Instructions Parts

CARBON STEEL

Check???Mate??? 800 Pumps

With Priming Piston and Severe???Duty Rod and Cylinder

308351K

Refer to page 2 for Table of Contents.

US Patent Nos. 5,147,188 and 5,154,532.

Other patents pending.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions. See page 2 for model numbers and maximum working pressures.

Models 237265,

246940 and 246941

Models 198466

and 246938

Models 236471

and 246942

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.

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 5.

1.King Pumps: use a ground wire and clamp. See Fig. 1. Remove the ground screw (Z) and insert through eye of ring terminal at the end of ground wire (Y). Fasten ground screw back onto pump and tighten securely. Connect the other end of the wire to a true earth ground. Order Part No. 222011 Ground Wire and Clamp.

All other Pumps: use a ground wire and clamp.

See Fig. 2. Loosen the grounding lug locknut (W) and washer (X). Insert one end of a 1.5 mm2 (12 ga) minimum 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. 222011 Ground Wire and Clamp.

Z Y

W

X

Y

Z

0864

Fig. 2

Fig. 1

TI1052

All Systems

NOTE: Reference numbers and letters in parentheses in the text refer to the callouts in the figures and parts drawings.

The Typical Installations shown in Figs. 3 and 4 are only guides for selecting and installing system compo- nents and accessories. Contact your Graco distributor for assistance in designing a system to suit your particular needs.

Accessories are available from Graco. If you supply your own accessories, be sure they are adequately sized and pressure???rated to meet the system???s re- quirements.

System Accessories

Air and Fluid Hoses

Be sure all air hoses and fluid hoses are properly sized and pressure-rated for your system. Use only electri- cally conductive hoses. Fluid hoses must have spring guards on both ends.

Mounting Accessories (Except 198466, 198475 and 246938)

Mount the pump (A) to suit the type of installation planned. Fig. 3 on page 8 illustrates a ram-mounted pump in a multi-gun header system. Pump dimensions and the mounting hole layout are shown on page 49.

If you are mounting the pump on a ram, refer to the separate ram manual for installation and operation instructions. Mounting Kit 222776 is available to mount the pump on a 55 gallon (200 liter) ram.

F

G

Fig. 3

CH

N

V

S RMM

NN

M

S R

05097

WARNING

A main air bleed valve (C), pump air bleed valve (E), and fluid drain valve (M) are required. These accessories help reduce the risk of serious injury, including fluid injection and splashing of fluid in the eyes or on the skin, and injury from moving parts if you are adjusting or repairing the pump.

The main air bleed valve (C) shuts off the air to the pump and ram. The pump air bleed valve (E) relieves air trapped between this valve and the pump after the air is shut off. Trapped air can cause the pump to cycle unexpectedly. Locate the valve close to the pump. Order Part No. 107141.

The fluid drain valve assists in relieving fluid pres- sure in the displacement pump, hose, and gun. Triggering the gun to relieve pressure may not be sufficient. Order Part No. 210658.

Air Line Accessories

Install the following accessories in the order shown in Fig. 3, using adapters as necessary:

DAn air line lubricator (D) provides automatic air motor lubrication. Locate in the position shown.

DA main air bleed valve (C) is required in your system to shut off the air supply to the pump and ram (see the WARNING above). When closed, the valve will bleed off all air in the ram and pump, and the ram will slowly lower. Be sure the valve is easily accessible from the pump, and is located upstream from the air manifold (G).

DA pump air bleed valve (E) is required in your system to relieve air trapped between it and the air motor when the valve is closed (see the WARNING at left). Be sure the bleed valve is easily accessible from the pump, and is located downstream from the air regulator.

DAn air regulator (F) controls pump speed and outlet pressure by adjusting the air pressure to the pump. Locate the regulator close to the pump, but upstream from the pump air bleed valve.

DA pump runaway valve (V) senses when the pump is running too fast and automatically shuts off the air to the motor. A pump which runs too fast can be seriously damaged. Locate in the position shown.

DAn air manifold (G) has a swivel air inlet. It mounts to a ram, and has ports for connecting lines to air accessories, such as the ram air regulator

(T) and ram director valve (U).

DAn air line filter (J) removes harmful dirt and moisture from the compressed air supply. Also, install a drain valve (W) at the bottom of each air line drop, to drain off moisture.

DAn air shutoff valve (K) isolates the air line acces- sories for servicing. Locate upstream from all other air line accessories.

Fluid Line Accessories

Install the following accessories in the positions shown in Figs. 3 and 4, using adapters as necessary:

DInstall a fluid shutoff valve (P) at each gun/valve drop, to isolate the gun/valve and fluid accessories for servicing.

DInstall a fluid drain valve (M) near the pump fluid outlet, and at each gun/valve station. The drain valves are required in your system to relieve fluid pressure in the displacement pump, hose and gun/valve (see the WARNING at left). Drain valves at the gun/valve stations may be mounted in the base of a fluid regulator (L), using an adapter.

DA fluid regulator (L) controls fluid pressure to the gun/valve, and dampens pressure surges.

DA gun or dispense valve (S) dispenses the fluid. The gun shown in Fig. 3 is a high pressure dispens- ing gun for highly viscous fluids.

DA gun/valve swivel (R) allows freer gun/valve movement.

CAUTION

The Hydraulic Power Supply must be kept clean at all times to avoid damage to the motor and hydraulic power supply.

1.Blow out hydraulic lines with air and flush thor- oughly before connection to the motor.

2.Plug hydraulic inlets, outlets, and line ends when disconnecting them for any reason.

Always plug the hydraulic inlets, outlets and lines when disconnecting them for any reason to avoid introducing dirt and other contaminants into the system.

Be sure that your hydraulic power supply is equipped with a suction filter to the hydraulic pump and a system return line filter of 10 micron size. Carefully follow the manufacturer???s recommendations on reservoir and filter cleaning and periodic changes of hydraulic fluid.

NOTE: Hydraulic fluid is exhausted from differential hydraulic motors only on the upstroke of the operating cycle. The oil return line must have at least twice the flow capacity as the oil supply line. Otherwise, back pressure on the hydraulic motor piston will slow down the motor and the fluid displacement pump, resulting in a loss of pump performance.

On the hydraulic oil supply line (P), install a shutoff valve (G) to isolate the system for servicing; a fluid pressure gauge (H) to monitor hydraulic oil pressure to the motor and avoid overpressurizing the motor or displacement pump; a pressure- and temperature- compensated flow control valve (J) to prevent the motor from running too fast; a pressure reducing valve

(K) with a drain line (L) running directly into the hydrau- lic return line (Q); and an accumulator (N) to reduce the hammering effect caused by the motor reversing direction.

On the hydraulic return line (Q), install a shutoff valve

(M) for isolating the motor for servicing.

Pressure Relief Procedure

WARNING

SKIN INJECTION HAZARD

The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid

under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:

Dare instructed to relieve the pressure,

Dstop spraying/dispensing,

Dcheck or service any of the system equipment,

Dor install or clean the spray tip/nozzle.

1.Lock the gun/valve trigger safety.

2.Shut off the power to the pump.

3.In an air-powered system, close the air regulator and close the bleed-type master air valve.

4.In a hydraulic-powered system, close the hy- draulic supply line shutoff valve first, then the return line shutoff valve.

5.Unlock the gun/valve trigger safety.

6.Hold a metal part of the gun/valve firmly to the side of a grounded metal pail, and trigger the gun/valve to relieve pressure.

7.Lock the gun/valve trigger safety.

8.In an air???powered system, open the drain valve (required in your system), having a container ready to catch the drainage. Leave the drain valve open until you are ready to spray/dispense again.

If you suspect that the spray tip/nozzle or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip/nozzle or hose.

Packing Nut/Wet-Cup

Before starting, fill the packing nut (2) 1/3 full with Graco Throat Seal Liquid (TSL) or compatible solvent. See Fig. 5.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure at left.

The packing nut is torqued at the factory and is ready for operation. If it becomes loose and there is leaking from the throat packings, relieve pressure, then torque the nut to 128???156 N.m (95???115 ft-lb) using the supplied wrench (109). Do this whenever necessary. Do not overtighten the packing nut.

109

2 2

20

29 1

19

(95???115 ft-lb).

04995

Fig. 5

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. See Flushing on page 16.

Starting and Adjusting the Pump

WARNING

MOVING PARTS HAZARD

Keep hands and fingers away from the priming piston (21) during operation and whenever the pump is charged with air.

The priming piston extends beyond the intake housing (19) to pull material into the pump and can amputate a hand or finger caught between it and the intake housing. Follow the Pressure Relief Procedure on page 12, before checking, clearing, or cleaning the priming piston.

WARNING

SKIN INJECTION HAZARD

To reduce the risk of fluid injection, do not use your hand or fingers to cover the bleed hole on the underside of the bleeder valve body (29) when priming the pump. Use a crescent wrench to open and close the bleeder plug (20). Keep your hands away from the bleed hole.

CAUTION

Do not allow the pump to run dry. It will quickly accelerate to a high speed, causing damage. If your pump is running too fast, stop it immediately and check the fluid supply. If the container is empty and air has been pumped into the lines, refill the con- tainer and prime the pump and the lines, or flush and leave it filled with a compatible solvent. Eliminate all air from the fluid system.

WARNING

COMPONENT RUPTURE HAZARD

To reduce the risk of overpressurizing your system, which could cause compo-

nent rupture and serious injury, never exceed the Maximum Input Pressure to the pump

(see the Technical Data on pages 38???46).

Air???Powered Systems

1.Supply fluid to the pump, per the requirements of your system.

2.See Fig. 3. Close the air regulator (F).

3.Open all air bleed valves (C, E).

4.Hold a metal part of the gun/valve (S) firmly to the side of a grounded metal pail and hold the trigger open.

5.Slowly open the air regulator 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/valve trigger and lock the trigger safety. The pump should stall against pressure.

8.If the pump fails to prime properly, open the bleeder valve plug (20) slightly. Use the bleed hole, on the underside of the valve body (29), as a priming valve until the fluid appears at the hole. See Fig. 5. Close the plug.

NOTE: When changing fluid containers with the hose and gun/valve already primed, open the bleeder valve plug (20), to help prime the pump and vent air before it enters the hose. Close the plug when all air is elimi- nated.

9.With the pump and lines primed, and with ade- quate air pressure and volume supplied, the pump will start and stop as you open and close the gun/valve. 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 (F) to control the pump speed and the fluid pressure. Always use the lowest air pressure necessary to get the desired results. Higher pressures cause premature tip/nozzle and pump wear.

Hydraulic???Powered Systems

Refer to the warnings on page 13.

1.Supply fluid to the pump, per the requirements of your system.

2.Open the shutoff valves between the pump and supply tanks.

3.Open the dispensing valve(s) or spray gun(s).

4.To adjust the system, perform the following proce- dure:

a.Turn on the hydraulic power supply.

b.Open the flow control valve all the way.

c.Adjust the pressure???reducing valve until you get the desired fluid pressure. Run the pump until all air is purged from the fluid lines.

d.Count the cycle rate of the pump.

e.Close the flow control valve until the cycle rate and fluid pressure start to drop.

f.Open the flow control valve slightly until the cycle rate and fluid pressure return to the desired level. This method of setting the hy- draulic controls ensures proper pump opera- tion and will prevent pump runaway and dam- age if the fluid supply runs out.

g.Close the gun or valve.

Shutdown and Care of the Pump

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 12.

For overnight shutdown, stop the pump at the bottom of the stroke to prevent fluid from drying on the ex- posed displacement rod and damaging the throat packings. Relieve the pressure.

Always flush the pump before the fluid dries on the displacement rod. Refer to Flushing below.

Flushing

WARNING

FIRE AND EXPLOSION HAZARD

Before flushing, read the section FIRE AND EXPLOSION HAZARD on page 5. Be sure the entire system and flush- ing pails are properly grounded. Refer to

Grounding on page 6.

Flush with a fluid that is compatible with the fluid you are pumping and with the wetted parts in your system. Check with your fluid manufacturer or supplier for recommended flushing fluids and flushing frequency. Always flush the pump before fluid dries on the dis- placement rod.

CAUTION

Never leave water or water-base fluid in the pump overnight. If you are pumping water-base fluid, flush with water first, then with a rust inhibitor such as mineral spirits. Relieve the pressure, but leave the rust inhibitor in the pump to protect the parts from corrosion.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 12.

1.Relieve the pressure.

2.Remove the spray tip/nozzle from the gun/valve.

3.Hold a metal part of the gun/valve firmly to the side of a grounded metal pail.

4.Start the pump. Always use the lowest possible fluid pressure when flushing.

5.Trigger the gun/valve.

6.Flush the system until clear solvent flows from the gun/valve.

7.Relieve the pressure.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 12.

1.Relieve the pressure.

2.Check all possible problems and causes before disassembling the pump.

Fluid is too heavy for pump priming.

Use the bleeder valve (see page 13 or 14); use a ram.

Required Tools

DTorque wrench

DBench vise, with soft jaws

DRubber mallet

DHammer

DO-ring pick

D13 mm (1/2 in.) dia. brass rod

DSet of socket wrenches

DSet of adjustable wrenches

DPipe wrench

DPacking nut wrench (109, supplied)

DThread lubricant

DThread sealant

Disconnecting the Displacement Pump

1.Flush the pump, if possible. Stop the pump at the bottom of its stroke.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 12.

2.Relieve the pressure.

3.Disconnect all hoses from the pump and motor.

4.Disconnect the displacement pump (106) from the motor (101) as follows. See Fig. 6. Be sure to note the relative position of the pump???s fluid outlet (X) to the motor inlet (Y). If the motor does not require servicing, leave it attached to its mounting.

CAUTION

Be sure to use at least two people when lifting, moving, or disconnecting the pump. This pump is too heavy for one person. If you are disconnecting the displacement pump from a motor which is still mounted (for example, on a ram), be sure to support the displacement pump while it is being discon- nected, to prevent it from falling and causing injury or property damage. Do this by securely bracing the pump, or by having at least two people hold it while another disconnects it.

5.Using an adjustable wrench (or a hammer and rod), unscrew the coupling nut (104) from the motor shaft (Z). Do not lose or drop the coupling collars (105). See Fig. 6.

6.Hold the tie rod flats with a wrench to keep the rods from turning. Unscrew the nuts (103) from the tie rods (102). Carefully remove the displacement pump (106) from the motor (101).

7.Refer to page 20 for displacement pump service. To service the motor, refer to the separate motor manual, supplied.

Service

Reconnecting the Displacement Pump

1.Make sure the coupling nut (104) and the coupling collars (105) are in place on the displacement rod

(1). See Fig. 6.

Y

2.Use at least two people to hold the displacement pump while another reconnects it to the motor (see the CAUTION on page 18). Orient the pump???s fluid outlet (X) to the air or hydraulic inlet (Y) as was noted in step 4 under Disconnecting the Dis- placement Pump. Position the displacement pump (106) on the tie rods (102).

3.Screw the nuts (103) onto the tie rods (102) and torque to 68???81 N.m (50???60 ft-lb).

102

101

Z 105

4. Screw the coupling nut onto the motor shaft loose- ly. Hold the motor shaft (Z) flats with a wrench to keep it from turning. Use an adjustable wrench to tighten the coupling nut. Torque to 196???210 N.m (145???155 ft-lb).

5. Torque the packing nut (2) to 128???156 N.m (95???115 ft-lb).

6. Reconnect all hoses. Reconnect the ground wire if it was disconnected. Fill the wet-cup (2) 1/3 full of

1

104 2

1

2 3

109 4

X

7.Turn on the power supply. Run the pump slowly to ensure proper operation.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 12.

106

Torque to 68???81 N.m

1(50???60 ft-lb).

Torque to 196???210 N.m

2(145???155 ft-lb).

Torque to 128???156 N.m

3(95???115 ft-lb).

Square hole is for use

4with torque wrench.

04994

308351 19

Disassembly

When disassembling the pump, lay out all the removed parts in sequence, to ease reassembly. Clean all parts with a compatible solvent and inspect them for wear or damage. Refer to Fig. 9 for a cutaway view of the pump.

NOTE: Packing Repair Kits are available. See page 36. For the best results, use all the new parts in the kit. Kit parts are marked with an asterisk, for example (7*).

1.Remove the displacement pump from the motor as explained on page 18. Place the pump in a vise, with the outlet housing (9) positioned as shown in Fig. 8.

2.Hold the flats of the priming piston rod (18) with an adjustable wrench, and use a second wrench to unscrew the priming piston seat (22) from the rod. Slide the priming piston (21) off the rod. Inspect the inner and outer surfaces of the piston (21) for scoring, wear, or other damage.

3.Loosen the packing nut (2) using the wrench (109) supplied.

NOTE: These instructions are written with the pump separating at joint A. If it separates at joints B or C, disassemble it at that joint, place the intake housing (17) in a vise, and continue with step 5.

5.Unscrew the intake valve housing (17) from the cylinder (10). Pull the housing off the pump. The intake check valve assembly (V, see Fig. 7) should slide down the priming piston rod (18) as you remove the housing; if it does not slide easily, firmly tap on the top of the housing (17) with a rubber mallet to loosen.

DETAIL OF INTAKE CHECK VALVE

2

3

See Fig. 10

9

1

See Fig. 12

8

See Fig. 7

18

21

22

Fig. 9

29

20

8

10

17a, b, c

19

05002

6.Pull the intake seat (37) and seal (38) out the bottom of the intake valve housing (17). Take care not to drop the check valve assembly (V) as it comes free, and set it aside for later. See Fig. 7.

NOTE: If the seat (37) is difficult to remove, insert a hammer and brass rod through the top of the housing (17) and drive the seat out.

7.Using a rubber mallet, drive the displacement rod

(1) and the priming piston rod (18) out of the outlet housing (9) and cylinder (10). Inspect the outer surfaces of the rods for damage by running a finger over the surface.

8.Unscrew the packing nut (2). Unscrew the packing housing (3) and remove the seal (42). Remove the throat glands and packings (T). See Fig. 10.

THROAT PACKING DETAIL

2

3

42*

T

05002

Fig. 10 Model 236611 Displacement Pump Shown

9.Remove the seal (8) from the bottom of the cylin- der (10). See Fig. 12. Shine a light into the cylinder to examine the inside surface for scoring or dam- age. Only if the cylinder is damaged, or there is evidence of leaking around the top cylinder seal (8), unscrew the cylinder from the outlet housing, using a pipe wrench. Remove the top cylinder seal.

10.Place the flats of the displacement rod (1) in a vise. Unscrew the piston (12) from the displace- ment rod; the priming piston rod (18) will come with it. Slide the piston guide (11) and seat (14) off the piston (12).

11. It is not necessary to remove the priming piston rod (18) from the piston (12) unless your inspec- tion reveals damage to either part. To disas- semble, place the piston flats in a vise and un- screw the rod.

12.Place the piston guide (11) in a vise, as shown in Fig. 11. Using an adjustable wrench, unscrew the piston seat (14) from the guide. Remove the seal (13); always replace it with a new one. Inspect the mating surfaces (M) of the piston (12) and piston seat (14) for damage or wear. See Fig. 12.

13. To disassemble the intake check valve assembly (V), place the intake valve body (16) in a vise and unscrew the packing nut (15). Remove the seal (39) from the nut, and the glands and packings (P) from the valve body. Inspect the mating surfaces

(N) of the intake valve body (16) and seat (37) for damage or wear. See Figs. 7 and 13.

DETAIL OF PISTON CHECK VALVE

03832

1 Torque to 125???139 N.m (92???102 ft-lb).

2 1

2Torque to 324???368 N.m (239???271 ft-lb).

3Lubricate.

11

12

M

3 *8

1 18

10

13* 3

14

17a, b, c

05002

Reassembly

Fig. 16 shows a cutaway of the entire pump.

1.Lubricate the intake packings and install them in the valve body (16), with the lips of the v-pack- ings facing up. Install the v-packings in the order shown in Fig. 13.

2.With the beveled side facing up, press the intake valve seal (39*) into the recess of the intake valve packing nut (15) until it snaps into place. The nose of the seal should be flush with or slightly recessed into the face of the packing nut.

3.Place the flats of the valve body (16) in a vise. Screw the packing nut into the valve body hand- tight. Set the intake housing assembly aside.

1Lubricate.

2Lips of v-packings must face up.

Optional Displacement Pump 237945

3uses all PTFE v-packings (item 24).

16

4.Lubricate the piston seal (13*) and install it on the piston seat (14). Apply thread sealant to the threads of the seat and the piston guide (11). Screw the guide onto the seat (14). Place the guide in a vise as shown in Fig. 11 and torque the seat to 77???85 N.m (57???63 ft-lb).

5.If it was necessary to remove the priming piston rod (18) from the piston (12), place the flats of the piston in a vise. Using an adjustable wrench on the flats of the rod, screw the rod into the piston. Torque to 125???139 N.m (92???102 ft-lb). Be careful not to create burrs on the flats of the rod.

6.Place the piston seat/guide assembly onto the piston (12) so the 45_ beveled seating surfaces match. Screw the displacement rod (1) into the piston (12) hand tight, then torque the rod to 324???368 N.m (239???271 ft-lb).

39*

15

23*

26* 1 2 3

24* 1 2

26* 1 2 3

24* 1 2

25*

7.If the cylinder (10) was removed from the outlet housing (9), lubricate the seal (8*) and place it on the top of the cylinder. (The cylinder is symmetri- cal, so either end can be the top.) Screw the cylinder into the outlet housing. See Fig. 16.

8.Lubricate the seal (42*) and install it in the groove on the bottom of the packing housing (3). Screw the packing housing into the outlet housing (9) and torque to 176???258 N.m (130???190 ft-lb). See the Detail in Fig. 16.

9.Lubricate the throat packings and glands, and install them in the packing housing (3) one at a time, with the lips of the v-packings facing down. Install the v-packings in the order shown in the Detail in Fig. 16. Loosely install the packing nut

(2).

10.Lubricate the displacement rod (1). Slide the rod, piston assembly, and priming piston rod (18) into the cylinder (10) from the bottom, until the top of the rod (1) protrudes from the packing nut (2).

11.Lubricate the seal (8*) and install it on the bottom of the cylinder (10). Slide the intake valve housing (17) onto the priming piston rod (18), making certain that the smooth surface of the valve stop (VS) is facing down toward the pump intake. Screw the housing onto the cylinder. See Fig. 16.

12.Lubricate the priming piston rod (18), then slide the assembled intake valve (V) onto the rod, making certain that the packing nut (15) goes on the rod first. Push the valve assembly up the rod, stopping before it reaches the intake valve housing (17). See Fig. 14.

13.Hold the valve body (16) steady with a wrench while using an adjustable wrench to tighten the packing nut (15). See Fig. 14. Torque to 97???107 N.m (71???79 ft-lb). Use a rubber mallet on the priming piston rod (18), to drive the valve assem- bly up to the stop (VS).

14.The intake seat (37) is reversible. Inspect both sides of the seat and install it with the best side facing into the housing (17). Push it into the hous- ing until it seats securely. Lubricate the seal (38*) and install in the bevel around the bottom of the seat. See Fig. 16.

1

18

2

1

Hold valve body (16) steady.

Torque packing nut (15) to 97???107 N.m (71???79 ft-lb).

04992

15.Screw the intake cylinder (19) into the intake housing (17). Using a pipe wrench on the hex of the cylinder (19), torque the cylinder to 468???590 N.m (345???435 ft-lb). This will also torque the intake valve housing (17) and pump cylinder (10) into the outlet housing (9). See Fig. 15.

16.Screw the bleeder valve plug (20) into the valve body (29). The plug has two sets of threads. When reassembling, be sure to screw the plug complete- ly into the valve body. See Fig. 16.

17.Check that the flats of the priming piston rod (18) are accessible below the intake cylinder (19). If not, tap on the top of the displacement rod (1) with a rubber mallet, until the flats are exposed.

18.Slide the priming piston (21) onto the rod (18) until it stops. Hold the rod (18) steady with an adjust- able wrench on the flats, and screw the seat (22) onto the rod with another wrench. Torque to 77???85 N.m (57???63 ft-lb). See Fig.15.

19.Reconnect the displacement pump to the motor as explained on page 19.

20.Allow 2 hours for the thread sealant to cure before returning the pump to service.

THROAT PACKING DETAIL 3 4

1

1Piston check valve (see Fig. 12).

2Intake check valve (see Fig. 13).

3Lubricate.

4Lips of v-packings must face down.

5Screw valve plug (20) completely into valve body (29).

6Torque to 128???156 N.m (95???115 ft-lb).

7Torque to 176???258 N.m (130???190 ft-lb).

8Torque to 468???590 N.m (345???435 ft-lb).

9 Torque to 125???139 N.m (92???102 ft-lb).

10Torque to 77???85 N.m (57???63 ft-lb).

Optional Displacement Pump 237945

11uses all PTFE v-packings (item 4).

Fig. 16

2

6

3

7

42*

3

9

1

3 *8

VS

2

9 18

21

10 22

1

29

20

5

8* 3

10

17a, b, c

37

38* 3

19 8

05002

Servicing the Throat Packings

NOTE: The throat packings are available as a preas- sembled, pre???lubricated kit. For series B pumps, order Part No. 241782. For series A pumps order Part No. 237905. Parts included in these kits are marked with an asterisk, for example (3*). Part No. 237905 includes items 3, 5 (qty: 1), 6, and 47.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page12.

1.Relieve the pressure.

2.See Fig. 17. Unscrew the packing nut (2) using a pipe wrench. Remove the o-ring (6) and washer (47) from the bottom of the packing housing (3) or from the outlet housing (9).

3.Place the flats of the packing nut (2) in a vise. Unscrew the packing housing (3) and discard it and the packings. Remove the washer (46), seal (5), and backup washer (45) from the packing nut.

4.The throat repair kit is preassembled. Screw the kit into the packing nut (2), making sure that the backup washer (45*), seal (5*), and washer (46*) are properly positioned on top of the packing housing (3*), with the lips of the seal facing down. Torque the packing housing (3*) to 97???106 N.m (71???78 ft-lb). See Fig. 17.

5.Check that the washer (47*) and o-ring (6*) are properly installed on the bottom of the packing housing (3*).

6.Screw the packing nut (2) into the outlet housing

(9). Torque to 190???217 N.m (140???160 ft-lb).

2

*43

*5

*44

*5

*3

*45

*6

9

Displacement Pump Parts

1

39 15 23

26

24

25

16

37

8

19

04989

2

Throat

Packing Stack.

See page 36.

3

*42

9

Displacement Pump Parts

1

*8

19

04989

*These parts are included in Repair Kit 222864, which may be purchased separately. See page 34 for additional parts included in the kit.

*7

04989

To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (lpm/gpm) and operating air pressure (psi/MPa/bar):

1.Locate desired flow along bottom of chart.

2.Follow vertical line up to intersection with selected fluid outlet pressure curve (black). Follow left to scale to read fluid outlet pressure.

To find Pump Air Consumption (m#/min or scfm) at a specific fluid flow (lpm/gpm) and air pressure (psi/MPa/bar):

1.Locate desired flow along bottom of chart.

2.Read vertical line up to intersection with selected air consumption curve (dashes). Follow left to scale to read air consumption.

To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (lpm/gpm) and operating air pressure (psi/MPa/bar):

1.Locate desired flow along bottom of chart.

2.Follow vertical line up to intersection with selected fluid outlet pressure curve (black). Follow left to scale to read fluid outlet pressure.

To find Pump Air Consumption (m#/min or scfm) at a specific fluid flow (lpm/gpm) and air pressure (psi/MPa/bar):

1.Locate desired flow along bottom of chart.

2.Read vertical line up to intersection with selected air consumption curve (dashes). Follow left to scale to read air consumption.

A

B

C

To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (lpm/gpm) and operating air pressure (psi/MPa/bar):

1.Locate desired flow along bottom of chart.

2.Follow vertical line up to intersection with selected fluid outlet pressure curve (black). Follow left to scale to read fluid outlet pressure.

To find Pump Air Consumption (m#/min or scfm) at a specific fluid flow (lpm/gpm) and air pressure (psi/MPa/bar):

1.Locate desired flow along bottom of chart.

2.Read vertical line up to intersection with selected air consumption curve (dashes). Follow left to scale to read air consumption.

A

B

C

To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (lpm/gpm) and operating air pressure (psi/MPa/bar):

1.Locate desired flow along bottom of chart.

2.Follow vertical line up to intersection with selected fluid outlet pressure curve (black). Follow left to scale to read fluid outlet pressure.

To find Pump Air Consumption (m#/min or scfm) at a specific fluid flow (lpm/gpm) and air pressure (psi/MPa/bar):

1.Locate desired flow along bottom of chart.

2.Read vertical line up to intersection with selected air consumption curve (dashes). Follow left to scale to read air consumption.

To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (lpm/gpm) and operating air pressure (psi/MPa/bar):

1.Locate desired flow along bottom of chart.

2.Follow vertical line up to intersection with selected fluid outlet pressure curve (black). Follow left to scale to read fluid outlet pressure.

To find Pump Air Consumption (m#/min or scfm) at a specific fluid flow (lpm/gpm) and air pressure (psi/MPa/bar):

1.Locate desired flow along bottom of chart.

2.Read vertical line up to intersection with selected air consumption curve (dashes). Follow left to scale to read air consumption.

liters/minute

A

B

C

gpm 0.0

liters/minute

A

C

Fluid Outlet Pressure

Air Consumption

cycles per minute

Sound Power Levels dB(A)

(tested in accordance with ISO 3744)