Graco Z-Pump S1 Series Parts list manual

For pumping plural component materials. For professional use only.
Not for use in explosive atmospheres.
3500 psi (24 MPa, 241 bar) Maximum Working Pressure
See page 3 for model information, including maximum working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.
r_257891_3a0019_1h
Instructions-Parts
Z-Pump S1, S3, and
S4 Series 3A0019ZAC
EN

2 3A0019ZAC
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Important Isocyanate (ISO) Information. . . . . . . . . 7
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 7
Keep Components A and B Separate . . . . . . . . . 7
Material Self Ignition . . . . . . . . . . . . . . . . . . . . . . . . 7
Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 7
Keep Components A and B Separate. . . . . . . . . . . 8
Foam Resins with 245 fa Blowing Agents . . . . . . . 8
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Identification . . . . . . . . . . . . . . . . . . . . 9
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 10
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Grease Cup Maintenance . . . . . . . . . . . . . . . . . 10
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inlet Housing Disassembly . . . . . . . . . . . . . . . . . 11
Inlet Housing Assembly . . . . . . . . . . . . . . . . . . . 13
Pump Disassembly. . . . . . . . . . . . . . . . . . . . . . . 14
Pump Rod Assembly . . . . . . . . . . . . . . . . . . . . . 16
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Complete Pump Assemblies for S1, S3, and S4 20
Various Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Seal Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Displacement Rod Kits. . . . . . . . . . . . . . . . . . . . 38
Check Valve Kits for S1 and S3 Pumps . . . . . . . 43
Check Valve Kits for S4 Pumps . . . . . . . . . . . . . 44
O-Ring Inlet Kit, All Pump Sizes . . . . . . . . . . . . . 45
Z-Pump Grease Cup Conversion Kits . . . . . . . . 46
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Outlet Housing Mounting Hole Layout. . . . . . . . 48
Technical Specifications . . . . . . . . . . . . . . . . . . . . 49
Graco Standard Warranty. . . . . . . . . . . . . . . . . . . . 50
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 50
Related Manuals
Manual in
English Description
313997 HFR, Setup - Operation
3A1961 HFR for NVH Foam - Modular, Setup -
Operation
3A6165 EFR, Instructions - parts

Models
3A0019ZAC 3
Models
* Due to a small seal cross-section, use unfilled
catalysts to achieve the best seal life results.
** S3 pump models are for NVH system use only.
Model Pump Size System Used On
*L005S1 5cc HFR
L010S1 10cc HFR
L015S1 15cc HFR
L020S1 20cc HFR
L025S1 25cc HFR
L030S1 30cc HFR
L035S1 35cc HFR
L040S1 40cc HFR
L045S1 45cc HFR
L050S1 50cc HFR
L060S1 60cc HFR
L065S1 65cc HFR
L070S1 70cc HFR
L075S1 75cc HFR
L080S1 80cc HFR
L086S1 86cc HFR
L090S1 90cc HFR
L100S1 100cc HFR
L105S1 105cc HFR
L120S1 120cc HFR
L140S1 140cc HFR
L150S1 150cc HFR
L160S1 160cc HFR
**L010S3 10cc NVH
**L020S3 20cc NVH
*L005S4 5cc EFR
L010S4 10cc EFR
L015S4 15cc EFR
L020S4 20cc EFR
L025S4 25cc EFR
L030S4 30cc EFR
L035S4 35cc EFR
L040S4 40cc EFR
L045S4 45cc EFR
L050S4 50cc EFR
L060S4 60cc EFR
L055S4 65cc EFR
L070S4 70cc EFR
L075S4 75cc EFR
L080S4 80cc EFR
L086S4 86cc EFR
L090S4 90cc EFR
L100S4 100cc EFR
L105S4 105cc EFR
L120S4 120cc EFR
L140S4 140cc EFR
L150S4 150cc EFR
L160S4 160cc EFR
Model Pump Size System Used On

Warnings
4 3A0019ZAC
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk.
Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this
manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
• Use equipment only in well-ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static sparking).
• Ground all equipment in the work area.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, 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 dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.

Warnings
3A0019ZAC 5
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) from distributor or
retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
WARNING

Warnings
6 3A0019ZAC
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 Safety Data Sheets (SDSs) for handling instructions and to know the specific hazards of the
fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area
well-ventilated and always wear appropriate personal protective equipment. See Personal
Protective Equipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying, servicing
equipment, or when in the work area. Protective equipment helps prevent serious injury, including
long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and
hearing loss. This protective equipment includes but is not limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local
regulatory authority.
• Protective eyewear and hearing protection.
WARNING

Important Isocyanate (ISO) Information
3A0019ZAC 7
Important Isocyanate (ISO) Information
Isocyanate Conditions Keep Components A and B
Separate
Material Self Ignition
Moisture Sensitivity of
Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with
moisture (such as humidity) to form small, hard,
abrasive crystals, which become suspended in the
fluid. Eventually a film will form on the surface and the
ISO will begin to gel, increasing in viscosity. If used, this
partially cured ISO will reduce performance and the life
of all wetted parts.
The amount of film formation and rate of crystallization
varies depending on the blend of ISO, the humidity, and
the temperature.
Spraying or dispensing fluids that contain
isocyanates creates potentially harmful mists,
vapors, and atomized particulates.
• Read and understand the fluid manufacturer’s
warnings and Safety Data Sheets (SDSs) to know
specific hazards and precautions related to
isocyanates.
• Use of isocyanates involves potentially hazardous
procedures. Do not spray with this equipment
unless you are trained, qualified, and have read and
understood the information in this manual and in
the fluid manufacturer’s application instructions
and SDSs.
• Use of incorrectly maintained or mis-adjusted
equipment may result in improperly cured material.
Equipment must be carefully maintained and
adjusted according to instructions in the manual.
• To prevent inhalation of isocyanate mists, vapors,
and atomized particulates, everyone in the work
area must wear appropriate respiratory protection.
Always wear a properly fitting respirator, which
may include a supplied-air respirator. Ventilate the
work area according to instructions in the fluid
manufacturer’s SDSs.
• Avoid all skin contact with isocyanates. Everyone in
the work area must wear chemically impermeable
gloves, protective clothing and foot coverings as
recommended by the fluid manufacturer and local
regulatory authority. Follow all fluid manufacturer
recommendations, including those regarding
handling of contaminated clothing. After spraying,
wash hands and face before eating or drinking.
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or
damage equipment. To prevent cross-contamination:
• Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
Some materials may become self-igniting if applied
too thickly.. Read material manufacture’s warnings
and material MSDS.

Keep Components A and B Separate
8 3A0019ZAC
To prevent exposing ISO to moisture:
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
• Keep the ISO lube pump reservoir (if installed) filled
with Graco Throat Seal Liquid (TSL™), Part 206995.
The lubricant creates a barrier between the ISO and
the atmosphere.
• Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Never use solvent on one side if it has been
contaminated from the other side.
• Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
Keep Components A and
B Separate
Foam Resins with 245 fa
Blowing Agents
Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure, especially
if agitated. To reduce frothing, minimize preheating in a
circulation system.
Changing Materials
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after flushing.
• Check with your material manufacturer for chemical
compatibility.
• Most materials use ISO on the A side, but some use
ISO on the B side.
• Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
To prevent cross-contamination of the equipment’s
wetted parts, never interchange component A
(isocyanate) and component B (resin) parts.

Component Identification
3A0019ZAC 9
Component Identification
Key:
A Displacement Rod (inside main cylinder)
B Throat Cartridge/Retainer
C Outlet Housing
D Main Cylinder
E Crossover Tube
F Tie Bolt
G Inlet Housing
H Inlet Cap
J Fluid Outlet
K Fluid Inlet (bottom of inlet housing)
L Pump Mounting Holes
M Pressure Transducer Port
N Linear Transducer Mounting Hole
P Identification Tag
R Rod Adapter (not on all models)
S Pump Coupler
T Coupler Cover
U Coupler Clamp
FIG. 1: Component Identification
40cc pump shown
Outlet Housing (C)
F
CD
E
A
H
J
G
K
L
M
N
P
R
S
B
T
U

Operation
10 3A0019ZAC
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Press the enable/disable key on the ADM to
disable the EFR/HFR, and verify it is inactive.
2. relieve pressure and shut off the supply systems.
See your appropriate supply system manual.
3. Turn the PRESSURE RELIEF/DISPENSE valves to
PRESSURE RELIEF/CIRCULATION. Route the fluid
to grounded waste containers or supply tanks.
4. For models with a dispense valve with a safety lock,
engage the dispense valve safety lock,
Flushing
• Flush out old fluid with new fluid, or flush out old
fluid with a compatible solvent before introducing
new fluid.
• Flush at the lowest pressure possible. Check
connectors for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted parts
Maintenance
NOTE: If the quick lube system is installed on the
Z-Pump, use one of the following operation manuals for
instructions: 313997, 3A1961, or 3A6165. If the quick
lube fittings are not installed then the Grease Cup
Maintenance procedures are used.
Grease Cup Maintenance
To manually grease the pump, the M5 grease fitting
(123) must be installed into the throat cartridge (119).
The M5 screw (124) is installed after the procedure is
done. These fittings are packaged separately, with the
pump
Frequency of greasing intervals is dependent on
material being pumped. As a basic schedule, lubricate
pump with grease after 250 gallons of material (five of
fifty five gallon drums) has been passed through the
pump.
If the grease has become hardened, remove the
materials or grease, and shorten the intervals between
greasing the pump.
If the grease remains clear and free of material, intervals
between greasing the pump can be increased.
To Grease the Pump
1. If previously installed, Remove the M5 screw (124)
to permit grease to circulate through the pump cor-
rectly.
2. Attach grease gun to the M5 grease fitting (123).
Pump new grease into the pump until fresh grease
is observed from grease relief hole (E).
3. Replace and re-tighten the M5 screw (124). See
FIG. 2.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before clean-
ing, checking, or servicing the equipment.
To avoid fire and explosion, always ground
equipment and waste container. To avoid static
sparking and injury from splashing, always flush at
the lowest possible pressure.
Hot solvent may ignite. To avoid fire and explosion:
• Flush equipment only in a well-ventilated area
• Ensure main power is off and the heater is cool
before flushing
• Do not turn on heater until fluid lines are clear of
solvent
FIG. 2
123
E
124
119