Graco 918316 Operation manual

200 LITER (55 GALLON) DRUM SIZE
165 MM (6.5 IN.) DUAL POST
Air-Powered
Ram Supply Unit
Instructions–Parts List
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 1996, Graco Inc. is registered to I.S. EN ISO 9001
310524W
Model 918316
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
See page 2 for Models and Table of Contents.
8934B

2 310524
Table Of Contents
Part Number Air Motor Ratio Pump Wiper Max. Fluid Working Pressure Page
* 918316 Premiert80:1 Check-Mate 1000 EPDM 32.7 MPa, 327 bar (4800 psi) 25
* 918303 Premier 39:1 Check-Matet2100 PVC 27 MPa, 269 bar (3900 psi) 27
687105 Kingt65:1 Check-Mate 800 EPDM 33 MPa, 332 bar (4875 psi) 29
246966 Bulldog 31:1 Check-Mate 800 EPDM 21 MPa, 211 bar (3100 psi) 30
246967 Kingt65:1 Check-Mate 800 EPDM 33 MPa, 332 bar (4875 psi) 32
* 918313 King 65:1 Check-Mate 800{PVC 40 MPa, 403 bar (5850 psi) 35
* 234122 Senator 34:1 Check-Mate 450 EPDM 23 MPa, 234 bar (3400 psi) 35
* 918315 King 50:1 Check-Mate 1000 EPDM 31 MPa, 310 bar (4500 psi) 37
* 918597 King 65:1 Check-Mate 800 EPDM 40 MPa, 403 bar (5850 psi) 39
* 918314 Quiet King 65:1 Check-Mate 800{EPDM 40 MPa, 403 bar (5850 psi) 41
* 918469 Premier 34:1 Dura-Flot2400 PVC 23 MPa, 234 bar (3400 psi) 43
* 918481 Premier 45:1 Dura-Flo 1800 PVC 31 MPa, 310 bar (4500 psi) 45
C59702 Premier 67:1 Dura-Flo 1200{PVC 34 MPa, 345 bar (5000 psi) 47
* 261629 Quiet King 24:1 Check-Mate 800 –16.6 MPa, 166 bar (2400 psi) 9
* These products are CE marked.
Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Selection Chart 6. . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a Location for the Ram 8. . . . . . . . . . . . . .
System Accessories and Modules 8. . . . . . . . . . . . .
Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Ram 10. . . . . . . . . . . . . . . . . . . . . . . . . .
Ground The System 10. . . . . . . . . . . . . . . . . . . . . . . .
Starting Up the System 11. . . . . . . . . . . . . . . . . . . . .
Initial Material Loading 12. . . . . . . . . . . . . . . . . . . . . .
Operation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 13. . . . . . . . . . . . . . . . . .
Raising and Lowering the Ram 14. . . . . . . . . . . . . .
Changing Empty Drums 14. . . . . . . . . . . . . . . . . . . .
Shutdown 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Safety 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ram Pressure Relief Procedure 18. . . . . . . . . . . . .
Removing a Material Drum from
the Supply Unit 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Follower 19. . . . . . . . . . . . . . . . . . . . . .
Removing/Re-installing the King, Senatorr,
or BulldogrPump from the Ram 20. . . . . . . . . . . . .
Removing/Re-installing the Premier Pump
from the Ram 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection Frequency 23. . . . . . . . . . . . . . . . . . . . . .
Parts (see table above) 25. . . . . . . . . . . . . . . . . . . . . . .
Model 918304, Cold Pump Mounting Kit
for Check-Mate Pumps 49. . . . . . . . . . . . . . . . . . . . .
Model 918309, Cold Pump Mounting Kit 50. . . . . .
Model 243785, Ram Air Control Module for
King, Bulldog & Senator 51. . . . . . . . . . . . . . . . . . . .
Model 918306, Ram Air Control Module
for Premier 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 244072, Air Control Assembly 53. . . . . . . . .
Accessories 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Publications 57. . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 58. . . . . . . . . . . . . . . . . . . . .
Graco Information 58. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3310524
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the corresponding
instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
corresponding instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, warnings, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain about usage, call the
distributor closest to you.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck the equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed 125 psi (8.8 bar) maximum inbound air pressure to the ram.
DNever exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the Technical Data on page 56.
DBe sure that all spray/dispensing equipment and accessories are rated to withstand the maxi-
mum working pressure of the pump. Do not exceed the maximum working pressure of any
component or accessory used in the system.
DRoute the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces.
DDo not expose Graco hoses to temperatures above 82_C (180_F) or below -40_C (-40_F).
DDo not use the hoses to pull the equipment.
DUse fluids and solvents that are chemically compatible with the equipment wetted parts. See
the Technical Data sections of all the equipment manuals. Always read the material manufac-
turer’s literature before using fluid or solvent in this pump.
DAlways wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid
and solvent manufacturers.
DWear hearing protection when operating this equipment.
DComply with all applicable local, state and national fire, electrical and other safety regulations.

4 310524
WARNING
SKIN INJECTION HAZARD
Spray from the spray gun, hose leaks, or ruptured components can inject fluid into your body and
cause extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on
the skin can also cause serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
surgical treatment.
DDo not point the gun/valve at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip/nozzle.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DAlways have the trigger guard on the gun when dispensing.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DBe sure the gun/valve trigger safety operates before dispensing
DB
e sure
th
e gun
/
va
l
ve
t
r
i
gger sa
f
e
t
y opera
t
es
b
e
f
ore
di
spens
i
ng.
DLock the gun/valve trigger safety when you stop dispensing.
DFollow the Pressure Relief Procedure on page 13 if the nozzle clogs, and before cleaning,
checking or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immedi-
ately. Do not repair high pressure couplings; you must replace the entire hose.
DUse only Graco approved hoses. Do not remove the spring guard that is used to help protect
the hose from rupture caused by kinks or bends near the couplings.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor air ventilation, open flames or sparks can cause a hazardous condition
and result in fire or explosion and serious injury.
DGround the equipment and the object being sprayed, and all other electrically conductive
objects in the dispense area. Proper grounding dissipates static electricity generated in the
equipment. See Ground the System on page 10.
DIf there is any static sparking or you feel an electric shock while using the equipment, stop dis-
pensing immediately. Do not use the equipment until you have identified and corrected the
problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvent or material.
DDo not smoke in the dispense area.
DExtinguish all open flames or pilot lights in the dispense area.
DDo not turn on or off any light switch in the dispense area.
DKeep the dispense area free of debris, including solvent, rags, and gasoline.

5310524
WARNING
MOVING PARTS HAZARD
Moving parts, such as the ram follower plate/pump inlet can pinch or amputate fingers.
DDo not operate the equipment with the guard removed.
DKeep clear of all moving parts when starting or operating the equipment.
DKeep hands and fingers away from the priming piston during operation and whenever the pump
is charged with air.
DKeep clear of the follower plate, pump fluid inlet, and lip of the fluid container when raising or
lowering the ram.
DBefore checking or servicing the ram or pump, follow the Pressure Relief Procedure on
page 13.
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.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all
local, state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
DProvide adequate ventilation.

6 310524
Pump Selection Chart
Pump Model and Description Maximum Fluid Working
Pressure Maximum Pump Air Input Pressure Part Number
34:1 Premier, DF2400, CS Lower
34:1 Premier, DF2400, SST Lower
39:1 Premier, CM2100, CS Lower
39:1 Premier, CM2100, SST Lower
23 MPa, 234 bar (3400 psi)
23 MPa, 234 bar (3400 psi)
26.9 MPa, 269 bar (3900 psi)
26.9 MPa, 269 bar (3900 psi)
0.7 MPa, 7 bar (100 psi)
0.7 MPa, 7 bar (100 psi)
0.7 MPa, 7 bar (100 psi)
0.7 MPa, 7 bar (100 psi)
222942
222943
222940
222941
45:1 Premier, DF1800, CS Lower
45:1 Premier, DF1800, SST Lower
45:1 Premier, DF1800, SST Lower
45:1 Premier, DF1800, SST Lower
80:1 Premier, CM1000, CS Lower
80:1 Premier, CM1000, SST Lower
31 MPa, 310 bar (4500 psi)
31 MPa, 310 bar (4500 psi)
31 MPa, 310 bar (4500 psi)
31 MPa, 310 bar (4500 psi)
40 MPa, 403 bar (5850 psi)
40 MPa, 403 bar (5850 psi)
0.7 MPa, 7 bar (100 psi)
0.7 MPa, 7 bar (100 psi)
0.7 MPa, 7 bar (100 psi)
0.7 MPa, 7 bar (100 psi)
0.5 MPa, 5 bar (73 psi)
0.5 MPa, 5 bar (73 psi)
222938
222939
234667
234824
237518
237520
50:1 King, CM1000, CS Lower
50:1 King, CM1000, SST Lower
65:1 King, CM800, CS Lower
65:1 King, CM800, SST Lower
31 MPa, 310 bar (4500 psi)
31 MPa, 310 bar (4500 psi)
40 MPa, 403 bar (5850 psi)
40 MPa, 403 bar (5850 psi)
0.6 MPa, 6.2 bar (90 psi)
0.6 MPa, 6.2 bar (90 psi)
0.6 MPa, 6.2 bar (90 psi)
0.6 MPa, 6.2 bar (90 psi)
237707
237708
236471
236462
31:1 Bulldog, CM800, CS Lower
19:1 Senator, CM800, CS Lower
65:1 Reduced Icing Quiet King,
CM800, CS Lower
31:1 Reduced Icing Quiet Bulldog,
CM800, CS Lower
21 MPa, 214 bar (3100 psi)
13 MPa, 131 bar (1900 psi)
40 MPa, 403 bar (5850 psi)
21 MPa, 214 bar (3100 psi)
0.7 MPa, 7 bar (100 psi)
0.7 MPa, 7 bar (100 psi)
0.6 MPa, 6.2 bar (90 psi)
0.7 MPa, 7 bar (100 psi)
237261
237264
237265
237274
12:1 Bulldog, CM2100, SST Lower
12:1 Quiet Bulldog, CM2100,
SST Lower
24:1 King, CM2100, SST Lower
24:1 Quiet King, CM2100, SST Lower
8 MPa, 83 bar (1200 psi)
8 MPa, 83 bar (1200 psi)
14.9 MPa, 149 bar (2160 psi)
14.9 MPa, 149 bar (2160 psi)
0.7 MPa, 7 bar (100 psi)
0.7 MPa, 7 bar (100 psi)
0.6 MPa, 6.2 bar (90 psi)
0.6 MPa, 6.2 bar (90 psi)
222904
222903
222836
222905
67:1 Premier, DF1200, SST Lower 34 MPa, 345 bar (500 psi) 0.5 MPa, 5.2 bar (75 psi) 245171
Viscount Hydraulic Motor, CM2100,
SST Lower
15 MPa, 156 bar (2300 psi) N/A 222906
34:1 Senator, CM4500, CS Lower 23 MPa, 234 bar (3400 psi) 0.7 MPa, 7 bar (100 psi) 222769

7310524
Typical Installation
A Air Line Filter
B Accessory Bleed-Type Master Air Valve
(required)
C Pump Bleed-Type Master Air Valve (required)
D Pump Air Regulator
E Main Air Line Supply
F Air Manifold
G Follower Plate Blowoff Button
H Ram Air Supply Hose
I Air Line Lubricator
J Fluid Drain Valve (required)
K Fluid Regulator
L Applicator Gun or Valve
M Gun Swivel
N Mounting Plate
10 Follower Rod
20 Pump Assembly
30 Ram Hand Valve
40 Ram Module
50 Follower Gasket
60 Follower Plate Assembly
70 Wiper Seals
80 Drum Clamp
90 Grounding Wire (required)
Fig. 1
10
20
90
H
30
G
40
50
60
70
80
J
L M
K
B
IAE
D
F
C
N
8328B

8 310524
Typical Installation
The typical installation discussed below is only a guide
for selecting and installing system components and
accessories. Contact your Graco distributor for help in
designing a system to suit your particular needs.
This air-powered ram extruder forces high viscosity
fluids into the intake valve of the fluid pump. Wiper
rings and other accessory equipment for use with this
ram are listed in the Accessories section on page 54.
Selecting a Location for the Ram
Refer to the Ram Mounting and Clearance Dimensions
drawing (Fig. 14 on page 55) for ram mounting and
clearance dimensions.
When selecting a location for the ram, keep the follow-
ing in mind:
1. There should be sufficient space for installing and
using the equipment.
DMake sure there is sufficient overhead clear-
ance for the pump and ram when the ram is in
the fully raised position.
DMake sure the air regulators for the pump and
ram are fully accessible.
2. Make sure that you will be able to level the base of
the ram using metal shims.
3. When you bolt the ram to the floor, the anchors
should be long enough to prevent the unit from
tipping. Refer to the Dimensional Drawing on page
55 for more information.
System Accessories and Modules
Before you install the system you should be familiar
with the parts discussed below. For more information,
refer to Fig. 1, Typical Installation, on page 7.
Air and Fluid Hoses
When installing a system, make sure:
Dall air and fluid hoses are properly sized for your
system.
Dto use only electrically conductive air and fluid
hoses.
Dto use only Graco approved hoses. Do not remove
the spring guard that is used to help protect the
hose from rupture caused by kinks or bends near
the couplings.
To allow the gun to move more freely, use a short whip
hose between the main fluid hose and the gun.
Air Line Modules
WARNING
PRESSURIZED FLUID HAZARD AND
MOVING PARTS HAZARD
The pump bleed-type master air valve,
(C) in Fig. 1, is required in your system
to relieve air trapped between this valve
and the pump after the pump air regula-
tor is closed. Trapped air can cause the
pump to cycle unexpectedly, which could
result in serious injury, including splashing in the
eyes or on the skin and injury from moving parts.
3-Regulator Air Control Modules (shown in Fig. 1)
The following components are supplied with your
pump:
DPump Bleed-type Master Air Valve (C) is required in
your system to relieve air trapped between it and
the air motor when the valve is closed (see the
WARNING above). Be sure the bleed valve is
easily accessible from the pump, and is located
downstream from the air regulator.
DPump 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.
DRam Down Air Regulator (not shown) controls the
air pressure to the ram.
DRam Up Air Regulator (not shown) controls the air
pressure to the ram.
DRam Air Supply Hose (H) connects the ram air
regulator to the air manifold.
DAir Manifold (F) divides the main air supply into
separate lines for the pump and ram.

9310524
Installation
Air Line Accessories
If you have a 3-Regulator Air Control Module, install
the following accessories, using adapters as neces-
sary:
DPump runaway valve senses when the pump is
running too fast and automatically shuts off the air
to the motor. A pump that runs too fast can be
seriously damaged.
DAir line lubricator provides automatic air motor
lubrication (standard on the 4-Regulator Air Control
Module).
DAir line filter removes harmful dirt and moisture
from the compressed air supply (standard on the
4-Regulator Air Control Module).
DAccessory bleed-type air valve isolates the air line
accessories for servicing. Locate upstream from all
other air line accessories. This isolates the acces-
sories for servicing.
Fluid Line Accessories (Fig. 1)
Install the following accessories in the positions shown
in the Typical Installation, using adapters as neces-
sary:
A fluid drain valve (J) is required in your system to
relieve fluid pressure in the hose and gun (see the
WARNING on page 8). When you install the fluid
drain valve:
1. Screw the drain valve into the open branch of a tee
mounted in the fluid line.
2. Install the drain valve pointing down, but so the
handle points up when the valve is opened.
A fluid regulator (K) controls fluid pressure to the
gun/valve, and dampens pressure surges.
A gun or valve (L) dispenses the fluid. The gun shown
in the Typical Installation is a dispensing gun for highly
viscous fluids.
A gun swivel (M) allows the gun to move more freely.

10 310524
Installation
The installation procedure includes:
Dlocating and installing the ram. See Form# 310523
for further information.
Dgrounding the system
Dstarting up the system
Dinitially loading material
Installing the Ram
To install the ram, follow the procedure below. Refer to
the Ram Mounting and Clearance Dimensions drawing
(Fig. 14 on page 55) for ram mounting and clearance
dimensions.
1. Select a convenient location for the equipment.
Check that there is sufficient overhead clearance
for the pump and ram when the ram is in the fully
raised position. Make sure the air regulators for the
pump and ram are fully accessible.
2. Level the base of the ram, using metal shims.
3. Using the holes in the base as a guide, drill holes
for 13 mm. (1/2 in.) anchors. Bolt the ram to the
floor anchors, which are long enough to prevent
the unit from tipping. Refer to the Dimensional
Drawing on page 55.
Ground The System
Ground the supply unit as instructed here and in the
individual component manuals.
WARNING
FIRE AND EXPLOSION HAZARD
When installing the pump, ground the
system as explained below. Also read
the section FIRE AND EXPLOSION
HAZARD on page 4.
To reduce the risk of static sparking, ground the pump,
object being sprayed, and all other spraying/dispensing
equipment used or located in the spraying/dispensing
area. Check your local electrical code for detailed
grounding instructions for your area and type of equip-
ment.
1. Pump: connect a ground wire and clamp to a true
earth ground as shown in Fig. 2.
a. Loosen the grounding lug locknut (W) and
washer (X).
b. Insert one end of a 1.5 mm2(12 ga) minimum
ground wire (Y) into the slot in lug (Z) and
tighten the locknut securely.
c. Connect the other end of the wire to a true
earth ground.
To maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
spray gun/dispensing valve firmly to the side of a
grounded metal pail, then trigger the gun/valve.
Fig. 2
w
XY
Z
2. Fluid and air hoses: use only electrically conduc-
tive materials and air hoses, and fluid hoses.
3. Air compressor: follow the manufacturer’s recom-
mendations.

11310524
Installation
Ground The System (continued)
Material Drums
Ground material drums according to your local code.
Use only metal drums, which are conductive, placed
on a grounded surface. Do not place the drum on a
nonconductive surface, such as paper or cardboard,
which interrupts the grounding continuity.
Maintain Grounding Continuity When Purging Or
Relieving Pressure
Follow the instructions in your separate gun manual for
safely grounding your gun while purging.
Starting Up the System
WARNING
PRESSURIZED EQUIPMENT HAZARD
To help reduce the risk of injury or equip-
ment damage:
DMake sure all material hose connec-
tions are secure.
DDo not pressurize the system until
you have verified the system is ready
and it is safe to do so.
1. Check all material hoses and fittings to insure
tightness and to prevent any material leakage.
2. Check all system air lines. Make sure that all rout-
ing of air lines will not interfere with any moving
components within the fixture.
3. Raise the ram, using the following procedure:
a. Close all air regulators.
b. Move the ram hand valve lever to the UP posi-
tion.
c. Slowly open the air appropriate regulator(s)
until the ram starts to move up.
d. When the follower plate is above the height of
the material drum to be used, move the ram
hand valve lever to OFF.

12 310524
Installation
Initial Material Loading
WARNING
PRESSURIZED FLUID HAZARD
To reduce the risk of serious bodily inju-
ry, such as fluid injection or splashing
fluid in the eyes or on the skin, ALWAYS
wear eye protection and protective cloth-
ing when installing, operating, or servic-
ing this dispensing system.
MOVING PARTS HAZARD
Moving equipment parts can cause
personal injury, including severing of
hands or fingers. Make sure all person-
nel are clear of moving parts before
operating the equipment.
CAUTION
The use of a non-compatible lubricant can cause
material contamination or inadequate perfor-
mance. Use only a lubricant compatible with the
material to be pumped. Check with the material sup-
plier for a recommended lubricant.
To help avoid damage to equipment, do not use a
drum of material that has been dented or otherwise
damaged; damage to the follower wipers may result.
An empty drum clamp can interfere with up and
down operation of the ram. When raising or lower-
ing the ram, make sure the drum clamp stays clear
of the follower assembly.
For information about specific air pressure settings,
refer to the Graco system documentation.
1. Raise the follower plate high enough to put a drum
of material under it. Make sure the drum clamp
stays clear of the follower assembly.
2. Open a drum of the proper material and place it
under the elevated follower plate.
NOTE: Whenever drum changes are required, re-
move the cover from a drum of new material by hold-
ing it level and lifting it straight up. Tipping the cover
may allow accumulated dirt to spill into the drum,
which may result in damage to the equipment.
3. Lubricate the follower wipers with a lubricant com-
patible with the material to be pumped. Check
with your material supplier for compatibility.
4. Before lowering the pump into the drum, make
sure that nothing is between the follower plate and
the drum, or between the ram tie bar and the top
of the ram posts.
5. Lower the pump and follower into the drum of ma-
terial:
a. Move the hand valve lever to the DOWN
position and lower the ram until the follower
plate is just ready to enter the drum, then
move the valve to OFF. If necessary, reposi-
tion the drum so the wipers will not hit the
drum lip, then open the vent valve (not shown)
on the follower plate.
b. Move the ram hand valve lever to the DOWN
position and slowly open the air regulator.
c. As the follower enters the drum, loosen the
bleed stick. Loosening the bleed stick allows
trapped air between the follower plate and the
top of the material to escape.
d. When air stops exhausting from the bleed stick
port, replace and tighten the bleed stick.
6. Place a material waste container under the dis-
pense gun.
7. Slowly adjust the pump air regulator. This will
start the pump and fill the material passage.

13310524
Operation
Pressure Relief Procedure
This procedure describes how to relieve pressure for
the supply unit. Use this procedure whenever you shut
off the dispenser/sprayer and before checking or
adjusting any part of the system, to reduce the risk of
serious injury.
WARNING
MOVING PARTS HAZARD
Follow this Pressure Relief Procedure
before checking or repairing the ram or
any other part of the system, and when
shutting down the system. Keep hands and fingers
away from the follower plate, fluid pump inlet, and
lip of the fluid container when raising or lowering
the ram to reduce the risk of pinching or amputat-
ing hands or fingers.
During operation, also keep hands and fingers
away from limit switches to reduce the risk of
pinching or amputating hands or fingers.
SKIN INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
Dare instructed to relieve the pressure
Dstop spraying/dispensing
Dinstall or clean the spray tip/nozzle
Dcheck or service any of the system equipment
PRESSURIZED FLUID HAZARD
Do not operate the 80:1 Premier above 5
bar (73 psi) air pressure. The CM1000
lower is rated to 403 bar (5850 psi)
Maximum Fluid Working Pressure. The pump
supply unit is equipped with a pressure relief valve
to prevent the user from operating the pump air
pressure regulator above the recommended 5 bar
(73 psi). For further technical assistance, contact
your Graco distributor.
1. Lock the gun/valve trigger safety.
2. Shut off the main air supply to the pump.
3. Close all air bleed valves.
4. Unlock the gun/valve trigger safety.
5. Hold a metal part of the gun/valve firmly to the side
of a grounded metal drum, and trigger the gun/
valve to relieve pressure.
6. Lock the gun/valve trigger safety.
7. Have a container ready to catch the drainage, then
open the drain valve or pump bleed valve.
8. Leave the drain valve open until you are ready to
spray/dispense again.
NOTE: 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 to relieve pressure gradually, then loosen
completely. Then clear the tip/nozzle or hose.
9. If you want to relieve pressure in the ram, see the
Ram Pressure Relief Procedure on page 18.

14 310524
Operation
Raising and Lowering the Ram
CAUTION
An empty drum clamp can interfere with up and
down operation of the ram. When raising or lowering
the ram, make sure the drum clamp stays clear of
the follower assembly.
Fig. 1. The ram hand valve (30) on the ram air control
has 3 positions:
DRam UP raises the ram
DRam DOWN lowers the ram
DRam OFF puts the ram in “neutral.” Moving the
hand valve to OFF does not change the position of
the ram, but it stops the air pressure from attempt-
ing to move the ram either up or down.
Changing Empty Drums
WARNING
MOVING PARTS HAZARD
To reduce risk of injury or damage to
equipment, take care when adjusting
blow off pressure. Too much pressure
can cause the follower plate to rise very
quickly or burst the drum. Too little pres-
sure can cause the ram to lift the entire
drum from the ground.
PRESSURIZED FLUID HAZARD
Bursts of material and air will exit the
bleed port! To reduce risk of injury or
damage to equipment, wear eye
protection, gloves and protective clothing
whenever working with this supply
system.
CAUTION
To help avoid damage to equipment:
DBe sure to reload the empty supply unit with a full
drum of material immediately. Do not allow the
supply units to operate when empty, which would
cause a pump runaway and cause damage to the
system.
DDo not raise the ram and remove the follower
plate from the empty drum until you are ready to
immediately install the new drum.
DDo not use a drum of material that has been
dented or otherwise damaged; damage to the
follower wipers may result.
An empty drum clamp can interfere with up and
down operation of the ram. When raising or lower-
ing the ram, make sure the drum clamp stays clear
of the follower assembly.

15310524
Operation
Changing Empty Drums (continued)
Read all warnings and instructions before
attempting this procedure!
When a drum of material is empty, follow this proce-
dure to load a new drum of material:
1. Stop the pump by closing the pump’s bleed-type
master air valve.
2. Raise the follower out of the drum:
a. Leave the ram down regulator to 6.8 (100 psi).
b. Set the ram UP air regulator to 0.68–1.02 bar
(10–15 psi).
c. Move the ram hand valve lever to the UP posi-
tion. Adjust the ram up regulator to make the
ram slowly raise. At the same time, open and
close the follower blow-off valve carefully to
equalize the pressure in the drum. If more air
line pressure is needed for the follower blower-
off, then carefully increase the pressure at the
air inlet regulator.
3. With the follower completely out of the drum, re-
move the empty drum from the ram.
4. Being careful not to damage the follower wiper,
scrape any material or material build-up from the
follower plate and wiper.
5. Apply a lubricant to the wipers. The lubricant
should be compatible with the material to be
pumped. (Check with the material supplier for a
compatible lubricant.)
6. Place the new drum in the ram:
a. Remove the cover from a drum of appropriate
material.
b. Remove any other packing from the drum, to
expose the material. Make sure that there are
no foreign objects on the material surface.
NOTE: Whenever drum changes are required, re-
move the cover from a drum of new material by hold-
ing it level and lifting it straight up. Tipping the cover
may allow accumulated dirt to spill into the drum,
which may result in damage to the equipment.
c. Place the drum under the raised follower plate.
7. Lower the follower into the drum:
a. Move the ram hand valve lever to the DOWN
position.
b. Check the drum position as the follower low-
ers. If necessary, stop lowering the follower
before contacting the drum, and adjust the
drum and/or clamp positions to align the drum
with the follower plate.
c. Continue lowering the follower. As the follower
enters the drum, loosen the air bleed stick.
Loosening the bleed stick allows trapped air
between the follower plate and the top of the
material to escape.
d. When air stops exhausting from the bleed stick
port, replace and tighten the bleed stick.
8. Adjust the ram air pressure for normal operation.
9. Bleed, from the material pump, the air that was
introduced during the drum change:
a. Place a waste container under the pump bleed
port.
b. Open the bleed port and turn on pump air
pressure.
c. Allow material to flow from the bleed port until
it is air-free.
d. Shut off air to the pump and close the bleed
port.
e. Turn air on to the pump and set the pump air
regulator for normal operation.
10. Resume normal operation.

16 310524
Operation
Shutdown
To shut down the supply unit:
1. Fig. 1. Move the ram hand valve (30) to the OFF
position. Shut off the air supply to the ram and
pump.
WARNING
To reduce the risk of serious injury, whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure (page 13).
2. Relieve the pressure.
Emergency Stop
1. Fig. 3. Stop the pump by closing the Pump’s
Bleed-type Master Air Valve closest to the motor’s
air inlet (C).
Fig. 3
B
C
2. Stop the ram from moving by:
a. Closing the master accessory air valve (B).
b. Moving the ram hand valve lever to the OFF
position.
Flushing Safety
WARNING
Use fluids and solvents that are chemically compat-
ible with the equipment wetted parts. See the
Technical Data sections of all the equipment
manuals. Always read the material manufacturer’s
literature before using fluid or solvent in this pump.
1. Before flushing, be sure the entire system and
flushing drums are properly grounded. Refer to
Ground The System, on page 10.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure (page 13).
2. Relieve the pressure.
WARNING
PRESSURIZED FLUID HAZARD
Always use the lowest possible fluid
pressure, and maintain firm
metal-to-metal contact between the
gun/valve and the drum during flushing
to reduce the risk of fluid injection injury,
static sparking and splashing.
3. Remove the spray tip/nozzle from the spray gun/
dispensing valve.

17310524
Troubleshooting
PROBLEM CAUSE SOLUTION
Ram won’t raise or lower Closed main air valve or clogged
air line
Open air valve, clean air line
Ram won’t raise or lower Not enough air pressure Increase ram pressure
Worn or damaged piston Replace piston. See procedure in Form
#310523.
Hand valve closed or clogged Open, clear hand valve or exhaust
Ram raises or lowers too fast Ram air pressure too high Decrease ram air pressure
Air leaks around cylinder rod Worn rod seal Replace o-rings in guide sleeve. See
procedure in form #310523.
Fluid squeezes past follower plate
i
Ram air pressure too high Decrease ram air pressure
wipers Worn or damaged wipers Replace wipers. See procedure on page
19
Material pump won’t prime proper-
ly, only pumps air.
Closed main air valve or clogged
air line
Open air valve, clear air line
Not enough pump air pressure increase pump pressure
Worn or damaged piston Replace piston. See procedure in Form
# 310523.
Hand valve closed or clogged Open, clear hand valve or exhaust
Hand valve dirty, worn or dam-
aged
Clean, service hand valve
Bent drum has stopped follower Replace drum
Air pressure won’t hold drum
down or push plate up
Closed main air valve or clogged
air line
Open air valve, clear air line
Not enough ram air pressure Increase ram air pressure
Valve passage clogged Clean valve passage
Worn piston seal Replace seal

18 310524
Service
To relieve ram air pressure, follow the procedure
below. For more more information about servicing the
ram, see Form# 310523, 165 mm (6.5 in.) Global
Ram Module.
Ram Pressure Relief Procedure
WARNING
To reduce the risk of serious injury whenever you
service the ram, always follow the procedure
below.
To relieve air pressure in the ram:
1. Relieve the supply unit pressure.
WARNING
To reduce the risk of serious injury, whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure (page 13).
2. Fig. 1. Using the ram hand valve (30) on the air
control, move the ram to the DOWN position.
3. When the ram reaches the full down position,
move the ram hand valve lever to OFF.
4. On the air regulator panel, set the ram regulator
pressure for:
DRAM UP to 0 (zero)
DRAM DOWN to 0 (zero).
5. Exhaust air from both sides of the ram:
a. Move the ram hand valve lever to the DOWN
position until all air is exhausted from one side
of the ram.
b. Move the ram hand valve lever to the UP
position until all air is exhausted from the other
side of the ram.
6. Fig. 4. Close the bleed–type master accessory air
valve (B).
Fig. 4
B

19310524
Service
Removing a Material Drum from the
Supply Unit
WARNING
PRESSURIZED FLUID HAZARD
Bursts of material and air will exit the
bleed port! To reduce risk of injury or
damage to equipment, wear eye
protection, gloves and protective clothing
whenever working with this supply
system.
Before you perform the procedures in this section,
remove the material drum from the supply unit. Ob-
serve the cautions and warnings, then follow steps 1
through 4 of the procedure for Changing Empty
Drums on page 14.
Servicing the Follower
This section describes how to service the wipers
without removing the follower plate from the supply
unit.
Servicing Wipers
For replacing T–Wipers (243279), see Graco form
309161. To replace worn or damaged wipers (w):
Fig. 5
w
1. Raise the follower plate up out of the drum by
observing the cautions and warnings, then follow-
ing steps 1 through 4 of the procedure for Chang-
ing Empty Drums on page 14.
2. Separate the wiper butt joint and bend back the
strapping that covers the clamp. Loosen the clamp
by unscrewing the worm gear, then remove the
wiper.
3. Thread the strapping through the new wiper.
4. Install the wiper on the follower plate.
a. Position the wipers so the butt joints are 180_
apart (Fig. 5).
b. Insert the end of the strap through the clamp
and tighten.
5. Pound the wiper all the way around the follower
plate, with a rubber mallet, until the ends are
butted tightly together.
6. Repeat steps 2–5 for the second wiper.
7. Apply a lubricant to the wipers. The lubricant
should be compatible with the material to be
pumped. (Check with the material supplier for a
compatible lubricant.)

20 310524
Service
Removing/Re-installing the King, Senator,
or Bulldog Pump from the Ram
Removing the Pump Assembly
Fig. 6. Remove pump assembly from ram as follows:
NOTE: The pump assembly consists of the air motor
(A) and the pump (B). It is not necessary to remove
the entire pump assembly just to remove the pump.
See the next section, Separating the Pump from the
Air Motor to just remove the pump.
1. If material drum has already been removed from
supply unit, go to step 2. To remove material
drum, observe cautions and warnings, then follow
steps 1 through 4 of procedure for Changing
Empty Drums on page 14.
2. Make sure ram hand valve is in OFF position.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure (page 13).
3. Relieve the supply unit pressure.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve ram pressure, always
follow the Ram Pressure Relief Procedure
(page 18).
4. Relieve the ram air pressure.
5. Bleed off pressure in system and excess material
by opening dispense gun and catching material in
waste container.
6. Make note of air and material hose connections
and routings. Use note when re–installing hoses.
7. Disconnect all air and material hoses.
8. Using capable hoist, secure pump assembly to
hoist.
9. Remove four screws (47) and lockwashers (48)
securing pump assembly to mounting plates (32).
10. Remove four screws (27) and lugs (26) attaching
pump assembly to follower plate (10).
NOTE: If necessary for pump clearance, loosen set
screws (31) and slide two mounting plates (32) down
and away from pump.
11. Using hoist, lift and remove pump assembly from
ram and follower plate. Take care not to damage
o-ring (29), used on some units, located between
pump assembly and follower plate.
12. Inspect and lubricate o-ring (29) when reinstalling
pump assembly, replace if damaged.
13. Service pump assembly as needed. To remove the
pump from air motor, go to next section, Separat-
ing the Pump from the Air Motor. See pump ma-
nual for further servicing information.
Fig. 6
31
32 47,
48
A
B
26,
27
29
10
ti7939a