INSTRUCTIONS-PARTS LIST e

Transcription

1 INSTRUCTIONS-PARTS LIST e This manual contains IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE GRACO Rev B SUPERSEDES A AIR-POWERED, DIVORCED DESIGN HYDRAULIC FLUID SUPPLY PUMPS 35:l Senator Model Series A 4200 psi (290 bar) MAXIMUM WORKING PRESSURE 6O:l Bulldog Model Series A 6aKI psi 1413 bar) MAXIMUM WORKING PRESSURE GRACO INC. P.O. Box GRACO INC. MN

2 WA RIVING HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY. OBSERVE ALL WARNINGS. FOR PROFESSIONAL USE ONLY. Read and understand all instruction manuals, tags, and warnings before operating equipment. Fluids under high pressure from spray or leaks can penetrate the skin and cause extremely serious injury, including the need for amputation. Check operation of all equipment safety devices before each use. Even after you shut off air supply to the pump, there is high pressure in the pump and lines until you relieve it. Always relieve pressures after shutting off air supply to the pump and before servicing, cleaning or removing any parts. To relieve pressure, close the bleed-type master air valve (required in system) and open any equipment drain valves (required in system 1. NEVER try to stop or deflect leaks with your hand or body. MEDICAL TREATMENT,aa~~!oI::p! :$j. i;:: :$~;r~:;+,: 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. For treatment instructions have your doctor call the NATIONAL POISON CENTER NETWORK (412M Fluids under high pressure from leaks can penetrate the skin and cause extremely serious injury including the need for amputation. The maximum working pressure of the 89:l Bulldog pump is!x00 psi (413 bar) which is developed with the maximum incoming air pressure to the air motor of 100 psi (7 bar). The maximum working pressure of the 35:l Senator pump is 4299 psi (299 bar) which is developed with the maximum incoming air pressure to the air motor of 120 psi (8 bar). AL WAYS be sure all components of the svstem have a pressure rating at least as hjgh as that stated on the pump. NEVER exceed the maximum ooeratina air oressure or the maximum fluid working pressure* of the-pump to reduce the risk of component rupture. Before each use, check all fluid line connections for leaks and tighten securely. Replace any damaged lines immediately. IF PUMP IS USED FOR AN AIRLESS SPRAY APPLICATION, take the additional following precautions. SPRAYGUN SAFETY:...,,:.I ;I.:.: 9 AL WAYS be sure all equipment and objects being sprayed are properly grounded. Use only static free air and fluid hoses. Be sure gun is grounded through hose connections. Ground the pump as described on page 3. Follow the compressor manufacturer s recommendations for grounding the compressor. The high velocity flow of fluid creates static electricity which can cause electric shock. Sparks may cause fire or explosion and result in serious bodily injury or property damage. When flushing equipment, remove spray tip, use the lowest possible pressure, and maintain firm metal to metal contact between gun and metal waste container. This reduces the chance of static sparking and splashing. AVOID COMPONENT RUPTURE.;a.., >,i...:,::. NEVER point the spray gun at anyone or any part of the body. NEVER put hand or fingers over the spray tip. ALWAYS have tip guard in place when spraying. NEVER try to blow back paint; this is not an air spray system. When spray gun is not actually spraying, always set the gun safety latch in the closed or SAFE position, making the gun inoperative. DO NOT REMOVE OR MODIFY any part of the gun.removal or modification of any part of the gun could cause it to malfunction resulting in serious bodily injury. CHECK OPERATION OF ALL GUN SAFETY DEVICES BEFORE EACH USE. Always remove the tip from the gun to clean it. Do not use chemicals or agents in the hose which are not compatible with the tube and cover of the hose. Damage to the hose caused by the use of such chemicals or a ents can result in hose failure which can cause serious I! odily injury or property damage. Use only with hose having a sprin guard helps protect the hose from dl guard. The sprin amage which coul fl result in hose rupture and serious bodily injury, including injection. Be very careful when removing the spray tip or hose fromgun. A plugged line contains fluid under pressure. If tip or line is plugged, shut off air supply to the pump and close the bleed-type master air valve (required in system). Trigger the spray gun, engage the gun safety latch, and open the drain valve (required in system). Then loosen tip guard or hose coupling slightly and relieve the pressure slowly before removing completely. The gun diffuser breaks up spray and helps reduce the risk of injection when the tip is not installed. Check diffuser operation regularly. Be sure fluid pressure is relieved, then remove spray tip, aim gun into metal waste container with metal part of gun firmly held to the container, then using the lowest possible pressure, trigger the gun. If fluid emitted is not diffused into an irregular stream, replace diffuser immediately. 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 should be consulted

3 -f 21 l/2 (649.1 mm) mm) ( 11 (279 mm) dia (Model ) 9 3/4 (249 mm) dia (Model holes, mm) die on 10.5 (267 mm) bolt circle 9.75 (248 mm) dia USE GASKET mm) R AIR CONSUMPTION CURVE : i :-.... :- :j.: l/2 npt(f) MATERIAL OUTLET l npt(f) MATERIAL INLET (Model :l Senator Pump) Ratio : 35:l Maximum operating air pressure : 120 psi (8 bar) Material discharge pressure : 4200 si (290 bar) Approx. cycles per gallon : 40 (1 P cycles per liter) Arr Consumption : See chart at right Air inlet : 3/4 npsm Material outlet : l/2 npt(f) Weight : 85 lb (27 kg) Wetted parts : Chrome Plated Stainless Steel, Chrome Alloy, Zinc ~~~b~rsteel, Polyethylene,../ )- a0 I I I I j,... l..l I 4 (.a*- I I :. J / ** %. I. (Model O:l Bulldog Pump) Ratio Maximum operating air pressure Material discharge pressure Approx. cycles per gallon Air consumption Air inlet Material outlet Weight Wetted parts : 5O:l : 100 psi (7 bar) : 5000 si (413 bar) : 40 (1 Pcycles per liter) : See chart at right : 314 npsm : l/2 npt(f) : 72 lb (32 kg) : Chrome Plated Stainless Steel, Chrome Alloy, Zinc ~~~b;rsteel, Polyethylene, NOTE: These pumps have been tested at 100 psi (7 bar) air supply pressure using No. 10 oil at 70 F 121 C). TO FIND PUMP AIR CONSUMPTION KFM/mg/min) at a specific delivery (gpm/l/min): 1. Locate desired delivery along bottom of chart. 2. Read vertical line up to intersection with air consumption curve. Curve slopes down from right to left. Follow right to scale and read air consumption. TO FIND OUTLET PRESSURE (psi/bar) at a specific delivery IgpmlVmin.): :: Locate desired delivery along bottom of chart. Read vertical line up to intersection with fluid outlet pressure curve. Curve slopes down from left to right. Follow left to scale and read outlet pressure

4 The dimensional drawing on Page 2 gives measurements needed for installing pump on a custom designed mounting. NOTE: Reference numbers and letters in parentheses in the text refer to Figs 1, 2 and the Parts Drawing. Ground the Pump _-. - WARNING ALWAYS be sure all equipment is grounded properly. Use only static free air and fluid hoses. Ground the pump as described below. Follow the compressor manufacturer s recommendations for grounding the compressor. The high velocity flow of fluid creates static electricity which can cause electric shock. Sparks may cause fire or explosion and result in serious bodily injury or property damage. To ground the pump, connect a ground wire to pump air motor. Loosen grounding lug locknut (A) a Y washer (BI. Insert one end of a 12 ga (1.5 mm ) minimum ground wire (D) into slot in lug (C) and tighten locknut securely. See Fig 1. Connect the other end of wire to a true earth ground. Check all local electrical codes for more information on grounding. System Accessories Two accessories, a bleed-type master air valve, and a fluid drain valve are required for your system to help prevent serious bodily injury from moving parts or injection when shutting off the pump. Fig 1 The bleed-type master air valve relieves trapped air between the valve and the pump after the pump is shut off. Trapped air can cause the pump to cycle unexpectedly and result in serious bodily injury while adjusting or repairing the pump. The fluid drain valve helps relieve fluid pressure in the displacement pump and lines when shutting off the pump. In the air line, upstream from the pump air inlet, you should install an air line oiler for automatic pump lubrication, an air regulator to control pump speed and fluid pressure, and an air line filter to remove harmful dirt and moisture from your compressed air supply. The bleed-type master air valve should be installed in the air line, within reach of the pump area. Downstream from the pump, in the fluid line, you should install a fluid filter and a drain valve (required). OPERAT,ON,., :.. -,;::.:i:.:\; Flush Pump Before Using Pumps are tested with No. 10 motor oil which is left in to protect pump parts. To prevent contamination of material, flush pump with a compatible solvent before using. If pump is being used to supply a circulating system, allow solvent to circulate for at least 10 minutes. Starting and Adjusting Pump Open the fluid supply shut off valve and the system drain valve. Open the bleed-type master air valve and slowly-open the air regulator until the pump starts to cycle (about 20 psi (1.4 bar)). Allow pump to cycle slowly until all air is purged from lines. The lines are purged when the fluid emitted from the drain valve is flowing in a steady stream. With the lines purged, close the system drain valve. The pump will stall against pressure. With pump and lines primed, and with adequate air pressure and volume supplied, the pump will start and stop as supply demands or until the b!eed-type master air Vak! is shut off. NEVER exceed the maximum operating air pressure stated on the pump to avoid excessive in component rupture and serious bodily injury Check tightness of throat packing nut weekly. Packing nut should be tight enough to:+revent leakage - no tighter. ALWAYS shut off and relieve air pressure to the pump and relieve material pressure before adjusting packing nut to reduce the risk of serious bodily injury. NEVER allow the pump to run dry of material 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 material supply. If the supply container is empty and air has been pumped into lines, prime pump and lines with material, or flush and leave filled with compatible solvent. Be sure to eliminate all air from fluid system to prevent corrosion. Use an adequately sized air regulator to control pump speed and material pressure. Always use the lowest air pressure necessary to give you the results you want

5 WARNING Pressure Relief Procedure To reduce the risk of serious bodily injury, including injection, always relieve system pressures after shutting off air supply to the pump and before servicing, cleaning or removing any parts. To relieve pressure, close the bleed-type master air valve. If pump is being used for an airless application, trigger the spray gun and engage the gun safety latch. Then slowly open any equipment drain valves. Leave the drain valve(s) open until you are ready to use the system again. from amputation by moving parts. TROUBLESHOOTING CHART PROBLEM Pump fails to operate. CAUSE Restricted line or inadequate air supply* Insufficient air pressure. Closed or clogged air valves, etc. Exhausted material supply. Damaged air motor. Dried material seizure of displacement rod. SOLUTION Clear line or increase line size. Open air valves, clean if necessary. Refill. Service. See air motor instruction manual (supplied). Remove. Pump operates but output low on Restricted line or inadequate air Clear line or increase line size. both strokes. line supply. Insufficient air pressure. Closed Open air valves, clean if or clogged air valves, etc. necessary. Obstructed material line, valves, gun, etc. Tight throat packing nut. Clear. Loosen. Pump operates but output low on Held open or worn fluid intake Clear, service. See Service downstroke. valve. Section. Pump operates but output low on Held open or worn fluid piston Clear, service. See Service Secupstroke. valve or packing leaking. tion. Erratic or accelerated operation. Exhausted material supply. Refill. Held open or worn fluid intake valve. Held open or worn piston valve or packing leaking. Clear, service See Service Section. Clear, service. See Service Section. *Release pressures and disconnect material line. Reduce the air pressure to 20 psi (1.4 bar). If pump starts when air is turned on again, the line, etc. is clogged. Check all other remedies before disassembling pump

6 DlSpmCEMENT PUMP SERVICE,::,lbt;f:j8~I~If;Il(;~ik~Bd:.^,.,.;j; _:,, I,,,,,,,,Y,,:,, IS,,i,.,!;;,:;s$ Disconnect Displacement Pump From Air Motor To disconnect displacement pump from air motor, disconnect fluid line from fluid outlet of pump. Unscrew coupling nut (4) from air motor. See Parts Drawing on page 7. Unscrew locknuts (8) from tie rods (14) and remove displacement pump from air motor. Remove cotter pin (7) from connecting rod coupling (5) and screw connecting rod coupling, with o-ring (241, off of displacement rod. See Parts Drawing on page 7. ITI h V-packings must face DOWN NOTE: If you are using a repair kit to service the pump, use all the new parts, even if the old ones look good. The old parts will wear faster, making pump service needed again sooner. See page 8 for available repair kit. Disassemble Pump Remove intake valve housing (20) from pump housing (3) and remove o-ring (181, pin (171 and ball (19) from valve housing. See Fig 2. Clean all parts thoroughly, inspect for wear or damage and replace parts as necessary. Loosen throat packing nut (21, push displacement rod (1) down until you can grasp piston (16) and pull piston and displacement rod out through the bottom of pump housing. must face UP Fig 2 Secure flats of piston (16) in vise, unscrew and disconnect displacement rod (11, piston valve housing (11) and piston (16). Remove ball (131, washer (141, glands (7 & 15) and packings (5 8 6). Unscrew packing nut (2) from pump housing (3) and remove throat packings (5 Et 6) and glands (7 Et 15). Inspect sleeve (10) for score marks. If sleeve (10) needs to be replaced, first install gasket (9) and then be sure to install sleeve with tapered end down. If you cannot remove sleeve easily, contact the nearest Grace Factory branch, or authorized service agency. A special sleeve removal tool (Part No. M-174) is available. Clean all parts thoroughly, inspect for wear and damage, and replace parts as neccessary. Assemble Pump Secure flats of piston (16) in a vise. Install glands (7 & 15) and packings (5 & 6) on piston as shown in Fig 2. Be sure the lips of the V-packings face UP. Install ball (13) and washer (14) on piston. Apply Loctite@ No. 242 to threads of piston and screw piston valve housing onto piston. Apply Loctite@ No. 242 to threads of piston valve housing (11) and screw displacement rod (1) onto piston valve housing. Torque displacement rod to ft-lb (102-l 15 N-m). Lubricate the inside of the throat packings and install glands (7 & 15) and throat packings (5 8 6) in pump housing (3). Be sure the lips of the V-packings face DOWN as shown in Fig 2 and install packings one at a time to be sure they nest properly. Install packing nut (2) leaving it loose. Lubricate the outside of piston packings (5 & 6) and insert displacement rod up through bottom of pump housing (3). Install ball (19) and pin (17) into intake valve housing (20). Then install o-ring (18) on intake valve housing and screw valve into pump housing (3). Torque intake valve to ft-lbs ( N.m). Tighten packing nut (2) just tight enough to stop leakage - no tighter. Connect Displacement Pump To Air Motor Apply lithium base grease to o-ring (24) and threads of displacement rod. Install o-ring on displacement rod. Slide coupling nut (4) onto connecting rod coupling (5) and then screw connecting rod coupling onto displacement rod until hole in coupling is aligned with hole in displacement rod. See Parts Drawing on page 7. Install cotter pin (71 through hole in coupling and displacement rod. Connect diplacement pump to air motor using three tie rods (14) and locknuts (8). Screw coupling nut (4) onto air motor piston rod and tighten securely

7 PARTS LIST : -_ Model 218-m 35:l SENATOR PUMP REF PART DESCRIPTION QTY W t : :: :: AIR MOTOR See for parts NUT, shouldered COUPLING, connecting rod PIN, cotter, in x 1.5 in. NUT, lock; w/nylon inserts; 5/8-11 DISPLACEMENT PUMP ASSEMBLY See page 8 for parts TAG, warning RIVET, blind LABEL, warning ROD, tie PLATE, serial 1 : ; : 2 ii & 307numbers in descriptions refer to separate instruction manuals. *Recommended tool box spare parts. Keep on hand to reduce down time. 5 Order parts by name and series letter of the assembly for which you are ordering

8 PARTS DRAWING :.>,:;;;:,I- (.~.;, ~:,, PARTSLIST : I : ;..? :; pi, :,:-.:I.: :,.:, Model O:l Bulldog Pump REF PART QTY z i : ;: AIR MOTOR See 307-W for parts NUT, shouldered COUPLING, connecting rod PIN, cotter; in. x 1.5 in NUT, lock; w/nylon inserts; 5/8-11 DISPLACEMENT PUMP ASSEMBLY See page 7 for parts TAG, warning PLATE, serial RIVET, blind ROD, tie LABEL, warning 1 : ii : 1 s numbers in descriptions refer to separate instruction manuals. *Recommended tool box spare parts. Keep on hand to reduce down time. Order parts by name and series letter of the assembly for which you are ordering

9 Model Displacement Pump REPAIR KIT? (must be purchased separately) consists of: 24 REF QTY TORQUE TO ft-lb WI-190 N-m) ft-lb ( N.rn) REF PART z ii ii l * l * l * ? l * :: :: l *1Cr1-454 l * :: DESCRIPTION QTY ROD, displacement NUT, packing HOUSING, pump PACKING, vee, polyethylene PACKING, vee, rubber GLAND, male ADAPTER, pipe (includes item 8al.PACKING, o-ring, Viton GASKET, PTF SLEEVE, cylinder E HOUSING, valve, piston BALL, steel, dia WASHER, spring GLAND, female PISTON PIN, stop, ball 1 REF PART DESCRIPTION QTY 18 * PACKING, o-ring, BALL, steel, 1 dia E HOUSING, valve, intake 1 E PLATE, serial SCREW, drive type U, no. 6 x l/ TAG, warning PACKING, o-ring, Nitrile rubber : *Recommended tool box spare parts. Keep on hand to reduce down time. **Supplied in repair kit 218~CQ0 PTF Order parts by name and series letter of the assembly for which you are ordering.

10 ACCESSORIES : : j ;. I I,.; : ( :_ :. : : ; : AIR PRESSURE REGULATOR 3m psi 121 bar) MAXIMUM WORKING PRESSURE l/2 npt inlet Et outlet /4 npt inlet Et outlet See Maunual AIR LINE FILTER 250 psi / 17.5 bar) MAXIMUM WORKING PRESSURE l/2 npt inlet & outlet /4 npt inlet Et outlet AIR LINE OILER 2527 psi (77.5 bar) MAXIMUM WORKING PRESSURE l/2 not inlet 8 outlet /4 npt inlet Et outlet BLEED-TYPE MASTER AIR VALVE 300 psi (21 bar) MAXIMUM WORKING PRESSURE Relieves air trapped in the air line between the pump air inlet and this valve when closed /4 nptfm x f) inlet & outlet l/2 npt(m x f) inlet & outlet AIR SUPPLY HOSE, grounded 175 psi 112 bad MAXIMUM WORKING PRESSURE Availble through special order. Contact the nearest Grace Factory Branch or authorized Grace Distributor. THE GRACO WARRANTY Grace Inc. warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship under normal use and service. This warranty extends to the original purchaser for a period of 12 months from the date of purchase and applies only when the equipment is installed and operated in accordance with written factory recommendations. This warranty does not cover damage or wear which, in the reasonable judgment of Grace,, arises from misuse, abrasion, corrosion, negligence, accident, substitution of non-grace parts, faulty mstallation or tempering. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective for examination by Grace to verify the claimed defect. If the claimed defect is verified, Grace 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 workmanship or material, repairs will be made at a reasonable charge and return transportation will be charged. THIS LIMITED WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES (EX- PRESS 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. EQUIPMENT NOT COVERED BY GRACO WARRANTY. Accessories or components of equipment sold by Grace that are not manufactured by Grace (such as electric motors, switches, hose, etc.) are subject to the warranty, if any, of their manufacturer. Grace will provide purchaser with reasonable assistance in making such claims. Factory Branches:Atlanta, Dallas, Detroit, Los Angeles, West Caldwell (N.J.) Subsidiary and Affiliate Companies:Canada: England: Franca; Germany; Hong Kong; Japan GRACO INC. I. 0. Box 1441 MINNEAPOLIS, MN PRINTED IN U.S.A Revised 3-84