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Graco Series A Operation manual

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INSTRUCTIONS-PARTS
LIST
Thls manual contalns IMPORTANT
WARNINGS AND INSTRUCTIONS
READ ANDRETAINFORREFERENCE
SEVERE-DUTY, STAINLESS STEEL
10:l
RATIO STANDARD PUMP
PAIL AND WALL MOUNT SYSTEMS
950
psi
(66
bar)
MAXIMUM
WORKING
PRESSURE
Model
222-252,
Series A
Basic Pump
Pail Mount System
Includes pump, pail kit, airlfluid regulator kit,
hose kit, air-assisted airless spray
gun.
and 415 tip
Wall Mount System
Includes pump, wall mount kit, airlfluid regulator kit,
hose
kit, air-assisted airless spray
gun,
and 415 tip
Model
222-390
Model
222-393
INDEX
Warnings
.............................
2.
3
Installation
............................
4-6
Operation
................................
7
Troubleshooting
..........................
8
Service
.............................
9. 10
Parts Drawings and Lists
..............
11-16
Accessories
............................
17
Dimensional Drawing
....................
18
Pump Performance Chart
................
19
Technical Data
..................
Back Cover
Warranty
.......................
Back Cover
307-917
GRILCO
Rev
A
i
BASIC PUMP
MODEL 222-252
GRACO INC. P.O.
BOX
1441 MINNEAPOLIS,
MN
55440-1444
COPYRIGHT 1988, GRACO
INC.
Gencaral
Safcatv
This equlpment generates very hlgh fluld pressme. Spray
from
the spray gun, leaks or ruptured components can Inject fluid
thrauah
vow
skin and Into vour bodv and cause extremelv serl-
-
-
.
.
-
.
I.
"
.
-.
,
~~
~"
,
".
~~
,~~
~~
I
~ ~
-
~~~~ ~ -.,
-
~
ous bodily Injury, including the need for amputation. Also, fluld
Inlected or splashed Into the eves or on the skin can cause sed-
ous
damage.
NEVER polnt the spray gun
at
anyone or at any part of the body.
NEVER put hand or fingers over the spray tlp. NEVER try
to
blow back" paint: this Is NOT an air spray system.
ALWAYS follow the Pressure Relief Procedure. right, before
ment.
cleaning or removlng the spray tip or servlclng any system equlp-
NEVER try to stop or deflect leaks wlth your hand or body.
Be sure equipment safety devices are operating properly before
each use.
Medical
Alert--Airless
Spray
Wounds
If any fluld appears to penetrate your skin, get EMERGENCY
CUT. Tell the doctor exactly what fluid was injected.
MEDICAL CARE AT ONCE. DO NOTTREAT AS
A
SIMPLE
it Is important
to
treat
the
Injury surglcally
as
soon
as
Note to Physician: Injection
in
the skin
Is
a traumatic
injury.
lfyls a concern with some exotic coatlngs Injected directlylnto
posslble.
DO
not delaytreatment toresearch toxicity.
TOXIC-
constructive
hand surgeon may
be
advlsable.
the blood stream. Consultatlon with a plastlc surgeon or ra-
Spray
Gun
Safety
Devices
Be sure all spray gun safety devices are operating properly De-
fore each use. Do not remove or modify any part
of
the spray
gun: this can cause a malfunction and result
In
serious bodily
In-
Jury.
Whenever you stop spraying, even for a moment, always set the
Safety
Latch
spray gun safety latch
In
the closed or 'safe' position, maldng
the spray gun Inoperative. Failure
to
set the safety latch can re-
sult
In
accidental triggerlng of the spray gun.
The spray gun dlffuser breaks up spray and reduces the rlsk of
fluld Injection when the tip
Is
not Installed. Check the dlffuser op-
eration reoularlv. Follow the Pressure Relief Procedure. be-
~ ~~~~~~
low. then remove the spray tip. Aim the spray
gun^
into ~a
grounded metal pall, holding the spray gun flrmly to the pall. Us-
Ing the lowest possible pressure. trlgger the spray gun. If the
fluid emitted Is not diffused Into an irregular stream. replace the
diffuser lmmedlately.
Spray
Tip
Safety
Use extreme caution when cleanlng or changing spray tips, If the
spray tip clogs while spraylng, engage the spray gun safety latch
Immediately. ALWAYS follow the Pressure Rellef Procedure
and then remove the spray tlp to clean It.
NEVER wipe off build-up around the spray tip until pressure 1s
fully relieved and
the
spray
gun
safety latch is engaged.
~
~~.
~ ~
Pressure
Relief
Procedure
To reduce the rlsk
01
serlous bodily
Inlury.
lncludlng fluld
Inlectlon. splashing In the eyes or on the skin, orlnluryfrom
moving parts, always follow this procedure whenever
you
shut off the pump, when checklng or servicing any part of
the spray system. when Installing, cleaning or changing
spray tips, and whenever
you
Stop spraying.
1.
Engage the spray gun safety latch.
2.
Shut
off
the alr to the
pump.
3.
Close the bleed-type master air valve (required in your
4.
Disengage the spray gun safety latch.
5.
Hold a metal part of the spray gun firmly to the side of a
grounded metal pall. and trlgger the spray gun to re-
lleve pressure.
system).
6.
Engage the spray gun .safety latch.
7.
Open the draln valve (required In your system), having
8.
Leave the draln valve open Until you are ready to spray
If you suspect that the spray tlp or hose Is completely
following the steps.above. VERY SLOWLY loosen the alr
clogged, or that pressure has not been fully relieved after
then loosen completely. Now clear the tip or hose.
cap or hose end coupling and relieve pressure gradually,
a container ready to catch the drainage.
again.
General
Safety
Any misuse
of
the spray equipment or accessories, such as
overpressurlzing, modifyhg parts, uslng Incompatlble
chemicals
rupture and result in fluld Injeotlon, splashing In the eyes or on the
and flulds, or uslng worn or damaged parts, can cause them to
damage.
skin, or other serious bodily Injury, or fire. exploslon or property
NEVER alter or modify any part of this equlpment: doing
so
could
cause It to malfunction.
CHECK all spray equipment regularly and repair or replace worn
or damaged parts immediately.
Always wear protectbe eyewear. gloves, clothlng and resplrator
as recommended by the fluld and solvent manufacturer.
System Pressure
WORKING PRESSURE at
95
psi
(6.5
bar) MAXIMUM INCOMING
The
1O:l
ratio pump can develop
950
psl
(66
bar) MAXIMUM
the pump.
AIR PRESSURE. NEVER exceed
95
psi
(6.5
bar) air pressure to
withstand the maxlmum working pressure of the pump.
DO
NOT
Be
sure that ail spray equipment and
accessories
are rated
to
exceed the maximum working pressure of any component or ac-
cessory used in the system.
Fluid
Compatibility
patible wlth the wetted parts shown In the TECHNICAL DATA
BE SURE that ail flulds and solvents used are chemically com-
on the back page, Always read the manufacturer's literature
before uslng fluld or solvent In this pump.
I
hose develops a leak, spilt or rupture due to any kind of wear,
High pressure fluld
In
the hoses can be very dangerous. If the
)
cause
a
fluld Injection injury or other serious bodily Injury or prcp-
damage or misuse, the hlgh pressure spray emltted from
It
can
erty damage.
ALL FLUID
HOSES
MUST HAVE SPRING GUARDS ON
BOTH ENDS! The spring guards help protect the hose from
kinks or bends at or close tc the coupling which can result In hose
rupture.
TIGHTEN all fluid connections securely before each use. High
pressure fluid can dislodge a loose coupling or allow hlgh pres-
sure spray to be emltted from the coupling.
NEVER
use a damaged hose. Before each use. checkthe entire
hose for cuts, leaks. abraslon, bulging cover. or damage or
movement of the hose coupllngs. If any of these conditions ex-
pressure hose or mend
It
with tape or any other devlce.
A
re-
1st. replace the hose immediately.
DO
NOT
try
to recouple high
palred hose cannot safely contaln the hlgh pressure fluid.
hoses to move equipment.
Do
not use fluids which are not com-
HANDLE AND
ROUTE
HOSES CAREFULLY.
Do
not pull on
patible with the inner tube and cover of the hose.
DO
NOT ex-
pose Graco hoses to temperatures above
1800
F
(820
C)
or
be-
low
-4OO
F
(-400
C).
Hose
Grounding Continuity
Proper hose grounding continuity
IS
essential to malntainlng a
grounded spray system. Check the electrical resistance of your
have a tag on
It
which specifies the maxlmum electrical resls-
air and fluid hoses at least once a week. If your hose does not
tance. contact the hose supplier or manufacturer for the maxl-
mum resistance limits. Use a resistance meter In the approprl-
tance exceeds therecommended
IlmltS.
replaceltlmmedlately.
ate range for your hose to check the reslstance. If the resls-
hazardous. Also. read-FIRE
OR
EXPLOSION HAZARD. be-
An ungrounded or poorly grounded hose can make your system
low.
parts. KEEP CLEAR of moving parts when starting or operating
Moving parts can pinch or amputate Your flngers or other body
the pump. Before checklng or servlclng the pump or any system
component, follow
the
Pressure Rellef Procedure on page
2.
to prevent the pump from starting accidentally.
Static electricity Is created by the flow of fluld through the pump
and hose. If every part of the spray equipment
1s
not properly
grounded, sparking may occur, and the system may become
hazardous. Sparklng may also occur when plugging In or unplug-
ging a power supply cord. Sparks can Ignite fumes from solvents
and the fluid being sprayed, dust partlcles and other flammable
substances. whether
you
are spraylng indoors or outdoors, and
can cause a fire or exploslon and serious bodily Injury and prcp-
erty damage.
Do
not plug In or unplug any power supply cords In
the spray area when there Is any chance
of
Igniting fumes still In
)
the air.
uslng thls equipment. STOP SPRAYING IMMEDIATELY.
If
you experlence any static sparking or even a slight shock while
Check the entire system for proper grounding.
Do
not use the
system again until the problem has been Identifled and ccr-
rected.
"""""FI
To reduce the rlsk of Static sparking. ground the pump, object
being sprayed. and all other spray equipment used or located
in
the snrav area. CHECK vour local electrlcal code far detailed
I
~~~ ~
grounding Instructionsfor your area and type of equlpment. BE
SURE to ground all
of
this spray equlpment:
1,
Pump: use
a
ground wlre and clamp as shown
in
Fig
1,
2.
Air
hoses: use only grounded
alr
hoses.
3.
Fluid
hoses: use Only grounded fluld hoses.
4.
Air
compressor: follow manufacturer's recommendations.
5.
Spray gun: grounding
Is
obtained through connection to a
6.
Fluid
supply coniainer: accordlng to your local code.
7.
Obleci being sprayed: according to your local code.
,~~~~
~~~ ~ ~~
properly grounded fluid hose and pump.
8.
All
soiveni pails used when flushing. accordlng to local
code. Use only metal pails. which are conductive, placed on
a grounded surface.
Do
not place the pall on a nonconduc-
tlve surface. such as paper or cardboard, which Interrupts
the groundlng contlnuity.
8.
All
soiveni pails used when flushing. accordlng to local
code. Use only metal pails. which are conductive, placed on
a grounded surface.
Do
not place the pall on a nonconduc-
tlve surface. such
as
naoer or cardboard. which lnterructs
9.
To
mainiain groundlng coniinuity when flushing or reliev-
ing
pressure, always hold a metal part of the spray gun
firmly to the side of a grounded meial pall, then trigger the
spray gun.
;I
'0
ground the pump:
'0
ground the pump, loosen the groundlng lug locknut
(W)
md washer
(X).
Insert one end of a
1.5
mmz
(12
gal mini-
ium ground wire
(Y)
Into the slot In lug
(21
and tighten the
lcknut securely. See Fig
1.
Connect the other end of the
/Ire to a true earth ground.
W
'ig
1
Before flushing, be sure the entlre system and flushing pails are
Flushing Safety
properly grounded. Refer to Groundlng, at the left. Follow the
Pressure Rellef Procedure on page
2,
and remove the spray
tip from the Spray gun. Always use the lowest possible fluid
pressure. and malntaln flrm metal-to-metal contact between
the spray gun and the pall during flushlng to reduce the rlsk of
fluid Injection Injury, statlc sparking and splashing.
Ventilate the Spray Booth
TO prevent hazardous concentratlon of toxic andlor flammable
vapors, spray Only
In
a properly ventilated spray booth.
NEVER
operate the spray gun unless the ventilating fans are op-
erating.
NOTE:
Be
sure that all operators read and understand
this entire manual and any separate manuals
supplied with components and accessories
before using this equipment.
Numbers and letters in parentheses refer
to
the parts lists and the callouts in Figs. 1-5.
The Typical installations shown in Figs.
2
and 3
are only examples. For assistance in designing
a system
to
meet your particular needs, con-
tact your Graco representative. Accessories
mentioned in the
text
are shown on page
17.
Typical Installation:
Pall
Mount
Systems
KEY
A
B
C
D
E
F
0
H
18
204
205
206
401
207
402
403
506
503
PAIL MOUNT SYSTEM INSTALLATION
(Refer
to Fig.
2)
-.
Place the pail cover
(206)
on the pail (204), and
se-
cure with the three thumbscrews
(207).
Install the
two hex screws (203).
bung adapter plate
(205)
on the pail cover, using the
valve. Lower the pump (A) through the adapter plate
Screw the pipe nipple
(208)
into the pump's intake
and cover into the pail,
so
the inlet is 112 in. (13 mm)
off the bottom of the pail. Screw the pump's bung
adapter (18) into the bung adapter plate tightly.
plete the installation.
Refer to "Instailation Procedure
-
All
Models" to com-
D
Pump
Pump Air Regulator
Gun Air Regulator
Air Line Filter
Main Air Line
Bleed-Type Master Alr Valve
Drain Valve
Spray Gun
Bung Adapter
Dall
. -..
Bung Adapter Plate
Pall Cover
Thumbscrews
Fluld Hose
Fluld Filter
Gun Alr Hose
Air Line Coupler
Safety Valve
506
C
206
207
204
G
401
Fig.
2
"
nn-7
",7
..
..
,.
..
.
..
'.
.
.. .
..
i
WALL MOUNT
SYSTEM
INSTALLATION
(Refer
to Fig.
3)
Install the bung adapter plate (306)
on
the wall
bracket, using the two hex screws (303) and nuts
(304).
Mount the wall bracket (305)
5
ft (1.5 m) above the
floor. Refer to wall bracket manual 306-783 for in-
structions.
Be
sure the wall is strong enough to support
the weight of the equipment, fluid, and hoses, and
stress caused during pump operation.
Typical Installation: Wall Mount Systems
KEY
A
B
C.
D
E
F
G
H
18
305
307
306
401
402
403
503
506
Pump
Pump Air Regulator
Air
Line Filter
Gun Alr Regulator
Maln AIr Une
Draln Valve
Bleed-Type Master
Alr
Valve
Spray Gun
Wall Bracket
Bung Adapter
bracket. Screw the pump's bung adapter
(18)
into the
bung adapter piate (306) tightly.
.~
Screw the Suction tube assembly (307) into the
pump's fluid intake valve.
Refer to "Installation Procedure
-
AII
Models" to corn-
Dlete the installation.
E
D
Fig.
3
307-917
5
!
''
1
i
!
i
!
!
!
i
!
i
'I
!
j
i
I
.I
!
i
,
..
.
i
.I
!
I
I
i
i
..
i
I
i
!
INSTALLATION PROCEDURE
-
ALL MODELS
rWARNING
1
(Refer to Figs.
2
and
3)
To
prevent hazardous concentrations of toxic
andlor flammable vapors, spray only in a prop-
THE SPRAY GUN UNLESS VENTILATION FANS
erly ventilated spray booth. NEVER OPERATE
ARE
OPERATING.
Check and follow all of the National, State and
Local codes regarding air exhaust velocity re-
quirements.
AirlFluid Regulator Kit
The AirlFiuid Regulator Kit is an assembled unit. It con-
sists of the following parts:
a pre-set safety valve
(506),
which prevents over-
pressurization of the spray gun by opening auto-
matically
if
the incoming air pressure to the pump
exceeds
95
psi
(6.6
bar)
one air regulator (B) to control the air pressure to
the pump (A), and a second regulator
(C)
to con-
trol the air pressure to the spray gun (H)
an air line fitting
(502)
and coupler (503), to con-
nect the main air line to the airlfluid regulator kit
connectors and fittings.
Connect the pump air regulator (B) to the pump's air
inlet. Use this regulator to control pump speed and
fluid pressure.
The regulator kit's air inlet consists of a quick-discon-
the coupler from the pin fitting and screw it onto the
nect coupler (503) and a pin fitting (502). Disconnect
end of your air supply hose, but do not reconnect the
coupler to the pin fitting yet.
System Accessories
Install an air line filter
(D)
in the main air line (E), to
remove harmful dirt and moisture from the com-
pressed air supplied to the pump and gun. Down-
stream from the pump air regulator (B), install a
bleed-type master air valve
(F),
using necessary
adapters.
R
?n7-Q17
valve
(G).
Near the pump's fluid outlet., install a tee and drain'
7
WARNING
Two accessories are required in your system: a
bleed-type master air valve (F) and a fluid drain
valve (G). These accessories help reduce the
tion, splashing in the eyes or on the skin, or in-
risk of serious bodily injury including fluid injec-
jury from moving parts
if
you are adjusting or
repairing the pump.
The bleed-type master air valve relieves air
trapped between this valve and the pump after
the air is shut off. Trapped air can cause the
close to the pump.
pump to cycle unexpectedly. Locate the valve
The
fluid
drain valve assists in relieving fluid
gun: triggering the gun to relieve pressure may
pressure in the displacement pump, hose, and
not be sufficient.
Hose and Gun Connections
The Hose Kit consists of the spray gun's air and fluid
supply hoses. The fluid hose (401) has spring guards
on both ends, and includes an in-line fluid filter (402)
at the gun end. The hoses are tied together for ease of
movement.
Connect the male end of the air hose (403) to the 114
connect the female end to the air inlet in the spray gun
npsm(f) swivel outlet of the gun air regulator
(C),
and
(H)
handle.
Connect the male end of the fluid hose (401) to the
pump's fluid outlet, and connect the female end to the
gun's fluid inlet.
DO
NOT install the spray tip in the gun
yet.
um
GROUNDING
~~~~~
WARNING
Before operating the pump, ground the system as
explained under
FIRE
OR
EXPLOSION HAZARD
and Grounding on page
3.
.:
1
I
I
I
!
... .
..
.
..
.
.
..
..
WARNING
To
reduce the risk of serious bodily injury, includ-
Pressure Relief Procedure
ing fluid injection, splashing in the eyes or on the
skin,
or
injury from moving parts, always follow
when checking
or
servicing any part of the spray
this procedure whenever you shut off the pump,
spray tips, and whenever you stop spraying.
system, when installing, cleaning or changing
1.
Engage the spray gun safety latch.
2.
Shut off the air to the pump.
3.
Close the bleed-type master air valve (re-
4.
Disengage the spray gun safety latch.
5.
Hold a metal part of the spray gun firmly
to
the
side of a grounded metal pail, and trigger the
spray gun to relieve pressure.
quired
in
your system).
6.
Engage the spray gun safety latch.
7.
Open the drain valve (required in your sys-
tem), having a container ready
to
catch the
drainage.
8.
Leave the drain valve open until you are ready
to
spray again.
If
you suspect that the spray tip or hose
is
com-
pletely clogged,
or
that pressure has not been
fully relieved after following the steps above,
VERY
SLOWLY
loosen the
air
cap
or
hose end
coupling and relieve pressure gradually, then
loosen completely. Now clear the tip or hose.
WARNING
For~your safety, before operating the equipment
be sure all operators have read and fully under-
stand all the warnings, cautions and instructions
in this manual and all manuals supplied with
each component or accessory.
Flush the Pump
Before
Using
Pumps are tested with lightweight oil which
is
left in
to
protect the pump parts. To prevent contamination of
the fluid, flush the pump with
a
compatible solvent be-
fore using
it.
WARNING
Before flushing, be sure the entire system and
flushing pails are properly grounded. Refer to
Grounding
on
page
3.
Follow the Pressure
Re-
spray
tip
from fhe gun. Always
use
the lowest
lief Procedure
Warning above, and remove
the
possible fluid pressure, and maintain firm
metal-to-metal contact between the gun and
the pail during flushing to reduce the risk of fluid
eyes
or
on the skin.
injection, static sparking, and splashing in the
Starting and Adjusting the Pump
Be
sure the two air regulators
(507)
and the bleed-
type master air valve
(D)
are closed.
DO
NOT /NSTALL
THE SPRAY T/P
YET!
Connect the air line coupler
(503)
to the pin fitting
(502).
Open the bleed-type master air valve
(D)
and the gun
to the side of a grounded metal pail and trigger the
air regulator. Hold a metal part of the spray gun firmly
gun. Slowly open the pump air regulator until the pump
starts.
Allow
the pump
to
cycle
slowly
until all the air
ger and engage the safety latch: the pump
wiii
stall
Is
pushed Out of the fluid lines. Release the gun trig-
against the pressure.
With the pump and lines primed, and with adequate air
pressure and volume supplied, the pump will start and
stop as the spray gun is triggered and released.
Follow the Pressure Relief Procedure Warning at left,
then instail the spray tip in the gun.
Use
the pump air regulator to control the pump speed
and fluid pressure. Always
use
the lowest pressure
necessary to achieve the desired results. Higher pres-
sures waste fluid and cause premature wear of the
pump packings and spray tip.
Keep the packing nutlwet-cup
(1
14)
filled with Graco
Throat Seal Liquid
(TSL)
to help prolong the packing
The packing nut should be just tight enough to prevent
life. Check the tightness of the packing nut weekly.
leakage
-
no
tighter. Always follow the Pressure
Relief
Procedure Warning at left before adjusting the pack-
ing
nut.
pumped.
A
dry pump
will
quickly accelerate to a high
Never allow the pump to run dry of the fluid being
speed, possibly damaging itself. If your pump acceler-
ates quickly, or is running too fast, stop it immediately
empty and air has been pumped into the lines, refill the
and check the fluid supply.
If
the supply container is
fluid, being sure to eliminate all air from the fluid sys-
supply container and prime the pump and lines with
tern,
or
flush the pump as described in "Shutdown and
Care." below.
Shutdown and Care
Always foiiow the Pressure Relief Procedure Warning
at left. whenever you shut off the pump. Stop the
pump at the bottom of its stroke
to
keep fluid from
drying on the exposed displacement rod and damag-
ing the throat packings.
Always flush the pump with a compatible solvent be-
fore the fluid can dry
on
the displacement rod, and at
the end of each day.
If
you are pumping water-based
to protect
the
pump parts.
If
you
are pumping oil-
fluid, flush first with water and then with mineral spirits
based fluids, flush with mineral spirits only.
Relieve pressure and leave the mineral spirits in the
pump to prevent corrosion.
NOTE:
Due
to the vented seat
(1021.
this oumo stalls
~~ ~
.
..
only on the upstroke.
..
307-917
7
TROUBLESHOOTING CHART
I
WARNING
Pressure Relief Procedure
To
reduce the riskof serious bodily injury, including
5.
Hold a metal part of the spray gun firmly to the
fluid injection, splashing in the eyes
or
on the skin,
side
of a grounded metal pail. and trigger the
or
injury from moving parts, always follow this pro- spray gun to relieve pressure.
cedure
whenever
YOU
shut off
the
Pump,
when
6.
Enaaoe the smav aun safetv iatch.
checking
or
servicing any part of the spray system,
7.
Open the drain valve (required in your system),
when installing, cleaning
or
Changing spray tips,
and whenever you stop spraying. having a container ready to catch the drainage.
8.
Leave the drain valve open until you are ready
to spray again.
"
.
_-
1.
Engage the spray gun safety latch. If vou susmct that the swav tio
or
hose is com-
2.
Shut off the air to the pump.
.I.
p6tely Clogged,
or
that pressure has not been fully
3.
Close
the bleed-type master air valve (required SLOWLY the
air
cap
or
hose end
coupling
relieved after following the steps above,
VERY
4.
Disengage the spray gun safety latch.
and relieve pressure gradually. then
loosen
com-
pletely. Now clear the tip or hose.
in your system).
NOTE: Check all other possible remedies before disassembling pump.
PROBLEM
Pump fails to operate
Pump operates but output low
on both strokes.
Pump operates but output low
on downstroke.
Pump operates but output low
on upstroke.
Erratic or accelerated operation.
CAUSE
Packlng
nut
too tight.
Dirty or worn alr motor.
Inadequate
air
supply or
restricted line.
Clogged fluld hose, gun or tlp.
Drled fluld selzure of
displacement rod.
Clogged fluid
hose.
gun or tip.
restricted line.
Inadequate air supply or
Exhausted fluid supply.
Worn or damaged plston packing.
Worn or darnaged plston packing.
valve.
Held open or worn fluld Intake
Worn or damaged plston packing.
valve.
Held open or worn fluld plston
Exhausted fluid supply.
Broken air motor compression
spring,
Worn
or
damaged piston packlng.
valve.
Held open or worn fluid intake
valve.
Held open or worn fluid plston
SOLUTION
prevent leakage
-
no tlghter.
Tighten Just enough to
Clean, service: see
307-456.
Increase or clean.
Clear.
Disassemble and clean.
Clear.
1
Increase or clean.
Refill.
SeNiCe.
SeNlCe.
Clear. service.
SeNlCe.
Clear.
SBNiCe.
Refill.
SeNlCe:
See
307-456.
service.
Clear, se~ice.
Clear, service.
REPAIR NOTES
1.
To
service the air motor, disconnect it from the
displacement pump as explained below, and refer
to
the air motor manual 307-456.
2. Packing Repair Kit 222-344 is available. Parts in-
cluded in the kit are designated with an asterisk,
for example, (103'). For best
results,
use
all of
the parts in the kit, even if the old parts look good.
Lubricate the packings before installing.
DISPLACEMENT PUMP SERVICE
(See
Figs.
4
&
5)
1.
Flush the pump and stop it at the bottom of its
stroke.
2. Before repairing the pump, follow the Pressure
Relief Procedure Warning on page
8.
3. Disconnect the air and fluid hoses. Unscrew the
Loosen the screw (16) and'remove the bung
bung adapter (16) and pump from the mounting.
adapter from the pump.
4. Remove the three locknuts (4) and unscrew the tie
rods (3).
See
Fig. 4.
5.
Remove the spring clip
(6)
and pin
(5)
holding the
coupling (115) in the air motor (1). Unscrew the
coupling from the air motor.
Pull
the air motor (1)
off the displacement pump (2).
TORQUE
TO
13.5-20
N.m
(10-15
11-lb)
4\
6.
Hold the pump upside down and unscrew the in-
take valve (102) from the pump cylinder (101).
See
Fig. 5. Remove the ball guide (105), ball
(104), and ball stop pin (106) from the cylinder,
being careful that they do not fall
out.
Remove the
or
damage. Check the ball and seat for nicks.
gasket (103). Clean all parts and inspect for wear
7. Loosen, but do not remove the packing nut
(1
14).
Unscrew the coupling (115) from the displace-
ment rod (107) and push the rod down until
it
clears the bottom of the cylinder (101). Puli the
displacement rod out the bottom of the cylinder.
8.
Unscrew the piston stud (108) from the displace-
ment rod (107). Remove the piston nut (1 11) and
piston packing (121). Drive the pin (109) out of the
piston and remove the ball (1 10). Clean and in-
spect all parts for wear or damage.
9.
Unscrew
the
cylinder (101) from the outlet housing
the outer surface of the displacement rod
(107)
(1
13).
Inspect the inner surface of the cylinder and
for scoring which can damage the throat packings.
Remove and inspect the O-ring (1 12).
10.
Unscrew the packing nut (114) and remove the
throat packings from the outlet housing (113).
Clean and inspect all parts for wear or damage.
VI
u
Fig.
4
307-917
9
11. Install the throat packings in the outlet hOUSing
v-packings facing
down:
male gland (1
l8'),
one
(1 13) one at a
time
as follows,
with the
lips
of
the
UHMWPE v-packing (120'), the v-packing
the female gland (1 17'). Lubricate the threads of
(1 19"). the other UHMWPE v-packing (120'), and
the packing nut (1 14) and
loosely
install
in
the out-
let housing.
See
Fig. 5.
12. Install the ball (1 10) in the piston stud (108). Press
fit the ball stop pin (109) in the hole of the piston
stud
so
it is flush with or below the stud's surface.
Apply thread sealant to the displacement rod
(107) threads and screw the piston stud (108)
onto the rod. Torque to 20.3-27
N.m
(15-20 ft-
Ib).
13. Install the piston packing (1 21 *) on the piston stud
(108). Apply sealant to the threads
of
the piston
stud (108) and screw the piston nut (111) ontothe
stud. Torque to 20.3-27
N.m
(15-20 ft-lb).
14. Lubricate the O-ring (1 12) and install it in the outlet
der (101) and screw it into the outlet housing.
housing (1 13). Lubricate the threads
of
the.cylin-
Torque to 34-40
N.m
(25-30 ft-lb). Push the dis-
placement rod (107) up into the pump cylinder
from the bottom until
it
clears the packing nut
(114).
15. Apply sealant to the threads of the displacement
rod (107) and screw the coupling (115) onto the
rod. Torque to 20.3-27
N.m
(15-20 ft-lb).
16. Torque the packing nut (114) to 34-40
N.m
(25-30
ft-lb).
17. Install the pin (106) in the ball guide (105). Insert
the ball guide into the pump cylinder (101)
so
the
pin (106) is toward the top of the pump.
18. Install thegasket (103') on the intake valve
(102).
Place the ball (104) on the seat
of
the intakevalve,
and screw the valve into the cylinder. Torque to
34-40
N.m
(25-30 ft-lb).
19.
Screw the coupling (115) into the air motor (1).
Line up the holes and secure with the pin
(5)
and
spring clip (6).
See
Fig. 4.
20. Apply sealant to the threads of the tie rods (3) and
screw the rods into the outlet housing (1 13).
the locknuts
(4)
onto the tie rods loosely.
Mount the air motor (1) on the tie rods (3). Screw
21. Reinstall the bung adapter (1
8)
on the pump. Low-
er the pump through its mounting and screw the
pump and bung adapter into the mounting.
22.
Reconnect the air and fluid hoses to the pump.
Re-
connect the QrOtJnding wire if it was disconnected
during service.
23. Run the pump slowly to check for binding of the
tie
rods. Adjust as necessary and torque the locknuts
(4)
to 13.5-20
N.m
(10-15 ft-lb).
APPLY
THREAD
SEALANT
115
TORQUE
TO
20.3-27
N.m
(15-20
It-lb)
,101
,110
i/
TORQUE
TO
34-40
N.m
(25-30
ft-lb)
Fig.
5
PTFE