Graco 307619L HYDRA-SPRAY 23:1 Ratio Monark Pump Owner's Manual


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Graco 307619L HYDRA-SPRAY 23:1 Ratio Monark Pump Owner's Manual | Manualzz

INSTRUCTIONS–PARTS LIST

This manual contains important warnings and information.

READ AND RETAIN FOR REFERENCE

HYDRA-SPRAY

23:1 Ratio Monark Pump

2760 psi (190 bar) Maximum Fluid Working Pressure

120 psi (8.4 bar) Maximum Air Input Pressure

Part No. 223–596, Series B

with Severe-Duty Displacement Pump* and Stainless Steel Glands,

Intake Housing, Piston Valve and Ball Stop

* Severe-Duty Displacement Pumps have abrasion-resistant displacement rod and sleeve. Refer to Technical Data on page 18 for Wetted Parts information.

307–619

Rev. L

Supersedes K and PCN L

Table of Contents

Warnings

Installation

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

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

2–4

4–5

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

6–7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Service

Parts

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

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

9–11

13–15

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data

16–17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

19

19

20

20

02097

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

COPYRIGHT 1983, GRACO INC.

WARNINGS

High Pressure Spray 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

This equipment generates very high fluid pressure. Spray from the spray gun, 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.

Never point the spray gun at anyone or at any part of the body. Never put hand or fingers over the spray tip.

Diffuser

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 Proce-

dure, below, 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.

Always have the tip guard in place on the spray gun when spraying.

Tip Guard

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.

Always follow the Pressure Relief Procedure, right, before cleaning or removing the spray tip or servicing any system equipment.

Spray Tip Safety

Use extreme caution when cleaning or changing spray tips. If the spray tip clogs while spraying, engage the spray gun safety latch immediately. Always follow the Pressure Relief

Procedure and then remove the spray tip to clean it.

Never try to stop or deflect leaks with your hand or body.

Never wipe off build-up around the spray tip until pressure is fully relieved and the spray gun safety latch is engaged.

Be sure all 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.

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 system, when installing, cleaning or changing spray tips, and whenever you stop spraying.

1.

Engage the spray gun safety latch.

NOTE TO PHYSICIAN: Injection into 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.

2.

Shut off the air to the pump.

3.

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

4.

Disengage the gun safety latch.

Spray Gun Safety Devices

Be sure all spray gun safety devices are operating properly before each use. Do not remove or modify any part of the gun; this can cause a malfunction and result in serious bodily injury.

5.

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

Safety Latch

Whenever you stop spraying, even for a moment, always set the spray gun safety latch in the closed or “safe” position, making the gun inoperative. Failure to set the safety latch can result in accidental triggering of the gun.

6.

Engage the gun safety latch.

7.

Open the drain valve (required in your system), having a grounded metal container ready to catch the drainage.

Trigger Guard

Never operate the spray gun with the trigger guard removed.

This guard helps prevent the gun from triggering accidentally if it is dropped or bumped.

8.

Leave the drain valve open until you are ready to spray again.

If you suspect that the spray tip 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 or hose.

EQUIPMENT MISUSE HAZARD

General Safety

Any misuse of the spray 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.

System Pressure

The 23:1 ratio pump develops 2760 psi (190 bar) Maximum

Fluid Working Pressure at 120 psi (8.4 bar) air inlet pressure.

Never exceed 120 psi (8.4 bar) air supply pressure to the pump.

Never alter or modify any part of this equipment; doing so could cause it to malfunction.

Be sure that all spray equipment and accessories are rated to withstand the maximum working pressure of the pump. Do not exceed the maximum working pressure of any component or accessory used in the system.

Check all spray equipment regularly and repair or replace worn or damaged parts immediately.

Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.

Fluid Compatibility

Be sure that all fluids and solvents used are chemically compatible with the wetted parts shown in the Technical Data on page 18. Always read the manufacturer’s literature before using any fluid or solvent in this pump.

FIRE OR EXPLOSION HAZARD

Static electricity is created by the flow of fluid through the pump and hose. If every part of the spray 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 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 area when there is any chance of igniting fumes still in the air.

7.

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.

8.

To maintain proper grounding continuity when flushing or relieving pressure, always hold the metal part of the spray gun firmly to the side of a grounded metal pail, then trigger the gun/valve.

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.

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.

Grounding

To reduce the risk of static sparking, ground the pump, object being sprayed, and all other spray equipment used or located in the spray area. Check your local code for detailed grounding instructions for your area and type of equipment. Be sure to ground all of this spray equipment:

Z

Y

1.

Pump: use a ground wire and clamp. See Fig. 1.

2.

Air and fluid hoses: use only grounded hoses with a maximum of 500 ft (150 m) combined hose length to ensure grounding continuity. Refer to Hose Grounding

Continuity on page 4.

3.

Air compressor: follow manufacturer’s recommendations.

4.

Spray gun or dispensing valve: grounding is obtained through connection to a properly grounded fluid hose and pump.

5.

Object being sprayed: according to your local code.

6.

Fluid supply container: according to your local code.

Fig. 1

X

W

Flushing Safety

Before flushing, be sure the entire system and flushing pails are properly grounded. Refer to Grounding, at left. Follow the Pressure Relief Procedure on page 2, and remove the spray tip from the spray gun. Always use the lowest possible fluid pressure, and maintain firm metal-to-metal contact between the gun and the pail during flushing to reduce the risk of fluid injection injury, static sparking and splashing.

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 hoses must have 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.

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 EXPLO-

SION HAZARD on page 3.

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 180 F (82 C) or below

–40 F (–40 C).

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 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.

4

Installation

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

Mounting the Pump

Mount the pump (A) to suit the type of installation planned. The pump dimensions and mounting hole layout are shown on page 19.

See pages 16 and 17 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 in Fig. 2 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

WARNING

A bleed-type master air valve (D) and a fluid drain valve (J) are required in your system. 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.

Grounding

The bleed-type master air valve relieves air trapped between this valve and the pump after the air is shut off. Trapped air can cause the pump to cycle unexpectedly. Locate the valve close to the pump.

WARNING

Before operating the pump, ground the system as explained under FIRE OR EXPLOSION HAZARD and Grounding on page 3.

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.

307-619

KEY

A Pump

B Wall Bracket

C Air Line Lubricator

D Bleed-Type Master Air Valve (required, for pump)

E Pump Air Regulator

F Air Line Filter

G Bleed-Type Master Air Valve (for accessories)

H Air Supply Hose

J Fluid Drain Valve (required)

K Fluid Filter

L Fluid Supply Hose

M Spray Gun

N Fluid Suction Hose

Y Ground Wire (required; see page 3 for installation instructions)

Installation

G F

H

N

E D C

A

Y

B

M

K

J

L

Fig. 2

Air and Fluid Hoses

Be sure all air and fluid hoses are properly sized and pressure-rated for your system. Use only grounded air and fluid hoses. Use a 1/2 in. (13 mm) ID (minimum) air hose (H) to supply air to the pump.

Fluid hoses must have spring guards on both ends.

Connect a fluid hose (L) to the pump’s 3/8 npt(f) fluid outlet. Use of a short whip hose between the main fluid hose (L) and the gun (M) allows freer gun movement.

Connect a fluid suction hose or tube (N) to the pump’s

3/4 npt(m) fluid intake.

Air Line Accessories

Install the following accessories in the order shown in

Fig. 2, using adapters as necessary:

An air line lubricator (C) provides automatic air motor lubrication.

A bleed-type master air valve (D) is required in your system to relieve air trapped between it and the air motor when the valve is closed (see the

WARNING on page 4). Be sure the bleed valve is easily accessible from the pump, and is located

downstream from the air regulator.

02098

An air regulator (E) 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 (F) removes harmful dirt and moisture from the compressed air supply.

A second bleed-type air valve (G) isolates the air line accessories for servicing. Locate upstream from all other air line accessories.

Fluid Line Accessories

Install the following accessories in the positions shown in Fig. 2, using adapters as necessary:

A fluid drain valve (J) is required in your system to relieve fluid pressure in the hose and gun (see the WARNING on page 4). Install the drain valve pointing down, but so the handle points up when opened.

A fluid filter (K) filters harmful particles from the fluid.

A spray gun (M) dispenses the fluid. The gun shown in Fig. 2 is an airless spray gun.

307-619 5

Operation

Starting and Adjusting the Pump 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 system, when installing, cleaning or changing spray tips, and whenever you stop spraying.

1. Engage the spray gun safety latch.

2. Shut off the air to the pump.

3. Close the bleed-type master air valve

(required in your system).

4. Disengage the gun safety latch.

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

6. Engage the gun 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 again.

If you suspect that the spray tip or hose is com pletely clogged, or that pressure has not been fully relieved after following the steps above, very slow-

ly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip or hose.

WARNING

Moving parts can pinch or amputate your fingers or other body parts. When air is supplied to the motor, the air motor piston (located behind the air motor plates) moves. See Fig. 3. Therefore, never operate the pump with the air motor plates (P) removed.

See Fig. 2 on page 5. Be sure the air regulator (E) and bleed-type master air valve (D) are closed. Do not install the spray tip yet!

Connect a suction hose (N) to the pump’s fluid inlet, or lower the pump into a fluid supply container. Hold a metal part of the spray gun (M) firmly to the side of a grounded metal pail and hold the trigger open. Then open the pump’s bleed-type master air valve (D). Now slowly open the air regulator (E) 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 spray gun 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 spray gun is opened and closed. In a circulating system, the pump will run continuously and speed up or slow down as supply demands until the air supply is shut off.

Use an adequately sized air regulator (E) to control the pump speed and the fluid pressure. See Accessories on page 16. 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.

Flush the Pump Before Using

The pump is tested with lightweight oil, which is left in to protect the pump parts. If the fluid you are using may be contaminated by the oil, flush it out with a compatible solvent before using the pump. If the pump is being used to supply a circulating system, allow the solvent to circulate until the pump is thoroughly flushed.

WARNING

For your safety, read the warning section, FIRE

OR EXPLOSION HAZARD on page 3 before flushing, and follow all the recommendations given there.

WARNING

To reduce the risk of overpressurizing your system, which could result in component rupture and cause serious bodily injury, never exceed 120 psi (8.4 bar)

Maximum Incoming Air Pressure to the pump.

Operation

Keep the packing nut/wet-cup (104) filled with Graco

Throat Seal Liquid (TSL) or compatible solvent, to help prolong the packing life. Adjust the packing nut weekly so it is just tight enough to prevent leakage; do not overtighten. See Fig. 3. Always follow the Pressure

Relief Procedure Warning on page 6 before adjusting the packing nut.

Never allow the pump to run dry of the fluid being pumped. A dry pump will quickly accelerate to a high speed, possibly damaging itself. If your pump accelerates quickly, or is running too fast, stop it immediately and check the fluid supply. If the supply container is empty and air has been pumped into the lines, 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.

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 the stroke to prevent the fluid from drying on the exposed displacement rod and damaging the throat packings.

Always flush the pump before the fluid dries on the displacement rod. Never leave water or water-based fluid in the pump overnight. First, flush with water or a compatible solvent, then with mineral spirits. Follow the Pressure Relief Procedure Warning on page 6, but leave the mineral spirits in the pump to protect the parts from corrosion.

P

Fig. 3

104

02097

Troubleshooting

NOTE: Check all possible problems and solutions before disassembling pump.

Problem

Pump fails to operate.

Cause Solution

Restricted line or inadequate air supply.

Clear; increase air supply.

Insufficient air pressure; closed or clogged air valves, etc.

Exhausted fluid supply.

Open; clean (be sure to use air filter).

Refill; purge all air from pump and fluid lines.

Service air motor (see 307–043).

Damaged air valving mechanism; stalling.

Dried fluid seizure of displacement rod

(103).

Clean, check or replace throat packings

(114, 124); always stop pump at bottom of stroke and keep wet-cup filled with compatible solvent.

Restricted line or inadequate air supply.

Clear; increase air supply.

Pump operates but output is low on both strokes.

Insufficient air pressure; closed or clogged air valves, etc.

Exhausted fluid supply.

Open; clean (be sure to use air filter).

Clogged fluid line, valves, etc.

Packing nut (104) is too tight.

Loose packing nut (104) or worn throat packings (114, 123).

Held open or worn intake valve.

Refill; purge all air from pump and fluid lines.

Clear* (be sure to use fluid filter)

Loosen (see page 7).

Tighten packing nut (see page 7); replace throat packings.

Clear; service. See page 10.

Pump operates but output is low on downstroke.

Pump operates but output is low on upstroke.

Erratic or accelerated operation.

Held open or worn fluid piston valve or packings (115, 124).

Exhausted fluid supply.

Clear; service. See page 10.

Held open or worn intake valve.

Held open or worn fluid piston valve or packings (115, 124).

Refill; purge all air from pump and fluid lines.

Clear; service. See page 10.

Clear; service. See page 10.

* To determine if the fluid hose or gun is obstructed, follow the Pressure Relief Procedure Warning below. 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.

8

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 system, when installing, cleaning or changing spray tips, and whenever you stop spraying.

1.

Engage the spray gun safety latch.

2.

Shut off the air to the pump.

4.

Disengage the gun safety latch.

WARNING

3.

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

5.

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

6.

Engage the gun 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 again.

If you suspect that the spray tip 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 or hose.

307-619

Disconnecting the Displacement Pump

Service

1. Flush the pump if possible. Stop the pump at the bottom of its stroke. Follow the Pressure Relief

Procedure Warning on page 8.

Lubricate.

Torque to 10–15 ft–lb

(14–20 N.m).

2. Disconnect the air and fluid hoses. Remove the pump from its mounting. Note the relative position of the pump’s fluid outlet (R) to the air motor’s air inlet (S).

3. Unscrew the tie rod locknuts (4) from the tie rods

(10). Remove the cotter pin (3). Unscrew the displacement rod (103) from the air motor (12). Carefully pull the displacement pump (13) off the air motor (12). Inspect the o-ring (6). See Fig. 4.

4. Refer to page 10 for displacement pump service.

To service the air motor, refer to the separate air motor manual 307–043, supplied.

Reconnecting the Displacement Pump

1. Lubricate the o-ring (6) and check that it is in place on the displacement rod (103). Orient the pump’s fluid outlet (R) to the air motor’s air inlet (S) as was noted in step 2 under Disconnecting the Dis-

placement Pump. Position the displacement pump (13) on the tie rods (10). See Fig. 4.

2. Screw the locknuts (4) onto the tie rods (10) loosely. Screw the displacement rod (103) into the shaft of the air motor (12) until the pin holes in the displacement rod and motor shaft align. Install the cotter pin (3*).

3. Mount the pump and reconnect all hoses. Reconnect the ground wire if it was disconnected during repair. Tighten the packing nut/wet-cup (104) so it is just snug – no tighter. Fill the wet-cup with Graco Throat Seal Liquid or compatible solvent.

4. Tighten the tie rod locknuts (4) evenly, and torque to 10–15 ft–lb (14–20 N.m).

5. Start the pump and run it at about 40 psi (2.8 bar) air pressure, to check that it is operating properly.

Fig. 4

6

103

104

R

10

3*

4

13

12

S

02099

Service

Displacement Pump Service

Disassembly

When disassembling the pump, lay out all removed parts in sequence, to ease reassembly. Refer to Fig. 5.

NOTE: Repair Kit 235–636 is available. For the best results, use all the new parts in the kit. Parts included in the kit are marked with one asterisk, for example

(3*).

Reassembly

1. Lubricate the throat packings and install them in the outlet housing (107) one at a time as follows, with the lips of the v-packings facing down: the washer (119), male gland (118*), one leather v-packing (114*), one leather (114*), PTFE

PTFE v-packing (123*),

(123*), and the female gland

(116*). Install the packing nut (104) loosely. See

Detail A of Fig. 5.

Conversion Kit 223–674 is available to convert the pump packings to UHMWPE and leather. Conversion

Kit 236–724 is available to convert the pump packings to PTFE See page 15 for details.

2. If you removed the sleeve (106), reinstall it in the outlet housing (107), making sure to replace the gasket (120). Be sure the tapered end of the sleeve faces down, toward the pump intake.

Clean all the parts thoroughly when disassembling.

Check them carefully for damage or wear, replacing parts as needed.

1. Remove the displacement pump from the air motor as explained on page 9.

2. Unscrew the intake valve housing (105) from the outlet housing (107). If it is difficult to remove, squirt penetrating oil around the threads and gently tap around the valve housing with a plastic hammer to loosen it. See Fig. 5.

3. Remove the ball stop pin (113), o-ring retainer

(108), o-ring (109), ball guide (101) and ball (112).

4. Loosen the packing nut (104). Push the displacement rod (103) down as far as possible, then pull it out of the outlet housing (107).

5. Secure the flats of the displacement rod (103) in a vise. Screw the piston stud (102) out of the rod.

Remove the ball (110), retainer (122), packings

(124, 115) and glands (117, 121).

6. Remove the packing nut (104), throat packings

(123, 114), glands (116, 118), and washer (119) from the outlet housing (107).

7. Inspect all parts for damage. Clean all parts and threads with a compatible solvent before reassembling. Inspect the polished surfaces of the displacement rod (103) and sleeve (106) for scratches, scoring or other damage, which can cause premature packing wear and leaking. To check, run a finger over the surface or hold the part up to the light at an angle. Replace any worn or damaged parts.

NOTE: If the sleeve (106) needs replacement and is hard to remove, contact Graco Technical Assistance

(see back page).

3. Lubricate the piston packings and install them onto the piston stud (102) one at a time in the following order, with the lips of the v-packings facing up: the female gland (121*), one PTFE v-packing (124*), one leather v-packing (115*), one PTFE (124*), one leather (115*), the male gland (117*), and the packing retainer (122*). See Detail B of Fig. 5.

4. Apply thread sealant to the piston stud (102). Install the piston ball (110*) on the piston and screw the piston valve assembly into the displacement rod (103). Torque to 35–40 ft–lb (47–54 N.m).

5. Insert the displacement rod (103) into the bottom of the outlet housing (107), being careful not to scratch the sleeve (106). Push the rod straight up until it protrudes from the packing nut (104).

6. Install the ball (112*), guide (101), o-ring (109*), retainer (108), and ball stop pin (113) in the intake valve housing (105). Screw the intake housing into the outlet housing (107). Torque to 55–65 ft–lb

(75–88 N.m).

7. Reconnect the displacement pump to the air motor as explained on page 9.

Service

1

2

3

4

Lubricate.

See Detail A.

Lips of v-packings must face down.

Tapered end must face down, toward pump intake.

103

7

8

5

6

9

See Detail B.

Lips of v-packings must face up.

Apply thread sealant.

Torque to 35–40 ft–lb (47–54 N.m).

Torque to 55–65 ft–lb (75–88 N.m).

Detail A: Throat Packings 1 3

104 104

(REF

)

116*

107

(REF)

*123

*114

*123

*114

118*

2

120

119

7 8 102

5

108

101

9

105

106 4

107

113

103

(REF)

*110

7 8 102

(REF)

*122

*117

*115

*124

*115

*124

*121

Detail B: Piston Packings 1 6

*112 109*

02100

Fig. 5

Notes

Model 223–596, Series B

23:1 Ratio Monark Pump

12

Parts

Ref

No.

3*

4

6

10

12

13

Part

No.

Description Qty

101–946 PIN, cotter; stainless steel;

0.12” (3.2 mm) x 1.5” (38 mm)

101–566 NUT, lock; 3/8–16

154–771 SEAL, o-ring; buna-N

164–722 ROD, tie; carbon steel;

4.375” (112 mm) shoulder-to-shoulder 3

205–530 AIR MOTOR

See 307–043 for parts

223–595 DISPLACEMENT PUMP ASSY

See pages 14 and 15 for parts

1

1

1

1

3

* These parts are included in Repair Kit 235–636, which may be purchased separately. See pages 14 and 15 for other kit parts.

6

10

3*

4

13

02099

Parts

Model 223–595, Series C

Severe-Duty Displacement Pump with Stainless Steel Glands, Intake Housing, Piston Valve, and Ball Stop

104

*116

*123

*114

*123

*114

*118

119

103

107

120

106

122*

117*

115*

124*

115*

124*

121*

110*

102

113

108

101

109*

112*

105

02101

14 307-619

Parts

Model 223–595, Series C

Severe-Duty Displacement Pump with Stainless Steel Glands, Intake Housing, Piston Valve, and Ball Stop

Ref

No.

Part

No.

Description Qty

101

102

103

104

105

186–187 GUIDE, ball, intake; stainless steel 1

223–591 STUD, piston; stainless steel with tungsten carbide seat

223–603 ROD, displacement; stainless steel

206–269 PACKING NUT/WET-CUP; carbon steel

223–593 HOUSING, valve, intake; stainless steel

1 with tungsten carbide seat 1

1

1

178–898 SLEEVE, housing; stainless steel

207–011 HOUSING, outlet; carbon steel

186–183 RETAINER, o-ring; stainless steel

1

1

1

106

107

108

109* 165–052 O-RING; PTFE 1

110* 112–722 BALL; chrome; 0.31” (7.9 mm) dia.

112* 112–721 BALL; chrome; 0.5” (13 mm) dia.

113 186–179 PIN, ball stop, intake; stainless steel 1

114* 164–397 V-PACKING, throat; leather

115* 164–715 V-PACKING, piston; leather

1

1

2

2

116* 186–194 GLAND, throat, female; stainless steel 1

117* 186–195 GLAND, piston, male; stainless steel 1

118* 186–196 GLAND, throat, male; stainless steel 1

119 186–197 WASHER, flat; stainless steel 1

120 164–480 GASKET, flat; PTFE 1

121* 186–198 GLAND, piston, female; stainless steel 1

122* 186–199 RETAINER, packing; stainless steel 1

2 123* 164–913 V-PACKING, throat; PTFE

124* 164–912 V-PACKING, piston;

125 172–479

PTFE

TAG, warning (not shown)

129 172–477 TAG, warning (not shown)

2

1

1

* These parts are included in Repair Kit 235–636, which may be purchased separately. See page 13 for additional parts.

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

Manual Change

Assembly

Changed

223–595

Displ.

Pump, to

Series C;

223–596

Pump to

Series B; and Repair

Kits

235–636 &

223–674

Summary

Part

Status

Old

New

Old

New

Ref

No.

110

110

112

112

Part No.

Name

102–119

112–722

101–750

112–721

SST Ball

Chrome Ball

SST Ball

Chrome Ball

PTFE Conversion Kit 236–724

Use to convert the pump to all PTFE

Kit must be purchased separately.

Kit includes: packings.

Part

No.

Description

101–946

101–545

165–052

102–119

101–750

186–194

186–195

186–196

186–198

186–199

164–912

164–913

UHMWPE/Leather Conversion Kit 223–674

Use to convert the pump to UHMWPE and leather packings. Kit must be purchased separately.

Kit includes:

Part

No.

Description

101–946

165–052

112–722

112–721

164–397

164–715

186–194

186–195

186–196

186–198

186–199

108–455

108–456

PIN, cotter; stainless steel

PIN, cotter (for old-style ball checks)

O-RING; PTFE

BALL; stainless steel;

0.31” (7.9 mm) dia.

BALL; stainless steel;

0.5” (13 mm) dia.

GLAND, throat, female; stainless steel

GLAND, piston, male; stainless steel

GLAND, throat, male; stainless steel

GLAND, piston, female; stainless steel

RETAINER, packing; stainless steel

V-PACKING, piston; PTFE

V-PACKING, throat; PTFE

PIN, cotter; stainless steel

O-RING; PTFE

BALL; chrome;

0.31” (7.9 mm) dia.

BALL; chrome;

0.5” (13 mm) dia.

V-PACKING, throat; leather

V-PACKING, piston; leather

GLAND, throat, female; stainless steel

GLAND, piston, male; stainless steel

GLAND, throat, male; stainless steel

GLAND, piston, female; stainless steel

RETAINER, packing; stainless steel

V-PACKING, throat; UHMWPE

V-PACKING, piston; UHMWPE

Qty

1

1

1

1

Qty

1

1

1

1

1

2

1

1

1

1

2

2

2

1

1

1

1

1

1

4

4

307-619 15

Accessories

Use Only Genuine Graco Parts and Accessories

Grounding Clamp and Wire 222–011

25 ft (7.6 m) long,

12 gauge (1.5 mm )

Air Regulator

300 psi (21 bar) Maximum Working Pressure

104–266 0–250 psi (0–18 bar) Regulated

Pressure Range;

1/2 npt(f) inlet and outlet.

Bleed-Type Master Air Valve

300 psi (21 bar) Maximum Working Pressure

107–142 1/2 npt(m) inlet x 1/2 npt(f) outlet

Relieves air trapped in the air line between the pump air inlet and this valve when closed.

Air Line Filter

250 psi (17.5 bar) Maximum Working Pressure

106–149 1/2 npt(f) inlet and outlet

Grounded 1/2 in. (13 mm) Buna-S Air Hose

175 psi (12 bar) Maximum Working Pressure

Part No.

ID Length

205–418 1/2” (13 mm) 6 ft (1.8 m)

205–216 1/2” (13 mm) 15 ft (4.5 m)

205–273 1/2” (13 mm) 25 ft (7.6 m)

208–594 1/2” (13 mm) 50 ft (15.2 m)

Fluid Drain Valve

5000 psi (350 bar) Maximum Working Pressure

Open to relieve fluid pressure in hose and gun.

Thread Size

1/2 npt(m)

1/2 npt(m)

1/2 npt(m)

1/2 npt(m)

210–657 1/4 npt (mbe). Carbon Steel.

210–658 3/8 npt (mbe). Carbon Steel.

210–659 1/4 npt x 3/8 npt (mbe). Carbon Steel.

235–992 1/4 npt x 3/8 npt (mbe). Stainless Steel.

Air Line Lubricator

250 psi (17.5 bar) Maximum Working Pressure

214–848 8 oz (0.24 liter) bowl capacity.

1/2 npt(f) inlet and outlet

Fluid Filter

5000 psi (350 bar) Maximum Working Pressure

60 mesh (250 micron) stainless steel screen.

218–029 Carbon steel bowl and polyethylene support.

223–160 Stainless steel bowl and polyethylene support.

218–029 Shown

Accessories

Use Only Genuine Graco Parts and Accessories

Wall Bracket 207–365

For mounting the Monark Pump to a wall.

Suction Hose 214–961

500 psi (35 bar) Maximum Working Pressure

6 ft (1.8 m) long, coupled 3/4 npt (mbe), neoprene.

Spring guard both ends.

55 Gal. (200 Liter) Suction Tube 206–266

Use with Suction Hose 214–961 to draw fluid from a

55 gal. (200 liter) drum. Carbon Steel.

Drum Cover and Agitator 207–199

Fits a 55 gal. (200 liter) drum.

Graco Throat Seal Liquid

Non-evaporating solvent for wet-cup.

206–995 1 quart (0.95 liter)

206–996 1 gallon (3.8 liter)

Technical Data

Maximum fluid working pressure

Maximum air input pressure

Wetted parts . . .

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

Maximum flow at continuous duty

Air consumption

Weight

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2760 psi (190 bar)

Pump cycles per 1 gallon (3.8 liters)

120 psi (8.4 bar)

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

Maximum recommended pump speed for continuous operation

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

. . . . . . . . .

0.5 gallon (1.9 liters) at 75 cycles/min

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 30 scfm (0.84 m /min) at 1 gpm (3.8 liters/min) at 120 psi (8.4 bar) air pressure

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

PTFE

150

75 cycles per min approx. 24 lb (11 kg)

Carbon Steel; AISI 304, 316, 420, and 17–4 PH grades of Stainless Steel;

Chrome; Chrome and Zinc Plating; Tungsten Carbide;

; Leather

PTFE

KEY: Fluid Outlet Pressure – Black Curves

Air Consumption – Gray Curves

psi bar cycles/min

2800

196

30

8.4 bar (120 psi) air pressure

2400

168

60 75

NOTE: Pump may be operated continuously to shaded area.

90 120 150 scfm m /min

48

1.344

2000

140

40

1.120

1600

112

4.9 bar (70 psi) air pressure

32

0.896

1200

84

24

0.672

8.4 bar (120 psi) air pressure

800

56

2.8 bar (40 psi) air pressure

4.9 bar (70 psi) air pressure

16

0.448

400

28

8

0.224

2.8 bar (40 psi) air pressure

gpm liters/min

0

0.0

0.2

0.8

0.4

1.5

0.6

2.3

0.8

3.0

FLUID FLOW (TEST FLUID: NO. 10 WEIGHT OIL)

To find Fluid Outlet Pressure (bar/psi) at a specific fluid flow (lpm/gpm) and operating air pressure (bar/psi):

1. Locate desired flow along bottom of chart.

2. Follow vertical line up to intersection with selected fluid outlet pressure curve (black). Follow left to scale to read fluid outlet pressure.

18 307-619

1.0

3.8

To find Pump Air Consumption (m /min or scfm) at a specific fluid flow

(lpm/gpm) and air pressure (bar/psi):

1. Locate desired flow along bottom of chart.

2. Read vertical line up to intersection with selected air consumption curve (gray). Follow right to scale to read air consumption.

3/8 npt(f)

Air Inlet

Dimensions Mounting Hole

Layout

Use Gasket 161–023

(order separately)

0.28 in. (7.1 mm) diameter

28.5 in.

(724 mm)

4.38 in.

(111.3 mm) diameter

2.5 in.

(64 mm)

5.0 in. (127 mm)

14.6 in.

(371 mm)

9.7 in.

(246 mm)

3/8 npt(f)

Fluid Outlet

3/4 npt(m)

Fluid Intake

02097

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 WAR-

RANTIES (EXPRESS OR IMPLIED), INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PUR-

POSE, 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.

Graco Phone Numbers

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

FOR TECHNICAL ASSIST ANCE, service repair information or assistance regarding the application of

Graco equipment: 1–800–543–0339 Toll Free

Sales Offices: Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.)

Foreign Offices: Canada; England; Korea; Switzerland; France; Germany; Hong Kong; Japan

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

PRINTED IN U.S.A. 307–619 5/83 Revised 7/94

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