Graco Series A Use and care manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001
309577D
Repair - Parts
Displacement Pump
FOR USE WITH REACTOR™ELECTRIC PROPORTIONERS
3500 psi (24.5 MPa, 245 bar) Maximum Working Pressure
Component A (ISO) Pumps
with wet-cup flush feature
Part No. 246830, Series A
0.396 in.2(2.55 cm2)
Part No. 246831, Series A
0.552 in.2(3.56 cm2)
Part No. 246832, Series A
0.743 in.2(4.79 cm2)
Component B (Resin) Pumps
Part No. 245970, Series A
0.396 in.2(2.55 cm2)
Part No. 245971, Series A
0.552 in.2(3.56 cm2)
Part No. 245972, Series A
0.743 in.2(4.79 cm2)
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
TI2663A
TI3733a

Manual Conventions
2309577D
Contents
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 2
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 5
Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clean and Inspect Parts . . . . . . . . . . . . . . . . . . . . . 6
Supply Wet-cups with Throat Seal Liquid . . . . . . . 7
Cutaway Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 28
Manual Conventions
Warning
Caution
Note
Related Manuals
The following manuals are available for the Reactor™.
Refer to these manuals for detailed equipment informa-
tion.
WARNING
A warning alerts you to possible serious injury or
death if you do not follow instructions.
Symbols, such as fluid injection (shown), alert you to a
specific hazard and direct you to read the indicated
hazard warnings on pages 3-4.
CAUTION
A caution alerts you to possible equipment damage or
destruction if you do not follow instructions.
A note indicates additional helpful information.
Reactor Electric Proportioner
Part No. Description
309551 Reactor Electric Proportioner,
Operation Manual (English)
309574 Reactor Electric Proportioner,
Repair-Parts Manual (English)
309911 Reactor Pump Wet-Cup Flush
Kits

Warning
309577D 3
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. 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 gun fluid nozzle.
• 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.
• Follow Pressure Relief Procedure, page 5, when you stop spraying and before cleaning, checking,
or servicing equipment.
• Use lowest possible pressure when flushing, priming, or troubleshooting.
• Engage spray gun piston safety lock when not spraying.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. High pres-
sure hose cannot be recoupled; replace the entire hose.
FIRE AND EXPLOSION HAZARD
Solvent and fumes in work area can ignite or explode. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources, such as pilot lights, cigarettes and plastic drop cloths (potential static
arc).
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep the work area free of debris, including solvent, rags, and gasoline.
• Ground equipment and conductive objects. See Grounding in your Reactor manual.
• Hold gun firmly to side of grounded pail when triggering into pail.
• Use only grounded hoses.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
EQUIPMENT MISUSE HAZARD
Misuse can cause serious injury or death.
• For professional use only.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Read manuals, warnings, tags, and labels before operating equipment. Follow instructions.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not alter or modify equipment. Use only Graco parts and accessories.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not use hoses to pull equipment.
• Comply with all applicable safety regulations.

Warning
4309577D
BURN HAZARD
This equipment is used with heated fluid, which can cause equipment surfaces to become very hot. To
avoid severe burns:
• Do not touch hot fluid or equipment.
• Allow equipment to cool completely before touching it.
• Wear gloves if fluid temperature exceeds 110°F (43°C).
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read Material Safety Data Sheet (MSDS) to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear proper protective equipment when operating, servicing, or when in the operating area of
the equipment to help protect you from serious injury, including eye injury; inhalation of toxic fumes; and
hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Gloves, clothing, and respirator as recommended by the fluid and solvent manufacturer
• Hearing protection.
WARNING

Pressure Relief Procedure
309577D 5
Pressure Relief
Procedure
WARNING
Read warnings, page 3.
1. Relieve pressure in gun and perform gun shut-
down procedure. See gun manual.
2. Close gun fluid manifold valves A and B.
TI2421A
3. Shut off feed pumps and agitator, if used.
4. Turn PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF. Route fluid to waste
containers or supply tanks. Ensure that gauges
drop to 0.
TI2481a
SA SB

Tools Needed
6309577D
Tools Needed
• Vise with flat jaws
• 12 in. adjustable, open end wrench (2)
• Non-sparking hammer, 20 oz maximum
• Small screwdriver
• Throat Seal Liquid (TSL), Graco Part No. 206995
• ISO Pump Oil, Graco Part No. 217374
• Pick or long small screwdriver
• Snap-ring pliers
• 1/2 in. (13 mm) diameter plastic rod
• 7/8 in. deep-well socket (246830 and 245970 only)
• 1/2 in. (13 mm) x 2.5 in. (64 mm) bolt with washers
and nut
• Channel locks
• Dropcloth and rags
Repair Kits
A repair kit is available for your pump. Kit parts are
marked with an asterisk, for example (3*). See page 23.
Kit must be purchased separately. For best results, use
all parts in the kit.
Clean and Inspect
Parts
1. Clean and inspect all parts. Intake and piston
ball seats, sleeve, and displacement rod must
not be worn, scratched, or damaged.
2. Remove and clean sleeve when repacking
pump.

Supply Wet-cups with Throat Seal Liquid
309577D 7
Supply Wet-cups with
Throat Seal Liquid
WARNING
Pump rod and connecting rod move during operation.
Moving parts can cause serious injury such as pinch-
ing or amputation. Keep hands and fingers away from
wet-cup during operation. Turn main power OFF
before filling wet cup.
1. Component A (ISO) Pump: Keep reservoir (R)
3/4 filled with Graco Throat Seal Liquid (TSL),
Part No. 206995. Wet-cup piston (28) circulates
TSL through packing nut/wet-cup (19), to carry
away isocyanate film on displacement rod.
After some time TSL will thicken and darken,
and must be replaced. Thick, dirty TSL will not
pump through lines and will harden in wet-cup.
Check condition of TSL every week, minimum,
and change when needed.
R
TI3765a-2
2. Component B (Resin) Pump: Check felt wash-
ers (21) in packing nut/wet-cup (19) daily. Keep
saturated with Graco Throat Seal Liquid (TSL),
Part No. 206995, to prevent material from hard-
ening on displacement rod. Replace felt wash-
ers when worn or contaminated with hardened
material.
19
TI3765a-1

Supply Wet-cups with Throat Seal Liquid
8309577D

Cutaway Views
309577D 9
Cutaway Views
Component A (ISO) Pump Component B (Resin) Pump
1
19†
†*22
†25
24*†
*17
*20
2
*16
*15
5
3*
4
14*
7
13*
3*
11*
9
10*
‡*8
12
TI3734b
26*†
27*†
†28
1
19†*22
*21
*17
*20
2
*16
*15
5
3*
4
14*
7
13*
3*
11*
9
10*
‡*8
12
TI2668b

Disassembly
10 309577D
Disassembly
WARNING
Pump rod and connecting rod move during operation.
Moving parts can cause serious injury such as pinch-
ing or amputation. Keep hands and fingers away from
connecting rod during operation.
1. Shut off , , and heat zones.
2. Flush pumps. See Reactor manual.
3. Relieve pressure, page 5.
4. Press . Motor will run until pumps are at
bottom of strokes, then shut off.
5. Turn main power OFF . Disconnect
power supply.
Steps 6-8 apply to pump A. See FIG. 1. To dis-
connect pump B, go to steps 9 and 10. Use
dropcloth or rags to protect Reactor and sur-
rounding area from spills.
AB
6. Disconnect fluid inlet (C) and outlet (D). Also
disconnect steel outlet tube from heater inlet.
7. Disconnect tubes (T). Remove tube fittings (U)
from wet-cup.
8. Loosen star-shaped locknut (G) by hitting firmly
with a non-sparking hammer. Unscrew pump far
enough to expose retaining pin under plastic fin-
ger guard. Push retaining spring up. Push pin
out. Continue unscrewing pump.
Steps 9 and 10 apply to pump B. See FIG. 2.
Use dropcloth or rags to protect Reactor and
surrounding area from spills.
9. Disconnect fluid inlet (C) and outlet (D). Also
disconnect steel outlet tube from heater inlet.
10. Push retaining spring (E) up. Push pin (F) out.
Loosen star-shaped locknut (G) by hitting firmly
with a non-sparking hammer. Unscrew pump.

Disassembly
309577D 11
FIG. 1. Disconnect Pump A
TI3765a-2
C
U
G
D
T
FIG. 2. Disconnect Pump B
TI3765a-1
C
F
G
D
E

Disassembly
12 309577D
11. Remove packing nut/wet-cup as follows:
a. Component A (ISO) Pumps:
• Remove packing nut/wet-cup
assembly.
• Compress piston (28) into wet-cup
(19), using a 1/2 in. (13 mm) x 2.5
in. (64 mm) bolt with washers and
nut.
• Remove retaining ring (22).
• Remove bolt, washers, and nut.
• Remove piston (28), spring (25),
and o-rings (24, 26, 27).
b. Component B (Resin) Pumps:
Unscrew packing nut (19). Remove
retaining ring (22) and felt washers (21).
TI3735a
19
25
28
24
22
26
27
TI2662A
19
22
21
12. Loosen intake valve housing (5) with non-spark-
ing hammer, then unscrew. Remove o-ring (15).
13. Disassemble intake valve. Be sure to remove
o-ring (10).
Spring (8) is on Models 246832 and 245972
only.
TI2664A
15
5
TI2665A
5
11
9
10
8
12

Disassembly
309577D 13
14. Tap rod (1) with non-sparking hammer to drive it
out of cylinder (2).
Sleeve (4) may come out with rod.
15. Using screwdriver in groove (H), remove sleeve
(4) from cylinder (2), or pull it off rod. Remove
o-rings (3).
Be sure top o-ring (3) comes out.
TI2672A
1
2
4
TI2670A
2
3
4
H
3
16. Remove bushing (17).
17. Unscrew piston (7) from rod (1). Remove ball
(16), u-cup (13), and bushing (14).
18. Insert piston end of rod (1) into cylinder (2) and
push u-cup (20) out.
TI2669B
17
2
TI2666A
1
16
14
13
7
TI2671A
1
2
20

Disassembly
14 309577D

Reassembly
309577D 15
Reassembly
Coat all non-Loctited parts with Graco 217374
ISO Pump Oil before reassembly, to ease future
disassembly.
1. Install ball (16*) in rod (1). Center u-cup (13*) on
rod (1). Lips of u-cup must face up. Use piston
(7) to evenly push u-cup onto rod, then remove
piston. Slide bushing (14*) onto rod (1). Wide
end of bushing must face up, toward u-cup.
Sealing patch on piston threads is good for four
repackings. Use Loctite®on piston threads
after four repackings; be sure none gets on ball.
2. Install piston (7). Be careful not to damage seal-
ing edges of u-cup. Torque as specified below.
Model Torque
ft-lb (N•m)
246830 and 245970 24-30 (32-40)
246831 and 245971 47-53 (63-71)
246832 and 245972 47-53 (63-71)
TI2666A
1
16*
14*
*13
7
TI2818A
1
Lips face up.
1
3. Install throat u-cup as follows:
a. Models 246831, 246832, 245971, and
245972: Grease u-cup (20*) and cylin-
der (2). Place u-cup in cylinder with lips
facing down. Be careful not to damage
sealing edges of u-cup. Install packing
nut (19) to properly insert and align
u-cup, then remove packing nut.
b. Models 246830 and 245970: Grease
u-cup (20*) and cylinder (2). Place seal
installation tool (23*) in cylinder. Place
u-cup in tool with lips facing down. Be
careful not to damage sealing edges of
u-cup. Press u-cup in place with 7/8 in.
deep-well socket (S). Remove socket
and tool.
TI2675A
19
20*
2
TI2818A-1
1
Lips face down.
1
TI2700A
23*
20*
2
S

Reassembly
16 309577D
4. Insert bushing (17*). Press bushing in place to
seat u-cup.
5. Assemble packing nut as follows:
a. Component A (ISO) Pump:
• Install spring (25) in wet-cup (19).
• Install o-rings (24*, 26*) on piston
(28) and insert piston in wet-cup.
• Compress piston (28) into wet-cup,
using a 1/2 in. (13 mm) x 2.5 in. (64
mm) bolt with washers and nut.
• Install retaining ring (22*) in groove.
• Remove bolt, washers, and nut.
• Install o-ring (27*) on wet-cup.
• Install packing nut/wet-cup assem-
bly handtight. Screw assembly all
the way down, so external o-ring
(27) seats on top of cylinder (2).
TI2669B
*17
2
TI3735b
19
25
28
24*
22*
26*
27*
2
b. Component B (Resin) Pump: Install
felt washers (21*) into packing nut (19).
Install retaining ring (22*). Install pack-
ing nut handtight.
Groove (H) in sleeve outer surface must be
toward bottom.
6. Lubricate piston u-cup and sleeve top edge.
Push piston assembly into top of sleeve (4).
Drive in with non-sparking hammer.
TI2701A
22*
21*
19
TI2673A
H
4

Reassembly
309577D 17
7. Lubricate top 1-2 in. (25-50 mm) of displace-
ment rod (1) and outside of sleeve (4). Grease
o-rings (3*) and place one in cylinder and other
on bottom of sleeve.
8. Slide sleeve/rod assembly into bottom of cylin-
der (2). Drive in with hammer until top of groove
(H) aligns with bottom of cylinder (L). Use plastic
rod to drive displacement rod until 1/4-3/8 in.
(6-10 mm) of its greatest diameter is visible
above packing nut (19).
TI2674A
19
*3
2
L
4
3*
H
9. Reassemble intake valve with o-ring (10*), seat
(9), and ball (11*). Install ball guide (12). Models
246832 and 245972 only: Install spring (8*) with
screw at top.
Seat may be flipped over and used on other
side. Clean seat thoroughly. No scratches per-
mitted on sealing edge.
10. Replace o-ring (15*). Install intake valve. Torque
housing (5) as follows, or be sure intake valve is
snug against cylinder.
Model Torque
ft-lb (N•m)
246830 and 245970 65-75 (88-101)
246831 and 245971 75-85 (101-114)
246832 and 245972 145-155 (195-209)
TI2665A
5
*11
9
10*
8*
12
TI2687A
15*
19
5

Reassembly
18 309577D
a. Pump A: Wrap base of wet-cup (19)
with a rag and tighten securely with
channel locks.
b. Pump B: Torque packing nut (19) to
90-110 in-lb (10-12 N•m).
11. Tighten packing nut/wet-cup.
Do not overtighten packing nut/wet-cup. Throat
u-cup (20) is not adjustable.
WARNING
Pump rod and connecting rod move during operation.
Moving parts can cause serious injury such as pinch-
ing or amputation. Keep hands and fingers away from
connecting rod during operation.
12. Reconnect power supply. Turn main power ON
.
13. Press . Motor will run until pumps are at
bottom of strokes, then shut off.
14. Turn main power OFF . Disconnect
power supply.
Steps 15-18 apply to pump B. See FIG. 3. To
reconnect pump A, go to step 19.
15. Ensure star-shaped locknut (G) is screwed on
pump with flat side up. Screw pump into bearing
housing (M) until pin holes align. Push pin (F) in.
Pull retaining spring (E) down.
16. Continue screwing pump into housing until fluid
outlet (D) is aligned with steel tube and top
threads are +/- 1/16 in. (2 mm) of bearing face
(N).
17. Tighten star-shaped locknut (G) by hitting firmly
with a non-sparking hammer.
18. Reconnect fluid inlet (C) and outlet (D).

Reassembly
309577D 19
FIG. 3. Reconnect Pump B
C
D
F
E
G
M
N
1
TI3765a-1
Flat side faces up.
1
Lubricate threads with ISO oil
or grease.
2
22
2
3
Pump top threads must be nearly
flush with bearing face (N).
3

Reassembly
20 309577D
Steps 19-32 apply to pump A only. See FIG. 4.
19. Screw pump into bearing housing (M) until top
threads are level with bearing face (N). Rotate
pump to align pump outlet fitting to outlet tube.
20. Wet-cup has four 1/8 npt ports. Two will be inac-
cessible when pump is installed. Note or mark
these ports. Remove pump. Apply thread seal-
ant and install plugs in the two ports. Torque
plugs to 10-15 ft-lb (14-20 N•m). Do not over-
tighten.
21. Ensure star-shaped locknut (G) is screwed on
pump with flat side up. Carefully twist and
extend the rod (1) 2 in. (51 mm) above the
wet-cup assembly.
22. Start threading pump into bearing housing (M).
Place finger guard (P) over rod when it is acces-
sible through window of bearing housing. When
pin holes align, insert pin. Pull retaining spring
down.
Finger guard is not used on Model E-30.
23. Seat finger guard (P) on wet-cup (19). Continue
threading pump into bearing housing (M) until
top threads are +/- 1/16 in. (2 mm) of bearing
face (N).
24. Apply thread sealant and screw barbed fitting
into motor side of wet-cup. Torque to 10-15 ft-lb
(14-20 N•m). Do not overtighten.
25. Apply thread sealant and screw elbow (U) into
remaining wet-cup port. Torque to 10-15 ft-lb
(14-20 N•m). Do not overtighten.
26. Apply thread sealant and screw barbed fitting
into elbow (U). Torque to 10-15 ft-lb (14-20
N•m). Do not overtighten.
27. Connect component A outlet tube loosely at
pump and at heater. Line up tube, then tighten
fittings securely.
28. Tighten star-shaped locknut (G) by hitting firmly
with a non-sparking hammer.
29. Apply thread sealant and screw barbed fitting
into elbow (U). Torque to 10-15 ft-lb (14-20
N•m). Do not overtighten.
30. Apply thin film of TSL to barbed fittings. Using
two hands, support tubes (T) while pushing
straight onto barbed fittings. Do not let tubes
kink or buckle. Secure each tube with a wire tie
between two barbs.
31. Reconnect fluid inlet (C) and outlet (D).
32. Purge air and prime the system. See Reactor
operation manual.