Graco Check-Mate 800 User manual

Instructions-Parts
Check-Mate® 800
Displacement Pump
334127A
EN
For use with hot-melt applications. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual and in related
system manuals. Save these instructions.
Maximum Operating Temperature 400°F
(204 °C)
Maximum Fluid Working Pressure 5850
psi (40 MPa 403 bar)
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Models............................................................... 2
Related Manuals ................................................ 2
Warnings ........................................................... 3
Component Identification..................................... 6
Installation.......................................................... 7
rounding ................................................... 7
Connect to a raco Air Motor ....................... 7
Pressure Relief Procedure .................................. 8
Pump Startup, Adjustment, and Shutdown
Instructions ........................................... 8
Repair................................................................ 9
Required Tools ............................................ 9
Disconnect the Pump ................................... 9
Replace Throat Packings.............................. 10
Replace Priming Piston ................................ 11
Replace Intake Valve ................................... 12
Repair Piston............................................... 14
Parts.................................................................. 16
Technical Specifications...................................... 20
Notes ............................................................... 21
raco Standard Warranty.................................... 22
Models
Part Drum Size Seal material
24W152 5 allon (20
Liter) Carbon Filled PTFE
24W153 5 allon (20
Liter) lass Filled PTFE
24W150 55 allon (200
Liter) Carbon Filled PTFE
24W151 55 allon (200
Liter) lass Filled PTFE
Related Manuals
Manuals are available at www.graco.com
Component manuals in English:
334128 Throat Seal Repair Kit,
Instructions-Parts
334131 Bulldog
®
and Senator
®
Air Motor Tie
Rod Kit, Instructions-Parts
334132 NXT
®
Air Motor Tie Rod Kit,
Instructions-Parts
2334127A

Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation 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.
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce
skin. This may look like just a cut, but it is a serious injury that can result in amputation. et
immediate surgical treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
•Followthe Pressure Relief Procedure when you stop dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
MOVIN 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.
334127A 3

Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area canigniteorexplode.Tohelp
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.
• round all equipment in the work area. See rounding 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.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot fluid or equipment.
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
manufacturer’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.
4334127A

Warnings
WARNING
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.
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. This 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.
334127A 5

Component Identification
Component Identification
Key:
A Displacement Pump
BWetcup
CThroat Packing
DOutlet Housing
EFluid Outlet
FBleedValve
Cylinder
H Intake Housing
JIntake Cylinder
KPrimingPiston
6334127A

Installation
Installation
Grounding
The equipment must be grounded to reduce the
risk of static sparking. Static sparking can cause
fumes to ignite or explode. rounding provides an
escape wire for the electric current.
Pump: the pump is grounded with a wire connecting
the pump from the control enclosure. Locate the
small hole (W) in the pump outlet housing. Attach
the ground wire (Y) to the pump outlet housing using
the ground screw (X) supplied with your system.
Tighten the ground screw securely. Do not operate
the equipment without the ground wire in place.
Air compressor: follow manufacturer’s
recommendations.
Fluid supply container: follow your local code.
Object being dispensed to: follow your local code.
Figure 1 rounding Screw
Connect to a Graco Air Motor
The displacement pump may be installed on Senator,
Bulldog, King, and NXT raco air motors using Tie
Rod Kits. See kit manual for installation instructions.
Manual Tie Rod Kit Air Motor
334131 24V752 Bulldog
Senator
King
334132 24V754 NXT
334127A 7

Pressure Relief Procedure
Pressure Relief Procedure
Follow the Pressure Relief Procedure
whenever you see this symbol.
This equipment stays pressurized until pressure
is manually relieved. To help prevent serious
injury from pressurized 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
equipment.
Heated fluid can cause severe burns and can
cause equipment surfaces to become very
hot. Wear protective gloves and clothing when
operating this equipment in a heated system. Allow
the equipment to cool thoroughly before servicing.
1. Lock the gun/valve trigger safety.
2. Close all air bleed valves (required in your
system) to shut off the air supply to the pump.
3. Unlock the gun/valve trigger safety.
4. Hold a metal part of the gun/valve firmly to the
side of a grounded metal pail, and trigger the
gun/valve to relieve pressure.
5. Lock the gun/valve trigger safety.
6. Open the pump bleeder valve (required in your
system), having a container ready to catch the
drainage.
7. Leave the pump bleeder valve open until you are
ready to spray/dispense again.
If you suspect that the spray tip/nozzle or hose is
completely clogged, or that pressure has not been
fully relieved after following the steps above, very
slowly loosen the tip retaining nut or hose end
coupling and relieve pressure gradually, then loosen
completely. Now clear the tip/nozzle or hose.
Pump Startup,
Adjustment, and
Shutdown Instructions
See your separate system manual instructions.
8334127A

Repair
Repair
Required Tools
• Torque wrench
• Bench vise, with soft jaws
• Rubber mallet
•Hammer
• O-ring pick
• 13mm(1/2in.)dia.brassrod
• Set of socket wrenches
• Set of adjustable wrenches
•Pipewrench
• Screwdriver
• Heat gun
• loves
• Thread lubricant
• Thread sealant
Disconnect the Pump
Heated fluid can cause severe burns and can
cause equipment surfaces to become very
hot. Wear protective gloves and clothing when
operating this equipment in a heated system. Allow
the equipment to cool thoroughly before servicing.
Note
Theprimingpistoncanbeserviced
without disconnecting the displacement
pump from the motor. see
Replace Priming Piston, page 11.
1. Flush the pump, if possible. Stop the pump at the
bottom of its stroke, to prevent fluid from drying
on the exposed displacement rod.
2. Relieve the pressure. See
Pressure Relief Procedure, page 8 .
3. Allow the pump to cool if being used in a heated
system.
Note
It may be necessary to use a heat gun to
ease disassembly of some parts.
4. Disconnect the air and fluid hoses.
5. Disconnect the pump from the heated platen.
6. Disconnect the displacement pump from the
motor as explained in your separate system
manual.
334127A 9

Repair
Replace Throat Packings
Note
The throat packings are available as a
preassembled kit.
Pump Part No. Throat Seal Repair
Kit
24W152 24V752
24W153 24V753
24W150 24V752
24W151 24V753
1. Relieve the pressure. See
Pressure Relief Procedure, page 8 .
2. See Fig. 2. Unscrew the packing nut (2) using a
pipe wrench. Remove the o-ring (27) and washer
(26) from the bottom of the packing housing (25)
or from the outlet housing (3).
3. Place the flats of the packing nut (2) in a vise.
Unscrew the packing housing (25) and discard it
and the packings. Remove the washer (24), seal
(23), and backup washer (22) from the packing
nut.
4. The throat repair kit is preassembled. Screw the
kit into the packing nut (2), making sure that the
backup washer (22), seal (23), and washer (24)
are properly positioned on top of the packing
housing (25), with the lips of the seal facing
down. Torque the packing housing (25) to 225
±10 ft-lb (305 ± 14 N•m).
5. Before installing packing housing into pump,
generously lubricate seals with high temperature
grease supplied with repair kit.
6. If necessary, use an arbor press to install o-ring
(27) in packing housing (25).
7. Screw the packing nut (2) and packing housing
(25) into the outlet housing (3). Torque to 150 ±
30 ft-lb (203 ± 41 N•m).
Figure 2 Throat Packings
1
Torque to 225 ± 10 ft-lb (305 ± 14 N•m).
2
Torque to 150 ± 30 ft-lb (203 ± 41 N•m).
3
Lips of u-cup packing must face down.
10 334127A

Repair
Replace Priming Piston
Pump Part No. Repair Kit
24W152 237910
24W153 237910
24W150 237909
24W151 237909
1. Stop the pump on the downstroke, with the flats
of the priming piston rod (17) exposed below
the intake cylinder (18). It is not necessary to
disconnect the displacement pump from the
motor, but you may have to disconnect it from
the heated platen.
2. Relieve the pressure. See
Pressure Relief Procedure, page 8 .
3. Hold the flats of the priming piston rod (17) with
an adjustable wrench, and use a second wrench
to unscrew the priming piston seat (21) from the
rod. Slidetheprimingpiston(20)offtherod.
Inspect the inner and outer surfaces of the piston
(20) for scoring, wear, or other damage.
4. Slide the priming piston (20) onto the rod (17)
until it stops. Hold the rod (17) steady with a
wrench on the flats, and screw the seat (21) onto
the rod with another wrench. Torque to 60 ± 3
ft-lb(81±4N•m).
Figure 3 Priming Piston
1
Torque to 60 ± 3 ft-lb (81 ± 4 N•m).
2
Torque to 390 ± 45 ft-lb (529 ± 61 N•m).
3
Torque to 150 ± 30 ft-lb (203 ± 41 N•m).
334127A 11

Repair
Replace Intake Valve
Note
The intake valve (V) is available as a
preassembled, pre–lubricated kit. The kit
includes the valve and all seals and packings,
and also includes the intake valve seat (15)
and seal (16). See Fig. 5.
Pump Part No. Repair Kit
24W152 253546
24W153 237907
24W150 253546
24W151 237907
1. Relieve the pressure. See
Pressure Relief Procedure, page 8 .
2. Disconnect the displacement pump. See system
manual for instructions.
3. Place the pump in a vise, with the outlet housing
(3) positioned as shown.
4. Remove priming piston (20). See
Replace Priming Piston, page 11.
5. Usingapipewrenchonthehexoftheintake
cylinder (18), unscrew it from the intake housing
(13).
Figure 4 Intake Valve
12 334127A

Repair
6. Pull the intake seat (15) and seal (16) out the
bottom of the intake housing (13).
Note
If the seat (15) is difficult to remove,
insert a brass rod through the top of the
housing (13) and drive the seat out with
a hammer.
Figure 5
7. Firmly tap the piston rod with a rubber mallet and
until the valve assembly comes free. Take care
not to drop the valve assembly (V) as it comes
free.
8. To repair the piston, cylinder, seals, and rods,
see Repair Piston, page 14.
9. Slide the intake housing (13) onto the priming
piston rod (17), making certain that the smooth
surfaceofthevalvestop(VS)isfacingdown
toward the pump intake. Screw the housing (13)
onto the cylinder (8).
10. Lubricate the priming piston rod (17), then slide
the preassembled intake valve (V) onto the rod,
making certain that the packing nut (31) goes on
the rod first. Push the valve assembly up the
rod as far as possible. Use a rubber mallet on
theprimingpistonrod(17),todrivethevalve
assembly up to the stop (VS).
11. The intake seat (15) is reversible. Push it into
the housing (13) until it seats securely. Lubricate
the seal (16) and install in the bevel around the
bottom of the seat.
12. Screw the intake cylinder (8) into the intake
housing(13).Usingapipewrenchonthehexof
the cylinder (8), torque the cylinder to 385–400
ft-lb (522–542 N•m).
13. Replace priming piston. See
Replace Priming Piston, page 11.
14. Reconnect the displacement pump to the air
motor as explained in your separate system
manual.
Figure 6
334127A 13

Repair
Repair Piston
Note
The piston valve is available as a
preassembled, pre–lubricated kit. The kit
includes the piston seat/guide assembly (P,
items 6, 9, 10, 11, and 12). Order Part No.
237906.
1. Follow Replace Intake Valve, page 12,to
disassemble the pump.
2. Remove outlet housing (3).
3. Using a rubber mallet, drive the displacement
rod (1) and the priming piston rod (17) out of the
cylinder (8). Inspect the outer surfaces of the
rods for damage by running a finger over the
surface.
Figure 7
4. Remove the seal (6) from the bottom of the
cylinder (8). See Fig. 7. Shine a light into the
cylindertoexaminetheinsidesurfaceforscoring
or damage. Only if the cylinder is damaged,
or there is evidence of leaking around the top
cylinder seal (6), unscrew the cylinder from the
outlet housing, using a pipe wrench. Remove the
top cylinder seal.
Figure 8
5. Place the flats of the displacement rod (1)
in a vise. Unscrew the piston (9) from the
displacement rod; the priming piston rod (17)
will come with it. Slide the piston seat/guide
assembly (10, 11, and 12) off the piston (9).
Figure 9
14 334127A

Repair
6. Place the piston (9) flats in a vise and unscrew
the rod (17).
7. Place the preassembled piston seat/guide
assembly (P, items 10, 11, and 12) onto the
piston (9) so the 45 beveled seating surfaces
match.
8. Place the flats of the displacement rod (1) in a
vise. Screw the piston (9) onto the displacement
rod (1) hand tight, then torque to 250–265 ft-lb
(339–359 N•m).
Figure 10
9. Using an adjustable wrench on the flats of the
priming piston rod (17), screw the rod into the
piston (9). Torque to 92–101 ft-lb (125–137 N•m).
Be careful not to create burrs on the flats of the
rod.
Figure 11
10. If the cylinder (8) was removed from the valve
housing (13), lubricate the seal (6) and place
it on the top of the cylinder. (The cylinder is
symmetrical, so either end can be the top.)
Screw the cylinder into the valve housing.
Figure 12
11. Screw the outlet housing (3) onto the cylinder.
Torque to 390±45 ft-lbs (528± 61 N•m).
12. Lubricate the displacement rod (1). Slide the rod,
piston assembly, and priming piston rod (17) into
the cylinder (10) from the bottom, until the top of
the rod (1) protrudes from the packing nut (2).
Figure 13
13. Lubricate the seal (6) and install it on the bottom
of the cylinder (8).
14. Follow ReplaceIntakeValve,page12,to
assemble the pump.
334127A 15

Parts
Parts
5 Gallon 20 Liter) Pumps
24W152, Pump with Carbon Filled Seals
24W153, Pump with Glass Filled Seals
1
Torque to 25 +/- 2 ft-lbs (25 +/- 2.7 N•m)
2
Torque to 390 +/- 45 ft-lbs (528 +/- 61 N•m)
3
Torque to 150 +/- 30 ft-lbs (203 +/- 40 N•m)
4
Torque to 60 +/- 3 ft-lbs (81 +/- 4 N•m)
5
Torque to 97 +/- 5 ft.-lbs (131 +/- 7 N•m)
6
Torque to 225 +/- 10 ft-lbs (131 +/- 13 N•m)
7
Torque to 255 +/- 16 ft-lbs (345 +/- 21 N•m)
8
Torque to 75 +/- 4 ft-lbs (101 +/- 5 N•m)
9
Apply lubricant.
10
Apply sealant to threads.
16 334127A

Parts
24W152, Pump with Carbon Filled Seals
24W153, Pump with Glass Filled Seals
Ref. Part Description Qty
1 16Y958 ROD, displacement,
chromex, 11cm 1
2 237799 NUT, packing 1
3 190598 HOUSIN , outlet 1
4 237908 BLEEDER VALVE KIT 1
5190620 FLAN E 1
6* 113040 PACKIN , o-ring 2
7* 15M521 BEARIN , piston guide 1
8 189437 CYLINDER, pump 1
9* 189439 SEAT, piston, sst 1
10* 15M520 UIDE, piston, 200 1
11* 113355 BEARIN , piston 1
12* 189441 SEAT, piston 1
13 190597 HOUSIN , valve 1
14 189514 VALVE, intake 1
15 189446 SEAT, valve 1
16 113041 PACKIN , o-ring 1
17 184400 ROD, piston 1
18 190608 CYLINDER, intake 1
19 113054 PACKIN , o-ring 1
20
 190606 PISTON, pump 1
21
 190607 SEAT, piston 1
22
★ 195233 WASHER, seal back-up 1
Ref. Part Description Qty
23
★ 120286 PACKIN , u-cup (assembly
24W152 only) 2
113021 PACKIN , u-cup (assembly
24W153 only) 2
24
★ 195234 WASHER, scraper 1.476 x
2.157 1
25
★ 190585 NUT, packing 1
26
★ 195232 WASHER, rod scraper 1
27
★ 104537 PACKIN , o-ring, ptfe 1
28
 113015 RIN , retainer 1
29
 190523 WASHER, retainer 1
30
 120285 PACKIN , u-cup (assembly
24W152 only) 1
113020 PACKIN , u-cup (assembly
24W153 only) 1
31
 190762 NUT, seal 1
32
 184246 LAND, packing male 1
33
 109301 PACKIN , vee 4
34
 184196 LAND, packing female 1
35 100508 SCREW, drive 6
36 189848 PLATE, designation 1
37 101754 PLU , pipe 1
38
▲ 184090 LABEL, warning 1
39
▲ 172479 TA , warning 1
▲
Replacement Warning labels signs tags and
cards are available at no cost.
Repair Kits 24W152 24W153
Throat ★ 24V572 24V573
Piston * 237906
Repair Kits 24W152 24W153
Intake Valve  253546 237907
Priming Piston  237910
334127A 17

Parts
55 Gallon 200 Liter) Pumps
24W150, Pump with Carbon Filled Seals
24W151, Pump with Glass Filled Seals
1
Torque to 25 +/- 2 ft-lbs (25 +/- 2.7 N•m)
2
Torque to 390 +/- 45 ft-lbs (528 +/- 61 N•m)
3
Torque to 150 +/- 30 ft-lbs (203 +/- 40 N•m)
4
Torque to 60 +/- 3 ft-lbs (81 +/- 4 N•m)
5
Torque to 97 +/- 5 ft.-lbs (131 +/- 7 N•m)
6
Torque to 225 +/- 10 ft-lbs (131 +/- 13 N•m)
7
Torque to 255 +/- 16 ft-lbs (345 +/- 21 N•m)
8
Torque to 75 +/- 4 ft-lbs (101 +/- 5 N•m)
9
Apply lubricant.
10
Apply sealant to threads.
18 334127A

Parts
24W150, Pump with Carbon Filled Seals
24W151, Pump with Glass Filled Seals
Ref Part Description Qty
1 16Y958 ROD, displacement,
chromex,11cm 1
2 237799 NUT, packing 1
3 190598 HOUSIN , outlet 1
4 237908 BLEEDER VALVE KIT 1
6* 113040 PACKIN , o-ring 2
7* 15M521 BEARIN , piston guide
cm200 1
8 189437 CYLINDER, pump 1
9* 189439 SEAT, piston, sst 1
10* 15M520 UIDE, piston, 200 1
11* 113355 BEARIN , piston 1
12* 189441 SEAT, piston 1
13 190597 HOUSIN , valve 1
14 189514 VALVE, intake 1
15 189446 SEAT, valve 1
16 113041 PACKIN , o-ring 1
17 184400 ROD, piston 1
18 190586 CYLINDER, intake 1
19 109482 PACKIN , o-ring 1
20
 276378 PISTON, 1
21
 190241 SEAT, piston 1
22 195233 WASHER, seal back-up 1
Ref Part Description Qty
23
★ 113021 PACKIN , u-cup (24W151
only) 2
120286 PACKIN , u-cup (24W150
only) 2
24
★ 195234 WASHER, scraper 1.476 x
2.157 1
25
★ 190585 NUT, packing 1
26
★ 195232 WASHER, rod scraper 1
27
★ 104537 PACKIN , o-ring, ptfe 1
28
 113015 RIN , retainer 1
29
 190523 WASHER, retainer 1
30
 113020 PACKIN , u-cup 1
31
 190762 NUT, seal 1
32
 184246 LAND, packing male 1
33
 109301 PACKIN , vee 4
34
 184196 LAND, packing female 1
35 100508 SCREW, drive 6
36 189848 PLATE, designation 1
37 101754 PLU , pipe 1
38
▲ 184090 LABEL, warning, moving
parts 2
39
▲ 172479 TA , warning 2
▲
Replacement Warning labels signs tags and
cards are available at no cost.
Repair Kits 24W150 24W151
Throat ★ 24V572 24V573
Piston * 237906
Repair Kits 24W150 24W151
Intake Valve  237907 253546
Priming Piston  237909
334127A 19

Technical Specifications
Technical Specifications
Check-Mate 800 Displacement Pump
US Metric
Maximum fluid working pressure 5850 psi 40 MPa, 403 bar
Displacement pump effective area 1.24 in.
2
8cm
2
Maximum pump operating
temperature 400°F 200°C
Fluid outlet size 1 in. npt(f)
Wetted parts Carbon steel, chrome, zinc, nickel plating, alloy steel, ductile iron,
fluoroelastomer, PTFE, bronze, stainless steel (304, 316, 440, and
17–4 PH)
Weight
24W152 59 lb 27 kg
24W153 59 lb 27 kg
24W150 59 lb 27 kg
24V020 59 lb 27 kg
Length
On Upstroke 31.15 in 791.2 mm
On Downstroke (priming piston
exposed) 33.75 in 857.2 mm
20 334127A