Graco 198466 User manual

Instructions
PROVEN QUALITY. LEADING TECHNOLOGY.
CARBON STEEL
Check–Mate™800 Pumps 308351N
EN
With Priming Piston and Severe–Duty Rod and Cylinder
Refer to page 2 for Table of Contents.
Models 198466
and 246938
Models
237265, 246940
and 246941
Models 236471
and 246942
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions. See page 2 for model
numbers and maximum working pressures.

2 308351
List of Models
Table of Contents
List of Models .............................................................. 2
Symbols ...................................................................... 3
Warnings ..................................................................... 3
Installation ................................................................... 6
Operation/Maintenance ............................................. 12
Service
Troubleshooting ................................................... 17
Required Tools ..................................................... 18
Disconnecting the Displacement Pump ............... 18
Reconnecting the Displacement Pump ................. 19
Displacement Pump Service ................................. 20
Parts .......................................................................... 28
Technical Data and Performance Chart ..................... 38
Dimensions ................................................................ 49
Mounting Hole Layout ............................................... 49
Graco Standard Warranty ......................................... 50
Graco Information ...................................................... 50
Part No. Series Pump Model Ratio
Maximum Fluid
Working Pressure
Maximum Air
(or Hydraulic*)
Input Pressure
236471 BKing™65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
237265 BReduced Icing
Quiet King™
65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
240945 BQuiet King™65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
253376 CQuiet King™65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
237261 ABulldog®31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
241901 ABulldog®
(55 Gallon/200
Liter Size)
31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
237274 AReduced Icing
Quiet Bulldog®
31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
237264 ASenator®19:1 15 MPa, 157 bar (2280 psi) 0.8 MPa, 8.4 bar (120 psi)
198475 AQuiet King™65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
198466 AViscount®II 40 MPa, 403 bar (5850 psi) 10.3 MPa*, 103 bar* (1500 psi*)
246942 BKing™65:1 48 MPa, 483 bar (7000 psi) 0.7 MPa, 7 bar (100 psi)
246940 BBulldog®31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
246941 BSenator®19:1 15 MPa, 157 bar (2280 psi) 0.8 MPa, 8.4 bar (120 psi)
246938 BViscount®II 40 MPa, 403 bar (5850 psi) 10.3 MPa*, 103 bar* (1500 psi*)

308351 3
Symbols
Warning Symbol Caution Symbol
WARNING CAUTION
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage
to or destruction of equipment if you do not follow
the instructions.
WARNING
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.
• 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 the Techni-
cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
• Do not use hoses to pull equipment.
• Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82°C (180°F) or below -40°C (-40°F).
• Wear hearing protection when operating this equipment.
• Do not lift pressurized equipment.
• Comply with all applicable local, state, and national fire, electrical, and safety regulations.

4 308351
WARNING
SKIN INJECTION HAZARD
Spray from the spray gun/dispense valve, leaks or ruptured components can inject fluid into your body
and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on
the skin can also cause serious injury.
• Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi-
cal treatment.
• Do not point the gun/valve at anyone or at any part of the body.
• Do not put your hand or fingers over the spray tip/nozzle.
• Do not stop or deflect leaks with your hand, body, glove or rag.
• Do not “blow back” fluid; this is not an air spray system.
• Always have the tip guard and the trigger guard on the gun when spraying.
• Check the gun diffuser operation weekly. Refer to the gun manual.
• Be sure the gun/valve trigger safety operates before spraying.
• Lock the gun/valve trigger safety when you stop spraying.
• Follow the Pressure Relief Procedure on page 12 if the spray tip/nozzle clogs and before clean-
ing, checking or servicing the equipment.
• Tighten all fluid connections before operating the equipment.
• Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
• Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
MOVING PARTS HAZARD
Moving parts, such as the priming piston, can pinch or amputate your fingers.
• Keep clear of all moving parts when starting or operating the pump.
• Before servicing the equipment, follow the Pressure Relief Procedure on page 12 to prevent the
equipment from starting unexpectedly.

308351 5
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
• Ground the equipment and the object being sprayed. Refer to Grounding on page 6.
• If there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing dispensing immediately. Do not use the equipment until you identify and correct the prob-
lem.
• Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed/dispensed.
• Keep the spray/dispense area free of debris, including solvent, rags, and gasoline.
• Electrically disconnect all equipment in the spray/dispense area.
• Extinguish all open flames or pilot lights in the spray/dispense area.
• Do not smoke in the spray/dispense area.
• Do not turn on or off any light switch in the spray/dispense area while operating or if fumes are
present.
• Do not operate a gasoline engine in the spray/dispense area.
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.

6 308351
Installation
Grounding
2. Air and fluid hoses: use only electrically
conductive hoses.
3. Air compressor: follow manufacturer’s
recommendations.
4. Spray gun/dispense valve: ground through
connection to a properly grounded fluid hose
and pump.
5. Fluid supply container: follow your local code.
6. Object being sprayed: follow your local code.
7. All solvent pails used when flushing: follow
your local code. Use only metal pails, which
are conductive, placed on a grounded surface.
Do not place the pail on a nonconductive
surface, such as paper or cardboard, which
interrupts the grounding continuity.
8. To maintain grounding continuity when
flushing or relieving pressure, always hold a
metal part of the gun/valve firmly to the side of
a grounded metal pail, then trigger the gun/
valve.
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground
the system as explained below. Also
read the section FIRE AND
EXPLOSION HAZARD on page 5.
1. King Pumps: use a ground wire and clamp. See
Fig. 1. Remove the ground screw (Z) and insert
through eye of ring terminal at the end of
ground wire (Y). Fasten ground screw back
onto pump and tighten securely. Connect the
other end of the wire to a true earth ground.
Order Part No. 222011 Ground Wire and
Clamp.
All other Pumps: use a ground wire and clamp.
See Fig. 2. Loosen the grounding lug locknut
(W) and washer (X). 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.
Connect the other end of the wire to a true earth
ground. Order Part No. 222011 Ground Wire
and Clamp.
Fig. 2
Fig. 1

308351 7
Installation
All Systems
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and parts
drawings.
The Typical Installations shown in Figs. 3 and 4 are
only guides for selecting and installing system
components and accessories. Contact your Graco
distributor for assistance in designing a system to suit
your particular needs.
Accessories are available from Graco. If you supply
your own accessories, be sure they are adequately
sized and pressure–rated to meet the system’s
requirements.
System Accessories
Air and Fluid Hoses
Be sure all air hoses and fluid hoses are properly
sized and pressure-rated for your system. Use only
electrically conductive hoses. Fluid hoses must
have spring guards on both ends.
Mounting Accessories (Except 198466, 198475
and 246938)
Mount the pump (A) to suit the type of installation
planned. Fig. 3 on page 8 illustrates a ram-
mounted pump in a multi-gun header system.
Pump dimensions and the mounting hole layout
are shown on page 49.
If you are mounting the pump on a ram, refer to the
separate ram manual for installation and operation
instructions. Mounting Kit 222776 is available to
mount the pump on a 55 gallon (200 liter) ram.

8 308351
Installation (Air–Powered Pumps)
KEY
APump
B200 Liter (55 Gallon) Air-Powered Ram
CMain Air Bleed Valve (required, for pump and ram)
DAir Line Lubricator (position only)
EPump Air Bleed Valve (required, for pump)
FPump Air Regulator
GAir Manifold
HElectrically Conductive Air Supply Hose
JAir Line Filter
KAir Shutoff Valve (for accessories)
LFluid Regulator
MFluid Drain Valve (required)
NElectrically Conductive Fluid Supply Hose
PFluid Shutoff Valve
RGun/Valve Swivel
SAirless Spray Gun or Dispensing Valve
TRam Air Regulator
URam Director Valve
VPump Runaway Valve (position only)
WAir LIne Drain Valve
YGround Wire (required, see page 6 for
installation instructions)
MAIN AIR LINE
FLUID HEADER PIPE
(3 in. Diameter
Fig.3

308351 9
Installation (Air–Powered Pumps)
Air Line Accessories
Install the following accessories in the order shown in
Fig. 3, using adapters as necessary:
•An air line lubricator (D) provides automatic air
motor lubrication. Locate in the position shown.
•A main air bleed valve (C) is required in your sys-
tem to shut off the air supply to the pump and ram
(see the WARNING above). When closed, the valve
will bleed off all air in the ram and pump, and the ram
will slowly lower. Be sure the valve is easily accessi-
ble from the pump, and is located upstream from the
air manifold (G).
•A pump air bleed valve (E) is required in your sys-
tem to relieve air trapped between it and the air
motor when the valve is closed (see the WARNING
at left). Be sure the bleed valve is easily accessible
from the pump, and is located downstream from the
air regulator.
•An air regulator (F) 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 pump air bleed valve.
•A pump runaway valve (V) senses when the pump
is running too fast and automatically shuts off the air
to the motor. A pump which runs too fast can be seri-
ously damaged. Locate in the position shown.
•An air manifold (G) has a swivel air inlet. It mounts
to a ram, and has ports for connecting lines to air
accessories, such as the ram air regulator (T) and
ram director valve (U).
•An air line filter (J) removes harmful dirt and mois-
ture from the compressed air supply. Also, install a
drain valve (W) at the bottom of each air line drop, to
drain off moisture.
•An air shutoff valve (K) isolates the air line acces-
sories for servicing. Locate upstream from all other
air line accessories.
Fluid Line Accessories
Install the following accessories in the positions shown
in Figs. 3 and 4, using adapters as necessary:
• Install a fluid shutoff valve (P) at each gun/valve
drop, to isolate the gun/valve and fluid accessories
for servicing.
• Install a fluid drain valve (M) near the pump fluid
outlet, and at each gun/valve station. The drain
valves are required in your system to relieve fluid
pressure in the displacement pump, hose and gun/
valve (see the WARNING at left). Drain valves at the
gun/valve stations may be mounted in the base of a
fluid regulator (L), using an adapter.
•A fluid regulator (L) controls fluid pressure to the
gun/valve, and dampens pressure surges.
•A gun or dispense valve (S) dispenses the fluid.
The gun shown in Fig. 3 is a high pressure dispens-
ing gun for highly viscous fluids.
•A gun/valve swivel (R) allows freer gun/valve move-
ment
WARNING
A main air bleed valve (C), pump air bleed valve
(E), and fluid drain valve (M) are required. These
accessories help reduce the risk of serious injury,
including fluid injection and splashing of fluid in the
eyes or on the skin, and injury from moving parts if
you are adjusting or repairing the pump.
The main air bleed valve (C) shuts off the air to the
pump and ram. The pump air bleed valve (E)
relieves air trapped between this valve and the
pump after the air is shut off. Trapped air can
cause the pump to cycle unexpectedly. Locate the
valve close to the pump. Order Part No. 107141.
The fluid drain valve assists in relieving fluid
pressure in the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may not be
sufficient. Order Part No. 210658.

10 308351
Installation (Hydraulic–Powered Pumps)
Fig. 4
KEY
AAccessory Pump Stand HHydraulic Pressure Gauge
(P/N 218742) JFlow Control Valve
BSurge Tank (P/N 218509 or KPressure Reducing Valve
238983) LDrain Line
C50 mm (2 in.) Diameter Pipe MHydraulic Return Line
DFull Flow, Non-Restrictive Shutoff Valve
Fluid Shutoff Valve NAccumulator
EFluid Supply Line PHydraulic Supply Line
FMix Tank QHydraulic Return Line
GHydraulic Supply Line YGround Wire (required,
Shutoff Valve see page 6)L-