Graco SERIES J Operation manual

INSTRUCTIONS–P ARTS LIST 306–934
Rev. K
Supersedes H
This manual contains IMPORT ANT
W
ARNINGS AND INSTRUCTIONS
READ AND RET AIN FOR REFERENCE
55 Gallon (200 Liter) Drum Size
AIR–POWERED RAM
150 psi (10.5 bar) MAXIMUM INBOUND AIR PRESSURE
Model 207–279, Series J
For use with high pressure extrusion pumps (see page 3).
Model 223–634, Series A
For use with Check–Mate  450 pumps
with Displacement Pump 222–790 (see page 3).
TABLE OF CONTENTS
Safety W arnings 2. . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Selection Chart 3. . . . . . . . . . . . . . . . . . . . . .
Installation 4–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart 8. . . . . . . . . . . . . . . . . . . . .
Service 9–12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawings and Lists
Model 207–279 14, 15 . . . . . . . . . . . . . . . . . . .
Model 223–634 16, 17 . . . . . . . . . . . . . . . . . . .
Accessories 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Drawing 19. . . . . . . . . . . . . . . . . . . . .
Technical Data Back Cover . . . . . . . . . . . . . . . . . .
Warranty Back Cover . . . . . . . . . . . . . . . . . . . . . . .
Toll–Free Graco Phone Numbers Back Cover . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Model 207–279 Shown

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SAFETY W ARNINGS
FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS.
Read and understand all instruction manuals before operating equipment.
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the ram or accessories, such as overpressurizing, modify -
ing parts, or using worn or damaged parts, can cause them to rupture and
result in serious bodily injury or property damage.
DO NOT exceed 150 psi (10.5 bar) MAXIMUM INBOUND AIR PRES -
SURE
to the ram.
NEVER alter or modify any part of the ram; doing so could cause it to mal -
function
and make it dangerous to operate.
CHECK all equipment regularly and repair or replace worn or damaged
parts immediately .
ALWAYS
use the ram only for its intended purpose as described in this
instruction manual.
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including fluid injection, splash -
ing
in the eyes or on the skin, or injury from moving parts, always relieve
all air and fluid pressure in the system before checking or repairing the
ram or any other part of the system and when shutting down the system.
1. Shut of f the air to the pump and ram.
2. Open the bleed–type master air valve to relieve trapped air .
3.
Shut of f the ram director valve.
4. T rigger the gun/dispensing valve to relieve fluid pressure.
5. Open all fluid drain valves in the system.
6. Leave the drain valves open until you are ready to spray/dispense
again.
MOVING P ARTS HAZARD
Moving parts can pinch or amputate your fingers or other body parts. The
ram plate/pump fluid inlet moves when the ram is in operation. Keep
hands
and fingers away from the ram plate, pump fluid inlet, and lip of the
fluid container when raising or lowering the ram. Keep clear of all moving
parts when starting or operating the ram or pump. Before checking or
servicing the ram or pump, always follow the Pressure Relief
Procedure,
above.

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PUMP SELECTION CHART
For Pump Model and Description Use Ram Model
10:1 Monark, Model 222–770, with Severe–Duty Check–Mate 450 Displacement Pump 223–634*
20:1 President, Model 222–768, with Severe–Duty Check–Mate 450 Displacement Pump 223–634*
34:1 Senator , Model 222–769, with Severe–Duty Check–Mate 450 Displacement Pump 223–634*
55:1 Bulldog, Model 222–778, with Severe–Duty Check–Mate 450 Displacement Pump 223–634*
15:1 Senator , Model 222–518, with Severe–Duty Displacement Pump 207–279
15:1 Senator , Model 222–489, with Nitralloy Displacement Pump 207–279
25:1 Senator , Model 222–525, with Severe–Duty Displacement Pump 207–279
25:1 Senator , Model 222–519, with Nitralloy Displacement Pump 207–279
10:1 Bulldog, Model 222–526, with Severe–Duty Displacement Pump 207–279
10:1 Bulldog, Model 204–287, with Nitralloy Displacement Pump 207–279
10:1 Bulldog, Model 207–172, with Stainless Steel Displacement Pump 207–279
or
954–285**
25:1 Bulldog, Model 222–527, with Severe–Duty Displacement Pump 207–279
25:1 Bulldog, Model 217–565, with Nitralloy Displacement Pump 207–279
40:1 Bulldog, Model 222–535, with Severe–Duty Displacement Pump 207–279
40:1 Bulldog, Model 220–448, with Nitralloy Displacement Pump 207–279
20:1 King, Model 222–539, with Severe–Duty Displacement Pump 207–279
20:1 King, Model 222–248, with Nitralloy Displacement Pump 207–279
20:1 King, Model 220–648, with Stainless Steel Displacement Pump 207–279
or
954–285**
55:1 King, Model 222–545, with Severe–Duty Displacement Pump 207–279
55:1 King, Model 217–566, with Nitralloy Displacement Pump 207–279
*
Mounting Kit 222–776 is required to mount a Check–Mate 450 Pump on Model 223–634 Ram.
** Stainless Steel Ram 954–285 does not include ram plate or tie rods.
NOTE: Model 207–279 Ram is shipped with optional seals (51 and 75), seal plates (76), an intake adapter (55), and
a mounting plate (58) for use with pumps not listed above (see the parts list on page 15). For application and
installation information regarding pumps not listed in this chart, contact your Graco representative or Graco
Technical Assistance at 1–800–543–0339.

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TYPICAL INSTALLATION
KEY
AAir
Line Filter
BBleed–T ype Master Air V alve
(required, for pump)
C Pump Air Regulator
D Air Manifold
E Air Supply Hose (for ram)
F Ram Air Regulator
GBleed–T ype Master Air V alve
(for accessories)
H Main Air Supply Line
J Drum Clamps
Y Ground Wire (required)
3 Support Beam
4 Ram Director Valve
26, 27 Pump Mounting Hardware
35 Mounting Bracket Setscrews
57
Pump Mounting Brackets
66 Air Manifold Mounting Bracket
A
D
EFG
H
Y
J
B
C
57,
35
3
4
26, 27
66
This
air–powered ram extruder forces high viscosity flu -
ids
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.
NOTE: To convert the ram from air to hydraulic opera-
tion, install piston kit 220–501 (see page 18).
Contact
your Graco representative for details.
Locating the Ram
NOTE: Refer to the Dimensional Drawing on page 19 for
ram mounting and clearance dimensions.
1. Select a convenient location for the equipment.
Check
that there is suf ficient 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
1/2 in. (13 mm) anchors. Bolt the ram to the floor with
anchors which are long enough to prevent the unit
from tipping. Refer to the Dimensional Drawing on
page
19.
4. Mount the pump on the ram, following the applicable
procedure on page 5 or 6.
Installing Accessories and Connecting Air
Lines
1. Install an air line filter (A) on the air supply line to re -
move harmful moisture and contaminants from the
compressed air supply .
2. Install
a bleed–type master air valve (B) downstream
from the pump air regulator (C).
WARNING
The
bleed–type master air valve (B) is required in
your system to relieve air trapped between this
valve
and the pump after the pump air regulator is
closed. Trapped air can cause the pump to cycle
unexpectedly,
which could result in serious bodily
injury, including splashing in the eyes or on the skin
and injury from moving parts.
3. Install an air manifold (D) on the mounting bracket
(66).
Connect a suitable air hose (E) between an out -
let
port of the air manifold and the air inlet of the ram
air regulator (F).
4. Install a second bleed–valve (G) upstream from all
accessories, to isolate the accessories for servicing.
Connect the main air supply line (H) to the manifold
(D).

306-934ą5
INSTALLATION
Mounting the Pump (Model 207–279 Ram)
NOTE: The Pump Selection Chart on page 3 lists pumps
commonly mounted on this ram. Installing other
pumps on the ram may require alternate parts,
which are packed in separate plastic bags. For
information, contact your Graco representative
or Graco Technical Assistance at
1–800–543–0339.
Mount
the pump as follows. Refer to the T ypical Installa -
tion
on page 4.
1. Remove the mounting plate (58); it is not required for
those pumps listed in the chart on page 3. Position
the mounting brackets (57) so that the top of the
pump
will clear the support beam (3). Set the pump
on the mounting brackets (57) with the air inlet
toward
the ram director valve (4). Attach the pump to
the mounting brackets with the screws (27) and
washers
(26) provided.
2. Remove the four screws (25) and washers (31)
holding
the standard seal plates (62) to the ram plate
(63) and remove the top seal plate (62) and seal (56).
Leave the bottom seal plate (62) and gasket (61) in
place.
See Fig 1.
3. For 15:1 and 25:1 ratio Senator , 25:1 and 40:1 ratio
Bulldog, and 55:1 ratio King standard extrusion
pumps,
slide the top seal plate (62) up over the pump
intake valve and push the seal (56) onto the pump
intake
housing. Then continue with step 4.
For 10:1 ratio Bulldog and 20:1 ratio King pumps with
a flanged intake housing, discard the top seal plate
(62) and seal (56). Remove and discard the bottom
seal plate (62). Align the holes in the intake valve
flange with those in the gasket (61) and ram plate
(63).
Then continue with step 4.
4. Loosen the mounting bracket setscrews (35), and
carefully
lower the pump until the intake valve is be -
low
the gasket (61), then tighten the setscrews.
5. If applicable for your installation, push the seal (56)
down
firmly against the bottom seal plate (62).
6. Align the holes in the top seal plate or pump intake
flange
(as applicable) with the holes in the ram plate
(63). Secure tightly to the ram plate with the four
screws
(25) and washers (31).
Fig 1
63
61
INTAKE
HOUSING
FLANGE
63
61
25, 31
25, 31
56
62
62
10:1 BULLDOG AND 20:1 KING PUMPS,
WITH FLANGED INT AKE HOUSING
ST ANDARD EXTRUSION
PUMPS
PUMP INT AKE
HOUSING

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INSTALLATION
Mounting the Pump (Model 223–634 Ram)
NOTE: Model 223–634 Ram is only for use with Check–
Mate 450 Pumps having a 222–790 Displace-
ment
Pump. The Pump Selection Chart on page
3 lists the Check–Mate 450 Pumps which can be
mounted on this ram.
This installation requires Mounting Kit 222–776.
See Accessories on page 18.
1. Place the gasket (K) from Mounting Kit 222–776 on
the ram plate. See Fig 2. Lower the Check–Mate 450
pump onto the gasket and plate. Secure the pump’ s
intake
flange to the plate with the screws (L) and lugs
(M) included in the mounting kit.
2. For Senator and Bulldog Check–Mate 450 Pumps
only:
Position the mounting brackets (57) under the
base
of the air motor . See the T ypical Installation on
page 4. Attach the motor to the mounting brackets
with
the screws (27) and washers (26) provided. The
mounting brackets (57) are not used with Monark
and
President Check–Mate 450 Pumps.
Fig 2
L
M
K
CHECK–MA
TE 450 PUMP
INT AKE FLANGE
RAM PLA TE

306-934ą7
OPERATION
WARNING
Follow
the Pressure Relief Procedure on page 8
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 ram plate,
fluid pump inlet, and lip of the fluid container when
raising or lowering the ram to reduce the risk of
pinching
or amputating hands or fingers.
Before Pumping Fluid
1. Turn the director valve knob (17) to OFF. Close the
ram
air regulator and main air control valve.
2. Turn the director valve knob to UP . Open the main air
control valve and ram air regulator until the ram starts
to move upward. Let the ram rise to its full height.
3. Set a full drum of fluid on the ram base, slide it back
against the tube stop, and center it under the ram
plate.
See the T ypical Installation on page 4 and the
Accessories section for drum clamps (J) that center ,
hold,
and properly align the drum with the ram. Then
remove the drum cover and smooth the surface of
the
fluid with a straightedge.
NOTE: Do not use drums that have side bungs or large
dents with this ram. Rough bung openings or
large dents will damage the wipers or stop the
ram
plate, resulting in a runaway pump.
4. Turn the director valve knob to the DOWN position
and
lower the ram until the ram plate is just ready to
enter the drum, then turn the valve to OFF. Reposi-
tion the drum so the wipers will not hit the drum lip,
then
open the vent valve (23) on the ram plate.
5. Turn the director valve knob to the DOWN position,
lower
the ram plate until all air is forced out and fluid
comes out of the vent opening. Then turn the director
valve knob to OFF and close the vent valve (23).
6. Set the air pressure to the ram at 50 psi (4 bar). T urn
the
director valve knob to the DOWN position. Start
the pump (open the bleed–type master air valve and
fluid dispensing valve). Let the pump run until the
system is primed and all air is forced out. Close the
bleed–type
master air valve or fluid dispensing valve
to stop the pump.
NOTE: Increase air pressure to the ram if the pump does
not prime properly with heavier fluids. If fluid is
forced
out around the top wiper , ram pressure is
too high and the air pressure should be de-
creased.
How to Use the Ram
1. To pump fluid from the drum, turn the director valve
knob to the DOWN position and start the pump. Al-
ways
use the lowest air pressure possible to both the
pump and ram.
2. To change drums, stop the pump and turn the air di -
rector
valve knob to UP . Push the air assist valve but -
ton
(14) in and hold until the ram plate clears the top
of the drum. When the ram reaches its maximum
height,
remove the empty drum and put a full drum in
its place. Follow the procedure under “Before Pump -
ing
Fluid”, at left.
Shutdown
1. T urn the director valve knob (17) to OFF .
2. Shut of f the air supply to the ram and pump and follow
the Pressure Relief Procedure on page 8.
Fig 3
14
14
17
17
23
Ram Air Controls
(Model 207–279)
Ram Air Controls
(Model 223–634)
Ram Plate and V ent V alve
(Model 207–279 Shown)

8ą306-934
TROUBLESHOOTING CHART
WARNING
Pressure
Relief Procedure
To reduce the risk of serious bodily injury, including
fluid
injection, splashing in the eyes or on the skin, or
injury from moving parts, always relieve all air and fluid
pressure in the system before checking or repairing
the
ram or any other part of the system and when shut -
ting
down the system.
1. Shut of f the air to the pump and ram.
2. Open the bleed–type master air valve to relieve
trapped air.
3.
Shut of f the ram director valve.
4. T rigger the gun/dispensing valve to relieve
fluid pressure.
5. Open all fluid drain valves in the system.
6. Leave the drain valves open until you are ready to
spray/dispense again.
PROBLEM CAUSE SOLUTION
Ram won’t raise or lower Closed air valve or clogged air line Open, clear
Not enough air pressure Increase
W
orn or damaged piston Replace
Director valve closed or clogged Open, clear
Ram raises or lowers too fast Air pressure too high
Decrease
Air leaks around cylinder Loose packing nut or worn packings T ighten, replace
packing nuts (46)
Fluid squeezes past Air pressure too high Decrease
ram plate wipers
W orn or damaged wipers Replace
Pump won’t prime properly or Closed air valve or clogged air line Open, clear
pumps air
Not enough air pressure Increase
W
orn or damaged piston Replace
Director valve closed or clogged Open, clear
Air director valve dirty , worn Clean, service
or damaged
Air director valve won’t hold Closed air valve or clogged air line Open, clear
drum down or push plate up Not enough air pressure
Increase
V
alve passage clogged Clean

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SERVICE
Air Director Valve Cleaning and Service
(Model 207–279 Ram)
1. Follow the Pressure Relief Procedure W arning on
page
8.
2. Pry out the button plug (16). See Fig 4.
3. Screw the stud (18) out of the housing (19), holding
your hand under the director valve to catch the ball
(6),
gland (74) and v–packing (7).
4. Remove the knob (17), and take the stud (18) and
springs
(10 and 12) out of the knob. Check the stud
o–rings (1 1) for damage.
5. Clean and inspect all parts for wear or damage. Re -
place
as needed.
Air Assist Valve Service
(Model 207–279 Ram)
1. Follow the Pressure Relief Procedure W arning on
page
8.
2. Screw the seat (15) out of the housing (19). Check
the
gasket (8) and o–ring (1 1) for damage. See Fig 4.
3. Remove the poppet (21) and spring (13).
4. Pull the stem (20) out of the seat (15).
5. Clean and inspect all parts for wear or damage. Re -
place
as needed.
Fig 4
14
20
15
8
11
21
13
196
1017
1118
16 1274 7 5

10ą306-934
SERVICE
Air Director Valve Cleaning or Service
(Model 223–634 Ram)
1. Follow the Pressure Relief Procedure W arning on
page
8.
2. Pry out the button plug (16). See Fig 5.
3. Screw the stud (18) out of the housing (19), holding
your hand under the director valve to catch the ball
(6)
and seal (7).
4. Remove the knob (17), and take the stud (18) and
springs
(10 and 12) out of the knob. Check the stud
o–rings (1 1) for damage.
5. Loosen the jam nut (15), unscrew the needle (20),
and
check the o–ring (9).
6. Clean and inspect all parts for wear or damage. Re -
place
as needed.
Air Assist Valve Service
(Model 223–634 Ram)
1. Follow the Pressure Relief Procedure W arning on
page
8.
2. Screw the stud (94) out of the housing (93). See Fig
6.
3. Remove the poppet (89) and spring (92).
4. Pull the stem (88) out of the stud (94).
5. Clean and inspect all parts for wear or damage. Re -
place
as needed.