Graco Orion 245934 Operation manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
Instructions/Parts List
Orion™Piston Pumps
and Spray Packages
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
309512C
ll 2 G

2309512
Contents
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bare Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Spray Packages . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Information . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mounting Accessories . . . . . . . . . . . . . . . . . . . . . 7
Install the Muffler . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air Inlet Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air and Fluid Hoses . . . . . . . . . . . . . . . . . . . . . . . 7
Air Line Accessories . . . . . . . . . . . . . . . . . . . . . . 7
Fluid Inlet Adapter . . . . . . . . . . . . . . . . . . . . . . . . 7
Fluid Line Accessories . . . . . . . . . . . . . . . . . . . . 7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 9
Flush the Pump Before First Use . . . . . . . . . . . . 9
Start and Adjust the Pump . . . . . . . . . . . . . . . . 10
Shutdown and Care of the Pump . . . . . . . . . . . 10
Flush the Equipment . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preventive Maintenance Schedule . . . . . . . . . . 12
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tighten Threaded Connections . . . . . . . . . . . . . 12
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disconnect the Motor from the Displacement Pump
15
Reconnect the Motor to the Displacement Pump 15
Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . 16
Air Motor Piston and Cylinder Repair . . . . . . . . 17
Bellows Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Displacement Pump Repair . . . . . . . . . . . . . . . . 21
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Complete Pump . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pump Lowers . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
028.050 and 015.085 . . . . . . . . . . . . . . . . . . . . . 26
Wall Mount Packages . . . . . . . . . . . . . . . . . . . . 28
234087 (015.085) and 234089 (028.050) . . . . . 28
Cart Mount Packages . . . . . . . . . . . . . . . . . . . . 29
Air Inlet Details . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Gun/Siphon Hose Kits . . . . . . . . . . . . . . . . . . . . 32
Alpha+ (246300) . . . . . . . . . . . . . . . . . . . . . . . . 32
Silver+ (246301) . . . . . . . . . . . . . . . . . . . . . . . . 33
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 35
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Graco Phone Numbers . . . . . . . . . . . . . . . . . . . . . 38
Manual Conventions
Warning Caution
Note
WARNING
A warning alerts you to the possibility of serious injury
or death if you do not follow the instructions.
Symbols, such as fire and explosion (shown above),
alert you to a specific hazard and direct you to read
the indicated hazard warnings (pages 4-5) for detailed
information.
CAUTION
A caution alerts you to the possibility of damage to or
destruction of equipment if you do not follow the
instructions.
A note calls attention to additional helpful informa-
tion.

Model Information
3309512
Model Information
Bare Pumps
Key to Pump Model Designation
* BSPP stands for British Standard Pipe Parallel Thread
npt stands for National Pipe Taper Thread
Spray Packages
When ordering a package, order Gun/Siphon Hose kit separately. See pages 32 and 33 for part numbers.
Related Manuals
This manual is available in the following languages:
Pump
Part No.
Thread
Type
Pump
Ratio
Pump Model
(see key
below)
Air Motor
diameter in. (mm)
Displacement Pump
Volume per Stroke
Maximum Air
Input Pressure
psi (bar, MPa)
Maximum Fluid
Working Pressure
psi (bar, MPa)
245934 BSPP 28:1 028.050.BSPP 6.30 (D160) 1.7 oz. (50 cc) 116 (8, 0.8) 3248 (224, 22.4)
245935 BSPP 15:1 015.085.BSPP 6.30 (D160) 2.8 oz. (85 cc) 116 (8, 0.8) 1740 (120, 12.0)
234084 npt 15:1 015.085.npt 6.30 (D160) 2.8 oz. (85 cc) 116 (8, 0.8) 1740 (120, 12.0)
234085 npt 28:1 028.050.npt 6.30 (D160) 1.7 oz. (50 cc) 116 (8, 0.8) 3248 (224, 22.4)
015 050 BSPP
Pressure Ratio 015 = 15:1
Volume per Stroke, in cc
Thread Type*
Sprayer
Part No. Series Ratio
Sprayer Includes: Mounting Configuration: Maximum Air
Input Pressure
MPa, (bar, psi)
Maximum Fluid
Working
Pressure
MPa, (bar, psi)
Pump
Model
Thread
Type
Air
Controls
Fluid
Filter
Wall
Bracket Cart
234087 A15:1 015.085 npt ✔ ✔ ✔ 0.8, (8, 116) 12.0, (120, 1740)
234089 A 28:1 028.050 npt ✔✔✔ 0.8, (8, 116) 22.4, (224, 3248)
234091 A15:1 015.085 npt ✔ ✔ ✔ 0.8, (8, 116) 12.0, (120, 1740)
234093 A 28:1 028.050 npt ✔✔ ✔ 0.8, (8, 116) 22.4, (224, 3248)
Manual Language Manual Language
309512 English 309671 German
309669 Spanish 309672 Swedish
309670 French 309673 Italian

Warnings
4309512
Warnings
allation
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
• This equipment is for professional use only.
• Read all instruction manuals, tags, and labels before operating the equipment.
• Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
• Do not alter or modify this equipment.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 34 for the maximum working pressure of this equipment.
• Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Techni-
cal Data section of all equipment manuals. Read the fluid and solvent manufacturer's warnings.
• Do not use hoses to pull equipment.
• Route 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).
• Wear hearing protection when operating this equipment.
• Do not lift pressurized equipment.
• Comply with all applicable local, state, and national fire, electrical, and safety regulations.
SKIN INJECTION HAZARD
Spray from the gun, 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.
• Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgical
treatment.
• Do not point the gun at anyone or at any part of the body.
• Do not put your hand or fingers over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove or rag.
• Do not “blow back” fluid; this is not an air spray system.
• Always have the tip guard and the trigger guard on the gun when spraying.
• Check the gun diffuser operation weekly. Refer to the gun manual.
• Be sure the gun trigger safety operates before spraying.
• Lock the gun trigger safety when you stop spraying.
• Follow the Pressure Relief Procedure on page 9 if the spray tip clogs and before cleaning, checking
or servicing the equipment.
• Tighten all fluid connections before operating the equipment.
• Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
• Do not repair high pressure couplings; you must replace the entire hose.

Warnings
5309512
MOVING PARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
• Before servicing the equipment, follow the Pressure Relief Procedure on page 9 to prevent the
equipment from starting unexpectedly.
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 and the object being sprayed. Refer to Grounding on page 6.
• If there is any static sparking or you feel an electric shock while using this equipment, stop spraying
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
sprayed.
• Keep the spray area free of debris, including solvent, rags, and gasoline.
• Electrically disconnect all equipment in the spray area.
• Extinguish all open flames or pilot lights in the spray area.
• Do not smoke in the spray area.
• Do not turn on or off any light switch in the spray area while operating or if fumes are present.
• Do not operate a gasoline engine in the spray 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.
WARNING

General Information
6309512
General Information
Grounding
1. Pump: use a ground wire and clamp. See FIG. 1.
Insert one end of a 1.5 mm3(12 ga) minimum
ground wire (Y) into the pump’s grounding clamp
(16) and tighten the screw (W) securely. Connect
the other end of the wire to a true earth ground.
Order Part No. 238909 Ground Wire.
2. Air and fluid hoses: use only electrically conductive
hoses.
3. Air compressor: follow manufacturer's recommen-
dations.
4. Spray gun: ground through connection 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. 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 card-
board, which interrupts the grounding continuity.
8. To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray
gun firmly to the side of a grounded metal pail, then
trigger the gun.
• Reference numbers and letters in parentheses
in the text refer to the callouts in the figures
and the parts drawing.
• Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor. If
you supply your own accessories, be sure they
are adequately sized and pressure-rated for
your system.
• These pumps are mounted with the air motor
below the fluid section (see FIG. 2) for two rea-
sons. First, this orientation positions the fluid
section so that the inlet is below the outlet to
ensure that all air is evacuated when the pump
is filled with fluid and to optimize suction capa-
bility. Second, this orientation eliminates the
need for springs on the ball checks, improving
flushability.
•F
IG. 2 is a guide for selecting and installing
system components and accessories. It is not
an actual system design. Contact your Graco
distributor for assistance in designing a system
to suit your particular needs.
WARNING
Before operating the pump, ground the system as
explained below. Read the warnings on page 5.
FIG. 1 Grounding Wire
W
16
TI1102 TI1102

General Information
7309512
Mounting Accessories
Mount the pump (E) to suit the type of installation
planned. FIG. 2 illustrates a wall mount system. Pump
dimensions are shown on page 36.
1. Be sure the mounting surface can support the
weight of the pump, bracket, hoses and accesso-
ries, as well as the stress caused during operation.
2. Position the wall bracket about 1.2-1.5 m (4-5 ft)
above the floor. For ease of operation and service,
make sure the pump air inlet, fluid inlet, and fluid
outlet are easily accessible.
3. Drill mounting holes in the wall. Attach the bracket to
the wall. Use screws that are long enough to keep
the pump from vibrating during operation. Be sure
the bracket is level.
Install the Muffler
The muffler (C) is shipped loose. Screw the muffler into
the muffler port before installing the pump.
Air Inlet Fitting
A 1/4 npt air inlet fitting 245718 (113) is supplied on bare
pumps 234084 and 234085. It is held in place with a set-
screw (47). Loosen the setscrew before removing the fit-
ting. Tighten the setscrew to hold the fitting in place.
A 3/8 bspp(m) air inlet fitting (245682) is supplied on
Models 245934 and 245935.
Air and Fluid Hoses
Be sure all air hoses (A, P) and fluid hoses (R, U) are
properly sized and pressure-rated for your system. Use
only electrically conductive fluid hoses. Fluid hoses
should have spring guards on both ends. Use a swivel
(S) between the fluid hose (R or U) and the gun (T) to
allow easier gun movement.
Air Line Accessories
Install the following accessories in the order shown in
FIG. 2, using adapters as necessary:
• A bleed-type master air valve (B) is required in your
system to relieve air trapped between it and the air
motor when the valve is closed. Be sure the bleed
valve is easily accessible from the pump.
• A pump air regulator (D) controls pump speed and
outlet pressure by adjusting the air pressure to the
pump. Locate the regulator close to the pump.
• A gun air regulator (N) controls air pressure to the
air-assisted spray gun.
• An air line filter (M) removes harmful dirt and mois-
ture from the compressed air supply.
• A second bleed-type air valve (L) isolates the air line
accessories for servicing. Locate upstream from all
other air line accessories.
Fluid Inlet Adapter
A 3/4 npt fluid inlet adapter (115) is supplied on Models
234084 and 234085 only. Models 245934 and 245935
have a 1” bspp female port.
Fluid Line Accessories
Install the following accessories in the positions shown
in FIG. 2, using adapters as necessary:
• A fluid filter (F) with a 60 mesh (250 micron) stain-
less steel element, to filter particles from the fluid as
it leaves the pump. Install a fluid drain valve (G),
which is required in your system to relieve fluid pres-
sure in the hose and gun.
• A fluid shutoff valve (H) shuts off fluid flow.
• A fluid pressure regulator (J) allows more precise
adjustment of the fluid pressure.
• A gun or valve (T) dispenses the fluid. The gun
shown in FIG. 2 is an air-assisted spray gun for light
to medium viscosity fluids.
• A fluid line swivel (S) allows easier gun movement.
• A suction kit (K) allows the pump to draw fluid from a
fluid container.
• A 3/8 BSPP female port (Z) allows for fluid recircula-
tion.
CAUTION
The pump must be suction-fed in order to operate
properly. Pressure feeding the pump will cause bel-
lows seal failure.
Y

General Information
8309512
Key:
A Pump Air Supply Line
B Bleed-Type Master Air Valve
C Muffler
D Pump Air Pressure Regulator
EPump
F Fluid Filter
G Fluid Drain Valve
H Fluid Shutoff Valve
J Fluid Pressure Regulator
K Fluid Suction Tube
L Air Shutoff Valve
M Air Line Filter
N Gun Air Pressure Regulator
P Gun Air Supply Line
R Gun Fluid Supply Line
S Gun Swivel
T Air-Assisted Spray Gun
U Fluid Whip Hose
Y Pump Ground Wire
Z Recirculation Port
FIG. 2 Typical Installation (Wall Mount Shown)
TI2364A
K
R
B
L
M
S
U
E
A
M
L
N
G
G
H
J
P
T
C
F
Y
D
Z

Operation
9309512
Operation
Pressure Relief Procedure
1. Lock the gun trigger.
2. Turn off the air bleed valves to the fluid source and
to the gun.
3. Unlock the gun trigger.
4. Trigger the gun into a grounded metal waste con-
tainer to relieve the fluid pressure.
5. Lock the trigger.
6. Open the drain valve on the fluid filter and all other
fluid drain valves in the system, having a waste con-
tainer ready to catch the drainage. Leave the drain
valve(s) open until you are ready to spray again.
7. If the nozzle or hose is completely clogged or pres-
sure is not fully relieved, slowly loosen the hose end
coupling. Now clear the nozzle or hose.
Flush the Pump Before First Use
The pump is tested with lightweight oil, which is left in to
protect the pump parts. If the fluid you are using may be
contaminated by the oil, flush it out with a compatible
solvent before using the pump. See Flush the Equip-
ment on page 11.
WARNING
Read the warnings on page 5, and follow the Pressure
Relief Procedure below whenever you:
• are instructed to relieve pressure
• stop spraying
• check or service any of the equipment
• install or clean the spray tip.
LOCK
UNLOCK
LOCK
OPEN
ti129
8

Operation
10 309512
Start and Adjust the Pump
1. Connect the suction kit (K) to the pump's fluid inlet,
and place the tube into the fluid supply.
2. Close the air regulator (D).
3. Open the pump's bleed-type master air valve (B).
4. Hold a metal part of the gun (T) firmly to the side of
a grounded metal pail and hold the trigger open.
5. Slowly open the air regulator (D) until the pump
starts.
6. Cycle the pump slowly until all air is pushed out and
the pump and hoses are fully primed.
7. Release the gun trigger and lock the trigger safety
latch. The pump should stall against pressure.
8. If the pump fails to prime properly, open the drain
valve (G). Use the drain valve as a priming valve
until fluid flows from the valve. Close the drain valve
when all air is eliminated.
9. With the pump and lines primed, and with adequate
air pressure and volume supplied, the pump will
start and stop as you open and close the gun. In a
circulating system, the pump will speed up or slow
down on demand, until the air supply is shut off.
10. Use the air regulator to control the pump speed and
the fluid pressure. Always use the lowest air pres-
sure necessary to get the desired results. Higher
pressures cause premature tip and pump wear.
Shutdown and Care of the Pump
For a brief shutdown, relieve the pressure (page 9). For
a longer shutdown, or overnight, always flush the pump,
(page 11) and relieve the pressure, (page 9).
LOCK
CAUTION
Never allow the pump to run dry of the fluid being
pumped. A dry pump will quickly accelerate to a high
speed, possibly damaging itself. If your pump acceler-
ates quickly, or is running too fast, stop it immediately
and check the fluid supply. If the supply container is
empty and air has been pumped into the lines, refill
the container and prime the pump and the lines with
fluid, or flush and leave it filled with a compatible sol-
vent. Be sure to eliminate all air from the fluid system.
OPEN CLOSED