Graco 970159 Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2000, Graco Inc. is registered to I.S. EN ISO 9001
55 Gallon, 20:1 King
Module Supply Units
1800 psi (124 bar) Maximum Working Pressure
* Model 970159, Tandem with Pneumatic Crossover (carbon steel pump)
* Model 288649, Tanden with Pneumatic Crossover (stainless steel pump)
Model 970160, Tandem with Electric Crossover
* Model 970163, Pneumatic Low Level Shutoff
* These models are CE certified.
310334 rev.D
Important Safety instructions
Read all warnings and instructions in this manual.
Save these instructions.
Model 970159 Tandem Shown

2 310334
Table of Contents
List of Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Information 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 7. . . . . . . . . . . .
System Setup 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Models
Part No. Pump Model Displacement Pump Model Ratio Maximum Fluid Working Pressure Maximum Pump Air Input Pressure Parts Page
* 970159 Quiet KingtDura–Flowt2400
(carbon steel) 20:1 125 bar, 13 MPa (1800 psi) 6 bar, 0.6 MPa (90 psi) 16
* 288649 Quiet KingtDura–Flowt2400
(stainless steel) 20:1 125 bar, 13 MPa (1800 psi) 6 bar, 0.6 MPa (90 psi) 16
970160 Quiet KingtDura–Flowt2400 20:1 125 bar, 13 MPa
(1800 psi) 6 bar, 0.6 MPa (90 psi) 17
* 970163 Quiet KingtDura–Flowt2400 20:1 125 bar, 13 MPa
(1800 psi) 6 bar, 0.6 MPa (90 psi) 18
* These models are CE certified.
Related Manuals
Ram–Mounted Pumps (Models C59769 and 288648) 308027
Pneumatic Crossover (Model 918468) 310293
Low–Level Shutoff (Model 918478) 310294
Electrical Crossover (Model C59519) 310295
Manual No.

310334 3
Warnings
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
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 your Graco
distributor.
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 75 psi (5.1 bar) maximum inbound air pressure to the air–powered ram.
DNever exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the Technical Data on page 21.
DBe sure that all spray/dispensing equipment and accessories are rated to withstand the maximum
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. Do 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. Refer to
the Technical Data sections of all the equipment manuals. Always read the material manufactur-
er’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 310334
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 surgi-
cal 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.
DLock the gun/valve trigger safety when you stop dispensing.
DFollow the Pressure Relief Procedure on page 12 if the nozzle clogs, and before cleaning, check-
ing 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 immediately.
Do not repair high pressure couplings; you must replace the entire hose.
DFluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
FIRE, EXPLOSION AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in fire, explosion, or electrostatic shock and other serious injury.
DGround the equipment, the object being dispensed, and all other electrically conductive objects in
the dispense area. Proper grounding dissipates static electricity generated in the equipment. Refer
to System Grounding on page 8.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvent or material.
DExtinguish all open flames or pilot lights in the dispense area.
DDo not turn on or off any light switch in the dispense area.
DDo not use this equipment with flammable liquids.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DKeep the dispense area free of debris, including solvent, rags, and gasoline.
DDo not smoke in the dispense area.
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 and corrected the
problem.

310334 5
WARNING
MOVING PARTS HAZARD
Moving parts, such as the ram follower plate/pump inlet can pinch 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 12.
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.
DAvoid exposure to heated material fumes.
DProvide adequate ventilation.

6 310334
System Information
System Description
System 970159 includes a dual 55 gallon supply unit
with pneumatic crossover for continuous material
supply. System 970160 includes a dual 55 gallon
supply unit with electric crossover for continuous
material supply. System 970163 is a single 55 gallon
supply unit with a low–level shutoff. See Fig. 1.
Each system air–powered ram pushes a follower
plate (C) into a drum of material, while the pump (A)
removes material from the drum and pushes it through
a supply hose to a customer–supplied header. Material
flows through the header to individual dispense drops.
WARNING
A main air bleed valve (E) and pump air bleed
valve (H), are required. These accessories help
reduce the risk of serious injury, including skin
injection and splashing of fluid in the eyes or on the
skin, and injury from moving parts if you are adjust-
ing or repairing the pump.
The main air bleed valve (E) shuts off and relieves
the air to the pump and ram. The ram will hold
pressure if the ram director valve (U) is in the
horizontal (neutral) position. To relieve air pressure
in the ram, close the main air bleed valve (E) and
move the director valve (U) to DOWN. The ram will
slowly drop.
The pump air bleed valve (H) relieves air trapped
between it and the pump after the air is shut off.
Trapped air can cause the pump to cycle unexpect-
edly. Locate the valve close to the pump.
The fluid drain valve assists in relieving fluid pres-
sure in the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may not be
sufficient.
System Accessories and Modules
Before you install the system, you should be familiar
with the parts discussed in the following paragraphs.
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
DMain air bleed valve (E) is required in your system
to shut off the air supply to the pump and ram
(Refer to the preceding WARNING ). When closed,
the valve bleeds off all air in the ram and pump, and
the ram slowly lowers. Be sure the valve is easily
accessible from the pump, and is located upstream
from the air manifold (F).
DPump air bleed valve (H) is required in your
system to relieve air trapped between it and the air
motor when the valve is closed (Refer to the pre-
ceding WARNING). Be sure the valve is easily
accessible from the pump, and is located down-
stream from the air regulator (G).
DAir regulator (G) controls pump speed and outlet
pressure by adjusting the air pressure to the pump.
Locate the regulator close to the pump, but up-
stream from the pump air bleed valve.
DAir manifold (F) has a swivel air inlet. It mounts to
the ram, and provides ports for connecting lines to
air-powered accessories.
DAir line filter (J) removes harmful dirt and moisture
from the compressed air supply.
DSecond bleed-type air valve (K) isolates the air
line accessories for servicing. Locate upstream
from all other air line accessories.
DPneumatic (Model 970159) or electrical (Model
970160) crossover (L) provides switching between
dual rams to provide a constant supply of material
to the system. The crossover controls the air supply
to each of the ram air motors. A low–level
shutoff (L) (Model 970163) provides automatic
shutdown of a single ram system when only a small
amount of material remains. The shutoff controls
the air supply to the ram air motor.
DRam air regulator (T) controls the air pressure to
the ram.
DRam director valve (U) controls the raising and
lowering of the ram.
DAir release valve (V) opens and closes the flow of
air to assist raising the ram plate (C) out of an
empty drum.
DBleed handle (CC) bleeds air from under the ram
plate (C) to assist in priming the pump and lowering
the ram plate into the drum.

310334 7
Component Identification and Function
Fig. 1
KEY
APump
BRam (two used on 970159 and 970160,
one used on 970163)
CRam Plate
DElectrically Conductive Air Supply Hose
E Main Air Bleed Valve (required, for pump
and ram)
FAir Manifold
GPump Air Regulator
HPump Air Bleed Valve
(required, for pump)
JAir Line Filter
KBleed-Type Air Valve
(for accessories)
LPneumatic Crossover (for 970159), Elec-
trical Crossover (for 970160), Low–level
Shutoff (for 970163)
NElectrically Conductive Fluid Hose
SBall Valve
TRam Air Regulator
URam Director Valve
VAir Release Valve
WAir Line Drain Valve
YGround Wire (required; Refer to
page 8 for setup)
AA Safety Valve
CC Bleed Handle
U
T
NV
E
J K
D
C
CC
B
A
AA
S
W
Y
H
G
F
Supply Unit A Supply Unit B
Model 970159 Tandem Shown
L
A
B
TI0360A

8 310334
System Setup
System Setup
The following typical system installation 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.
Air-powered ram extruder systems force high viscosity
fluids into the intake valve of the fluid pump. Make
certain all accessories are adequately sized and pres-
sure-rated to meet your system’s requirements.
Air and Fluid Hoses
Be sure all air hoses (D) and fluid hoses (N) are prop-
erly sized and pressure-rated for your system. Use
only electrically conductive hoses. See Fig. 1.
Selecting System Ram Locations
System rams are to be positioned so that air regulator
controls for pumps and rams are easily accessible.
Make sure there is overhead clearance for rams when
fully raised. Refer to Dimensional Drawing on page 19
and separate ram manual 306934 (supplied) for addi-
tional setup data.
Use holes in ram base as a guide, drill holes for 13 mm
(1/2 in.) anchors.
Check that ram base is level in all directions. If neces-
sary, level base using metal shims. Secure base to
floor using 13 mm (1/2 in.) anchors to prevent ram
from tipping.
System Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE, EXPLOSION AND
ELECTRIC SHOCK HAZARD on
page 4.
1. Ram Pumps: check ground wire and clamp. See
Fig. 2. To install, loosen grounding lug locknut (W)
and washer (X). Insert one end of 1.5 mm@(12 ga)
minimum ground wire (Y) into slot in lug (Z) and
tighten locknut securely. Connect other end of wire
to true earth ground.
Fig. 2
W
X
Y
Z
0864
Pump Ground
2. Air and fluid hoses: use only electrically conduc-
tive hoses.
3. Air compressor: follow manufacturer’s recom-
mendations.
4. Dispense gun: ground through connection to
properly grounded fluid hose and pump.
5. Material supply container: follow your local code.
6. Object material is applied to: follow your local
code.
7. Solvent pails used when flushing: follow your
local code. Use only metal pails, which are conduc-
tive, placed on grounded surface. Do not place pail
on nonconductive surface, such as paper or card-
board, which interrupts grounding continuity.
8. To maintain grounding continuity when flush-
ing or relieving pressure, hold metal part of
dispense gun firmly to side of grounded metal pail,
then trigger gun.

310334 9
System Setup
Pneumatic Crossover Setup
(Model 970159)
Install the pneumatic crossover as shown in Fig. 3.
Also See Schematic, Fig. 8, page 23.
NOTE: During system operation, as the ram ap-
proaches the drum bottom, the top of the ram contacts
the limit valve switch. The switch shuts off air to the
ram air motor via a 4–way piloted air valve (3). As the
valve stops air to one ram, it starts air to the other ram.
This allows constant material flow and changing out of
material drums.
After empty drum is replaced, open the primary valve
to allow the preparation of the full container
NOTE: The primary valve should only be used to
prime the off side pump. After the air has been re-
moved via the bleed stick, close the primary valve
immediately after priming is accomplished.
NOTE: The position of the limit valve (4) on the ram
determines when the ram air motor is turned on and
off. During operation, this position can be adjusted as
desired. See Fig. 3.
Fig. 3
1
KEY
1Primary Valve
2Regulator
34–Way Piloted Air Valve
4Limit Valves (2)
5Main Air Inlet
2 3
4
5
8582A
Pneumatic Crossover Setup (Model 970159)
!NG
TI0388

10 310334
System Setup
Electrical Crossover Setup (Model 970160)
The electrical crossover is setup as shown in Fig. 4
and the Unloader Crossover (1) must be connected to
a 120 Volt, 60 Hz supply.
During system operation, as the ram approaches the
drum bottom, the top of the ram contacts the limit valve
switch. The switch shuts off the air to one ram, and
starts the other ram. This allows constant material flow
and changing out of material drums.
The position of the empty level indicator kit (2) on the
ram determines when the ram air motor is turned on
and off. During operation, this position can be adjusted
as desired. See Fig. 4.
The crossover panel has a Prime Empty Pump button.
When making a change of material barrels, this button
must be pushed after the ram is in the new drum of
material and the majority of air has been removed via
the follower bleed stick. After pushing the button, open
the pump bleed valve slowly until all air escapes and
only material flows (minimum of 4 pump cycles). The
standby pump air shuts off automatically after 5 min-
utes.
8584A
Fig. 4
A A
KEY
1Unloader Crossover
2Empty Level Indicator Kit (2)
33/4 in. npt Muffler
4Solenoid Valve
53/4 in. Hex Nipple
1
2 2
Detail A
34
5
Electrical Crossover Setup (Model 970160)