Graco 24W181 User manual

334198K
EN
Instructions - Parts
55 Gallon (200 Liter) and
5 Gallon (20 Liter) Rams
For use to aid pump loading for transferring or dispensing sealants, adhesives, and other
medium to high viscosity fluids. For professional use only.
Not approved for use in explosive atmospheres.
See page 2 for model information. See page 28 for maximum working pressures.
Important Safety Instructions
Read all warnings and instructions in this
manual and in related manuals. Save these
instructions.
5 Gallon (20 Liter) Pneumatic Shown 55 Gallon (200 Liter) Hydraulic Shown

Models
2 334198K
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Component Identification . . . . . . . . . . . . . 5
Pneumatic Rams . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Ram . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Power Supply . . . . . . . . . . . . . . . . . . . 7
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Grounding the Hydraulic Power Supply . . . . . . . 8
Typical Pneumatic Ram Installation . . . . . . . . . . 9
Typical Hydraulic Ram Installation . . . . . . . . . . . 9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Relief Procedure . . . . . . . . . . . . . . . . 14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . 15
Checking the Hydraulic Fluid Level . . . . . . . . . . 15
Changing the Hydraulic Fluid Filter . . . . . . . . . . 15
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
24W181, Therm-O-Flow 20 . . . . . . . . . . . . . . . . 16
24W183, Therm-O-Flow 200 Pneumatic . . . . . . 18
24W184, Therm-O-Flow 200 Hydraulic . . . . . . . 20
918420, Hydraulic Ram Module . . . . . . . . . . . . 22
24V757, Hydraulic Reservoir . . . . . . . . . . . . . . . 24
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
24W181, Therm-O-Flow 20 Technical Data . . . 28
24W183, Therm-O-Flow 200 Pneumatic Technical
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
24W184, Therm-O-Flow 200 Hydraulic Technical
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
California Proposition 65 . . . . . . . . . . . . . . . . . . . 29
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 30
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 30
Models
Related Manuals
Part No. Description
24W181 5 Gallon (20 Liter) Pneumatic Ram
24W183 55 Gallon (200 Liter) Pneumatic Ram
24W184 55 Gallon (200 Liter) Hydraulic Ram
Part No. Description
334130 Therm-O-Flow®200, Instructions-Parts
334129 Therm-O-Flow 20, Instructions-Parts
308485 3:1 Fire-Ball®425 Pump, Instructions-Parts List
311238 NXT®Air Motor
308169 Air Filters, Lubricators, and Kits

Warnings
334198K 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause
serious injury.
• Follow the Pressure Relief Procedure when you stop spraying/dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are antistatic or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
WARNING

Warnings
4 334198K
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not
limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNING

System Component Identification
334198K 5
System Component Identification
Pneumatic Rams
5 Gallon (20 Liter) Pneumatic Shown
55 Gallon (200 Liter) Pneumatic Shown
C
A
E
A
C
E
D
D
B
F
FIG. 1
Ref. Description
ARam
BLift Strap Positions
CChemical Hose Support
DElectrical Control Panel Mounting Bracket
EDrum Stop
FPlaten Tie Rods
Ref. Description

System Component Identification
6 334198K
Hydraulic Ram
FIG. 2
55 Gallon (200 Liter) Hydraulic Shown
C
B
D
F
E
G
A
Ref. Description
ARam
BLift Strap Positions
CChemical Hose Support
DElectrical Control Panel Mounting Bracket
EDrum Stop
FPlaten Tie Rods
GHydraulic Power Supply

System Component Identification
334198K 7
Hydraulic Power Supply
AA
AB
AC
AD
AF
AG
AE
AH
AJ
AK
AL
FIG. 3
Ref. Description
AA Air Motor
AB Grounding Strap
AC Motor Air Inlet
AD Hydraulic Pressure Gauge
AE Ram Up Hydraulic Outlet
AF Ram Up Air Inlet
AG Ram Down Hydraulic Outlet
AH Ram Down Air Inlet
AJ Sandwich Plate
AK Relief Valve
AL Lubricator

Setup
8 334198K
Setup
Refer to the Therm-O-Flow 200 and Therm-O-Flow 20,
Instructions-Parts manuals for additional setup proce-
dures such as unpacking, location requirements, and
component installations.
Grounding
Refer to the Therm-O-Flow 200 and Therm-O-Flow 20,
Instructions-Parts manuals for the grounding of the unit.
Grounding the Hydraulic Power
Supply
To ground the hydraulic power supply unit pump, con-
nect the ground wire and clamp to a true earth ground
as shown.
1. Loosen the grounding screw and washer.
2. Insert one end of the 1.5 mm (12 gauge) minimum
ground wire into the slot in the lug and tighten the
locknut securely.
3. Connect the other end of the wire to a true earth
ground. See FIG. 4.
You must also provide an earth ground to the supply
unit electrical control box. Make sure the ram is installed
correctly to ensure that the ram is properly grounded.
For information about grounding other components in
your system, see the system or supply unit documenta-
tion, as well as the documentation for individual compo-
nents.
The equipment must be grounded to reduce the risk of
static sparking. Static sparking can cause fumes to
ignite or explode. Grounding provides an escape wire
for the electric current.
FIG. 4
WLD

Setup
334198K 9
Typical Pneumatic Ram
Installation
Contact your Graco representative or Graco Technical
Assistance for help in designing a system to suit your
specific needs. Refer to the Therm-O-Flow 200, Instruc-
tions-Parts or the Therm-O-Flow 20, Instructions-Parts
manuals for more information.
This ram extruder forces high viscosity fluids into the
intake valve of the fluid pump.
NOTE: To convert the ram from air to hydraulic opera-
tion, contact your Graco representative for details
Installing Accessories and Connecting Air
Lines
• Install an air line filter on the air supply line to
remove harmful moisture and contaminants from
the compressed air supply.
• The air motor slider valve is required in your system
to relieve air trapped between the master air valve
and the air motor when the valve is closed. This
valve should be easily accessible and located
down-stream from the air regulator.
• The system bleed-type master air valve is required
in your system to shut off the air supply to the entire
unit.
Locating the Ram
NOTE: Refer to Dimensions on page 26 for ram mount-
ing 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
1/2 in. (13 mm) anchors. Bolt the ram to the floor
using anchors which are long enough to prevent the
unit from tipping. Refer to Dimensions on page 26.
Typical Hydraulic Ram
Installation
The typical installation discussed below is only a guide
for selecting and installing system components and
accessories. Contact your Graco representative or
Graco Technical Assistance for help in designing a sys-
tem to suit your specific needs. Refer to the
Therm-O-Flow 200, Instructions-Parts or the
Therm-O-Flow 20, Instructions-Parts manuals for more
information.
This ram extruder forces high viscosity fluids into the
intake valve of the fluid pump.
Locating the Ram
NOTE: Refer to Dimensions on page 26 for ram mount-
ing 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.
Using the holes in the base as a guide, drill holes for 1/2
in. (13 mm) anchors. Bolt the ram to the floor using
anchors which are long enough to prevent the unit from
tipping. Refer to Dimensions on page 26.Installing
Hydraulic Power Supply
Follow the procedure below to install the hydraulic
power supply.
Bolting Hydraulic Power Supply to the
Floor
1. Select a convenient location for the power supply.
Make sure there is sufficient room to service the
unit. Make sure the air and hydraulic lines can be
easily connected to the supply unit.
2. Use metal shims to level the hydraulic power sup-
ply.
3. Use the holes in the base as a guide to drill holes for
3/8 in. anchors. Bolt the hydraulic power supply to
the floor anchors, which are long enough to prevent
the unit from tipping.

Setup
10 334198K
Connecting Hydraulic Hoses to the Ram
Connect the hydraulic lines from the hydraulic power
supply to the ram.
1. Connect the RAM DOWN hydraulic lines (D, C) to
the RAM UP connectors on the top of the ram.
2. Connect the RAM UP hydraulic lines (A, B) to the
RAM DOWN connectors on the bottom of the ram.
See FIG. 5.
Connecting Ram Air Hoses to Hydraulic
Supply
Connect the air hoses from the air control to the hydrau-
lic supply.
1. Connect the RAM DOWN line on the hydraulic sup-
ply to the RAM DOWN bulkhead on the air control.
2. Connect the RAM UP line on the hydraulic supply to
the RAM UP bulkhead on the air control.
3. Connect the hydraulic pilot down line to the hydrau-
lic pilot down bulkhead on the air control.
4. Connect the hydraulic pilot up line to the hydraulic
pilot up bulkhead on the air control.
5. Use the ram hand valve lever to raise the ram to the
UP position. If the ram goes down instead of up,
check your hydraulic line and air line connections;
you may have incorrectly connected the lines.See
FIG. 6.
6. After you have determined the hydraulic lines and
air lines are connected correctly, run the ram up and
down five or six times to bleed air from the hydraulic
lines.
Starting Up the Hydraulic Ram for the First
Time
You will need the following tools:
• 9/16 in. open-end wrench
• 5/32 in. hex key
Ram down pressure is controlled by the in-line hydraulic
fluid regulator. Before you start up the hydraulic ram,
you must determine the amount of air pressure needed
to produce the desired hydraulic pressure.
The maximum hydraulic pressure you can set is 225 psi
(16 bar, 1.6 MPa). Use the table, FIG. 7 below as a
guide for setting the regulator.
FIG. 5
WLD
&
'
$
%
5DP
GRZQ
5DP
XS
FIG. 6
FIG. 7
WLD
5DP83
5DP2))
QHXWUDO
5DP'2:1
0 25 50 75 PSI
0 1.8 3.5 5.3 Bar
0 0.18 0.35 0.53 MPa
Mpa Bar PSI
1.6 14.0 200
1.2 12.0 175
1.05 10.5 150
0.9 10.5 150
0.7 7.0 100
0.53 5.3 75
0.35 3.5 50
0.18 1.8 25
0 0 0
Hydraulic Down
Pressure
Hydraulic Down
Pressure
ti24668a

Setup
334198K 11
1. Check all air lines, hydraulic lines, and fittings to
insure tightness and to prevent any air or hydraulic
fluid leakage.
2. Check all system air and hydraulic lines. Make sure
that all routing of air and hydraulic lines will not inter-
fere with any moving components within the fixture.
NOTE: The hydraulic fluid regulator is factory set to 225
psi.
3. To adjust the hydraulic fluid regulator:
a. Loosen the locking nut (5) with a 9/16 in.
wrench.
b. Set fluid pressure to the desired pressure by
turning the regulator set screw (6) with a 5/32 in.
hex key. Watch the fluid pressure gauge (7) for
changes.
c. Tighten the locknut (5). See FIG. 8.
4. Raise the ram:
a. Close all air regulators.
b. Move the ram hand valve lever to the UP posi-
tion.
c. Slowly open the air regulators until the ram
starts to move upward. Do not apply more than
75 psi (5.3 bar, 0.53 MPa) inbound air pressure
to the hydraulic supply. If the ram does not
move in the expected direction, make sure that
you have correctly connected the hydraulic lines
and air lines. See Hydraulic Ram Installation
Drawing Overview, page 12.
d. Raise and lower the ram five or six times to
bleed air from the hydraulic system.
5. Perform the Checking the Hydraulic Fluid Level
procedure (see page 15). Add more hydraulic fluid,
if necessary.
6. After bleeding air from the hydraulic system, raise
the ram plate above the height of the material drum
to be used, then move the ram hand valve lever to
OFF.
NOTE: The sandwich plate relief valves (AK) are factory
set to 250 psi.
FIG. 8
ti24684b
7
5
6

Setup
12 334198K
Hydraulic Ram Installation Drawing
Overview
FIG. 9
WLE
5$083
5$0
'2:1
3/$7(1$,59$/9(
3/$7(1%/2:2))
&'
$%
5$0
'2:13,/27
5$0
833,/27
5$0
833,/27
5$0
'2:13,/27

Setup
334198K 13

Operation
14 334198K
Operation
Emergency Stop
To engage the Emergency Stop and stop the ram from
moving, perform the following steps:
1. Close the main air slider valve (CA). See FIG. 10.
2. Move the ram hand valve lever to the OFF position.
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
Follow the Pressure Relief Procedure found within the
Therm-O-Flow 200 and Therm-O-Flow 20, Instruc-
tions-Parts manuals.
FIG. 10
WLD
&$
This equipment stays pressurized until pressure is man-
ually relieved. To help prevent serious injury from pres-
surized fluid, such as skin injection, splashing fluid and
moving parts, follow the Pressure Relief Procedure
when you stop spraying and before cleaning, checking,
or servicing the equipment.

Maintenance
334198K 15
Maintenance
Monthly Maintenance
Periodically (approximately once a month) inspect the
ram guide sleeves, rods, and cylinders for wear or dam-
age; replace all worn parts.
Check the hydraulic fluid level. Add more hydraulic fluid
if the fluid level falls lower than 4 in. (102 mm) from the
top of the fluid gauge. See Checking the Hydraulic
Fluid Level, page 15.
Checking the Hydraulic Fluid
Level
Check the hydraulic fluid level in the supply unit. The
fluid level should be approximately 2–4 in. (51–102 mm)
from the top of the fluid level gauge (3). If necessary,
perform the following steps to add more hydraulic fluid:
1. Unscrew the breather (4).
2. Pour hydraulic fluid through the breather hole (13).
3. Replace the breather. See FIG. 11.
NOTE: Make sure hydraulic tank is filled to the correct
level. Overfilling tank can cause hydraulic fluid to spill
out the breather. See FIG. 12.
Changing the Hydraulic Fluid
Filter
The filter element (19) of the hydraulic fluid assembly
may become clogged with manufacturing residue after
the first 40 hours of operation. Change the filter element
after the first 40 hours of operation. For information
about starting up the rest of the system, refer to the
Therm-O-Flow 200 and Therm-O-Flow 20, Instruc-
tions-Parts manuals. See FIG. 13.
FIG. 11
WLE



FIG. 12
FIG. 13
FILL
LEVEL
Over Filled
Correctly
Filled
Under Filled
WLD


Parts
16 334198K
Parts
24W181, Therm-O-Flow 20
WLD
'(7$,/$





'(7$,/%






'(7$,/&


'(7$,/'






































Apply grease to o-rings.
Apply medium strength thread locker to
threads.
5
6

Parts
334198K 17
--- Parts not available for individual sale.
† Parts available in kit 255683.
Replacement Danger and Warning labels, tags, and
cards are available at no cost.
Ref Part Description Quantity
1 --- CART, TOF-20 1
2 15K702 ROD, lift 2
3 516587 BOLT, 3/4x1.5 hex head 2
4 101015 WASHER, lock 2
8 100214 WASHER, lock 2
9 617375 SLEEVE, guide 3" ram 2
10† 156593 PACKING, o-ring 2
11 128863 FITTING, elbow 3
12† 617373 RING, retaining 2
13† 162440 PACKING, o-ring 2
14† 160258 PACKING, o-ring 2
15† 156401 PACKING, o-ring 2
16† C36268 BUMPER 2
17† 183943 PISTON 2
18† 101533 WASHER, spring lock 2
19† 102301 NUT, hex 2
20 158962 FITTING, elbow 1
21 C20365 FITTING, tee 1
22 --- BRACKET 1
23 112166 SCREW, cap 4
24 110755 WASHER, plain 4
25 100016 WASHER, lock 4
26 517254 CLIP, tube 2
27 C19979 SCREW, cap 2
28 C20354 FITTING, elbow 3
29 C20344 FITTING, union, tee 1
30 17K543 STOP, drum 2
31 104034 WASHER, plain 2
32 101864 SCREW, cap 2
33C14023 LABEL, ram, up/down 1
3415J076 LABEL, safety, read manual 2
3515J074 LABEL, safety, crush & pinch 4
3615H668 LABEL, safety 2
37 054130 TUBE, nylon 7 ft
38 288543 BRACKET, hose spring 1
39 C38321 TIE, cable 2
45 --- KIT, TOF-20 1

Parts
18 334198K
24W183, Therm-O-Flow 200 Pneumatic
WLD
6(&7,21%%
;




'(7$,/ F





'(7$,/$






'(7$,/%






























;


;












Add 3 ounces of lubricant per cylinder before
and after inserting the piston.
Apply grease.
1
2

Parts
334198K 19
--- Parts not available for individual sale.
* Parts available in kit 255477.
** Parts available in kit 234966.
Parts available in kit 918432.
Replacement Danger and Warning labels, tags, and
cards are available at no cost.
Ref Part Description Quantity
101 --- MODULE, ram, 6.5, pneumatic 1
101.1 --- BEAM, tie 1
101.2 --- RAM 1
101.3 --- NUT, jam, hex 2
101.4 113993 WASHER, lock, helical 2
101.5 C32401 ROD 2
101.6 100040 PLUG, pipe 2
101.7 114153 FITTING, elbow, male, swivel 2
101.8* C32467 STOP, drum 2
101.9* C19853 SCREW, cap 2
101.10* C38185 WASHER, lock 2
101.11158776 PACKING, o-ring 2
101.12 C32405 PISTON, elevator air 2
101.13C38132 PACKING, o-ring 4
101.14C32408 BAND, guide 2
101.15C20417 RING, retaining 4
101.16--- RING, snap 2
101.17C31001 WIPER, rod 2
101.18 25T845 SLEEVE, guide 2
101.19C02073 PACKING, quad ring 2
101.20C32409 RING, retaining 2
102** 100307 NUT, hex 2
103** --- SCREW, hex head cap 1
104** --- WASHER, top hat 1
10515H668 LABEL, safety 2
106** 15G347 SUPPORT, hose hanger 1
107** 119958 SPRING, hose hanger, TOF 1
108** C34132 HANGER 1
109** 119832 BOLT, eye 1
110** 100023 WASHER, flat 2
11115J074 LABEL, safety, crush & pinch 4
112** 111218 CAP, tube, square 1
113** 100696 WASHER, wrought 2
114** 101213 NUT, full, hex 1
115 --- LABEL, brand, TOF-200 1
116 101015 WASHER, lock 2
117 C19187 NUT, nex 2
118 C32402 ROD, follower, heated 2
119 054130 TUBE, plyeth 9 ft
12015J076 LABEL, safety, read manual 2

Parts
20 334198K
24W184, Therm-O-Flow 200 Hydraulic
WLD






















6(&7,21%%
;




'(7$,/ F




