Graco Monark E Series Operation manual

307–056
Rev. K
Supersedes F
and PCN G

INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
DIVORCED DESIGN
5:1 Ratio Monark  Sanitary Pump
600 psi (41 bar) Maximum Fluid Working Pressure
120 psi (8 bar) Maximum Air Input Pressure
Model 207–550, Series E
55 gallon (200 liter) drum size
Table of Contents
Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety W arnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco T oll-Free Phone Number 16. . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1996, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

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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 .
D
This equipment is for professional use only .
D
Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor .
D
Do not alter or modify this equipment.
D Check equipment daily . Repair or replace worn or damaged parts immediately .
D Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
T echnical Data on page 15 for the maximum working pressure of this equipment.
D Use 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.
D Do not use hoses to pull equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 180 _F (82_ C) or below –40 _F (–40_C).
DW
ear hearing protection when operating this equipment.
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

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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
.

Ground the equipment. Refer to Grounding on page 4.
 If there is any static sparking or you feel an electric shock while using this equipment, stop dis-
pensing immediately . Do not use the equipment until you identify and correct the problem.
 Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
 Keep the dispense area free of debris, including solvent, rags, and gasoline.
 Electrically disconnect all equipment in the dispense area.
 Extinguish all open flames or pilot lights in the dispense area.
 Do not smoke in the dispense area.
 Do not turn on or of f any light switch in the dispense area while operating or if fumes are present.
 Do not operate a gasoline engine in the 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.
 Know the specific hazards of the fluid you are using.
 Store hazardous fluid in an approved container . Dispose of hazardous fluid according to all local,
state and national guidelines.
 Always wear protective eyewear , gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer .
MOVING P ARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
 Keep clear of all moving parts when starting or operating the pump.
 Before servicing the equipment, follow the Pressure Relief Procedure on page 6 to prevent the
equipment from starting unexpectedly .

4ą307056K
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 3.
1. Pump: use a ground wire and clamp. See Fig. 1.
Loosen the grounding lug locknut (W) and washer
(X). Insert one end of the 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. 237–569 Ground Wire and
Clamp.
Fig. 1
W
X
Y
Z
2.
Air and fluid hoses: use only electrically conductive
hoses.
3.
Air compressor: follow manufacturer ’ s recommen -
dations.
4. Dispense valve: ground through connection to a
properly grounded fluid hose and pump.
5. Fluid supply container: follow your local code.
6. Container being dispensed into: follow your local
code.
7.
Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continu -
ity.
8. T o maintain grounding continuity when flushing or
relieving pressure , hold a metal part of the dis -
pense valve firmly to the side of a grounded metal
pail, then trigger the valve.
General Information
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
NOTE: Always use Genuine Graco Parts and Acces -
sories, available from your Graco distributor . Refer to
the Product Data Sheet for the pump, Form No.
304–410. If you supply your own accessories, be sure
they are adequately sized and pressure rated for your
system.
Fig. 2 is only a guide for selecting and installing sys -
tem components and accessories. Contact your Graco
distributor for assistance in designing a system to suit
your particular needs.
Mounting the Pump
Mount the pump to suit the type of installation planned.
The pump dimensions are shown on page 14.
When mounting the pump in a 2 in. bung type drum,
use the accessory bung adapter 205–573. Remove the
intake valve as explained on page 10, slide the bung
adapter onto the cylinder , and replace the intake valve.
Screw the bung adapter tightly into the drum bung hole
and tighten the thumbscrew to hold the pump about
0.5” (13 mm) of f the bottom of the drum. Loosen the
drum vent plug to prevent a vacuum from forming.
When mounting the pump in an open container , use
the accessory pump clamp 204–858 and bung adapter
205–573.
Screw the air exhaust muf fler (A) into the 3/4 npt(f)
outlet (B) in the motor base.
WARNING
T o avoid contaminating the fluid with lubricants, air
line scale, rust, etc., pipe the exhaust air outside of
the fluid product area. Vent the exhaust to a safe
place, away from people, animals or food handling
areas.

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Installation
Main Air Line
Fluid Line
AB
C
DE
F
KEY
AAir Exhaust Muf fler (may alternately be
mounted remotely , using exhaust hose)
B 3/4 npt Exhaust Air Outlet
C Air Line Filter/Regulator
DBleed-T ype Master Air V alve (required)
E Air Solenoid V alve
F
3/8 npt Air Inlet
G Air Line Drain Pipe and V alve
H
1–1/2” Tube Size Flanged Fluid Outlet
J Dispensing V alve
KT
imer Control
L Air Regulator
M Bung-Mounted Sanitary Pump
N Dispensing V alve Air Exhaust Hose
P Sensing Device
Y Pump Ground Wire (required; see page
4 for installation instructions)
G
J
K
H
L
0591
D
E
D
G
M
N
Y
P
0.5” (13 mm) clearance
Fig. 2
System Accessories
Install a bleed-type master air valve (D) close to the
pump air inlet (F), to relieve air trapped between it and
the air motor .
WARNING
The bleed-type master air valve (D) is required in
your system to shut of f and relieve air pressure that
may be trapped in the air motor . This air could
cause the pump to cycle unexpectedly , which could
result in serious injury , including amputation or
splashing of fluid in the eyes or on the skin.
Install an air filter/regulator (C) in the pump air line,
upstream from the bleed valve , to control air inlet
pressure and to remove harmful dirt and contaminants
from your compressed air supply .
Install another bleed-type master air valve (D) up -
stream from all air line accessories and use it to isolate
the accessories during cleaning and repair .
On the air drop to the dispensing valve (J), install an
air regulator (L) to control air pressure to the valve.
Install a bleed valve (D) to use as a shutof f when
servicing the dispensing valve.
Connect air solenoid valves (E) to a timer control (K),
and set so the dispensing valve (J) will dispense at
proper intervals.
Connect the Hoses
Connect electrically conductive air supply hoses to the
air inlets of the pump and dispensing valve.
Connect the fluid line between the pump’ s 1–1/2”
flanged fluid outlet and the fluid inlet of the dispensing
valve.
NOTE: Be sure to install the complete system in
accordance with all state sanitary standard codes and
local regulations.

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Operation
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually relieved to
prevent the system from starting or spraying acci -
dentally. T
o reduce the risk of an injury from acci -
dental spray from the dispense valve, splashing
fluid, or moving parts, follow the Pressure Relief
Procedure whenever you:
D are instructed to relieve the pressure,
D stop dispensing,
D check or service any of the system equipment,
D or install or clean the dispense valve nozzle.
1. Shut of f the air supply to the pump.
2. Close the bleed-type master air valve (required in
system).
3.
Open the fluid ball valve and/or dispensing valve to
relieve fluid pressure.
NOTE: The sanitary pump was assembled using
sanitary lubricant on moving parts and was tested in
water . Flush the pump thoroughly with an approved
cleaning solution or disassemble and sanitize the parts
before using the pump. Refer to the Cleaning Proce -
dure on page 7. Check local and state codes for
specific limitations.
Adjusting the Pump Speed and Pressure
WARNING
COMPONENT RUPTURE HAZARD
T o reduce the risk of component rupture,
which could cause serious injury , never
exceed 120 psi (8 bar) air supply pres -
sure to the pump. Read the warning section
EQUIPMENT MISUSE HAZARD .
Open the bleed-type master air valve (D). Adjust the
pump air regulator (C) until the pump is running
smoothly.
Allow the pump to cycle slowly until all air is pushed
out of the lines (the fluid will be flowing in a steady
stream from the fluid outlet) and the pump is primed.
With the air supply turned on, the pump will start when
the dispensing valve is opened, and stall against
pressure when the valve is closed. In a circulating
system, the pump operates until the air supply is
turned of f.
Pump Shutdown
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
T o shut of f the pump, relieve the pressure.
Care of the Pump
CAUTION
Do not expose the air motor to temperatures higher
than 200 _F (93_ C) or the immersed fluid pump to
temperatures higher than 250 _F (121_ C). Excessive
temperatures may damage the pump packings and
seals.
If the pump accelerates quickly , or is running too fast,
stop the pump immediately and check the fluid supply .
If the supply is empty and air has been pumped into
the lines, refill the container and prime the pump and
lines with fluid. Be sure to eliminate all air from the
system.
CAUTION
Never allow the pump to run dry of fluid. A dry pump
will accelerate to a high speed, possibly damaging
itself.
Always stop the pump at the bottom of its stroke to
prevent fluid from drying on the displacement rod (the
air motor will exhaust at the bottom of the stroke).

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Maintenance
IMPORTANT NOTE:
The following instructions show a basic procedure for
cleaning a sanitary system. However , be sure to clean
the pump and system in accordance with your state
sanitary standard codes and local regulations.
Be sure to disassemble the pump in order to thor -
oughly clean it.
Cleaning Procedure
1. Remove the pump from the fluid container and
operate it until as much of the fluid as possible has
been pumped out.
2. Flush the system thoroughly with an approved
cleaning solution.
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
3. Relieve the pressure. Remove the air and fluid
hoses from the pump. Disassemble the fluid pump
and accessories. See Service to disassemble the
pump.
4. W
ash all the pump parts with an alkaline detergent
at the manufacturer ’ s recommended temperature
and concentration, using either a brush or other
C.O.P . methods.
5. Rinse all the pump parts again with water and
allow them to dry .
6.
Inspect all the pump parts and reclean any parts
that are still soiled.
WARNING
Any damaged rubber parts must be replaced as
they will harbor microorganisms that can contami -
nate the fluid.
7. Immerse all pump parts and the lubricant tube in
an approved sanitizer before assembly . T ake the
pump parts out of the sanitizer one-by-one as
needed.
8.
Lubricate the moving pump parts and o-rings,
packings and seals with approved waterproof
sanitary lubricant.
9. Circulate the sanitizing solution through the pump
and the system prior to use.

8ą307056K
Notes

307056Ką9
Troubleshooting
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
1. Relieve the pressure.
2. Check all possible remedies in the T roubleshooting
Chart before disassembling the pump.
Problem Cause Solution
Pump fails to operate Restricted air line or inadequate air
supply
Insuf
ficient air pressure; closed
or clogged air valves, etc.
Exhausted fluid supply
Damaged air motor
Clear air line or increase air supply .
Open or clean air valves, etc.
Refill fluid supply .
Service, see manual 307–043.
Pump operates but output
low
on both strokes Restricted air line or inadequate air supply
Insuf
ficient air pressure; closed
or clogged air valves, etc.
Exhausted fluid supply
Obstructed fluid line, valves, dispensing
valve, etc.
W orn throat packing (8)
Damaged cylinder o-rings (13)
Clear air line or increase air supply .
Open or clean air valves, etc.
Refill fluid supply .
Clear. (Relieve pressures and discon-
nect
fluid line. T urn on air; if pump starts,
the line, etc. is clogged.)
Replace throat packing.
Replace o-rings.
Pump operates but output
low
on down stroke
Held open or worn fluid intake valve
Damaged cylinder o-rings (13)
Clear or service fluid intake valve.
Replace o-rings.
Pump operates but output
low
on up stroke
Held open or worn fluid piston or
seal (19)
Clear or service fluid piston or seal.
Erratic or accelerated
operation
Exhausted fluid supply
Held open or worn fluid intake valve
Held open or worn fluid piston or
seal (19)
Refill fluid supply .
Clear or service fluid intake valve.
Clear or service fluid piston or seal.

10ą307056K
Service
Displacement Pump Disassembly
NOTE: Repair Kit 218–741 is available. The parts
included in the kit are marked with an asterisk (for
example, 8*). See page 13. Use all the parts in the kit
for the best results.
1. Remove the pump from the fluid container . Oper -
ate it until as much of the fluid has been pumped
out as possible.
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
2. Relieve the pressure and remove the air and fluid
hoses from the pump.
3. Remove the intake valve housing (18) by removing
the retaining pin (16) and the o-rings (20) and
pulling the valve out of the cylinder (2). Disas -
semble the valve. Clean and inspect the parts. See
Fig. 3.
4. Release the clamp (7) holding the retainer housing
(22) to the air motor base. Slide the displacement
cylinder (2) down from the air motor and pull the
displacement rod (3) out of the connecting rod
(21). Inspect the connecting rod o-ring (28).
5. Push the displacement rod out through the bottom
of the cylinder . Remove the piston housing (26) by
removing the retaining pin (25) and the o-ring (20)
and pulling the piston from the displacement rod.
Disassemble, clean and inspect the parts.
6. T ake the retainer housing (22) of f of the cylinder
(2) and remove the packing housing (24), bearing
(17) and packing (8).
7. Clean and inspect all the parts. Refer to the
Cleaning Procedure on page 7. Replace the
parts as necessary .
WARNING
Any damaged rubber parts must be replaced as
they will harbor microorganisms that can contami -
nate the fluid.
Displacement Pump Assembly
NOTE: Lubricate the o-rings, throat packings, and
piston seals with waterproof approved sanitary lubri -
cant when reassembling.
1. Install the u-cup packing (8*) and throat bearing
(17*) in the throat packing housing (24). The lips of
the u-cup must face down into the housing, and
the lip of the bearing must face up. Install the
o-ring (13*) on the outside of the housing. See
Detail A of Fig. 3.
2. Place the throat packing housing (24) on the top of
the cylinder (2). Make sure the gasket (12*) is in
place on the top of the cylinder (2). Install the
retainer housing (22) on the cylinder so the hole
(A) in the housing is slanting downward toward the
cylinder . Secure with the clamp (7).
3. Install the piston seal (19*) on the piston housing
(26). Place the ball (9) on the seat of the housing.
Install the piston housing in the displacement rod
(3) so the holes in both parts align. Secure with the
retaining pin (25) and one o-ring (20*). See Detail
B.
4.
Lubricate the connecting rod o-ring (28) with
sanitary lubricant. See the parts drawing, page 12.
5. Slide the displacement rod (3) up through the
cylinder (2) so it protrudes from the retainer hous -
ing (22). Install the gasket (12*) on the top of the
retainer housing. Make sure the drip shield (11) is
in place on the connecting rod (21), then reconnect
the displacement rod to the connecting rod.
6. Slide the retainer housing (22) and cylinder (2) up
to the base of the air motor (1), and secure with
the clamp (7). Make sure the drip shield (14) is in
place on the cylinder .
7.
Install the o-ring (13*) on the intake valve housing
(18). Place the ball (10) on the seat of the housing
(18), and install the ball stop pin (23) in the top
holes of the housing. See Detail C.
8. Slide the intake valve housing (18) up into the
cylinder (2) until the bottom holes of the housing
align with the holes in the cylinder . Secure using
the retaining pin (16) and two o-rings (20*).
9. Install the gasket (15*) and clamp (5) when recon -
necting the fluid line to the pump fluid outlet.
10. Reconnect the ground wire if it was disconnected
during service.