Graco C59519 Operation manual

310295
Revision B
First choice when
quality counts. t
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
3” AND 6.5” RAM
Electric Crossover Kit
250 psi (1.7 MPa, 17.2 bar) Maximum Air Inlet Pressure
Part No. C59519, Series A
Electric Crossover Kit
Part No. C59520, Series A
Electric Crossover Kit
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 4. . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 10. . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

2 310295
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNINGS
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to Technical
Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
Wear hearing protection when operating this equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.

310295 3
WARNINGS
MOVING PARTS HAZARD
Moving parts, such as the ram plate/pump inlet can pinch fingers.
Do not operate the equipment with the guard removed.
Keep clear of all moving parts when starting or operating the equipment.
Keep hands and fingers away from the priming piston during operation and whenever the pump is
charged with air.
Keep clear of the ram plate, pump fluid inlet, and lip of the fluid container when raising or lowering
the ram.
Before checking or servicing the ram or pump, follow the Pressure Relief Procedure in the ram or
pump manual.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
Avoid exposure to heated material fumes.
Provide adequate ventilation.
FIRE, EXPLOSION AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in fire, explosion, or electricshock and other serious injury.
Ground the equipment, the object being dispensed, and all other electrically conductive objects in
the dispense area. Proper grounding dissipates static electricity generated in the equipment. See
Ground the System in your system manual.
Do not use this equipment with flammable liquids.
Keep the dispense area free of debris, including solvent, rags, and gasoline.
If there is any static sparking while using the equipment, stop dispensing immediately. Identify
and correct the problem.
Make sure all electrical work is performed by a qualified electrician only.
Make sure all electrical equipment is installed and operated in compliance with applicable codes.
Make sure power is disconnected when servicing and repairing equipment.
Have any checks, installation, or service to electrical equipment performed by a qualified electrician
only.

4 310295
Component Identification and Function
Fig. 1
KEY
A3-Way Solenoid Valve (2)
BEmpty Level Kit (2) CLimitSwitch(2) DUnloaderCross-overPanel
8584A
AC
BAB
Supply Unit A Supply Unit B
NOTE: Viewed from the
loading direction.
C
D
CL3 CL1 CL4 CL2
8891A
A
C (hidden)
B
A
D
CL3 CL1 CL4 CL2
B
C (hidden)
Model C59519
Supply Unit A Supply Unit B
Model C59520

310295 5
Installation
Prepare the Site
NOTE: Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor. If you
supply your own accessories, be sure they are ade-
quately sized and pressure rated for your system.
NOTE: Letters and numbers in parenthesis refer to the
callouts and the parts list on page 10.
Bring a compressed air supply line from the air com-
pressor to the pump location. Be sure all air hoses are
properly sized and pressure-rated for your system.
Use only electrically conductive hoses. The air hose
should have a 3/4 npsm(m) thread.
Before installing any air line components, blow out the
air lines to remove scale and other debris. Use pipe
compound or tape sparingly and only on male threads.
Install a bleed-type shutoff valve in the air line up-
stream from all other air line components, to isolate
them for servicing.
Electrical Service
Electrical power to the crossover is supplied by a
power cord.
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
The electrical wiring shall be performed
only by trained and qualified personnel
to reduce the risk of serious injury and
electric shock.
Observe all local codes and regulations
regarding electrical wiring.
When installing in a flammable atmosphere (hazardous
location) refer to Article 500 of the US National Electric
Code or other applicable agency standards to plan the
work.
The operating voltage is 120VAC. This equipment re-
quires a 50/60 Hz, single-phase, 15 Ampere grounded
power supply.
Application
The electric crossover kit is designed to allow two
drum ram systems to be converted into a continuous-
flow system. It shifts pumping from an online ram
when the drum becomes empty.
Typical Electric Crossover Installation
WARNING
Never leave fingers between the ram plate and the
drum when the ram plate is being operated.
WARNING
Never enter the operating area of the ram , when
the ram is in the top position. When the air pres-
sure is lost or in the case of leaks in the air pres-
sure system, the ram plate may drop.
The typical installation, shown on page 4, Fig. 1 of this
manual, is only a guide. See the system manual for
your application or contact your Graco distributor for
assistance in designing a system to meet your needs.
See your ram manual if installing a new ram or relocat-
ing an existing ram.

6 310295
Installation
Electric Crossover Setup
NOTE: During system operation, as the ram ap-
proaches the drum bottom, the top of the ram contacts
the empty level indicator kit’s limit valve switch. The
switch shuts off air to the ram air motor via a solenoid
valve. As the valve stops air to one air motor, it starts
air to the other air motor. This allows constant material
flow and changing out of material drums.
The position of the empty level indicator kit (B) on the
ram determines when the ram air motor is turned on
and off. During operation, this position can be adjusted
as desired.
1. Install crossover unloader (1) on ram assembly,
using U-bolt (3), washer (4) and nut (5) as shown
in Parts. Connect air supply.
WARNING
ELECTRIC SHOCK HAZARD
Do not open the electrical control panel,
unless you are a trained professional.
Before opening the control panel, make sure that
all power has been removed from the control panel.
2. Connect electrical connectors to cross-over
unloader (see Fig. 2). Refer to Schematic,
Fig. 3.
Fig. 2
3. Install solenoid valve (7) and connect electrical
connector as shown in Parts.
4. Install 2 empty level kit assemblies (9) on each
ram assembly, using attaching parts, as shown in
Parts drawing.
5. Connect electrical connector to each empty level
kit assembly (9). Refer to Schematic, Fig. 3.
Fig. 3
6. Adjust limit switch (9c) to trip with the ram plate 1”
from base plate (see Parts).

310295 7
Parts
Model C59519 Electric Crossover
Includes items 1–13
Ref Part
No. No. Description Qty Ref Part No. No. Description Qty
1 C59528 CROSSOVER, unloader 2
2 617837 PLATE, mounting, J-box 4
3 C24332 U-BOLT, 3/8–16 2
4 107176 WASHER, lock, 3/8 4
5 100307 NUT, hex, 5/8–16 4
6 C06311 MUFFLER, 3/4 NPT 2
7 C06325 VALVE, solenoid, 3/4 NPT 2
8 175013 NIPPLE, hex, 3/4 NPT 2
9 C55333 KIT ASSEMBLY, empty level (includes
items 9a through 9g 2
9a C32111 S LIGHT FIXTURE 1
9b C07451 S CONNECTOR, receptacle 1
9c C07368 S LIMIT SWITCH w/lever 1
9d C55409 S BRACKET, limit switch 1
9e C19192 S NUT, hex, 3/8–16 2
9f C19213 SWASHER, lock 2
9g C24332 S U-BOLT 1
10 C19736 SCREW, drive 8
11 C19107 SCREW, hex hd, 5/16–18 4
12 C19211 WASHER, lock, 5/16 8
13 C19191 NUT, hex, 5/16–18 4
8584A
See below
3
4, 5
See below
2
1
See below
See below
10, 11, 12, 13
SOL 121 SOL 117 LS 109
Supply Unit #1 Supply Unit #2
8
76 Air Out to Motor
Air In
Top View
9a
9c
9b
9d
9e, 9f 9g

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Parts
Model C59520 Electric Crossover
Includes items 1–14
Ref Part
No. No. Description Qty Ref Part No. No. Description Qty
1 C59528 CROSSOVER, unloader 2
2 617837 PLATE, mounting, J-box 1
3 C32424 U-BOLT, 3/8–16 2
4 107176 WASHER, lock, 3/8 2
5 100307 NUT, hex, 5/8–16 4
6 C06311 MUFFLER, 3/4 NPT 2
7 C06325 VALVE, solenoid, 3/4 NPT 2
8 175013 NIPPLE, hex, 3/4 NPT 2
9 C59650 KIT ASSEMBLY, empty level (includes
items 9a through 9n 2
9a C32111 S LIGHT FIXTURE 1
9b C07451 S CONNECTOR, receptacle 1
9c C07368 S LIMIT SWITCH w/lever 2
9d 617352 S BRACKET, limit switch 1
9e 110344 S SCREW, cap 2
9f 100016 S WASHER, lock 2
9g 100643 SSCREW 2
9h C20819 SFITTING 1
9j 158491 SNIPPLE 2
9k 112776 SWASHER 2
9m 158683 SELBOW 1
9n 155470 SUNION, swivel 1
10 C19736 SCREW, drive 8
11 100450 SCREW, hex hd 4
12 100214 WASHER, lock 8
13 100188 NUT, hex 4
14 C50359 FITTING, union 2
9111A
8891A
7
8
6
9
See detail below
14
11, 12, 1, 2, 12, 13
3, 4, 5
See detail below
9a
9h
9j
9c
9f, 9g
9d, 9e, 9k
9b
9j, 9m, 9n
See detail below
9
See detail below
Air Out to Motor
Air In

310295 9
Notes

10 310295
Graco Standard Warranty
GracowarrantsallequipmentmanufacturedbyGracoandbearingitsnametobefreefromdefectsinmaterialandworkmanshiponthe
dateofsalebyanauthorizedGracodistributortotheoriginalpurchaserforuse. Withtheexceptionofanyspecial,extended,orlimited
warrantypublishedbyGraco,Gracowill,foraperiodoftwelvemonthsfromthedateofsale,repairorreplaceanypartoftheequipment
determined by Graco to be defective. This warranty applies only when the equipment is installed,operated and maintainedin accor-
dance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not beliable for generalwear and tear, or any malfunction,damage or wear causedby
faultyinstallation,misapplication,abrasion,corrosion,inadequateorimpropermaintenance,negligence,accident,tampering,orsub-
stitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verificationof the claimeddefect. If the claimeddefect isverified, Graco willrepair or replacefree of chargeany defective parts. The
equipmentwillbereturnedtotheoriginalpurchasertransportationprepaid. Ifinspectionoftheequipmentdoesnotdiscloseanydefect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES,EXPRESS ORIMPLIED, INCLUDINGBUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’ssoleobligationandbuyer’ssoleremedyforanybreachofwarrantyshallbeassetforthabove. Thebuyeragreesthatnoother
remedy(including,butnotlimitedto,incidentalorconsequentialdamagesforlostprofits,lostsales,injurytopersonorproperty,orany
otherincidentalorconsequentialloss)shallbeavailable. Anyactionforbreachofwarrantymustbebroughtwithintwo(2)yearsofthe
date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
withaccessories,equipment,materialsor componentssoldbutnotmanufacturedby Graco. Theseitems sold,butnotmanufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of theirmanufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
Thepartiesacknowledgethat theyhaverequiredthatthepresent document,aswellasalldocuments, noticesandlegalproceedings
enteredinto,givenorinstitutedpursuantheretoorrelatingdirectly orindirectlyhereto, bedrawnup inEnglish. Lespartiesreconnais-
sentavoir convenuquela rédactiondu présentedocumentsera enAnglais, ainsiquetous documents,avis etprocéduresjudiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Graco Phone Number
TO PLACE AN ORDER , contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–367–4023 Toll Free
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis, Detroit
Foreign Offices: Belgium, Korea, Hong Kong, Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
www.graco.com
PRINTEDIN USA 310295 December 1998 Revised April 1999