the pump, and inspect them for wear or damage. Replace parts as
needed. Scoring or irregular surfaces on the displacement rod or polished inner wall of the cylinder
cause premature packing wear and leaking. Check
these parts by rubbing a finger on the surface and by
holding the parts up to a light at an angle.
Repair
1. Flush the pump if possible. Stop the pump at the bottom of its stroke. Follow the Pressure Relief Procedure Warning on page 9. Disconnect the hoses. Remove the pump from its mounting.
2. Unscrew the intake valve housing (15). Remove the
valve seat (30), pin (17), and ball (5). See Fig 4.
3. Apply very low air pressure to the motor to force the
piston to the bottom of the stroke.
NOTE: For air motor parts and service information, refer
to manual 307–043.
4. Unscrew the cylinder (26) and slide it down just past
the coupling nut (25). See Fig 5.
5. Unscrew the coupling nut (25) and push the piston
assembly through the bottom of the cylinder. See Fig
5.
6. Hold the piston housing (11) with a wrench and screw
the piston seat (10) out of the housing.
7. Remove the ball, washers, spreaders, packings,
spacers, and o–ring from the piston seat.
8. Assemble a washer (29), spreader (28), packing
(13**), o–ring (8**), spacer (14), packing (13**),
spreader (28), and washer (29) onto the piston seat
(10). See the Piston Detail in Fig 4 for the proper direction of each of these parts.
9. Place the ball (4) on the piston seat (10) and screw
the seat firmly into the piston housing (11).
10. Check the piston ball travel. For medium viscosity
fluid, the clearance should be 0.19” (4.8 mm). See
Fig 4. Refer also to Check Valve Adjustment on
page 7.
11. Remove the cotter pin (2) from the top of the displacement rod (27) and unscrew the rod. Remove
the tie rod nuts (6) and pull the pump housing (36) off
the tie rods (24). See Fig 5.
DETAIL OF PISTON
11
FOR MEDIUM
VISCOSITY
0.19 in. (4.8 mm)
4*
29
28
**13
LIPS MUST
FACE UP
14
8**
26
**13
17
LIPS MUST
FACE DOWN
28
29
10
15
30 5
Fig 4
10
307–044
2
9
24
12. Loosen the packing nut (35) and push the rod (27)
through the bottom of the pump housing (36). Check
the outer surface of the rod for scoring or wear.
13. Remove the packing nut (35), glands (23, 21), bearings (22) and packings (19) from the pump housing.
27
35
22**
23**
19**
6
21**
36
20**
26
33
25
14. See Fig 5. install the male gland (21**). Then install
the four PTFE v–packings (19**) one at a time, making sure the lips of the v–packings are facing down.
Install the female gland (23**) and the two bearings
(22**). The bearings should have a gap of
0.020–0.050 in. (0.508–1.27 mm) when installed. Install the packing nut (35) loosely.
15. Lubricate the displacement rod (27) and slide it down
through the top of the pump housing (36).
16. Clamp the pump cylinder (26) in a vise. Inspect the
inner surface for scoring or wear . Lubricate the top
inside diameter of the cylinder with light machine oil.
17. A special assembly tool, Graco Part No. 168–085
should be used to install the piston assembly into the
cylinder. This tool is made from 0.016” (0.41 mm)
shim stock and helps protect the edges of the packings from damage during reassembly. Place the tool
around the piston packings as shown in Fig 6. Start
the bottom packings (13a) into the cylinder and then
remove the tool.
13a
37
26
3
26
4
11
SPECIAL TOOL
PART NO. 168–085
Fig 6
8**
10
17
19. Install the o–ring (9) around the top of the displacement rod (27). Position the pump housing (36) on the
tie rods (24). Screw the rod (27) into the motor and
install the pin (2). Screw the tie rod nuts (6) onto the
tie rods (24) and torque to 10–15 ft–lb (14–20 N.m).
20. Install a new o–ring (20) in the bottom of the pump
housing (36), then screw the cylinder (26) into the
housing.
21. Install the intake valve ball (5) in the valve seat (30).
insert the pin (17) in the proper set of holes (see
Check V alve Adjustment on page 7). Place the
seat in the valve housing (15) and screw the housing
firmly onto the cylinder.
15
30 5
Fig 5
18. Join the coupling nut (25) and displacement rod (27)
and tighten securely.
22. Reconnect the pump grounding wire if it was disconnected during service. Fill the wet–cup 1/2 full with
TSL or compatible solvent.
307–044 11
PARTS DRAWING
26
34
37
*9
25
*2
27
Ref. No. 1 includes
items 3–5, 8, 10–23,
25–30 and 35–37
3
11
4*
29
35
28
**13
LIPS MUST
FACE UP
**22
0.020–0.050 in.
(0.508–1.27 mm)
GAP WHEN
ASSEMBLED
24
TORQUE TO
10–15 ft–lb
(14–20 N.m)
36
23**
14
8**
**13
LIPS MUST
FACE DOWN
19**
28
LIPS OF
V–PACKINGS
MUST FACE
DOWN
29
21**
5*
10
30*
6
17
**20
15
33
12
307–044
PARTS LIST
Model 218–956, Series B
Includes items 1–37
REF PART
NO. NO.
1
220–465
Series B
2
100–103*
3
4
5
6
8
9
10
11
13
14
15
17
19
20
21
22
23
24
25
26
27
28
29
30
33
34
35
36
37
100–111
100–279*
101–178*
101–566
164–623**
156–082*
156–989
157–184
162–871**
158–857
159–839
160–726
162–866**
164–782**
164–837**
165–287**
165–288**
165–297
166–033
186–986
169–504
171–590
171–594
204–762*
222–308
205–997
208–312
208–313
208–314
*
DESCRIPTION
QTY
DISPLACEMENT PUMP
Includes items 3–5, 8, 10–23,
25–30, and 35–37
PIN, cotter; 0.12” (3.2 mm) dia.;
1.5” (38 mm) long
NUT, jam; 0.5–20
BALL, steel; 0.88” (22.4 mm) dia.
BALL, steel; 1.25” (31.8 mm) dia.
NUT, lock; 0.19 thd
O–RING; PTFE O–RING; nitrile rubber
SEAT, piston
HOUSING, piston
PACKING, cup; PTFE SPACER, packing
HOUSING, intake valve
PIN, stop
V–PACKING; PTFE O–RING; PTFE GLAND, male
BEARING; PTFE GLAND, female
ROD, tie; 4.75” (119 mm)
NUT, swivel
CYLINDER; stainless steel
ROD, displacement
SPREADER, packing
WASHER, backup
SEAT, intake valve
ADAPTER, bung; with screw
AIR MOTOR; see 307–043 for parts
NUT, packing
HOUSING, pump
ROD, piston
1
1
1
1
1
3
1
1
1
1
2
1
1
1
4
1
1
2
1
3
1
1
1
2
2
1
1
1
1
1
1
208–520 REPAIR KIT
Purchase kit separately.
Kit includes:
Ref No.
Qty
8
13
19
20
21
22
23
1
2
4
1
1
2
1
HOW TO ORDER PARTS
1
To be sure you receive the correct replacement parts, kits or
accessories, always give all of the information requested in the
chart below.
2. Check the parts list to identify the correct part number; do not use
the ref. no. when ordering.
3. Order all parts from your nearest Graco distributor.
6 digit
Part Number
Qty
Part Description
Recommended “tool box” spare parts. Keep on hand to reduce downtime.
** Included in Repair Kit 208–520.
307 numbers in descriptions refer to separate instruction manuals, supplied.
307–044
13
ACCESSORIES
USE GENUINE GRACO PARTS AND ACCESSORIES
Must be purchased separately.
GROUNDING CLAMP 103–538
GROUND WIRE 208–950
25 ft (7.6 m) long,
12 gauge (1.5 mm@)
BLEED–TYPE MASTER AIR VALVE 107–142
300 psi (21 bar) MAXIMUM WORKING PRESSURE
Relieves air trapped in the air line between the pump air
inlet and this valve when closed.
1/2 npt(m) inlet x 1/2 npt(f) outlet.
PUMP RUNAWAY VALVE 215–362
180 psi (12 bar) MAXIMUM WORKING PRESSURE
Shuts off air supply to the pump if the pump accelerates
beyond the pre–adjusted setting due to an empty supply
container, interrupted fluid supply to the pump, or excessive cavitation. 3/4 npt(f) inlet and outlet.
GROUNDED 1/2 in. (13 mm) BUNA–S AIR HOSE
175 psi (12 bar) MAXIMUM WORKING PRESSURE
Part No.
AIR LINE FILTER 106–148
250 psi (17.5 bar) MAXIMUM WORKING PRESSURE
Removes harmful moisture and contaminants from compressed air supply.
3/8 npt(f) inlet and outlet,
5 oz bowl capacity.
ID
Length
Thd. Size
214–650
1/2” (13 mm)
5 ft (1.5 m)
3/8 npt(m)
214–651
1/2” (13 mm)
17.5 ft (5.2 m)
3/8 npt(m)
214–655
1/2” (13 mm)
25 ft (7.6 m)
3/8 npt(m)
214–654
1/2” (13 mm)
50 ft (15.2 m)
3/8 npt(m)
214–653
1/2” (13 mm)
100 ft (30.4 m)
3/8 npt(m)
FLUID DRAIN VALVE
5000 psi (350 bar) MAXIMUM WORKING PRESSURE
Open to relieve fluid pressure in hose and gun.
AIR LINE LUBRICATOR 214–847
250 psi (17.5 bar) MAXIMUM WORKING PRESSURE
For automatic air motor lubrication.
3/8 npt inlet and outlet, 5 oz capacity.
AIR REGULATOR
300 psi (21 bar) MAXIMUM WORKING PRESSURE
0–200 psi (0–14 bar) Regulated Pressure Range.
202–858
202–156
3/8 npt(m) inlet; 1/2 npsm(f) outlet.
3/8 npt(f) inlet; 3/8 npt(f) outlet.
GRACO THROAT SEAL LIQUID
Non–evaporating solvent for wet–cup.
206–994
206–995
206–996
8 oz (0.24 liter)
1 quart (0.95 liter)
1 gallon (3.8 liter)
SPECIAL ASSEMBLY TOOL 168–085
Helps protect the piston packings from damage during
reassembly.
307–044
14
210–657
210–658
210–659
1/4 npt (mbe)
3/8 npt (mbe)
1/4 npt x 3/8 npt (mbe)
DRUM COVER 207–373
For mounting pump in open 55 gallon (200 liter) drum. Includes covered inspection port, lift handles, pump and
agitator gaskets, and provisions for mounting agitator
and Evenflor control.
PUMP CLAMP 204–858
For mounting pump in open 55 gallon (200 liter) drum.
DIMENSIONAL DRAWING
MOUNTING HOLE LAYOUT
TWO 0.31” (7.9 mm)
HOLES ON 5” (127 mm)
BOLT CIRCLE
4.38”
(111.3 mm)
DIA.
3/8 npt(f)
AIR INLET
2.5”
(64 mm)
54.281”
(1379 mm)
2” npt
BUNG
5.0”
(127 mm)
3/4 npt(f)
FLUID
OUTLET
42.75”
(1086 mm)
SERVICE INFORMATION
Listed below by the assembly changed are Old and New
parts.
Assembly
Changed Status
220–465
Displ.
Pump, to
Series B
Old
New
Ref
No.
Part No. Name
26
180–747 Cylinder
186–986 Cylinder
INTERCHANGEABILITY NOTE: New parts replace the
Old parts listed directly above them.
SERIES CHANGE NOTE: Model 218–956 Pump is advanced to Series B.
307–044
15
TECHNICAL DATA
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 psi (62 bar)
Maximum air input pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 psi (12.5 bar)
Pump cycles per 1 gallon (3.8 liters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maximum recommended pump speed . . . . . . . . . . 66 cycles per min; 2.5 gpm (9.5 liters/min)
Recommended speed for optimum pump life . . . . . . . . . . . . . . . . . . . . . . . . . 15–25 cycles/min;
0.5 to 0.9 gpm (1.9–3.3 liters/min)
Air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 8 scfm (0.23 m#/min)
at 1 gpm (3.8 liters/min) at 100 psi (7 bar) air pressure
Maximum operating temperature for displacement pump . . . . . . . . . . . . . . . . . . 250_F (121_C)
Maximum operating temperature for air motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200_F (93_C)
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carbon Steel; 304 Grade Stainless Steel;
Chrome Plating; PTFE r
PTFE
THE GRACO WARRANTY AND DISCLAIMERS
WARRANTY
Graco warrants all equipment manufactured by it 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. As purchaser’s sole remedy
for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the
equipment proven 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, 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 with Graco equipment of 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 claim. 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.
DISCLAIMERS AND LIMITATIONS
THE TERMS OF THIS WARRANTY CONSTITUTE PURCHASER’S SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF ANY OTHER WARRANTIES (EXPRESS OR IMPLIED), INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY NON–CONTRACTUAL LIABILITIES, INCLUDING PRODUCT LIABILITIES, BASED ON NEGLIGENCE OR STRICT LIABILITY.
EVERY FORM OF LIABILITY FOR DIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED. IN
NO CASE SHALL GRACO’S LIABILITY EXCEED THE AMOUNT OF THE PURCHASE PRICE. ANY ACTION FOR BREACH OF WARRANTY MUST
BE BROUGHT WITHIN TWO (2) YEARS OF THE DATE OF SALE.
EQUIPMENT NOT COVERED BY GRACO WARRANTY
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, WITH RESPECT TO ACCESSORIES, EQUIPMENT, MATERIALS, OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO.
These items sold, but not manufactured by Graco (such as electric motor, 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.
IMPORTANT PHONE NUMBERS
TO PLACE AN ORDER, contact your Graco distributor,
or call this number to identify the distributor closest to
you:
1–800–328–0211 Toll Free
FOR TECHNICAL ASSISTANCE, service repair information or assistance regarding the application of Graco
equipment: 1–800–543–0339 Toll Free
Factory Branches: Atlanta, Chicago, Dallas, Detroit, Los Angeles, West Caldwell (N.J.)
Subsidiary and Affiliate Companies: Canada; England; Switzerland; France; Germany; Hong Kong; Japan;
Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
16
307–044
PRINTED IN U.S.A. 307–044 11–70 Revised 4–91
3X7–044
Rev. L
Supersedes Rev. H and PCN K
Parts Change Notice
Some parts in Rev. H of manual 307–044 have changed but have not yet been changed in the
instruction manual. Please note the changes below and mark them in your manual or keep this
sheet with your manual.
Series
Letter
Change
Assembly No.
Model 218–956
Pump and Model
220–465
Displacement
Pump
D
Part That
Changed
Ref
No.
Part Description
Description of Change
208–313
or
205–999
(PCN K)
36
Outlet Housing
Replaced by Part No. 192–188 Outlet
Housing, which has a 3/4 npt(f) fluid
outlet port.
171–590
28
Packing Spreader
This part is deleted.
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.
December 3, 1996

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