Husky 307 Air-Operated Diaphragm Pumps

Transcription

1 INSTRUCTIONS PARTS LIST This manual contains important warnings and information. READ AND RETAIN FOR REFERENCE Rev. E Supersedes C and PCN D Husky 307 Air-Operated Diaphragm Pumps 100 psi (7 bar) MAXIMUM FLUID WORKING PRESSURE 100 psi (7 bar) MAXIMUM AIR INPUT PRESSURE ACETAL PUMPS Part No with PTFE Diaphragm Part No with PTFE Diaphragm (center housing is rotated 180) Part No with Hytrel Diaphragm POLYPROPYLENE PUMPS Part No with PTFE Diaphragm Part No with Hytrel Diaphragm US and Foreign Patents Pending GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN COPYRIGHT 1992, GRACO INC.

2 Table of Contents Safety Warnings , 3 Terms Typical Installation Drawings 55 Gallon Bung-Mount Transfer Installation Gallon Wall-Mount Transfer Installation Venting Exhaust Air (Pump Shown Submerged) Stand-Mounted Air Spray Installation Pail-Mounted HVLP Air Spray Installation Installation General Information Mountings Grounding Air Line Air Exhaust Ventilation Fluid Outlet Line Fluid Suction Line Operation Flush the Pump Before First Use Starting and Adjusting the Pump Pump Shutdown Maintenance Flushing Grounding Continuity Check Tightening Threaded Connections Tightening the Clamps Troubleshooting Guide Service Tools Required Replacing the Air Valve Repairing the Air Valve , 15 Ball Check Valves (Acetal Pumps) Ball Check Valves (Polypropylene Pumps) Diaphragm Repair , 19 Parts Drawings & Lists Air Valve Model and Model Model Model Repair Kits Accessories , 28 Dimensions Mounting Hole Layouts Technical Data and Performance Charts Models , and Models and Warranty Back Cover Graco Toll-Free Phone Numbers Back Cover WARNINGS For Professional Use Only. Observe All Warnings. Read and understand all instruction manuals before operating equipment. General Safety Any misuse of the equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in serious injury, including splashing in the eyes or on the skin, fire, explosion or property damage. EQUIPMENT MISUSE HAZARD Fluid Compatibility Be sure all fluids and solvents used are chemically compatible with the Wetted Parts and Non-wetted Parts shown in the Technical Data on pages 30 and 31. Always read the fluid and solvent manufacturer s literature before using them in this pump. Never alter or modify any part of this equipment; doing so could cause it to malfunction. Check all equipment regularly and repair or replace worn or damaged parts immediately. Take precautions to avoid a toxic fluid spill. See USING HAZ- ARDOUS FLUIDS, on page 3. System Pressure This pump develops 100 psi (7 bar) Maximum Fluid Working Pressure at 100 psi (7 bar) maximum incoming air pressure. Never exceed these maximum pressures, or the maximum working pressure of the lowest rated component in your system. Diaphragm failure will cause non-wetted parts to be exposed to fluid. This fluid will be exhausted with the air through the muffler. When pumping acids, flammable or hazardous fluids, you must vent the exhaust to a safe place, away from people, animals, food handling areas, and all sources of ignition. Put a container at the end of the air exhaust line to catch the fluid. See Fig. 4 on page 4. To pump acids, always use a polypropylene pump. Take precautions to avoid acid or acid fumes from contacting the pump housing exterior. Stainless steel parts will be damaged by exposure to acid spills and fumes. Never use an acetal pump to pump acids. Pressure Relief Procedure To reduce the risk of serious injury, including splashing fluid or solvent in the eyes or on the skin, always shut off the air to the pump, open the dispensing valve (if used), and open the fluid drain valve, to relieve all system pressure before checking, adjusting, cleaning, moving, or repairing any part of the system.

3 Improper handling of hazardous fluids or inhaling toxic vapors can cause extremely serious injury, even death, due to splashing in the eyes, ingestion, or bodily contamination. Know what fluid you are pumping and its specific hazards. Store hazardous fluid in an appropriate, approved container. Dispose of it according to all Local, State and Federal guidelines for hazardous fluids. Observe all the following precautions when handling known or potentially hazardous fluids. 1. Always wear appropriate clothing and equipment, such as eye protection and breathing apparatus, to protect yourself. Static electricity is created by the fluid flowing through the pump and hose. If the equipment is not properly grounded, sparking may occur, and the system may become hazardous. Sparks can ignite fumes from solvents and the fluid being pumped, dust particles and other flammable substances, whether you are pumping indoors or outdoors, and cause a fire or explosion, serious injury, and property damage. When pumping flammable fluids, always use an acetal pump. The acetal pump contains stainless steel fibers and is more conductive than a polypropylene pump. Never use a polypropylene pump with flammable fluids. If you experience any static sparking or even a slight shock while using this equipment, stop dispensing immediately. Do not use the system again until the cause of the problem is identified and corrected. USING HAZARDOUS FLUIDS FIRE OR EXPLOSION HAZARD 2. Pipe and dispose of the exhaust air safely. If the diaphragm fails, the fluid is exhausted along with the air. See Fig. 4 on page Secure the fluid outlet hose tightly into the receiving container to prevent it from coming loose and improperly draining the fluid. 4. Never move or lift a pump under pressure. If dropped, the fluid section may rupture. Always follow the Pressure Relief Procedure on page 2 before moving or lifting the pump. 3. Air compressor: according to manufacturer s recommendations. 4. All solvent pails used when flushing, according to local code. Use only metal pails, which are conductive. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts the grounding continuity. 5. Fluid supply container: according to local code. To ground the pump: secure a ground wire (Y) to the grounding strip (28), using a screw (30), lockwashers (31) and nut (29). See Fig. 1. Connect the clamp end of the ground wire to a true earth ground. Refer to the Accessories section to order a ground wire and clamp. Grounding 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 detailed grounding instructions for your area and type of equipment. Ground all of this equipment. 1. Pump: connect a ground wire and clamp as shown in Fig Y 2. Air and fluid hoses: use only grounded hoses with a maximum of 500 ft (150 m) combined hose length to ensure grounding continuity. Fig IMPORTANT United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards particularly the General Standards, Part 1910, and the Construction Standards, Part 1926 should be consulted. TERMS Identifies essential procedures or helpful informa- WARNING Alerts user to avoid or correct conditions NOTE that could cause bodily harm. tion. CAUTION Alerts user to avoid or correct conditions that could cause damage to or destruction of equipment.

4 Typical Installations BUNG-MOUNT TRANSFER INSTALLATION See Fig. 5 for list of accessories WALL-MOUNT TRANSFER INSTALLATION See Fig. 5 for list of accessories E F H B C N E F H B C J N Fluid Inlet Filter J Bung Adapter Y Y Wall Bracket L L Fig. 2 Fig. 3 VENTING EXHAUST AIR (Submerged Installation Shown) See Fig. 5 for accessories In a submerged installation (as shown), all wetted and non-wetted pump parts must be compatible with the fluid being pumped. Container For Remote Air Exhaust Muffler Fig. 4 Grounded Air Exhaust Hose 01445

5 Typical Installations STAND-MOUNTED AIR SPRAY INSTALLATION R E P Y F N B D G C M H A J K KEY A Husky 307 Pump B Bleed-Type Master Air Valve (required for pump) C Air Supply Line D Air Line Quick Disconnect E Master Air Valve (for accessories) F Air Line Filter G Gun Air Regulator H Pump Air Regulator J Fluid Drain Valve (required) K Fluid Recirculation Line L Fluid Suction Line M Surge Tank and Filter N Fluid Supply Hose P Gun Air Supply Hose R Air Spray Gun S Floor Stand Y Ground Wire (required; see page 3 for installation instructions) S L Fig PAIL-MOUNTED HVLP AIR SPRAY INSTALLATION KEY A Husky 307 Pump B Bleed-Type Master Air Valve (required for pump) C Air Supply Line D Air Line Quick Disconnect E Master Air Valve (for accessories) F Air Line Filter G Gun Air Regulator H Pump Air Regulator J Fluid Drain Valve (required) K Agitator L Fluid Suction Line M Fluid Regulator N Fluid Supply Hose P Gun Air Supply Hose R HVLP Air Spray Gun S Pail Cover Y Ground Wire (required; see page 3 for installation instructions) K S Y H A C D G B J F E P M R N L Fig

6 Installation General Information 1. The Typical Installations shown in Figs. 2 6 on pages 4 and 5 are only guides for selecting and installing system components. Contact your Graco distributor or Graco Technical Assistance (see back page) for assistance in planning a system to suit your needs. 2. See pages 27 and 28 for accessories available from Graco. Always use Genuine Graco Parts and Accessories. 3. Use a compatible, liquid thread sealant or PTFE tape on all male threads. Tighten all connections firmly to avoid air or fluid leaks. 4. Reference numbers and letters in parentheses refer to the callouts in the Figures and the parts lists on pages CAUTION Safe Operating Temperature Minimum: F (4.4C); Maximum: 150F (66C). These temperatures are based upon mechanical stress only and may be significantly altered by pumping certain chemicals. Consult engineering guides for chemical compatibilities and temperature limits, or contact Graco Technical Assistance: WARNING To reduce the risk of serious bodily injury and property damage from component rupture, always follow these precautions: 1. Never use fluids in this pump which are not compatible with the wetted parts listed in the Technical Data on pages 30 and 31, or with the diaphragm of this pump. 2. Read and follow all warnings regarding Fluid Compatibility on page 2 and USING HAZ- ARDOUS FLUIDS on page 3. Mountings CAUTION The pump exhaust air may contain contaminants. Ventilate to a remote area if the contaminants could affect your fluid supply. See Air Exhaust Ventilation, on page 7, and Fig. 4 on page The direction of the fluid inlet and outlet ports can be changed, if desired. Remove the bolts (24) holding the manifolds () to the covers (39). Always replace the o-rings (45) with new ones. Reverse the manifolds as desired, and reattach. Apply thread lubricant to the bolts and torque to in lb ( N.m). Do not over-torque. See Fig Be sure the mounting can support the weight of the pump, hoses, and accessories, as well as the stress caused during operation. 3. The Husky 307 Pump can be used in a variety of installations, some of which are shown on pages 4 and 5. Kits are available to adapt your pump to your system. Refer to the Accessories section on pages 27 and 28 for further information. 4. For all other mountings, be sure the pump is secured with screws and nuts. WARNING To reduce the risk of serious injury, splashing in the eyes or on the skin, and toxic fluid spills, never move or lift a pump under pressure. If dropped, the fluid section may rupture. Always follow the Pressure Relief Procedure Warning on page 2 before moving or lifting the pump. Grounding WARNING This pump must be grounded. Before operating the pump, ground the system as explained in FIRE OR EXPLOSION HAZARD on page 3. When pumping flammable fluids, always use an acetal pump. The acetal pump contains stainless steel fibers and is more conductive than a polypropylene pump. Never use a polypropylene pump with flammable fluids.

7 Installation Air Line WARNING A bleed-type master air valve (B) is required in your system to relieve air trapped between this valve and the pump. Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury, including splashing in the eyes or on the skin, injury from moving parts, or contamination from hazardous fluids. NOTE: On most models, the air inlet and the air exhaust port are on the opposite side of the pump from the grounding strip, as shown in Fig. 7. On Model only, the center housing is rotated 180 to put the air inlet and air exhaust port on the same side as the grounding strip. The air inlet is above the air exhaust port. 1. Install the air line accessories as shown in Figs. 2 6 on pages 4 and 5. Mount these accessories on the wall or on a bracket. Be sure the air line supplying the accessories is grounded. a. The fluid pressure can be controlled in one of two ways. To control it on the air side, install an air regulator (H). To control it on the fluid side, install a fluid regulator (M) near the pump fluid outlet (see Fig. 6). b. Locate one bleed-type master air valve (B) close to the pump and use it to relieve trapped air. See the WARNING above. Locate the other master air valve (E) upstream from all air line accessories and use it to isolate them during cleaning and repair. c. The air line filter (F) removes harmful dirt and moisture from the compressed air supply. 2. Install a grounded, flexible air hose (C) between the accessories and the 1/4 npt(f) pump air inlet. See Fig. 7. Use a minimum 1/4 (6.3 mm) ID air hose. Screw an air line quick disconnect coupler (D) onto the end of the air hose (C), and screw the mating fitting into the pump air inlet snugly. Do not connect the coupler (D) to the fitting yet. Air Exhaust Ventilation WARNING Be sure to read and follow the warnings and precautions regarding USING HAZARDOUS FLUIDS, and FIRE OR EXPLOSION HAZARD on page 3, before operating this pump. Be sure the system is properly ventilated for your type of installation. When pumping flammable or hazardous fluids, you must vent the exhaust to a safe place, away from people, animals, food handling areas, and all sources of ignition. If a diaphragm ruptures, the fluid being pumped will exhaust with the air. Place a container at the end of the air exhaust line to catch the fluid. See Fig. 4 on page Remove the muffler (27) from the pump air exhaust port. Install an exhaust hose and connect the muffler to the other end of the hose. Avoid sharp bends or kinks in the hose. WARNING To reduce the risk of serious eye injury from ice particles, never operate the pump with the air exhaust port open. Ice may form during pump operation, and ice particles will be ejected from the port along with the exhaust air. If the muffler (27) is removed, always connect an air exhaust hose to the exhaust port. 2. Place a container at the end of the air exhaust line to catch fluid in case a diaphragm ruptures. See Fig. 4.

8 Installation Fluid Outlet Line WARNING A fluid drain valve (J) is required in your system to relieve pressure in the hose if it is plugged. The drain valve reduces the risk of serious injury, including splashing in the eyes or on the skin, or contamination from hazardous fluids when relieving pressure. Install the valve close to the pump fluid outlet. Fluid Suction Line 1. Use grounded fluid hoses. The pump fluid inlet is 3/8 npt(f). See Fig. 7. Screw the fluid fitting into the pump inlet snugly. 2. At inlet fluid pressures greater than 15 psi (1.05 bar), diaphragm life will be shortened. 3. See the Technical Data on pages 30 and 31 for maximum suction lift and flow rate loss at various lift distances. 1. Use grounded fluid hoses (N). The pump fluid outlet is 3/8 npt(f). See Fig. 7. Screw the fluid fitting into the pump outlet snugly. Apply thread lube and torque to in lb ( N.m). Do not over-torque. 1/4 npt(f) Air Inlet 2. Install a fluid regulator (M) at the pump fluid outlet to control fluid pressure, if desired (see Fig. 6). See Air Line, step 1a., for another method of controlling pressure. 3. Install a fluid drain valve (J) near the fluid outlet. See the WARNING above. 3/8 npt(f) Fluid Inlet 3/8 npt(f) Fluid Outlet 3/8 npt(f) Air Exhaust Port On Model only, the center housing is rotated 180 to put the air inlet and air exhaust port on the same side as the grounding strip. CAUTION Some systems may require installation of a pressure relief valve at the pump outlet to prevent overpressurization and rupture of the pump or hose. See page 28. Thermal expansion of fluid in the outlet line can cause overpressurization. This can occur when using long fluid lines exposed to sunlight or ambient heat, or when pumping from a cool to a warm area (for example, from an underground tank). Overpressurization can also occur if the Husky pump is being used to feed fluid to a piston pump, and the intake valve of the piston pump does not close, causing fluid to back up in the outlet line. Fig

9 Operation Flush the Pump Before First Use The pump was tested in water. If the water could contaminate the fluid you are pumping, flush the pump thoroughly with a compatible solvent. Follow the steps under Starting and Adjusting the Pump. Starting and Adjusting the Pump 1. Be sure the pump is properly grounded. Read and follow FIRE OR EXPLOSION HAZARD, on page Check all fittings to be sure they are tight. Be sure to use a compatible liquid thread sealant or PTFE tape on all male threads. Tighten the fluid inlet and outlet fittings snugly. Do not overtighten the fittings into the pump. 3. Place the suction tube (if used) in the fluid to be pumped. 4. Place the end of the fluid hose (N) into an appropriate container. Close the fluid drain valve (J). 5. With the pump air regulator (H) closed, open all bleed-type master air valves (B, E). 6. If the fluid hose has a dispensing device, hold it open while continuing with the following step. Slowly open the air regulator (H) until the pump starts to cycle. Allow the pump to cycle slowly until all air is pushed out of the lines and the pump is primed. If you are flushing, run the pump long enough to thoroughly clean the pump and hoses. Close the air regulator. Remove the suction tube from the solvent and place it in the fluid to be pumped. Pump Shutdown If you are shutting down the pump, remove the suction hose from the fluid container and run the pump until the fluid is forced out of the system. Then shut off the air supply immediately. At the end of the work shift and before checking, adjusting, cleaning or repairing the system, follow the Pressure Relief Procedure Warning. WARNING Pressure Relief Procedure To reduce the risk of serious injury, including splashing fluid or solvent in the eyes or on the skin, always shut off the air to the pump, open the dispensing valve (if used), and open the fluid drain valve, to relieve all system pressure before checking, adjusting, cleaning, moving, or repairing any part of the system.

10 Maintenance Flushing Flush the pump often enough to prevent the fluid you are pumping from drying in the pump and damaging it. Always flush the pump and follow the Pressure Relief Procedure Warning on page 9 before storing it for any length of time. Use a compatible solvent. Grounding Continuity Check Check your system electrical continuity regularly to be sure proper grounding is maintained. Tightening the Clamps When tightening the clamps (26), apply thread lubricant to the bolts and be sure to torque the nuts to in lb ( N.m). See Fig. 8. Apply thread lube and torque nuts to In lb ( N.m) 26 Tightening Threaded Connections Before each use, check all hoses for wear or damage and replace as necessary. Check to be sure all threaded connections are tight and leak-free, but do not overtighten! At least every six months, check and retorque all threaded connections, including manifold screws, clamps, and valve screws. Do not overtighten! Fig

11 Pressure Relief Procedure To reduce the risk of serious injury, including splashing fluid or solvent in the eyes or on the skin, always follow this procedure before checking, adjusting, cleaning, moving, or repairing any part of the system. Troubleshooting WARNING 1. Shut off the air to the pump. 2. Open the dispensing valve, if used. 3. Open the fluid drain valve to relieve all fluid pressure, having a container ready to catch the drainage. NOTE: Check all possible problems and causes before disassembling the pump. PROBLEM CAUSE SOLUTION Pump will not cycle, or cycles once and stops. Air valve (2) is stuck or dirty. Turn reset screw (114). Disassemble and clean air valve. See pages 14, 15. Use filtered air. Broken or damaged springs (109, 112) and/or valve cup (110) and plate (104). Repair or replace. See pages 14, 15. Pump cycles at stall or fails to hold pressure at stall. Leaky check valves or o-rings (45). Repair or replace. See pages Worn check balls (46) or seat (42). Repair or replace. See pages Worn air valve cup (110) or plate (104). Repair or replace. See pages 14, 15. Worn shaft seals (21). Repair or replace. See pages 18, 19. Pump operates erratically. Clogged suction line. Inspect; clear. Sticky or leaking check valve balls (46). Clean or repair. See pages Diaphragm (44) ruptured. Replace. See pages 18, 19. Air bubbles in fluid. Suction line is loose. Tighten. Diaphragm (44) ruptured. Replace. See pages 18, 19. Loose manifolds () or damaged o-rings (45). Tighten manifold bolts (24) or nuts (25); replace o-rings (45). See pages Loose outer diaphragm plates (43). Tighten. See pages 18, 19. Fluid in exhaust air. Diaphragm (44) ruptured. Replace. See pages 18, 19. Pump exhausts air at stall. Worn air valve cup (110) or plate (104). Repair or replace. See pages 14, 15. Worn shaft seals (21). Repair or replace. See pages 18, 19. Pump exhausts air from clamps. Loose clamps (26). Tighten clamps. See page 10. Pump exhausts air near air valve. Air valve screws (18) are loose. Tighten screws. See page 12. Air valve o-ring (101) is damaged. Inspect; replace. See pages 14, 15. Pump leaks fluid from check valves. Worn or damaged o-rings (45). Inspect; replace. See page

12 Service Tools Required Torque wrench One 7/16 (11 mm) and two 1/2 (13 mm) socket wrenches Phillips screwdriver O-ring pick 13/32 EZY-OUT bearing extractor Rubber mallet Vise with soft jaws Replacing the Air Valve NOTE: Air Valve Kit is available. Parts included in the kit are marked with a dagger, for example (104). A tube of general purpose grease (121) is supplied in the kit. Install the kit as follows. 1. Follow the Pressure Relief Procedure Warning on page Unscrew the six mounting screws (18) and remove the air valve (2) from the pump. See Fig. 9. NOTE: On most models, the air valve (2) is on the same side of the pump as the grounding strip (28), as shown in Fig. 9. On Model only, the center housing (1) is rotated 180 to put the air valve on the opposite side of the pump. 3. Refer to the Valve Plate Detail in Fig. 9. Remove the two screws (102) holding the valve plate (104) to the pump. Use an o-ring pick to remove the valve plate, seal (103), and bearing (105). 4. Apply grease (121) to the bearing (105). Install the bearing and the seal (103) in the pump housing (1). Install the valve plate (104) and secure with the two screws (102). Torque the screws to 5 7 in lb ( N.m). 5. Make certain the o-ring (101) is in place on the air valve (2). 6. Apply grease (121) where shown in Fig Align the new air valve assembly so the reset screw (114) is at the top. Install the valve on the pump, making sure the valve saddle (118, see Fig. 10) engages the recessed area on the diaphragm shaft (22). Install the six screws (18) and torque oppositely and evenly, to 8 14 in lb ( N.m).

13 VALVE PLATE DETAIL GREASE APPLICATION Torque oppositely and evenly to 8 14 in lb ( N.m). Torque to 5 7 in lb ( N.m). Apply grease (121). On Model only, the center housing (1) is rotated 180 to put the air valve (2) on the opposite side of the pump. 015 Fig. 9

14 Service Repairing the Air Valve Disassembly 1. Follow the Pressure Relief Procedure Warning on page Unscrew the six mounting screws (18) and remove the air valve (2) from the pump. See Fig Remove the screw (119) and shift saddle (118). See Fig Disassemble the link assembly, consisting of the actuator link (117), spacer (120), detent link (113), spring (112), stop (111), and valve cup (110). 5. Remove the detent ball (107) and spring (109). The detent collar (108) is a press-fit and should not need removal; if it does require replacement, you should also replace the cover (106). 6. Remove the reset shaft (114), o-ring (115) and washer (116). 7. Clean all parts and inspect for wear or damage. Replace as needed. See Reassembly below. NOTE: ALL PARTS SHOWN ARE INCLUDED IN AIR VALVE KIT Apply grease (121). Torque oppositely and evenly to 8 14 in lb ( N.m) Fig Reassembly 1. If the detent collar (108) was removed, install a new collar in a new cover (106). Using a rubber mallet, carefully press fit the detent collar (108) into the cover (106). See Fig. 11. Apply grease (121). Press fit Grease the detent spring (109) and place it in the collar (108). Grease the ball (107) and set it on the spring. See Fig Apply grease (121) to the o-ring (115) and install it in the hole in the air valve cover (106), as shown in Fig. 11. Slide the washer (116) onto the blunt end of the reset screw (114). Insert the screw through the air valve cover (106) until it seats Fig

15 Service 4. Grease the spring (112). Place the link stop (111) inside the spring. 5. Grease the detent link (113) and link spacer (120). Assemble the detent link, link spacer, and actuator link (117) as shown in Fig. 12. The raised bumps on the links (113 and 117) must face up. 6. Squeeze the spring (112) and install it and the stop (111) in the link assembly. See Fig. 12. The spring tension will hold all these parts together. Grease the valve cup (110) and install it in the link assembly as shown. 7. Install the link assembly onto the air valve cover (106) so the pointed end of the reset screw (114) fits through the holes in the links and the square part of the reset screw engages the square hole in the detent link (113). Make certain the bumps on the detent link (113) engage the detent ball (107). See Fig. 12. Apply grease (121). Bumps face up. 8. Grease the inside surfaces of the shift saddle (118) and install it as shown in Fig. 13. Hold the link assembly firmly in place and install the screw (119). Torque to 8 14 in lb ( N.m). Install the o- ring (101) on the cover (106). 9. Align the air valve assembly so the reset screw (114) is at the top. Install the valve on the pump, making sure the valve saddle (118) engages the recessed area on the diaphragm shaft (22). Install the six screws (18) and torque oppositely and evenly, to 8 14 in lb ( N.m). See Fig. 9. Apply grease (121). Torque to 8 14 in lb ( N.m) Reset screw square must engage with square hole Fig Fig

16 Service Ball Check Valves (Acetal Pumps) 24 NOTE: Repair kits are available for both the PTFE and Hytrel ball check valves. Parts included in the kit are marked with a symbol, for example (41). Use all the parts in the kit for the best results. See page 26. NOTE: To ensure proper seating of the balls (46), always replace the guides (41) and seats (42) when replacing the balls. Also, replace the o-rings (45) with new ones whenever the old ones are removed. Apply thread lubricant. Flat side faces ball. Beveled end up. Torque to in lb ( N.m). Do not over-torque Follow the Pressure Relief Procedure Warning on page 11. Disconnect all hoses Remove the pump from its mounting Using a 1/2 socket wrench, remove the four bolts (24) and nuts (25) holding the top manifold () to the covers (39). Lift the top manifold off the pump. Remove the outer o-ring (45), ball guide (41), ball (46), seat (42), and inner o-ring (45) from each of the covers. See Fig Turn the pump over and remove the bolts (24), nuts (25), feet (23) and lower manifold (). 5. Remove the outer o-ring (45), seat (42), ball (46), ball guide (41), and inner o-ring (45) from each of the covers (39). 6. Clean all parts and inspect for wear or damage. Replace parts as needed Reassemble in the reverse order, following all notes in Fig. 14. Be sure the ball checks are assembled exactly as shown. 23 CAUTION Do not over-torque the manifold bolts (24). Doing so may cause the nuts (25) to spin in their housings, damaging the cover (39). Fig

17 Service Ball Check Valves (Polypropylene Pumps) 25 NOTE: Repair kits are available for both the PTFE and Hytrel ball check valves. Parts included in the kit are marked with a symbol, for example (41). Use all the parts in the kit for the best results. See page NOTE: To ensure proper seating of the balls (46), always replace the guides (41) and seats (42) when replacing the balls. Also, replace the o-rings (45) with new ones whenever the old ones are removed Follow the Pressure Relief Procedure Warning on page 11. Disconnect all hoses. Apply thread lubricant. 2. Remove the pump from its mounting. Flat side faces ball. Beveled end up Using a 1/2 socket wrench, remove the four nuts (25) and washers (53) holding the top manifold () to the covers (39). Lift the top manifold off the pump. Remove the outer o-ring (45), ball guide (41), ball (46), seat (42), and inner o-ring (45) from each of the covers. See Fig. 15. Torque to in lb ( N.m). Do not over-torque. Long threads at top Turn the pump over. Pull the tie rods (54) out of the pump, leaving the four nuts (25) on the rods. Remove the feet (23) and lower manifold () Remove the outer o-ring (45), seat (42), ball (46), ball guide (41), and inner o-ring (45) from each of the covers (39). 6. Clean all parts and inspect for wear or damage. Replace parts as needed. 7. Reassemble the intake ball checks in the bottom of the pump, following all notes in Fig. 15. Be sure the ball checks are assembled exactly as shown Set the lower manifold () and feet (23) in place on the bottom of the pump Insert the long threads of each tie rod (54) through the feet and lower manifold. Push the rods up through the fluid covers (39) until the nut (25) on the end of the rods bottoms on the foot. Make sure the rods are pushed all the way through. Turn the pump upright (the rods are a slight interference fit and will hold the pump parts securely in place) Reassemble the outlet ball checks in the top of the pump, following all notes in Fig. 15. Be sure the ball checks are assembled exactly as shown. 11. Install the top manifold (), four washers (53) and four nuts (25). Torque to in lb ( N.m). Do not over-torque. Fig

18 Service Diaphragm Repair Disassembly NOTE: Diaphragm repair kits are available. See page 26. Parts included in the kit are marked with an asterisk, for example (20*). Use all the parts in the kit for the best results. 1. Follow the Pressure Relief Procedure Warning on page Unscrew the six mounting screws (18) and remove the air valve (2) from the pump. See Fig Remove the manifolds () and disassemble the ball check valves as explained on pages Always replace the o-rings (45) with new ones. 4. Using a 7/16 socket wrench, remove the clamp nuts (X) and the grounding strip (28). Loosen the clamps (26) and slip them over the housing (1). Pull the covers (39) off the pump, then remove the clamps from the housing. See the Detail in Fig Using a 1/2 socket wrench on both outer diaphragm plates (43), unscrew one plate from the diaphragm shaft (22). Remove one diaphragm (44), inner diaphragm plate (19), and o-ring (47). Pull the opposite diaphragm assembly and the diaphragm shaft out of the pump housing (1). See Fig. 16. Clamp the shaft in a vise with soft jaws and unscrew the outer plate (43), then disassemble the remaining diaphragm assembly. 6. Inspect the diaphragm shaft (22) for wear or scratches. If it is damaged, check the bearings (20) also. Replace parts as needed. To remove the bearings, place a 13/32 EZY-OUT in a vise. Position the pump housing (1) over the EZY-OUT (see Fig. 16). Turn the housing in the direction shown by the arrows to remove the bearing. 7. Hook the shaft seals (21) with an o-ring pick and pull them out of the housing (1). 8. Clean all parts and inspect for wear or damage. Replace parts as needed. Reassembly 1. Install the shaft seals (21*) so the lips face into the housing (1). Using a rubber mallet, carefully drive the bearings (20*) flush into the housing so the holes face out. See Fig Grease the diaphragm shaft (22) and slide it into the housing (1). Install the o-rings (47*) in the grooves of the housing. 3. Assemble the inner diaphragm plates (19), diaphragms (44*), and outer diaphragm plates (43) as shown in Fig. 16. Torque the outer diaphragm plates to in lb ( N.m), using a 1/2 socket wrench. Do not over-torque. These parts must be assembled correctly. CAUTION Do not over-torque the outer diaphragm plates (43). Doing so will damage the hex heads. 4. When installing the covers (39), slip the clamps (26) over the housing (1) before positioning the covers. See the Detail in Fig. 16. Engage the notches in the covers with the locator tabs on the housing, then position the clamps over both parts. The clamp bolts should be on the air valve side of the housing, and pointing down toward the bottom of the pump. Install the grounding strip on the bolts. Apply thread lubricant to the bolts, then install the clamp nuts (X). Using a 7/16 socket wrench, torque the nuts to in lb ( N.m). 5. Reassemble the ball check valves and manifolds as explained on pages Always install new o-rings (45*). 6. Reinstall the air valve (2), using the six mounting screws (18). See Fig. 9.

19 Grease shaft. Apply thread lubricant. 24 Flat side faces ball Beveled end up. Lips face into housing. Round side must face toward diaphragm. Torque to in lb ( N.m). Torque to in lb ( N.m). Do not over-torque. * Notches must engage tabs *47 * X * DETAIL OF CLAMPS AND COVERS 47* 1 43 Model Shown FLUID SIDE AIR SIDE 21* * * *44 20* /32 IN. EZY-OUT CUTAWAY VIEW OF DIAPHRAGM ASSEMBLIES IN PUMP HOUSING DETAIL OF BEARING REMOVAL USING EZY-OUT Fig. 16

20 Parts Part No , Series A Air Valve Assembly Ref Part No. No. Description Qty O-RING; buna-n SCREW, pan hd, thread-forming; 4 20 size; in. (9.5 mm) long; see pages SEAL, plate, valve; buna-n; see pages PLATE, valve; stainless steel; see pages BEARING, link; acetal; see pages COVER, valve; polypropylene BALL, detent; tungsten carbide COLLAR, detent; stainless steel SPRING, compression; stainless steel 1 Ref Part No. No. Description Qty CUP, valve; acetal STOP, link; acetal SPRING, compression; stainless steel LINK, detent; stainless steel SHAFT, reset; stainless steel O-RING; buna-n WASHER, plain; stainless steel LINK, actuator; stainless steel SADDLE, shift; acetal SCREW, pan hd, thread-forming; size; 0.75 in. (19 mm) long SPACER, link; acetal GREASE, general purpose; oz (10.5 g); (not shown)

21 Model , Series A Acetal Pump with PTFE Diaphragm Parts Model , Series A Acetal Pump with PTFE Diaphragm (center housing is rotated 180) * 20* Ref Part No. No. Description Qty HOUSING, pump; polypropylene AIR VALVE KIT; Includes items; See parts list on page SCREW, pan hd, thread-forming; size; 0.75 in. (19 mm) long; stainless steel PLATE, diaphragm; stainless steel 2 20* BEARING; acetal 2 21* PACKING, u-cup; buna-n SHAFT, diaphragm; stainless steel FEET, pump; stainless steel BOLT, machine, hex washer hd; 5/16 18 unc 2a; 2.25 in. (57 mm) long NUT, hex; 5/16 unc 2b; zinc-plated stainless steel CLAMP; stainless steel MUFFLER; bronze, plated carbon steel STRIP, grounding; stainless steel NUT, hex; unc 2a; silver plated stainless steel SCREW, pan hd; unc 2a; 0.31 in. (8 mm) long LOCKWASHER, int tooth; no LABEL, warning COVER; acetal, w/stainless steel fibers MANIFOLD, pump; acetal with stainless steel ferrule GUIDE, ball; acetal SEAT, ball; acetal PLATE, diaphragm; acetal 2 44* DIAPHRAGM; PTFE 2 45* O-RING; PTFE BALL; in. (16 mm) dia.; PTFE 4 47* O-RING; buna-n 2 19 * * Included in PTFE Diaphragm Repair Kit , which may be purchased separately. See page * 43 On Model only, the center housing (1) is rotated 180 to put the air inlet and air exhaust port on the same side as the grounding strip (28). Included in Air Valve Kit , which may be purchased separately. See parts list on page 21. Included in PTFE Ball Repair Kit , which may be purchased separately. See page 26. Replacement Danger and Warning labels, tags and cards are available at no cost. 45* * Use only GENUINE GRACO PARTS AND ACCESSORIES * * 24 23

22 Model , Series A Acetal Pump with Hytrel Diaphragm 1 Parts * 20* Ref Part No. No. Description Qty HOUSING, pump; polypropylene AIR VALVE KIT; Includes items; See parts list on page SCREW, pan hd, thread-forming; size; 0.75 in. (19 mm) long; stainless steel PLATE, diaphragm; stainless steel 2 20* BEARING; acetal 2 21* PACKING, u-cup; buna-n SHAFT, diaphragm; stainless steel FEET, pump; stainless steel BOLT, machine, hex washer hd, 5/16 18 unc 2a; 2.25 in. (57 mm) long NUT, hex; 5/16 unc 2b; zinc-plated stainless steel CLAMP; stainless steel MUFFLER; bronze, plated carbon steel STRIP, grounding; stainless steel NUT, hex; unc 2a; silver plated stainless steel SCREW, pan hd; unc 2a; 0.31 in. (8 mm) long LOCKWASHER, int tooth; no LABEL, warning COVER; acetal, w/stainless steel fibers MANIFOLD, pump; acetal with stainless steel ferrule GUIDE, ball; acetal SEAT, ball; acetal PLATE, diaphragm; acetal 2 44* DIAPHRAGM; Hytrel 2 45* O-RING; PTFE BALL; in. (16 mm) dia.; Hytrel 4 47* O-RING; buna-n * * Included in Hytrel Diaphragm Repair Kit , which may be purchased separately. See page * 43 Included in Air Valve Kit , which may be purchased separately. See parts list on page 21. Included in Hytrel Ball Repair Kit , which may be purchased separately. See page 26. Replacement Danger and Warning labels, tags and cards are available at no cost Use only GENUINE GRACO PARTS AND ACCESSORIES * * * * 23

23 Parts Model , Series A Polypropylene Pump with PTFE Diaphragm * 43 45* * 20* 2 Ref Part No. No. Description Qty HOUSING, pump; polypropylene AIR VALVE KIT; Includes items See parts list on page SCREW, pan hd, thread-forming; size; 0.75 in. (19 mm) long; stainless steel PLATE, diaphragm; stainless steel 2 20* BEARING; acetal 2 21* PACKING, u-cup; buna-n SHAFT, diaphragm; stainless steel FEET, pump; stainless steel NUT, hex; 5/16 unc 2b; zinc-plated stainless steel CLAMP; stainless steel MUFFLER; bronze, plated carbon steel STRIP, grounding; stainless steel NUT, hex; unc 2a; silver plated stainless steel SCREW, pan hd; unc 2a; 0.31 in. (8 mm) long LOCKWASHER, int tooth; no LABEL, warning COVER; polypropylene MANIFOLD, pump; polypropylene with stainless steel ferrule GUIDE, ball; polypropylene SEAT, ball; polypropylene PLATE, diaphragm; polypropylene 2 44* DIAPHRAGM; PTFE 2 45* O-RING; PTFE BALL; in. (16 mm) dia.; PTFE 4 47* O-RING; buna-n WASHER, flat; M8; stainless steel ROD, tie; 5/16 18; stainless steel 4 19 * * Included in PTFE Diaphragm Repair Kit , which may be purchased separately. See page Included in Air Valve Kit , which may be purchased separately. See parts list on page 21. Included in PTFE Ball Repair Kit , which may be purchased separately. See page 26. Replacement Danger and Warning labels, tags and cards are available at no cost * Use only GENUINE GRACO PARTS AND ACCESSORIES * * 25 23

24 Parts Model , Series A Polypropylene Pump with Hytrel Diaphragm * 43 45* * 20* 2 Ref Part No. No. Description Qty HOUSING, pump; polypropylene AIR VALVE KIT; Includes items; See parts list on page SCREW, pan hd, thread-forming; size; 0.75 in. (19 mm) long; stainless steel PLATE, diaphragm; stainless steel 2 20* BEARING; acetal 2 21* PACKING, u-cup; buna-n SHAFT, diaphragm; stainless steel FEET, pump; stainless steel NUT, hex; 5/16 unc 2b; zinc-plated stainless steel CLAMP; stainless steel MUFFLER; bronze, plated carbon steel STRIP, grounding; stainless steel NUT, hex; unc 2a; silver plated stainless steel SCREW, pan hd; unc 2a; 0.31 in. (8 mm) long LOCKWASHER, int tooth; no LABEL, warning COVER; polypropylene MANIFOLD, pump; polypropylene with stainless steel ferrule GUIDE, ball; polypropylene SEAT, ball; polypropylene PLATE, diaphragm; polypropylene DIAPHRAGM; Hytrel 2 45* O-RING; PTFE BALL; in. (16 mm) dia.; Hytrel 4 47* O-RING; buna-n WASHER, flat; M8; stainless steel ROD, tie; 5/16 18; stainless steel 4 19 * * Included in Hytrel Diaphragm Repair Kit , which may be purchased separately. See page Included in Air Valve Kit , which may be purchased separately. See parts list on page 21. Included in Hytrel Ball Repair Kit , which may be purchased separately. See page 26. Replacement Danger and Warning labels, tags and cards are available at no cost * Use only GENUINE GRACO PARTS AND ACCESSORIES * * 25 23

25 Repair Kits Use Only Genuine Graco Parts and Accessories The Ref. No. shown in the kits below correspond to the reference numbers used in the parts lists on pages For the best results, use all the parts in the kit, even if the old parts still look good. Air Valve Kit Replaces the entire air valve assembly. For all pump models. See page 21 for parts list. PTFE Diaphragm Kit For Model , , and Pumps. Includes: Ref No. Part No. Description Qty BEARING; acetal U-CUP; buna-n DIAPHRAGM, pump; PTFE O-RING; PTFE O-RING; buna-n 2 Hytrel Diaphragm Kit For Model and Pumps. Includes: Ref No. Part No. Description Qty BEARING; acetal U-CUP; buna-n DIAPHRAGM, pump; Hytrel O-RING; PTFE O-RING; buna-n 2 PTFE Ball Repair Kit For Model and Acetal Pumps. Includes: Ref No. Part No. Description Qty GUIDE, ball; acetal SEAT, ball; acetal O-RING; PTFE BALL; PTFE 4 Hytrel Ball Repair Kit For Model Acetal Pump. Includes: Ref No. Part No. Description Qty GUIDE, ball; acetal SEAT, ball; acetal O-RING; PTFE BALL; Hytrel 4 PTFE Ball Repair Kit For Model Polypropylene Pump. Includes: Ref No. Part No. Description Qty GUIDE, ball; polypropylene SEAT, ball; polypropylene O-RING; PTFE BALL; PTFE 4 Hytrel Ball Repair Kit For Model Polypropylene Pump. Includes: Ref No. Part No. Description Qty GUIDE, ball; polypropylene SEAT, ball; polypropylene O-RING; PTFE BALL; Hytrel 4 Manual Change Summary Assembly Changed & Pumps Part Status Deleted New New Ref No Part No Name Bolt Washer (qty 4) Tie Rod (qty 4) NEW MODEL: Model Acetal Pump is added to the manual. This pump has a PTFE diaphragm and is identical to Model , except that the center housing is rotated 180, placing the air valve on the opposite side of the pump from the grounding strip. TORQUE CHANGE: The torque value for the air valve screws (18, 119) has changed to 8 14 in lb ( N.m).

26 Accessories Use Only Genuine Graco Parts and Accessories Grounding Wire and Clamp ft (7.6 m) long, 1.5 mm (12 ga.) Groundable Air Hose psi (21 bar) Maximum Working Pressure 10 ft (3 m) long, 1/2 in. (13 mm) ID, coupled 1/2 npt(m) x 1/4 npt(m). Groundable Fluid Hoses 5000 psi (345 bar) Maximum Working Pressure For use with flammable fluids. Nylon core, urethane cover. 3/8 in. (10 mm) ID, 3/8 npt(mbe). Bleed-Type Master Air Valve psi (21 bar) Maximum Working Pressure Relieves air trapped in the air line between the pump air inlet and this valve when it is closed. 1/4 npt(f) inlet and outlet. Air Line Quick Disconnect Coupler Coupler 1/4 npt(f) Fitting 1/4 npt(m) ft (1.52 m) long ft (7.6 m) long Fluid Hoses 300 psi (21 bar) Maximum Working Pressure Not for use with flammable fluids. Nylon core, synthetic rubber cover. 3/8 in. (10 mm) ID, 3/8 npt(fbe) ft (0.9 m) long ft (1.8 m) long ft (3.1 m) long ft (7.6 m) long ft (15.2 m) long Air Regulator and Gauge psi (21 bar) Maximum Working Pressure psi (0 11 bar) Adjustment Range Includes Gauge; psi (0 14 bar). 1/4 npt(f) inlet and outlet. Fluid Regulation Kit psi (17.5 bar) Maximum Working Pressure psi ( bar) Regulated Pressure Range Includes stainless steel regulator with PTFE diaphragm, gauge, and fittings. Instructions included. 3/8 npsm(f) inlet, 3/8 npt(f) outlet. Air Control Needle Valve psi (21 bar) Maximum Working Pressure 1/4 npt(m) inlet x 1/4 npt(f) outlet. Air Line Filter psi (21 bar) Maximum Working Pressure Reusable 20 micron filter and drain cock. 1/4 npt(f) inlet and outlet. Air Spray Hose and Gun Kits 200 psi (14 bar) Maximum Working Pressure Kits include Model 700 air spray gun, 25 ft (7.6 m) buna-n air hose with 1/4 npt(f) couplings, and 26 ft (7.9 m) nylon fluid hose with 3/8 npt(f) couplings Carbon Steel Stainless Steel Fluid Drain Valve 500 psi (35 bar) Maximum Working Pressure Use at fluid outlet to help relieve pressure Stainless steel and PTFE 3/8 npt(m x f) Steel and PTFE 3/8 npt(m x f) HVLP Hose and Gun Kit psi (7 bar) Maximum Working Pressure Kit includes Model 1265 HVLP spray gun, 25 ft (7.6 m) buna-n air hose with 1/4 npt(f) couplings, and 26 ft (7.9 m) nylon fluid hose with 3/8 npt(f) couplings.