Graco Check-Mate 800 Series User manual

Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions. See page 2 for model
numbers and maximum working pressures.
Instructions
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1995, Graco Inc. is registered to I.S. EN ISO 9001
CARBON STEEL
Check–Mate™800 Pumps
With Priming Piston and Severe–Duty Rod and Cylinder
Refer to page 2 for Table of Contents.
US Patent Nos. 5,147,188 and 5,154,532.
Other patents pending.
308351K
Models 236471
and 246942
Models 237265,
246940 and 246941
ti1447a
Models 198466
and 246938
4990B
04995
Parts

2 308351
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Models
Part No. Series Pump Model Ratio
Maximum Fluid
Working Pressure
Maximum Air
(or Hydraulic*)
Input Pressure
236471 B Kingt65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
237265 B Reduced Icing
Quiet Kingt
65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
240945 B Quiet Kingt65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
253376 B Quiet Kingt65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
237261 A Bulldogr31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
241901 A Bulldogr
(55 Gallon/200
Liter Size)
31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
237274 A Reduced Icing
Quiet Bulldogr
31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
237264 A Senatorr19:1 15 MPa, 157 bar (2280 psi) 0.8 MPa, 8.4 bar (120 psi)
198475 A Quiet Kingt65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
198466 A ViscountrII 40 MPa, 403 bar (5850 psi) 10.3 MPa*, 103 bar* (1500 psi*)
246942 A Kingt65:1 48 MPa, 483 bar (7000 psi) 0.7 MPa, 7 bar (100 psi)
246940 A Bulldogr31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
246941 A Senatorr19:1 15 MPa, 157 bar (2280 psi) 0.8 MPa, 8.4 bar (120 psi)
246938 A ViscountrII 40 MPa, 403 bar (5850 psi) 10.3 MPa*, 103 bar* (1500 psi*)

308351 3
Symbols
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 or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo 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.
DUse fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DDo not use hoses to pull equipment.
DRoute 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).
DWear hearing protection when operating this equipment.
DDo not lift pressurized equipment.
DComply 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.
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 leaks with your hand, body, glove or rag.
DDo not “blow back” fluid; this is not an air spray system.
DAlways have the tip guard and the trigger guard on the gun when spraying.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DBe sure the gun/valve trigger safety operates before spraying.
DLock the gun/valve trigger safety when you stop spraying.
DFollow the Pressure Relief Procedure on page 12 if the spray tip/nozzle clogs and before clean-
ing, checking or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged 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.
MOVING PARTS HAZARD
Moving parts, such as the priming piston, can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore 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.
DGround the equipment and the object being sprayed. Refer to Grounding on page 6.
DIf 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 problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed/dispensed.
DKeep the spray/dispense area free of debris, including solvent, rags, and gasoline.
DElectrically disconnect all equipment in the spray/dispense area.
DExtinguish all open flames or pilot lights in the spray/dispense area.
DDo not smoke in the spray/dispense area.
DDo not turn on or off any light switch in the spray/dispense area while operating or if fumes are
present.
DDo 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.
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.

6 308351
Installation
Grounding
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. 1 TI1052
Y
Z
Fig. 2
W
X
Y
Z
0864
2. Air and fluid hoses: use only electrically conductive
hoses.
3. Air compressor: follow manufacturer’s recommen-
dations.
4. Spray gun/dispense valve: ground through connec-
tion 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 con-
ductive, 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.

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 compo-
nents 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 re-
quirements.
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 electri-
cally 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)
05097
Fig. 3
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)
A
B
C
E
F
G
H
JK
M
Y
MAIN AIR LINE
R
S
TL
M
N
P
R
S
FLUID HEADER PIPE
(3 in. Diameter)
LP
M
N
D
W
U
V
N

308351 9
Installation (Air–Powered Pumps)
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 pres-
sure in the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may not be
sufficient. Order Part No. 210658.
Air Line Accessories
Install the following accessories in the order shown in
Fig. 3, using adapters as necessary:
DAn air line lubricator (D) provides automatic air
motor lubrication. Locate in the position shown.
DA main air bleed valve (C) is required in your
system 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
accessible from the pump, and is located upstream
from the air manifold (G).
DA pump air bleed valve (E) is required in your
system 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.
DAn 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.
DApump 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 seriously damaged. Locate in the position
shown.
DAn 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).
DAn air line filter (J) removes harmful dirt and
moisture from the compressed air supply. Also,
install a drain valve (W) at the bottom of each air
line drop, to drain off moisture.
DAn 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:
DInstall a fluid shutoff valve (P) at each gun/valve
drop, to isolate the gun/valve and fluid accessories
for servicing.
DInstall 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.
DA fluid regulator (L) controls fluid pressure to the
gun/valve, and dampens pressure surges.
DA 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.
DA gun/valve swivel (R) allows freer gun/valve
movement.

10 308351
Installation (Hydraulic–Powered Pumps)
KEY
A Accessory Pump Stand
(P/N 218742)
B Surge Tank (P/N 218509 or
238983)
C 50 mm (2 in.) Diameter Pipe
D Full Flow, Non-Restrictive
Fluid Shutoff Valve
E Fluid Supply Line
F Mix Tank
G Hydraulic Supply Line
Shutoff Valve
H Hydraulic Pressure Gauge
J Flow Control Valve
K Pressure Reducing Valve
L Drain Line
M Hydraulic Return Line
Shutoff Valve
N Accumulator
P Hydraulic Supply Line
Q Hydraulic Return Line
Y Ground Wire (required,
see page 6)
Fig. 4 01408
F
ED
A
ED
B
Y
D
F
K
J
L
HM
YC
N
GPQ