Graco ChemSafe 205 Parts list manual

Instructions-Parts
ChemSafe™ ChemSafe™
ChemSafe™205 205 205
Air Air
Air- - -Operated Operated OperatedDiaphragm Diaphragm DiaphragmPump Pump Pump334792G
EN
1/4–inch 1/4–inch
1/4–inchhigh high highpurity purity puritypump pump pumpfor for forindustrial industrial industrialapplications. applications. applications.
For For
Forprofessional professional professionaluse use useonly. only. only.Not Not Notapproved approved approvedfor for foruse use usein in inEuropean European Europeanexplosive explosive explosiveatmosphere atmosphere atmospherelocations. locations. locations.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanual.Save Save
Savethese these these
instructions. instructions.
instructions.
100psi(0.7MPa,7.0bar)MaximumAir
SupplyPressure
100psi(0.7MPa,7.0bar)Maximum
FluidWorkingPressure
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
Warnings...........................................................3
Con󰘰gurationNumberMatrix...............................6
Installation..........................................................8
GeneralInformation.....................................8
TightenFasteners........................................8
TipstoReduceCavitation.............................8
MountThePump.........................................9
GroundTheSystem.....................................10
AirLines......................................................10
AirExhaustVentilation.................................11
FluidSupplyLine.........................................12
FluidOutletLine...........................................12
Operation...........................................................13
TightenFasteners........................................13
FlushthePumpBeforeFirstUse..................13
StartandAdjustthePump............................13
PressureReliefProcedure............................14
PumpShutdown..........................................14
Maintenance......................................................15
MaintenanceSchedule.................................15
Lubrication...................................................15
TightenThreadedConnections.....................15
FlushingandStorage...................................15
Troubleshooting..................................................16
Repair................................................................18
DisassembletheFluidSection......................18
DisassembletheCenterSection...................19
ReassembletheCenterSection....................19
ReassembletheFluidSection.......................20
TorqueInstructions.............................................22
Notes.................................................................23
Parts..................................................................24
Kits....................................................................26
Dimensions........................................................27
PerformanceCharts............................................28
TechnicalData...................................................29
GracoStandardChemSafePump
Warranty...............................................30
2334792G

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Tohelp
prevent󰘰reandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareantistaticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
•Routeexhaustawayfromallignitionsources.Ifdiaphragmruptures,󰘱uidmaybeexhausted
withair.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
•Donotoperateelectrostaticgunsinequipmentworkarea.
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
334792G3

Warnings
WARNING WARNING
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestMSDSfromdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
THERMAL THERMAL
THERMALEXPANSION EXPANSION EXPANSIONHAZARD HAZARD HAZARD
Fluidssubjectedtoheatincon󰘰nedspaces,includinghoses,cancreatearapidriseinpressure
duetothethermalexpansion.Over-pressurizationcanresultinequipmentruptureandserious
injury.
•Openavalvetorelievethe󰘱uidexpansionduringheating.
•Replacehosesproactivelyatregularintervalsbasedonyouroperatingconditions.
PLASTIC PLASTIC
PLASTICPARTS PARTS PARTSCLEANING CLEANING CLEANINGSOLVENT SOLVENT SOLVENTHAZARD HAZARD HAZARD
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.
•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.
•SeeTechnical Technical
TechnicalData Data Datainthisandallotherequipmentinstructionmanuals.Read󰘱uidand
solventmanufacturer’sMSDSsandrecommendations.
4334792G

Warnings
WARNING WARNING
WARNING
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadMSDSstoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Routeexhaustawayfromworkarea.Ifdiaphragmruptures,󰘱uidmaybeexhaustedinto
theair.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
334792G5

CongurationNumberMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number Number
Matrix Matrix
Matrix
Checktheidenti󰘰cationplate(ID)forthe
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:205PT 205PT
205PT- - -P01APT3PTPTPOPT P01APT3PTPTPOPT P01APT3PTPTPOPT
205PT 205PT
205PTP01A P01A P01APT3 PT3 PT3PT PT
PTPT PT PTPO PO
POPT PT
PT
Pump
Model
Center
Section
andAir
Valve
Fluid
Covers
and
Manifolds
SeatsBallsDiaphragmsManifoldandSeatSeals
Pump Pump
PumpCenter Center
CenterSection Section Sectionand and andAir Air Air
Valve Valve
ValveMaterial Material Material
Fluid Fluid
FluidCovers Covers Coversand and andManifolds Manifolds Manifolds
205PT 205PT
205PT
1/4in.PTFEP01A P01A
P01APolypropylene
centerwithnpt
airinlet
PT3 PT3
PT3PTFE,npt
205 205
205UH UH UH
1/4in.UHMWPEP03A P03A
P03APolypropylene
centerwith
bsptairinlet
PT4 PT4
PT4PTFE,bspt
UH3 UH3
UH3UHMWPE,npt
UH4 UH4
UH4UHMWPE,bspt
Seat Seat
SeatMaterial Material MaterialBall Ball
BallMaterial Material MaterialDiaphragm Diaphragm DiaphragmMaterial Material MaterialManifold Manifold
Manifoldand and andSeat Seat Seat
Seal Seal
SealMaterial Material Material
PT PT
PTPTFEPT PT PTPTFEBN BN BNBunaNPT PT PTPTFE
EP EP
EPEPDM
PO PO
POPTFEOvermolded
6334792G

CongurationNumberMatrix
Models Models
Models
Model Model
ModelPump Pump PumpAir Air
Air& & &Fluid Fluid Fluid
Connection Connection
Connection
Threads Threads
Threads
Fluid Fluid
FluidCovers Covers Covers& & &
Manifolds Manifolds
Manifolds
Balls Balls
Balls& & &
Seats Seats
Seats
Diaphragm Diaphragm
DiaphragmManifold Manifold
ManifoldSeal Seal Seal
24X430 24X430
24X430‡bspt bspt
bspt
24X429 24X429
24X429‡1/4 1/4
1/4in. in. in.PTFE PTFE PTFEnpt npt
nptPTFE PTFE
PTFE
24X511 24X511
24X511bspt bspt
bspt
24X509 24X509
24X509npt npt
npt
PTFE/EPDM PTFE/EPDM
PTFE/EPDM
Overmolded Overmolded
Overmolded
24X532 24X532
24X532bspt bspt
bspt
24X533 24X533
24X533npt npt
nptEPDM EPDM
EPDM
24X508 24X508
24X508bspt bspt
bspt
24X507 24X507
24X507
1/4 1/4
1/4in. in. in.
UHMWPE UHMWPE
UHMWPE
npt npt
npt
UHMW UHMW
UHMW
PTFE PTFE
PTFE
Buna Buna
BunaN N N
PTFE PTFE
PTFE
‡ These models are FDA compliant
334792G7

Installation
Installation Installation
Installation
General General
GeneralInformation Information Information
TheTypicalInstallationshownisonlyaguidefor
selectingandinstallingsystemcomponents.Contact
yourGracodistributorforassistanceinplanninga
systemtosuityourneeds.AlwaysuseGenuine
GracoPartsandaccessories.Besureallaccessories
areadequatelysizedandpressureratedtomeetthe
system’srequirements.
Referencelettersinthetext,forexample(A),referto
thecalloutsinthe󰘰gures.
Variationsincolorbetweentheplasticcomponents
ofthispumparenormal.Colorvariationdoesnot
affecttheperformanceofthepump.
Storage: Storage:
Storage:Pumpsthatarenotputintooperation
upondeliverymustbestoredappropriately.See
FlushingandStorage,page15.
Tighten Tighten
TightenFasteners Fasteners Fasteners
Beforemountingandusingthepumpforthe
󰘰rsttime,checkandretorqueallexternalbolts.
Removeallprotectiveboltcovers(37).Follow
TorqueInstructions,page22,totightenallbolts.
Replacetheboltcovers(37).Afterthe󰘰rstdayof
operation,retorquethebolts.Retorquetheboltsifthe
pumphasbeenidleforanextendedtime,beenused
inthermalcyclingapplications,beendisassembled,
orifthereisalargedifferencebetweenenvironmental
temperaturesand󰘱uidtemperatures.
Tips Tips
Tipsto to toReduce Reduce ReduceCavitation Cavitation Cavitation
CavitationinanAODDpumpistheformationand
collapseofbubblesinthepumpedliquid.Frequent
orexcessivecavitationcancauseseriousdamage,
includingpittingandearlywearof󰘱uidchambers,
balls,andseats.Itmayresultinreducedef󰘰ciencyof
thepump.Cavitationdamageandreducedef󰘰ciency
bothresultinincreasedoperatingcosts.
Cavitationdependsonthevaporpressureofthe
pumpedliquid,thesystemsuctionpressure,andthe
velocitypressure.Itcanbereducedbychangingany
ofthesefactors.
1.Reducevaporpressure:Decreasethe
temperatureofthepumpedliquid.
2.Increasesuctionpressure:
a.Lowertheinstalledpositionofthepump
relativetotheliquidlevelinthesupply.
b.Reducethefrictionlengthofthesuction
piping.Rememberthat󰘰ttingsaddfriction
lengthtothepiping.Reducethenumberof
󰘰ttingstoreducethefrictionlength.
c.Increasethesizeofthesuctionpiping.
3.Reduceliquidvelocity:Slowthecyclicrateof
thepump.
Pumpedliquidviscosityisalsoveryimportantbut
normallyiscontrolledbyfactorsthatareprocess
dependentandcannotbechangedtoreduce
cavitation.Viscousliquidsaremoredif󰘰culttopump
andmorepronetocavitation.
Gracorecommendstakingalltheabovefactors
intoaccountinsystemdesign.Tomaintainpump
ef󰘰ciency,supplyonlyenoughairpressuretothe
pumptoachievetherequired󰘱ow.
Gracodistributorscansupplysitespeci󰘰c
suggestionstoimprovepumpperformanceand
reduceoperatingcosts.
8334792G

Installation
Mount Mount
MountThe The ThePump Pump Pump
Toavoidseriousinjuryfromtoxic󰘱uidorfumes:
•Ventilatetoaremotearea.Thepump
exhaustairmaycontaincontaminants.See
AirExhaustVentilation,page11.
•Nevermoveorliftapumpunderpressure.If
dropped,the󰘱uidsectionmayrupture.Always
followthePressureReliefProcedure,page14,
beforemovingorliftingthepump.
•ProlongedexposuretoUVradiationwilldegrade
naturalpolypropylenecomponentsofthepumps.
Topreventpotentialinjuryorequipmentdamage,
donotexposepumportheplasticcomponents
todirectsunlightforprolongedperiods.
1.Mountthepumpsotheexhaustportremains
clearoftheproductionarea.Exhaustairmay
containdebrisandcondensationfromtheair
supplyandairchamber.
2.Besurethemountingsurfacecansupportthe
weightofthepump,hoses,andaccessories,as
wellasthestresscausedduringoperation.
3.Forallmountings,besurethepumpissecured
withscrewsthroughthemountingfeet.Always
mountthepumpupright.
4.Makesurethesurfaceis󰘱atandthatthepump
doesn’twobble.
5.Foreaseofoperationandservice,mountthe
pumpsoairinlet,󰘱uidinletand󰘱uidoutletports
areeasilyaccessible.
Accessories/Components Accessories/Components
Accessories/ComponentsNot Not NotSupplied Supplied SuppliedSystem System SystemComponents Components Components
AAirsupplylineJAirinletport
BBleed-typemasterairvalve(required
foryourpump)
KExhaustportandmuf󰘱er
CAir󰘰lter/regulatorassemblyLFluidinletport
DMasterairvalve(toisolatethe
󰘰lter/regulatorforservice)
MFluidoutletport
EGrounded󰘱exible󰘱uidsupplylineNMountingfeet
FFluiddrainvalve(requiredforyour
pump)
GFluidshutoffvalve
HGrounded,󰘱exible󰘱uidoutletline
334792G9

Installation
Ground Ground
GroundThe The TheSystem System System
Theequipmentmustbegroundedtoreducethe
riskofstaticsparking.Staticsparkingcancause
fumestoigniteorexplode.Groundingprovidesan
escapewirefortheelectricalcurrent.
•Always Always
Alwaysgroundtheentire󰘱uidsystemas
describedbelow.
•Thepumpsarenot not
notconductive.Anysystem
usedtopump󰘱ammable󰘱uidsmustbeproperly
grounded.
•Followyourlocal󰘰recodes.
Beforeoperatingthepump,groundthesystemas
explainedbelow.
•Pump: Pump:
Pump:Always Always Alwaysgroundtheentire󰘱uidsystemby
makingsurethe󰘱uidhasanelectricalpathtoa
trueearthground.
•Air Air
Airand and and󰘱uid 󰘱uid 󰘱uidhoses: hoses: hoses:Useonly󰘱exiblegrounded
hoseswithamaximumof500ft.(150m)combined
hoselengthtoensuregroundingcontinuity.
•Air Air
Aircompressor: compressor: compressor:Followmanufacturer’s
recommendations.
•Fluid Fluid
Fluidsupply supply supplycontainer: container: container:Followlocalcode.
•Solvent Solvent
Solventpails pails pailsused used usedwhen when when󰘱ushing: 󰘱ushing: 󰘱ushing:Followlocal
code.Useonlyconductivemetalpails,placed
onagroundedsurface.Donotplacethepail
onanonconductivesurface,suchaspaperor
cardboard,whichinterruptsgroundingcontinuity.
Checkyoursystemelectricalcontinuityafterthe
initialinstallation,andthensetuparegularschedule
forcheckingcontinuitytobesurepropergrounding
ismaintained.
Air Air
AirLines Lines Lines
1.Installanairregulatorandgauge(C)tocontrol
the󰘱uidpressure.The󰘱uidstallpressurewillbe
thesameasthesettingoftheairregulator.
2.Locateableed-typemasterairvalve(B)closeto
thepumpanduseittorelievetrappedair.Be
surethevalveiseasilyaccessiblefromthepump
andlocateddownstreamfromtheregulator.
Trappedaircancausethepumptocycle
unexpectedly,whichcouldresultinserious
injuryfromsplashing.
3.Locateanothermasterairvalve(D)upstream
fromallairlineaccessoriesanduseittoisolate
themduringcleaningandrepair.
4.Anairline󰘰lter(C)removesharmfuldirtand
moisturefromthecompressedairsupply.
5.Installagrounded,󰘱exibleairhose(A)between
theaccessoriesandthe1/8npt(f)or1/8bspt
pumpairinlet.Useahosewithaminimum1/4in.
ID.Ifahoselongerthan10ft.(3m)isrequired,
usealargerdiameterhose.
10334792G

Installation
Air Air
AirExhaust Exhaust ExhaustVentilation Ventilation Ventilation
Ifpumpingtoxic󰘱uids,youmustventtheexhaust
awayfrompeople,animals,foodhandlingareas,
andallsourcesofignition.Followallapplicable
codes.
NOTE: NOTE:
NOTE:Donotrestricttheairexhaustport.Excessive
exhaustrestrictioncancauseerraticpumpoperation.
To To
Toprovide provide providea a aremote remote remoteexhaust: exhaust: exhaust:
1.UseKit17F610(NPT)or17F611(BSPT),sold
separately.
2.Removethemuf󰘱er(U)fromthepumpair
exhaustport(K).
3.Installtheadaptorfromthekit.
4.Installagroundedairexhausthose(S).Ifahose
longerthan10ft.(3m)isrequired,usealarger
diameterhose.Avoidsharpbendsorkinksin
thehose.
5.Placeacontainer(T)attheendoftheairexhaust
linetocatch󰘱uidincaseadiaphragmruptures.
Ifthediaphragmruptures,the󰘱uidbeingpumped
willexhaustwiththeair.
AAirsupplylineSGroundedairexhausthose
JAirinletport(notvisible)TContainerforremoteairexhaust
KExhaustportUMuf󰘱er
334792G11

Installation
Fluid Fluid
FluidSupply Supply SupplyLine Line Line
1.Usegrounded,󰘱exible󰘱uidhoses(E).See
GroundTheSystem,page10.
2.Iftheinlet󰘱uidpressuretothepumpismore
than25%oftheoutletworkingpressure,the
ballcheckvalveswillnotclosefastenough,
resultingininef󰘰cientpumpoperation.Excessive
inlet󰘱uidpressurealsowillshortendiaphragm
life.Approximately3–5psi(0.02–0.03MPa,
0.21–0.34bar)shouldbeadequateformost
materials.
3.Formaximumsuctionlift(wetanddry),see
TechnicalData,page29.Forbestresults,always
installthepumpascloseaspossibletothe
materialsource.Minimizesuctionrequirements
tomaximizepumpperformance.
Fluid Fluid
FluidOutlet Outlet OutletLine Line Line
1.Usegrounded,󰘱exible󰘱uidhoses.See
GroundTheSystem,page10,
2.Installa󰘱uiddrainvalve(F)nearthe󰘱uidoutlet.
3.Installashutoffvalve(G)inthe󰘱uidoutletline.
12334792G

Operation
Operation Operation
Operation
Tighten Tighten
TightenFasteners Fasteners Fasteners
Beforemountingandusingthepumpforthe
󰘰rsttime,checkandretorqueallexternalbolts.
Removeallprotectiveboltcovers(37).Follow
TorqueInstructions,page22,totightenallbolts.
Replacetheboltcovers(37).Afterthe󰘰rstdayof
operation,retorquethebolts.Retorquetheboltsifthe
pumphasbeenidleforanextendedtime,beenused
inthermalcyclingapplications,beendisassembled,
orifthereisalargedifferencebetweenenvironmental
temperaturesand󰘱uidtemperatures.
Flush Flush
Flushthe the thePump Pump PumpBefore Before BeforeFirst First FirstUse Use Use
Thepumpwastestedinwater.Ifwatercould
contaminatethe󰘱uidyouarepumping,󰘱ushthe
pumpthoroughlywithacompatiblesolvent.See
FlushingandStorage,page15.
Start Start
Startand and andAdjust Adjust Adjustthe the thePump Pump Pump
NOTICE NOTICE
NOTICE
Toavoiddamagetoyourpump,becertainthatall
pumped󰘱uidsarecompatiblewithwettedparts.
SeeTechnicalData,page29.
1.Besurethepumpisproperlygrounded.See
GroundTheSystem,page10.
2.Check󰘰ttingstobesuretheyaretight.Usea
compatibleliquidthreadsealantonmalethreads.
NOTICE NOTICE
NOTICE
Donotovertighten󰘱uidinletandoutlet󰘰ttings.
Thesoftplasticthreadscanbestrippedeasily.
3.Placethesuctiontube(ifused)in󰘱uidtobe
pumped.
NOTE: NOTE:
NOTE:If󰘱uidinletpressuretothepumpismore
than25%ofoutletworkingpressure,theball
checkvalveswillnotclosefastenough,resulting
ininef󰘰cientpumpoperation.
NOTICE NOTICE
NOTICE
Excessive󰘱uidinletpressurecanreduce
diaphragmlife.
4.Placetheendofthe󰘱uidhoseintoanappropriate
container.
5.Closethe󰘱uiddrainvalve(F).
6.Backouttheairregulatorknobandopenall
bleed-typemasterairvalves.
7.Ifthe󰘱uidhosehasadispensingdevice,hold
itopen.
8.Slowlyincreaseairpressurewiththeairregulator
untilthepumpjuststartstocycle.Allowthe
pumptocycleslowlyuntilallairispushedoutof
thelinesandthepumpisprimed.
NOTE: NOTE:
NOTE:Uselowestpossibleairpressuretoprime,
justenoughtocyclethepump.Ifthepumpdoes
notprimeasexpected,turnairpressureDOWN. DOWN.
DOWN.
9.Ifyouare󰘱ushing,runthepumplongenoughto
thoroughlycleanthepumpandhoses.
10.Closethebleed-typemasterairvalve.
334792G13

Operation
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressure
isrelievedmanually.Tohelppreventserious
injuryfrompressurized󰘱uid,suchassplashing
intheeyesoronskin,followthePressureRelief
Procedurewhenyoustoppumpingandbeforeyou
clean,check,orservicetheequipment.
1.Shutofftheairsupplytothepump.
2.Openthedispensingvalve,ifused.
3.Openthe󰘱uiddrainvalvetorelieve󰘱uid
pressure.Haveacontainerreadytocatchthe
drainage.
Pump Pump
PumpShutdown Shutdown Shutdown
Attheendoftheworkshiftandbeforeyoucheck,
adjust,clean,orrepairthesystem,followthe
PressureReliefProcedure,page14.
14334792G

Maintenance
Maintenance Maintenance
Maintenance
Maintenance Maintenance
MaintenanceSchedule Schedule Schedule
Establishapreventivemaintenanceschedule
basedonthepump’sservicehistory.Scheduled
maintenanceisespeciallyimportanttopreventspills
orleakageduetodiaphragmfailure.Aclogged
muf󰘱ermayrestrictpumpperformance.Inspect
airlinesandmuf󰘱ermediaregularlytomaintain
performance.
Lubrication Lubrication
Lubrication
Thepumpislubricatedatthefactory.Itisdesigned
torequirenofurtherlubricationforthelifeofthe
packings.Thereisnoneedtoaddaninlinelubricator
undernormaloperatingconditions.
Tighten Tighten
TightenThreaded Threaded ThreadedConnections Connections Connections
Beforeeachuse,checkallhosesforwearordamage
andreplaceasnecessary.Checktobesureall
threadedconnectionsaretightandleak-free.Check
mountingbolts.Checkbolts.Tightenorretorqueas
necessary.Althoughpumpusevaries,ageneral
guidelineistoretorqueboltseverytwomonths.See
TorqueInstructions,page22.
Flushing Flushing
Flushingand and andStorage Storage Storage
•Flushbefore󰘱uidcandryintheequipment,atthe
endoftheday,beforestoring,andbeforerepairing
equipment.
•Flushatthelowestpressurepossible.Check
connectorsforleaksandtightenasnecessary.
•Usesolventthatiscompatiblewiththeequipment
wettedpartsandthematerialbeingdispensed.
•Always󰘱ushthepumpandrelievethepressure
beforestoringitforanylengthoftime.
NOTICE NOTICE
NOTICE
Flushthepumpoftenenoughtopreventthe󰘱uid
youarepumpingfromdryingorfreezinginthe
pumpanddamagingit.
Storage: Storage:
Storage:Pumpsmustbestoredinanenvironment
wheretheyareclean,dry,andprotectedfrom
extremetemperatures,UVradiation,andvibration.
Gracorecommendsanambienttemperaturerangeof
60°F-80°F(15°C-25°C),withahumiditylevelbelow
65%.
334792G15

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
Problem Problem
ProblemCause Cause
CauseSolution Solution Solution
Pumpisrunningtoofast,causing
cavitationbeforeprime.
Lowerinletpressure.
Checkvalveballisseverelywarn
orwedgedinseatormanifold.
Replaceballandseat.
Seatisseverelyworn.Replaceballandseat.
Outletorinletisclogged.Unclog.
Inletoroutletvalveisclosed.Open.
Inlet󰘰ttingsormanifoldsareloose.Tighten.
Pumpcyclesbutwillnotprime.
Manifoldo-ringsaredamaged.Replaceo-rings.
Pumpcyclesatstallorfailstohold
pressureatstall.
Checkvalveballs,seatsoro-rings
areworn.
Replace.
Spoolvalveisstuckordirty.Disassembleandcleanair
valve.Usecleandryair.
Airsupplypressuretoolow.Increaseairsupplypressure.
Spoolvalveiswornordamaged.Replacespoolvalve.
Checkvalveballisseverelyworn
orwedgedinseatormanifold.
Replaceballandseat.
Dispensingvalveisclogged.Relievepressureandclearvalve.
Pumpwillnotcycle,orcyclesonce
andstops.
Diaphragmisruptured.Replace.
Suctionlineisclogged.Inspect;clear.
Checkvalveballsarestickyor
leaking.
Cleanorreplace.
Diaphragmisruptured.Replace.
Exhaustisrestricted.Removerestriction.
Spoolvalveisdamagedorworn.Replacespoolvalve.
Airsupplyiserratic.Repairairsupply.
Pumpoperateserratically.
Exhaustmuf󰘱erisicing.Usedrierairsupply.
Suctionlineisloose.Tighten.
Diaphragmisruptured.Replace.
Manifoldsareloose,orseatsor
manifoldo-ringsaredamaged.
Tightenmanifoldboltsorreplace
seatsand/oro-rings.
Diaphragmglidesealsoro-rings
aredamaged.
Replace.
Airbubblesin󰘱uid.
Pumpiscavitating.Reducepumpspeed,increase
suctionhosediameter,orincrease
inlethead.
Exhaustaircontains󰘱uidbeing
pumped.
Diaphragmisruptured.Replace.
Moistureinexhaustair.Inletairhashighhumidity.Usedrierairsupply.
16334792G

Troubleshooting
Problem Problem
ProblemCause Cause
CauseSolution Solution Solution
Pumpexhaustsexcessiveairat
stall.
Spoolvalvesealsarewornor
damaged.
Replace.
Fluidcoversareloose.Retorque.
Diaphragmisdamaged.Replace.
Pumpleaksairexternally.
Manifold󰘰ttingsarelooseRetorque.
Fluidcoversareloose.Retorque.
Pumpleaks󰘱uidexternally.
Diaphragmsaredamaged.Replace.
334792G17

Repair
Repair Repair
Repair
NOTE: NOTE:
NOTE:Beforerepairingthepump,followthe
PressureReliefProcedure,page14.
Disassemble Disassemble
Disassemblethe the theFluid Fluid FluidSection Section Section
1.Removeallboltcovers(37).
2.Usea3mmAllenwrenchtoremovethebase
plates(12)andtheinletmanifold(10).
3.Removethecheckseat(21)andball(22).
Withoutscratchingtheinnerbore,useahookto
removetheinletcheckcage(20).
4.Turnoverthepump.
5.Usea3mmAllenwrenchtoremovetheoutlet
manifold(8)andretainer(11).
6.Withoutscratchingtheinnerbore,useahookto
removetheoutletballretainer(19).Removethe
ball(22)andcheckseat(21).
7.Reattachthemanifoldbolts(29)tokeepthe󰘱uid
covernuts(18)aligned.
8.Removethenuts(28)andbolts(24)usingtwo7
mmsockets,toholdononesideandtoturnthe
other.Thenuts(28)willcomeoffofoneside.
Removethebolts(24).
NOTE: NOTE:
NOTE:Thenutsarepermanentlyaf󰘰xedtoone
endofthebolts.
9.Removethe󰘱uidcoverretainers(9)andthe󰘱uid
covers(6)fromthebody(1).
18334792G

Repair
Disassemble Disassemble
Disassemblethe the theCenter Center CenterSection Section Section
1.Onediaphragm(25)shouldscrewoffbyhand.
Slidetheseconddiaphragmoutwiththeshaft
(5)stillattached.
2.Usethesuppliedtool(46)toremovethemuf󰘱er
(14)fromthebody.Removeallmuf󰘱erparts.
Inspectthemeshbaf󰘱espacers(38)andfelt
muf󰘱ers(15).Replaceasneeded.
3.Usethesuppliedtool(45)toremovethesleeve
caps(3).Removetheshaftglideseal(17)and
o-ring(32)fromtheIDofthecaps.Remove
o-ring(32)fromthefaceofeachcap.Remove
theEPDMring(36)fromtheseatforeachsleeve
cap(3).
4.Useanappropriate-sizedsockettopressoutthe
mainandcentersleeveassemblies(2&4).
Reassemble Reassemble
Reassemblethe the theCenter Center CenterSection Section Section
1.Installaplug(40)ineachofthethreeunused
ports.
2.Installthemuf󰘱ermedia(15&38)intothe
muf󰘱er.Usethenewfeltmuf󰘱ers(15‡)supplied
intherebuildkit.Muf󰘱erpartsmustbeplaced
intheexactordershownintheillustration.Use
thesuppliedtool(46)toscrewthemuf󰘱er(14)
intotheexhaustport(theportwith2holesonthe
bottom).
3.Lubricateandinstallano-ring(32‡)andthenthe
shaftglideseal(17‡)intheIDofeachsleevecap
(3).Lubricateandinstallano-ring(32‡)onthe
faceofeachsleevecap(3).
4.LubricateandinstallanEPDMring(36‡)into
theseatforthesleevecap(3),inthecenterof
thebody(1).
5.Applymedium-strengththreadlockertothe
threadsofasleevecap(3).Usethetool(45)to
installitintoonesideofthebodyjustuntilitis
󰘱ushwiththesurface.Donotovertighten.
334792G19

Repair
6.Turnthecentersectionover.Spreadathin󰘰lm
oflubricantevenlyacrosstheo-ringsonthemain
andcentersleeveassemblies(2&4).Becareful
nottoplugtheairholes.Putthecenterassembly
(4)insidethemainassembly(2),andusean
appropriate-sizedsockettopressthesleeve
assembliesintothebody.
7.LubricateandinstallanEPDMring(36‡)into
theseatforthesleevecap(3),inthecenterof
thebody(1).
8.Applymedium-strengththreadlockertothe
threadsofthesecondsleevecap(3).Usethe
tool(45)toinstallthesecondsleevecap(3)into
thebody.Tightenjustuntilthecapis󰘱ushwith
thesurface.Donotovertighten.
9.Ifusingnewdiaphragms,removethethread
coveroneachdiaphragm(25†).
10.Tightenthepumpshaft(5)ontoonediaphragm,
handtightonly.Donotuseanytoolsontheshaft.
11.Lubricatetheshaft,theninstallitinthebody.
Turnthediaphragmasyoupushitin.Then,
tightentheotherdiaphragmontotheshaft,hand
tightonly.
Reassemble Reassemble
Reassemblethe the theFluid Fluid FluidSection Section Section
1.Insertthetoptwo󰘱uidcovernuts(18),threaded
end󰘰rst.
2.Threadthemanifoldbolts(29)afewturnsinto
thenuts(18),justtokeepthenutsfromrotating.
3.Repeatsteps1and2fortheother󰘱uidcover.
4.Installthe󰘱uidcoverswiththetopcheckstoward
theairinlet.
5.Placeabellevillewasher(27)withtherounded
sidetowardthenut,thena󰘱atwasher(26)on
eachtiebolt(24).Threadthe󰘰rsttiebolt(24)
throughone󰘱uidcoverretainer(9),andthenthe
secondtiebolt(24)throughtheother󰘱uidcover
retainer(9).Thisnecessarysothatthe󰘰rsttwo
tieboltscomeinfromoppositesidestohelpkeep
everythingtogetherbeforeclamping.
6.Threada󰘱uidcover(6),thecentersection
assembly,theother󰘱uidcover(6)ontothe󰘰rst
twotiebolts(24)andbetweenthe󰘱uidcover
retainers(9).
7.Placetheassemblyinaclamporvice.Tighten
sothe󰘰rsttwotiebolts(24)areexposedoneach
side.Threadtheremainingtiebolts(24)through
theassembly.
8.Placea󰘱atwasher(26),abellevillewasher(27),
andanut(28)oneachtiebolt.Tightenthebolts
hand-tight.Donottightentotorquespeci󰘰cation
yet.
9.Assemblethebottomchecks.Inserttheinletball
retainer(20†),theball(22†),andtheseat(21†),
withthechamferedsidedown(towardtheball).
10.Carefullyremovethemanifoldbolts(29)from
thebottomofthe󰘱uidcovers(6),keepingnuts
(18)aligned.
20334792G