Air???Powered Gluttonr

Pumps

307843ZAF

EN

2500 Series Pumps

2500 psi (17 MPa, 170 bar) Maximum Fluid Working Pressure

Model 220665, Series D

Model 237010, Series A

Carbon steel pumps*

Model 220668, Series D

Model 237013, Series A

Stainless steel pumps*

Electro-polished for use with waterborne coatings

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

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.

Mounting the Pump

D400 and 1200 Series Pumps: Mount the pump with the accumulators in the top position as shown in Fig. 1. The accumulators must be in the position shown or the pump will not prime.

DBe sure the pump is securely bolted to its mounting and that the mounting can support the weight of the pump, hoses, and stress caused during operation.

DThe outlet manifold can be removed and turned 180 degrees to change the direction of the outlet and ease installation, as shown in Fig. 3.

General Information

DThe installation shown in Fig. 4 is only a guide for selecting and installing system components. Con- tact your Graco distributor for assistance in plan- ning a system to suit your needs.

DSee pages 38 through 43 for accessories and kits available from Graco. Always use Genuine Graco Parts and Accessories.

DUse a thread sealant compatible with the fluid being pumped on all male pipe threads. Tighten all con- nections firmly to avoid air or fluid leaks.

DReference numbers and letters in parentheses in the text refer to the figure illustrations.

Grounding

WARNING

This pump must be grounded. The steps for grounding may differ from the way you ground other pumps. Carefully read and follow these grounding instructions. See FIRE AND EXPLO- SION HAZARD on page 5 before you operate the pump.

Static electricity is created by the high-velocity flow of fluid through the pump and hose. If every part of the equipment is not properly grounded, sparking may oc- cur. To reduce the risk of static sparking, ground the pump and all other equipment used or located in the pumping area. Check your local electrical code for de- tailed grounding instructions for your area and type of equipment. Ground all of the following equipment:

DPump: use a ground wire and clamp as shown in Fig. 2.

DFluid and air hoses: use only grounded hoses with a maximum of 500 feet (150 m) combined hose length to ensure grounding continuity.

DAir Compressor: Follow the manufacturer???s recom- mendations.

DSpray gun or dispensing valve: Obtain grounding through connection to a properly grounded fluid hose and pump.

DFluid supply container: Follow the local code.

DObject being sprayed: Follow the local code.

DAll solvent pails used when flushing: Follow the local code. Use only metal pails, which are conduc- tive. Do not place the pail on a non-conductive surface, such as paper or cardboard, which inter- rupts the grounding continuity.

To ground the pump: Loosen the grounding lug lock- nut (W) and washer (X). Insert one end of a 12 ga (1.5 mm@) minimum ground wire (Y) into the slot (Z) of the grounding lug, and tighten the locknut securely. Con- nect the clamp end of the ground wire to a true earth ground. To order a ground wire and clamp, order Part No. 222011.

Connect the Fluid Lines

1.Use grounded fluid hoses.

a.The pump fluid outlet (J) on the 400 and 1200 Series Pumps is 1 npt(f) .

b.The pump fluid outlet (J) on the 2500 Series Pump is 3/4 npt(f).

2.Install a fluid filter (F) and drain valve (E) near the fluid outlet. See Fig. 3.

WARNING

A fluid drain valve (E) is required in your system to relieve pressure in the fluid outlet hose (H) if the hose becomes plugged. See Fig. 3. Install a drain valve close to the pump???s fluid outlet. The drain valve reduces the risk of property damage or serious bodily injury, including splashing in the eyes or on the skin, or contamination from hazardous fluids.

WARNING

SUCTION HAZARD

Never place your hands on or near the pump fluid inlet. Powerful suction could cause serious bodily injury.

3.Install a control device, such as a gun, dispensing valve, or shutoff valve, on the grounded fluid hose (H).

Connect the Fluid Suction Line

CAUTION

The pump must be suction fed in order to operate properly. Pressure feeding or exceeding 15 psi (104 kPa, 1.04 bar) maximum fluid inlet pressure may cause premature bellows seal failure.

Connect the fluid suction hose (S) to the pump fluid inlet (M). See Fig. 4.

DThe pump fluid inlet (M) is 1.25 npt(f).

DThe maximum suction lift is 15 ft (4.57m) for the 400 Series and 1200 Series Pumps, and 6 ft (1.83 m) for the 2500 Series Pump.

J

H

F

M

E

02325

Connect the Air Lines

1.Install the air line accessories to the left of the pump as shown in Fig. 4. Mount these accessories on the wall or on a bracket. Be sure the air line supplying the accessories is grounded.

2.Install a flexible air hose between the accessories and the 1/2 in. npt(f) air inlet (G). Use a minimum 1/2 in. ID air hose.

3.Install an air line lubricator (B) upstream from the pump air inlet for automatic pump lubrication.

4.Install a pump runaway valve (T) to sense when the pump is running too fast and shut off the air supply to the motor. To order a pump runaway valve, order Part No. 224040.

5.Install an air regulator (D) to control air inlet pres- sure.

WARNING

A bleed-type master air valve (C) is required in your system to relieve air trapped between this valve and the pump after the air regulator is closed. Trapped air can cause the pump to cycle unexpect- edly, which could result in serious bodily injury, including splashing in the eyes, injury from moving parts, or contamination from hazardous fluids.

6.Install one bleed-type master air valve (C) down- stream from the air regulator and use it to relieve trapped air. Locate the other master air valve up- stream from all air line accessories and use it to isolate the accessories during cleaning and repair.

7.Install an air line filter (A) to remove harmful dirt and moisture from your compressed air supply.

8.Install a grounded air supply line (P) with a mini- mum 1/2 in. ID. See Fig. 4.

Ventilate the Air Exhaust

WARNING

Improper handling of hazardous fluids or inhaling their vapors can cause serious bodily injury, even death. For your safety, it is imperative that you read all product warning labels and Material Safety Data Sheets (MSDS) for the fluids you are using. An MSDS can be obtained from your fluid suppliers. It is also important that you read and understand the warnings and precautions regarding HAZARDOUS FLUID HAZARD on page 5 before you operate.

All systems using hazardous fluid in enclosed areas or within buildings should have a properly designed and installed ventilation system. Consult your local building code and other industrial and governmental standards for proper design criteria.

N

T

J F H

M

E

S

R

Pressure Relief Procedure

WARNING

The system pressure must be manually relieved to prevent the system from starting or spraying acci- dentally. To reduce the risk of an injury from acci- dental spray from the gun, splashing fluid, or moving parts, always follow the Pressure Relief Procedure whenever you

Dare instructed to relieve the pressure

DStop spraying

DCheck or service any of the system equipment

Dinstall or clean the spray nozzle.

1.* Engage the spray gun or dispensing valve safety latch.

2.Shut off the air supply.

3.* Disengage the gun or dispensing valve safety latch.

4.* Hold a metal part of the gun or valve firmly to a grounded metal waste container and trigger it to relieve the fluid pressure.

5.* Engage the safety latch again.

6.Open the pump drain valve (required in system), and have a container ready to catch the drainage.

7.Leave the drain valve open until you are ready to spray again.

*Applies only when using a spray gun or dispensing valve.

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

Flush the Pump Before First Use

WARNING

To reduce the risk of fluid injection injury, static sparking and splashing, read and follow Flushing Safety under FIRE OR EXPLOSION HAZARD on page 5.

The pump was tested with lightweight oil, which is left in to protect the pump parts. If this solution could con- taminate the fluid you are pumping, flush it thoroughly with a compatible solvent. To start the pump, follow the procedure in Start and Adjust the Pump, below.

Start and Adjust the Pump

NOTE: Check all fittings to be sure they are tight. Be sure to use a thread sealant compatible with the fluid being pumped on all male pipe threads.

1.Place the suction hose (S) in the fluid to be pumped. See Fig. 5.

2.Close the fluid drain valve (E).

3.With the air regulator (D) closed, open both bleed- type master air valves (C).

4.Open the fluid control device while continuing with the following steps.

5.Slowly open the air regulator (D). Adjust it until the pump runs smoothly.

6.Allow the pump to cycle slowly until all air is pushed out of the lines (the fluid will be flowing in a steady stream from the fluid outlet) and the pump is primed.

WARNING

To reduce the risk of component rupture, which could cause serious bodily injury, never exceed 100 psi (0.7 MPa, 7 bar) air supply pressure to the pump. Read the warning section EQUIPMENT MISUSE HAZARD on page 4.

7.If you are flushing:

a.Run the pump long enough to thoroughly clean the pump and hoses.

b.Close the fluid control device and air regulator

(D).

c.Remove the suction hose (S) from the solvent and place it in the fluid to be pumped.

8.If you are going to use the pump:

a.Start the pump. Be sure the suction hose is in the supply container.

b.If you are using this pump to spray fluid, re- lieve the pressure, then install a spray tip in the gun. Trigger the gun into a grounded metal waste container to prime the hose. Adjust the pump pressure just enough to completely at- omize the fluid. Higher pressures cause pre- mature spray tip and pump wear.

WARNING

PRESSURIZED EQUIPMENT HAZARD

To reduce the risk of a serious injury whenever you are instructed to relieve pressure, follow the Pres- sure Relief Procedure on page 10.

c.In a direct supply system, the pump will start and stop as the spray gun, dispensing valve, or fluid outlet valve is opened and closed.

d.In a circulating system, the pump runs continu- ously and speeds up or slows down as supply demands until the air supply is shut off.

C D C

CAUTION

Never allow the pump to run dry of fluid. A dry pump will accelerate to a high speed, possibly damaging itself. If your pump accelerates quickly, or is running too fast, stop it immediately and check the fluid supply. If the supply is empty and air has been pumped into the lines, refill the container and prime the pump and lines with fluid, or flush and leave filled with compatible solvent. Be sure to eliminate all air from the system. A Pump Runaway Valve, Part No. 224040, is available.

9.If you are shutting down the pump:

a.Flush the pump before shutting down, espe- cially if pumping a material that will set up.

b.Remove the suction hose from the fluid con- tainer and run the pump until the fluid is forced out of the system, then shut off the air supply immediately.

c.Relieve the pressure.

WARNING

PRESSURIZED EQUIPMENT HAZARD

To reduce the risk of a serious injury whenever you are instructed to relieve pressure, follow the Pres- sure Relief Procedure on page 10.

d.Refer to the Maintenance instructions on page 14.

Relieve the pressure, and check all probable causes before disassembling the pump.

WARNING

PRESSURIZED EQUIPMENT HAZARD

To reduce the risk of a serious injury whenever you are instructed to relieve pressure, follow the Pres- sure Relief Procedure on page 10.

Flush the Pump With Compatible Solvent

WARNING

To reduce the risk of fluid injection injury, static sparking and splashing, read and follow Flushing Safety under FIRE OR EXPLOSION HAZARD on page 5.

1.Flush often enough to prevent fluid from drying in the pump and damaging it.

2.Always flush before storing.

a.If you are pumping water-based fluid, first flush the pump with water, then with mineral spirits or a compatible oil-based solvent.

b.Leave the mineral spirits or oil-based solvent in the pump to protect the pump parts from corrosion.

3.Be sure to eliminate all air from the system.

Tighten Threaded Connections

1.Before each use, check all hoses for wear or dam- age and replace as necessary. Be sure all threaded connections are tight, and leak-free.

2.At least every six months, check and tighten all threaded connections, including manifold screws, clamps, plugs, and valve screws.

Check and Service the Lubricator, Regula- tor, and Filter

Check and service according to the instructions sup- plied with them. See Manual 308169 for oil recommen- dations.

Repairing the Ball Check Valves

NOTE: Parts marked with an asterisk are included in a repair kit, for example, (54*). See pages 38 and 39 for repair kit part numbers. Use all the parts in the kit for the best results.

Disassembly

1. Relieve the pressure.

WARNING

PRESSURIZED EQUIPMENT HAZARD

To reduce the risk of a serious injury whenever you are instructed to relieve pressure, follow the Pres- sure Relief Procedure on page 10.

2.Disconnect the air and fluid lines, remove the pump from its mounting, and place it on a bench.

3.Remove the cap (53) from each side of the outlet housing (33). See Fig. 6.

4.Remove the ball guide (56), ball (57), valve seat (49), and o-ring (48*) on each side of the outlet housing.

5.Inspect the ball stop (55) inside the cap (53) for wear. Remove o???ring (54). Replace if necessary.

6.Clean all parts and inspect for wear or damage. Replace as needed.

Assembly

1.Lubricate the o-rings (48*) and place one in the groove on each valve seat (49).

2.Install the valve seat (49) with the o-ring (48) fac- ing down, ball (57), and ball guide (56) into each outlet housing (33).

NOTE: Stainless steel seats are reversible.

3.Lubricate the o-rings (54*) and the cap (53) threads. Place one o-ring on each cap. Screw the caps into the housing and torque them to 55 to 85 ft-lb (75 to 115 NSm).

NOTE: On stainless steel pumps (Models 220666 through 220668 and Models 237011 to 237013), apply anti-seize lubricant to the threads of the cap (53).

Repairing the Fluid Piston and Seal

NOTE: Parts marked with an asterisk are included in a repair kit, for example, (52*). See pages 38 and 39 for repair kit part numbers. Use all the parts in the kit for the best results.

Disassembly

1. Relieve the pressure.

WARNING

PRESSURIZED EQUIPMENT HAZARD

To reduce the risk of a serious injury whenever you are instructed to relieve pressure, follow the Pres- sure Relief Procedure on page 10.

2.Loosen the tube nuts (A) and remove the outlet manifold (50). Unscrew the connectors (51). Re- move the o???ring (52). See Fig. 6.

3.Remove the screws (34), washers (35), outlet housing (33), piston seal (13*) and retaining plate (12). Remove the o???ring (18). Repeat on the other side of the pump.

4.Holding the screw (16) on one side of the pump, loosen the screw three or four turns on the oppo- site side of the pump, using a socket and breaker bar.

5.Remove the piston (17) by grasping it with your hand and and hit screw (16) with a plastic mallet to drive piston loose from shaft. Remove screw (16) and piston (17).

6.Remove the screws (32), washers (46 or 61), and inlet manifold (47). Remove o???rings (19).

7.Remove the intake housing (36), bellows (14*), and retaining plate (20).

8.Holding the piston shaft (15) flats with a wrench, remove the remaining screw (16).

9.Repeat steps 6 and 7 on the opposite end of the pump. Clean all parts and inspect for wear or dam- age. Replace as needed.

307843 15

Assembly

1.Slide the retaining plate (20), bellows (14*), and intake housing (36) onto the piston shaft (15). Do not force the bellows. Repeat on the other side.

CAUTION

To avoid damaging the bellows (14), do not force it onto the shaft. The bellows will press into place when the piston (17) is secured.

2.Install the piston (17) on the shaft (15) and secure it with the screw (16). Repeat on the opposite end of the pump.

3.Using a socket and breaker bar, torque one screw (16) to 40 to 50 ft-lb (54 to 67 NSm), then repeat with the other screw.

4.Grease and install an o-ring (19*) in each inlet. Install inlet manifold (47) with screws (32) and washers (46 or 61). Don???t torque screws yet.

CAUTION

To avoid loosening the piston stud (30) during disas- sembly, do not overtighten the screws (16).

NOTE: If using a formed UHMWPE seal, proceed to step 5. If using a flat nylon seal, proceed to step 6.

5.Grease and install the o-ring (18*) in the groove in the tapered side of the retaining plate (12). Grease the outlet housing (33) and install the piston seal (13*) and retaining plate (12). Be sure the flat side of the retaining plate faces the piston seal. Secure with the four screws (34) and washers (35).

6.Apply 10 psi air to move the piston to one side and hold it there. Replace the o???ring (18*) in the groove in the tapered side of the retaining plate (12).

Grease the oulet housing groove and set the nylon seal (13) inside the groove. Carefully tip the hous- ing (33) onto the inlet housing. Be sure the flat side of the retaining plate (12) faces the piston seal. Secure with the four screws (34) and washers (35).

Increase the air pressure to about 50 psi until the pump cycles and the piston drives to the other side.

Reduce the air pressure to 10 psi to hold in posi- tion. Repeat the seal installation pattern.

Increase the air pressure to 50 psi again to cause the pump to cycle again and form the seal on the first side.

NOTE: Torque the screws, on 400 and 1200 Series pumps, to 40 to 50 ft-lb (54 to 68 N-m). Torque the screws on the 2500 Series pump, to 35 to 40 ft-lb (47 to 54 N-m).

7.Torque the inlet manifold screws (32) to 7.4 to 12.5 ft-lb (10 to 17 N-m).

8.Replace the o-ring (52*) in each outlet manifold connector (51) and lubricate the threads. Install the outlet manifold (50), torquing the connectors to 55 to 85 ft-lb (75 to 115 NSm).

NOTE: On stainless steel pumps (Models 220666 through 220668 and Models 237011 to 237013), apply anti-seize lubricant to the threads of the connector (51).

8 1

A 4

NOTES:

1Lubricate threads. Torque to 55 to 85 ft-lb (75 to 115 NSm)

2Fit o-ring into groove

400 & 1200 Series pumps: Torque to

340 to 50 ft-lb (54 to 68 NSm)

2500 Series pumps: Torque to 35 to 40 ft-lb (47 to 54 NSm)

223111 & 220487 :Torque to 110 to 120 ft-lb (149 to 162 NSm)

4220491 & 220485: Torque to 140 to 150 ft-lb (190 to 203 NSm) See model and part number for specification.

6Torque to 7.4 to 12.5 ft-lb (10 to 17 NSm)

7Item 61 is used on stainless steel models only

Fig. 6

19*

47

16 5

02326

Repairing the Air Motor and Piston

NOTE: Parts marked with an asterisk are included in a repair kit, for example, (23*). See pages 38 and 39 for repair kit part numbers. Use all the parts in the kit for the best results.

Disassembly

1. Relieve the pressure.

WARNING

PRESSURIZED EQUIPMENT HAZARD

To reduce the risk of a serious injury whenever you are instructed to relieve pressure, follow the Pres- sure Relief Procedure on page 10.

2.Disassemble the pump as instructed under Re- pairing the Fluid Piston and Seal.

3.Remove the screws (3 & 4), washers (46), nuts (1), and lockwashers (2) from the cylinder cap (25). See Fig. 7.

4.Remove the pump from the mounting bracket (44).

5.Remove the cylinder cap (25) from each end of the air motor. If the hoses aren???t disconnected or the pilot valves removed, be careful not to pull on the hoses when removing the caps.

CAUTION

The shaft wiper (21) and bearing (22) are meant to remain in place. Remove only to replace. Removal will damage them.

6.Remove the shaft wiper (21) and bearing (22); only if they need to be replaced, and u-cup (23*) from each of the cylinder caps (25). Use a 0.875 in. di- ameter shaft to remove the bearing.

7.Remove the piston assembly (A) from the air mo- tor cylinder (27). Remove the seal (28).

8.Do not remove the piston shafts (15) unless re- placement is necessary as a high strength sealant was used on the threads. If the rods must be re- moved, heating the joint to 300_ F will ease disas- sembly. Place wrenches on the flats of the piston shaft to disconnect them from the piston stud (30).

9.Clean all parts and inspect for wear or damage. Replace as needed.

Assembly

1.Apply lithium base grease to all packings, seals, and the inside of the air motor cylinder (27) before assembling.

2.If the piston shafts (15) were removed from the piston stud (30), apply high strength sealant (such as Loctiter) to the threads of the piston stud, and assemble as shown in Fig. 7.

3.Install the quad ring (28*) in the groove on the pis- ton (29). Install the piston assembly (A) into the air motor cylinder (27).

4.Install a u-cup (23*) into each of the cylinder caps

(25).The lips of the u-cup must face in, towards the center of the pump, as shown in Fig. 8.

5.If the bearings (22) were removed, install a bearing into each cylinder cap (25). Press fit the bearing to flush, using an arbor press.

6.Install a shaft wiper (21) into each cylinder cap

(25)with the brass part of the wiper facing out, away from the center of the pump, as shown in Fig. 8. Carefully press the wiper into place, taking care to avoid damaging the brass piece.

7.Install an o-ring (26*) into the groove in each of the cylinder caps (25). Slide a cylinder cap (25) onto each end of the air motor. Align flat edges with air valve.

8.Secure the mounting bracket (44) and cylinder caps (25) on the pump with the screws (3 and 4), washers (46), nuts (1), and lockwashers (2). Tor- que the screws oppositely and evenly to 7.4 to 12.5 ft-lb (10 to 17 NSm).

Service

NOTES:

1Take care not damage tubes when re- moving cap (25)

2Apply high-strength sealant to threads

28*

REF

29

15

2

26*

27

A

28*

26*

46

25

23

4 22

5 21

3 4

1

Repairing the Air Control Valve

NOTE: Air Valve and Pilot Valve Repair Kit 220656 is available. See page 38 to order. Parts included in the kit are marked with an asterisk, for example, (40p*).

Use all the parts in the kit for the best results.

Disassembly

1. Relieve the pressure.

5.Thread one spool (40c) onto the stem (40d) and insert it into the center housing (40a); be careful not to dislodge the u-cups (40j) and retainers (40e). Thread the other spool onto the stem. With wrenches on the flats of the spools, apply oppos- ing force and tighten until snug; 7 to 13 in-lb (0.79 to 1.47 NSm). Do not overtighten.

WARNING

PRESSURIZED EQUIPMENT HAZARD

To reduce the risk of a serious injury whenever you are instructed to relieve pressure, follow the Pres- sure Relief Procedure on page 10.

2.Cut a small slit in the tube ends (72*, 42*, 40p*) and disconnect them from the pilot valve fittings (5h), air valve tees (40n), and barb fittings (40s). See Fig. 8.

3.Remove the valve end housings (40b) by unscrew- ing the screws (40k) and nuts (40m).

4.Center the valve spools (40c) in the housing (40a). Remove the spools and stem (40d) by applying opposing force with wrenches on the spool (40c) flats.

5.If the air filter (40q) needs cleaning or replace- ment, unscrew the filter housing (40r) and remove the filter. To clean them, soak the filter housing and the filter in solvent until they are clean. Blow them dry with low pressure air [under 30 psi (207 MPa, 2.1 bar)]. Press fit the filter into the housing, using 40 to 60 lb (18 to 27 kg) of force. Refer to Fig. 8. Apply sealant to the filter housing threads and turn it into the center housing (40a).

Assembly

1.Apply lithium-base grease to all o-rings, u-cups, gaskets and to the complete spool assembly be- fore installing them.

2.Remove the seal retainers (40e) from each side of the center housing (40a). Replace the u-cup (40j*), with the lips facing into the housing. Install the re- tainers with the flat side facing into the housing.

3.Replace the spools (40c) if damaged. Replace the o-ring (40h*) and u-cup (40i*) on each spool, being sure to seat them in the grooves. Install the u-cup with the lips facing towards the housing (40a).

4.Apply medium strength thread sealant to the spool stem (40d) threads. Remove the excess sealant.

CAUTION

Do not overtighten the spools (40c) as this can shear the spool threads.

6.Replace the gasket (40f*) in each end housing (40b) and the o-ring (40g*) on each end housing shoulder.

7.With the mufflers facing down, install the end housings (40b), onto the center housing (40a); be careful not to move the spool and dislodge the u- cups (40j) and retainers (40e). Secure the end housings with the four screws (40k) and nuts (40m), torquing them to 2.2 to 3.7 ft-lb (3 to 5 NSm).

CAUTION

If mufflers (38) are replaced, they must be installed with the lock rings (39) to avoid damage to the spool and o-rings during operation.

8.Replace the two o-rings (40h*) in the center hous- ing (40a).

9.Install the air valve on the pump with the four cap screws (43). Torque them alternately and evenly to 2.2 to 3.7 ft-lb (3 to 5 NSm).

10.Connect the new tubes (72*, 42*, 40p*) to the pilot valve fittings (5h), air valve tees (40n), and barb fittings (40s), as shown in Fig. 8.

1Torque to 2.2 to 3.7 ft-lb (3 to 5 NSm)

2Press fit using 40 to 60 lb (18 to 27 kg) force

3Lubricate with lithium-base grease

4Apply medium strength sealant to threads. Torque to 0.58 to 1.1 ft-lb (0.79 to 1.47 NSm)

5Apply sealant to threads

Fig. 8

3 40c

3 *40h

3 *40f

3 *40g

3 40b

40n

02328

Repairing the Pilot Valve

NOTE: Air Valve and Pilot Valve Repair Kit 220656 is available. See page 38 to order. Parts included in the kit are marked with an asterisk, for example, (5j*). Use all the parts in the kit for the best results.

Disassembly

1. Relieve the pressure.

WARNING

PRESSURIZED EQUIPMENT HAZARD

To reduce the risk of a serious injury whenever you are instructed to relieve pressure, follow the Pres- sure Relief Procedure on page 10.

2.Unscrew the valve cap (5c) from each of the valve housings (5d) and remove the parts. Clean and inspect the parts for damage. See Fig. 9.

3.To replace the rod seal (5j*):

a.Cut a small slit in the tube ends (72* and 42*) and disconnect them from the pilot valve fit- tings (5h) and air valve tees (40n).

b.Unscrew the cap screws (37) and remove the pilot valve housings (5d). Grease the rod seals (5j*) and install one on each side of the pump.

c.Secure the pilot valve housings (5d) to the pump with the cap screws (37).

d.Connect the new tubes (72* and 42*) to the pilot valve fittings (5h) and air valve tees (40n).

Assembly

1.Apply lithium base grease to the inside and outside of the air valve (5b), and to the o-rings and seals.

2.Install the o-ring (5e*), being sure to completely seat it on the flat in the valve housing (5d). Install the long end of the valve stem (5a) into the hous- ing.

3.Install the small spring (5g) over the valve stem (5a), the air valve (5b) over the spring, and the larger spring over the air valve.

4.With the copper gasket (5i*) in place on the valve cap (5c), screw the cap onto each of the valve housings (5d). Torque the cap to 7.4 to 12.5 ft-lb (10 to 17 NSm).

400 Series Carbon Steel Pumps

Model 220663, Series D

Model 237008, Series A

58

52*

33

35

34

19*

47

46

32

52*

51

73

50

28*

29

26*

15

25

46

4

2

26*

27

30

64

1

47

71

1

2

400 Series Carbon Steel Pumps

Model 220663, Series D

Model 237008, Series A

5

43

3942{

38

02333

*Parts included in Repair Kits 220949 (for pump Model 220663); and 237014 (for pump Model 237008), which may be purchased separately.

{Parts included in Repair Kit 220656, which may be purchased separately.

See pages 38 ??? 40 for description of all Repair Kits, Optional Repair Kits, and Conversion Kits available.

52*

33

35

34

2

52*51

7326*

50

27

30

28*

29

15

26*

25

61

4

64

3

44

32

1

47

71

1

2

400 Series Stainless Steel Pumps

Model 220666, Series D

Model 237011, Series A

60

72{ 59

40

37

02333

*Parts included in Repair Kits 220949 (for pump Model 220666); and 237014 (for pump Model 237011), which may be purchased separately.

{Parts included in Repair Kit 220656, which may be purchased separately.

See pages 38 ??? 40 for description of all Repair Kits, Optional Repair Kits, and Conversion Kits available.

53

55

54*

57

56

49

48*

58

52*

33

35

34

25

46

4

36

17

16

18*

12

13*

52*

51

73

50

27

30

28*

29

26*

15

31 22

21

20

32

19*

14*

19*

47

46

32

1

2

26*

47

71

1

2

1200 Series Carbon Steel Pumps

Model 220664, Series D

Model 237009, Series A

5

43

39 42{

38

02333

*Parts included in Repair Kits 221136 (for pump Model 220664); and 237017 (for pump Model 237009), which may be purchased separately.

{Parts included in Repair Kit 220656, which may be purchased separately.

See pages 38 ??? 40 for description of all Repair Kits, Optional Repair Kits, and Conversion Kits available.

29

26*

15

25

61

4

47

71

1

2

1200 Series Stainless Steel Pumps

Model 220667, Series D

Model 237012, Series A

60

72{ 59

40

37

02333

*Parts included in Repair Kits 221136 (for pump Model 220667); and 237017 (for pump Model 237012), which may be purchased separately.

{Parts included in Repair Kit 220656, which may be purchased separately.

See pages 38 ??? 40 for description of all Repair Kits, Optional Repair Kits, and Conversion Kits available.

2500 Series Carbon Steel Pumps

Model 220665, Series D

Model 237010, Series A

72{

60

59

40

37

*Parts included in Repair Kits 220950 (for pump Model 220665); and 237016 (for pump Model 237010), which may be purchased separately.

{Parts included in Repair Kit 220656, which may be purchased separately.

See pages 38 ??? 40 for description of all Repair Kits, Optional Repair Kits, and Conversion Kits available.

25

46

27

30

28*

29

26*

15

2500 Series Stainless Steel Pumps

Model 220668, Series D

Model 237013, Series A

60

72{ 59

40

37

5

43

38

02333

*Parts included in Repair Kits 220950 (for pump Model 220668); and 237016 (for pump Model 237013), which may be purchased separately.

{Parts included in Repair Kit 220656, which may be purchased separately.

See pages 38 ??? 40 for description of all Repair Kits, Optional Repair Kits, and Conversion Kits available.

Ref No. 40

Air Control Valve 220902

40r

40s

40p

40q

40m

40h*

40a

*40j

40e

40d

*40i

NOTE: This assembly is included with all pump models.

40k

40c

*40h

*40f

*40g

40b

*These parts are included in Repair Kit 220656. See pages 38 ??? 40 for description of all Repair Kits, Op- tional Repair Kits, and Conversion Kits available.

*These parts are included in Repair Kit 220656. See pages 38 ??? 40 for description of all Repair Kits, Op- tional Repair Kits, and Conversion Kits available.

Standard Air Valve and Pilot Valve Repair Kit 220656

Optional Air Valve/Pilot Valve Conversion Kit 253345, with Air???Assisted Pilot Valves

400 Series Optional Pump Repair Kit 24C134, with UHMWPE Bellows (for pump Models 220663 and 220666)

400 Series Optional Pump Repair Kit 24C135, with UHMWPE Bellows (for pump Models 237008 and 237011)

400 and 1200 Series Pumps Carbide Ball and Seat Conversion Kit 221134

1200 Series Optional Pump Repair Kit 24C130, with UHMWPE Bellows, (for pump Models 220664 and 220667)

1200 Series Standard Pump Repair Kit 237017

(for pump Models 237009 and 237012)

1200 Series Optional Pump Repair Kit 24C131, with UHMWPE Bellows (for pump Models 237009 and 237012)

2500 Series Standard Pump Repair Kit 220950

(for pump Models 220665 and 220668)

2500 Series Optional Pump Repair Kit 24C132, with UHMWPE Bellows, (for pump Models 220665 and 220668)

2500 Series Standard Pump Repair Kit 237016

(for pump Models 237010 and 237013)

2500 Series Optional Pump Repair Kit 24C133, with UHMWPE Bellows (for pump Models 237010 and 237013)

Drum Cover Kit 222655

Drum Cover Kit 222655 (shown below with a Glutton pump) is available.

4

2

1

Return Tube Kit 223319

Return Tube Kit 223319 (shown below) is available.

104

plug

NOTE: When installing the Return Tube Kit, remove plug and install the adapter (102) and elbow (101). Install tube (104) and nut (103) from the bottom.

Maximum working pressure . . . . . . . . . . . . . . . . 400 psi (2.8 MPa, 28 bar)

Maximum air input pressure . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)

Air operating range . . . . . . . . . . . . . . . . . . 25 to 100 psi (0.07 to 0.7 MPa, 1.73 to 7 bar)

Maximum continuous pump speed . . . . . . . . . . 60 cpm Fluid flow at 60 cpm . . . . . . . . . . . . 5.6 gpm (21.2 lpm) Fluid volume per cycle . . . . . . . . 0.096 gal (0.366 liter) Maximum suction lift (water) . . . . . . . . . . 15 ft (4.57 m) Maximum operating temperature . . . . . 150_ F (65_ C) Air inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt(f) Fluid inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 npt(f) Fluid outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 npt(f) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.5 lb (36.2 kg)

Wetted Parts:

Model 220663 and 237008:

carbon steel, stainless steel, polypropylene, ultra high molecular weight polyethylene{, Nylon},

PTFE

{ Model 220663 only } Model 237008 only

Model 220666 and 237011:

304 and 316 stainless steel, 17???4 PH stainless steel, polypropylene, ultra high molecular weight polyethylene{, Nylon}, PTFE

{ Model 220666 only } Model 237011 only

KEY: Fluid Outlet Pressure: black curves Air Consumption: gray curves

Aat 100 psi (0.7 MPa, 7 bar) air pressure

Bat 70 psi (0.48 MPa, 4.9 bar) air pressure

Cat 40 psi (0.28 MPa, 2.8 bar) air pressure

FLUID FLOW

To find outlet pressure (psi/MPa/bar) at a specific delivery (GPM, lpm) and operating air pressure (psi/MPa/bar):

1.Locate desired delivery along bottom of chart.

2.Read vertical line up to intersection with selected fluid outlet pressure curve. Follow left to scale and read outlet pressure.

To find pump air consumption (CFM, m3/min) specific de- livery (GPM, lpm) and operating air pressure (psi/MPa/bar):

1.Locate desired delivery along bottom of chart.

2.Read vertical line up to intersection with selected air con- sumption curve. Follow right to scale and read air con- sumption.

Maximum working pressure . . . . . . . . . . . . . . 1200 psi (8.3 MPa, 83 bar)

Maximum air input pressure . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)

Air operating range . . . . . . . . . . . . . . . . . . 25 to 100 psi (0.07 to 0.7 MPa, 1.73 to 7 bar)

Maximum continuous pump speed . . . . . . . . . . 60 cpm Fluid flow at 60 cpm . . . . . . . . . . . . . . . 2 gpm (7.5 lpm) Fluid volume per cycle . . . . . . . . 0.034 gal (0.128 liter) Maximum suction lift (water) . . . . . . . . . . 15 ft (4.57 m) Maximum operating temperature . . . . . 150_ F (65_ C) Air inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt(f) Fluid inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 npt(f) Fluid outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 npt(f) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 lb (35.1 kg)

Wetted Parts:

Model 220664 and 237009:

carbon steel, stainless steel, polypropylene, ultra high molecular weight polyethylene{, Nylon},

PTFE

{ Model 220664 only } Model 237009 only

Model 220667 and 237012:

304 and 316 stainless steel, 17???4 PH stainless steel, polypropylene, ultra high molecular weight polyethylene{, Nylon}, PTFE

{ Model 220667 only } Model 237012 only

KEY: Fluid Outlet Pressure: black curves Air Consumption: gray curves

Aat 100 psi (0.7 MPa, 7 bar) air pressure

Bat 70 psi (0.48 MPa, 4.9 bar) air pressure

Cat 40 psi (0.28 MPa, 2.8 bar) air pressure

FLUID FLOW

To find outlet pressure (psi/MPa/bar) at a specific delivery (GPM, lpm) and operating air pressure (psi/MPa/bar):

1.Locate desired delivery along bottom of chart.

2.Read vertical line up to intersection with selected fluid outlet pressure curve. Follow left to scale and read outlet pressure.

To find pump air consumption (CFM, m3/min) specific de- livery (GPM, lpm) and operating air pressure (psi/MPa/bar):

1.Locate desired delivery along bottom of chart.

2.Read vertical line up to intersection with selected air con- sumption curve. Follow right to scale and read air con- sumption.

Maximum working pressure . . . . . . . . . . . . . . 2500 psi (17 MPa, 170 bar)

Maximum air input pressure . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)

Air operating range . . . . . . . . . . . . . . . . . . 25 to 100 psi (0.07 to 0.7 MPa, 1.73 to 7 bar)

Maximum continuous pump speed . . . . . . . . . . 60 cpm Fluid flow at 60 cpm . . . . . . . . . . . . . 0.9 gpm (3.4 lpm) Fluid volume per cycle . . . . . . . . 0.015 gal (0.058 liter) Maximum suction lift (water) . . . . . . . . . . . 6 ft (1.83 m) Maximum operating temperature . . . . . 150_ F (65_ C) Air inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt(f) Fluid inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 npt(f) Fluid outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt(f) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 lb (27.5 kg)

Wetted Parts:

Model 220665 and 237010:

carbon steel, stainless steel, polypropylene, ultra high molecular weight polyethylene{, Nylon},

PTFE

{ Model 220665 only } Model 237010 only

Model 220668 and 237013:

304 and 316 stainless steel, 17???4 PH stainless steel, polypropylene, ultra high molecular weight polyethylene{, Nylon}, PTFE

{ Model 220668 only } Model 237013 only

KEY: Fluid Outlet Pressure: black curves Air Consumption: gray curves

Aat 100 psi (0.7 MPa, 7 bar) air pressure

Bat 70 psi (0.48 MPa, 4.9 bar) air pressure

Cat 40 psi (0.28 MPa, 2.8 bar) air pressure

FLUID FLOW

To find outlet pressure (psi/MPa/bar) at a specific delivery (GPM, lpm) and operating air pressure (psi/MPa/bar):

1.Locate desired delivery along bottom of chart.

2.Read vertical line up to intersection with selected fluid outlet pressure curve. Follow left to scale and read outlet pressure.

To find pump air consumption (CFM, m3/min) specific de- livery (GPM, lpm) and operating air pressure (psi/MPa/bar):

1.Locate desired delivery along bottom of chart.

2.Read vertical line up to intersection with selected air con- sumption curve. Follow right to scale and read air con- sumption.