Graco 307909B The Glutton Pump Conversion Kits Users Manual
2015-04-02
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Instructions – Parts List Parts The Glutton Pump Conversion Kits Air Valve Conversion Kit 222054 For Pump Models 218061, 218062, 218185 & 218079 Pilot Valve Conversion Kit 221152 For Pump Models 218060, 218061, 218062, 231019, 218185 & 218079 Table of Contents Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Read warnings and instructions. GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441 Copyright 1988, Graco Inc. is registered to I.S. EN ISO 9001 307909B Installation Pressure Relief Procedure WARNING 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: D D D D are instructed to relieve the pressure, stop spraying, check or service any of the system equipment, or install or clean the spray tips. 1. Engage the spray gun or dispensing valve safety latch.* 2 307909 2. Disengage the gun or dispensing valve safety latch.* 3. Hold a metal part of the gun or valve firmly to a grounded metal waste container and trigger it to relieve the fluid pressure.* 4. Engage the safety latch again.* 5. Open the pump drain valve (required in system), having a container ready to catch the drainage. 6. Leave the drain valve open until you are ready to spray again. *Applies only when using a spray gun or dispensing valve. 7. 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 hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip, nozzle, or hose obstruction. Installation Installing the Air Valve Conversion Kit 222054 1. Follow the Pressure Relief Procedure. 2. Assemble kit as shown in Fig. 1. 3. Remove mufflers and lock rings from old air valve and install them on new air valve. Fig. 1. 2 2 6 5 3 Lubricate (part of item 1) Lubricate 2 4 2 Torque to 27–45 in/lb (3–5 N.m) 1 Fig. 1 Installing the Pilot Valve Conversion Kit 221152 1. Follow the Pressure Relief Procedure. 2. Assemble kit as shown in Fig. 2. 5 2 7 Apply sealant to threads 2 6 1 3 Press fit using 40–60 lbs force 4 5 Apply sealant 4 Apply sealant Fig. 2 1 307909 3 Repair Repairing the Air Control Valve NOTE: An Air Valve and Pilot Valve Repair Kit is available, page 5. Parts included in the kit are marked with an asterisk, for example, (106*). Use all the parts in the kit for the best results. Disassembly 1. Follow the Pressure Relief Procedure on page 2. 2. Cut a small slit in the tube ends and disconnect them from the pilot valve fittings, air valve tees (113), and barb fittings (117). 3. Remove the valve end housings (102) by unscrewing the screws (111) and nuts (112). Refer to the Parts Drawing on page 8. 4. Center the valve spools (103) in the housing (101). Remove the spools and stem (104) by applying opposing force with wrenches on the spool (103) flats. 5. If the air filter (115) needs cleaning or replacement, unscrew the filter housing (116) 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 (2.1 bar)]. Press fit the filter into the housing, using 40–60 lbs. of force. Apply sealant to the filter housing threads and screw it into the center housing (101). Assembly 1. Apply lithium base grease to all o–rings, u–cups, gaskets and to the complete spool assembly before installing them. 2. Remove the seal retainers (105) from each side of the center housing (101). Replace the u–cup (110*), with the lips facing into the housing. Install the retainers with the flat side facing into the housing. 4 307909 3. Replace the spools (103) if damaged. Replace the o–ring (108*) and u–cup (109*) on each spool, being sure to seat them in the grooves. Install the u–cup with the lips facing towards the housing (101). 4. Apply medium strength thread sealant to the spool stem (104) threads. Remove the excess sealant. CAUTION Do not overtighten the spools (103) as this can shear the spool threads. 5. Thread one spool (103) onto the stem (104) and insert it into the center housing (101); be careful not to dislodge the u–cups (110) and retainers (105). Thread the other spool onto the stem. With wrenches on the flats of the spools, apply opposing force and tighten until snug; 7–13 in–lb (0.79–1.47 N.m). 6. Replace the gasket (106*) in each end housing (102) and the o–ring (107*) on each end housing shoulder. 7. Install the end housings (102) onto the center housing (101); be careful not to move the spool and dislodge the u–cups (110) and retainers (105). Secure the end housings with the four screws (111) and nuts (112), torquing them to 27–45 in–lb (3–5 N.m). CAUTION If the mufflers are replaced, they must be installed with the lock rings to avoid damage to the spool and o–rings during operation. 8. Replace the two o–rings (108*) in the center housing (101). 9. Install the air valve on the pump and connect the tubing as shown in Fig. 1. Repair Repairing the Pilot Valve NOTE: An Air Valve and Pilot Valve Repair Kit is available. See the back cover to order. Parts included in the kit are marked with an asterisk, for example, (210*). Use all the parts in the kit for the best results. Disassembly 1. Follow the Pressure Relief Procedure on page 2. 2. Unscrew the valve cap (203) from each of the valve housings (204) and remove the parts. Clean and inspect the parts for damage. Refer to the Parts Drawing on page 9. 3. To replace the rod seal (210*): a. Cut a small slit in the tube ends and disconnect them from the pilot valve fittings (208) and air valve tees. b. Unscrew the cap screws and remove the pilot valve housings (204). Grease the rod seals (210*) and install one on each side of the pump. 2. Install the o–ring (205), being sure to completely seat it on the flat in the valve housing (204). Install the long end of the valve stem (201) into the housing. 3. Install the small spring (207) over the valve stem (201), the air valve (202) over the spring, and the larger spring over the air valve. 4. With the copper gasket (209*) in place on the valve cap (203), screw the cap onto each of the valve housings (204). Torque the cap to 7.4–12.5 ft–lb (10–17 N.m). Repair Kit Air Valve and Pilot Valve Repair Kit 220656 Includes: Ref No. Secure the pilot valve housings (204) to the pump with the cap screws. 106 107 108 109 110 114 d. Connect the tubing to the pilot valve fittings (208) and air valve tees as shown in Fig. 2. 205 209 210 c. Assembly 1. Apply lithium base grease to the inside and outside of the air valve (202) and to the o–rings and seals. Part No. Description Qty 181464 GASKET, polyurethane 110782 O–RING, buna–n 107186 O–RING, buna–n 108781 U–CUP, polyurethane 108782 U–CUP, polyurethane 179861 TUBE, polyurethane, 0.25” OD; 6 in. 159589 O–RING, buna–n 156766 GASKET, copper 107161 SEAL, pilot valve rod, buna–n 183384 TUBE, polyurethane, 0.25” OD; 9.5 in. 108754 SEALANT, anerobic, medium strength, 0.5 cc tube 307909 2 2 4 2 2 3 2 2 2 1 1 5 Parts NOTE: This air valve can be used with the pump’s existing pilot valves. Connect the tubes as shown. 2 2 6 3 5 Lubricate (part of item 1) Lubricate 2 4 2 Torque to 27–45 in/lb (3–5 N.m) 1 Air Valve Conversion Kit 222054 For Pump Models 218061, 218062, 218185 & 218079 Includes items 1 to 6 REF NO. PART NO. DESCRIPTION 1 220902 2 3 054138 104092 4 101888 AIR VALVE ASSY. See pages 4 & 5 for parts & service instructions 1 TUBE, nylon 48 in. SCREW, cap, sch; 10–24 x 0.625 4 SCREW, cap, sch 10–24 x 0.875 4 6 307909 QTY REF NO. PART NO. DESCRIPTION 5 6 107186 183745 O–RING, buna–n PLATE, adapter QTY 2 1 Parts 5 2 7 Apply sealant to threads 2 6 1 3 Press fit using 40–60 lbs force 4 5 Apply sealant 4 Apply sealant 1 Pilot Valve Conversion Kit 221152 For Pump Models 218060, 218061, 218062, 231019, 218185 & 218079 Includes items 1 to 7 REF NO. PART NO. DESCRIPTION 1 221133 2 3 108383 159840 PILOT VALVE ASSY. See pages 6 & 7 for parts & service instructions FITTING, seal, o–ring BUSHING; 1/4–18 npt(f) x 1/8–27 npt(m) QTY 2 2 REF NO. PART NO. DESCRIPTION 4 5 6 7 107191 054138 160736 183620 TEE, barbed TUBE, polyurethane FILTER, air HOUSING, filter, air QTY 2 48 in. 1 1 1 307909 7 Parts Air Control Valve 220902 Includes items 101 to 117 116 Apply sealant to threads 117 114* 112 115 108* Press fit Lubricate Apply medium strength sealant to threads. Torque to 7–13 in/lb (0.79–1.47 N.m) 101 *110 105 Torque to 27–45 in/lb (3–5 N.m) 104 111 *109 Lubricate 103 *108 Lubricate *106 Lubricate *107 Lubricate 102 Lubricate 113 Apply sealant Air Control Valve 220902 Includes items 101 to 117 REF NO. PART NO. DESCRIPTION 101 102 103 104 105 106* 107* 108* 109* 110* 183370 183369 183368 183367 183366 181464 110782 107186 108781 108782 HOUSING, valve center HOUSING, valve end SPOOL, differential STEM, spool RETAINER, seal GASKET, polyurethane O–RING, buna–n O–RING, buna–n U–CUP, polyurethane U–CUP, polyurethane QTY 1 2 2 1 2 2 2 4 2 2 REF NO. PART NO. DESCRIPTION 111 108780 SCREW, cap, hex hd; M5 x 0.8 x 150 NUT, full hex; 10–24 UNC–2A TEE, barbed TUBE, polyurethane; 0.25” (6.35 mm) O.D. FILTER, air HOUSING, air filter FITTING, barbed, with buna–n o–ring 112 100179 113 107191 114* 179861 115 116 117 160736 183620 108383 *Included in Repair Kit 220656 on page 5 8 307909 QTY 4 4 2 2 1 1 2 Parts Pilot Valve 221133 Includes items 201 to 210 210* 204 Lubricate 205* Lubricate 201 207 202 Lubricate ID & OD 208 Torque to 27–45 in/lb (3–5 N.m) 206 209* 203 Torque to 7.4–12.5 ft/lb (10–17 N.m) Pilot Valve 221133 Includes items 201 to 210 REF NO. PART NO. DESCRIPTION 201 202 203 204 205* 206 183604 183603 183605 183606 159589 108961 STEM, valve VALVE, air CAP, valve HOUSING, valve O–RING, buna–n SPRING, compression QTY 1 1 1 1 1 1 REF NO. PART NO. DESCRIPTION 207 208 108960 108383 SPRING, compression FITTING, barbed, buna–n o–ring seal;10–32 UNF–2A GASKET, copper SEAL, pilot valve rod, buna–n 209* 156766 210* 107161 QTY *Included in Repair Kit 220656 on page 5. 307909 9 1 1 1 1 Graco Standard Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées. Graco Information TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers to identify the distributor closest to you: 1–800–367–4023 Toll Free 612–623–6921 612–378–3505 Fax All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. Sales Offices: Minneapolis, Detroit International Offices: Belgium, Korea, Hong Kong, Japan www.graco.com PRINTED IN USA 307909 04/1988, Revised 08/2002 10 307909
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