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  • 1. Thank you for selecting Ground Force Manufacturing, L.L.C. as yoursupplier of mining and construction support equipment. Our business is based on providing quality equipment and the service tosupport it. Our Parts Department in Post Falls is stocked with the commonlyused parts on your machinery and will be glad to assist you in any way toprovide replacement parts when they are needed, as quickly as you needthem. In addition, trained field mechanics are available to assist your in-houseservice personnel should the need arise. If you have any questions or if we can be of assistance at any time,please don’t hesitate to call us at (208) 664-9291. We look forward to a long and mutually rewarding association. Sincerely, Ground Force Manufacturing Documentation DepartmentPlease refer to the following information when calling about service or parts:UNIT SERIAL NUMBERS: 145-04-001 / 145-04-002Delivery Date: January 2005Original Customer: Borusan Makina Kazakhstan
  • 2. Operation, Service & Parts Manual FUEL / LUBE TRUCKS Borusan Makina Kazakhstan - Serial # 145-04-001 / 145-04-002© Copyright 2005, by Ground Force Mfg., L.L.C. All rights reserved. Nopart of this manual may be reproduced in any form or by any means(including electronic storage and retrieval or translation into a foreignlanguage) without prior agreement and written consent from Ground ForceMfg. as governed by United States and International copyright laws. Ground Force Mfg., L.L.C. E. 5650 Seltice Way Post Falls, Idaho 83854 (208) 664-9291Printing History: First Edition - July, 2001 Second Edition - November, 2002 Third Edition – February, 2005
  • 3. ContentsPart One: GENERALPart Two: OPERATIONPart Three: MAINTENANCE / TROUBLE SHOOTINGPart Four: HYDRAULICS / PNEUMATICS / ELECTRICALPart Five: PARTS
  • 4. 1. GENERAL
  • 5. G3 General defects arising from the selection of materials or theINTRODUCTION processes of manufacture is limited to the repair ofYour lube truck was built to provide many years of such defects or to the repair or replacement (with aoperation. Durability, ease of operation and high similar item free from the defect in question) of anyspeed product delivery have been the goals in the accessory, equipment, or part which is defective indesign of the unit. any such respects. D. The extent of Ground Force Mfg.’s liabilityThis booklet will give you the basic operating under this warranty as to defects inherent ininstructions in the use of your new truck. As with design is limited to the correction at its expenseany piece of equipment, each unit will have its own of all such defects becoming apparent in theindividual operating characteristics which will become machine, accessory, equipment or partfamiliar to an operator with time. purchased here within six months or 1,000 hours of use, whichever shall first expire.Should any questions arise while you become familiar E. The warranty of Ground Force Mfg. does notwith your unit please dont hesitate to call us at cover, and Ground Force Mfg. makes noGround Force Mfg. Our goal is satisfied customers warranty with respect to:and we will do all we can to assure we meet that goal. 1. Defects not reported and defective items not returned to Ground Force Mfg. within the warranty period;LW General 2. Failure and damages due to misapplication, lack of properLIMITED WARRANTY maintenance, abuse, improperA. Ground Force Mfg. warrants that the specialty installation, or abnormal conditions of equipment it manufactures, including temperature, moisture, dirt or corrosive accessory equipment and parts manufactured matter; by Ground Force Mfg., shall be free from: 3. Failure due to operations, intentional or 1. Defects in material and workmanship otherwise, in any improper manner; furnished by Ground Force Mfg. and 4. Damage caused by components, or used in the fabrication thereof; parts, or accessories built by others or 2. Defects arising from the selection of which were not manufactured or materials or processes of manufacture; installed by Ground Force Mfg. 3. Defects in the design thereof in view of 5. Any item which has in any way been the state of the art on the date hereof. altered by anyone other than anThe foregoing warranty shall apply also to authorized representative of Ground Forceaccessories, equipment and parts manufactured to Mfg.Ground Force Mfg.’s detailed design and 6. Any item damaged in shipment orspecifications and supplied to Ground Force Mfg. by otherwise without the fault of Groundother manufacturers. Force Mfg.B. Ground Force Mfg. makes no warranty with Ground Force Mfg. shall in no way be liable for any regard to component parts not manufactured or expenses incurred by the purchaser in any attempt to fabricated by it, but agrees to assign to the repair, replace or rework any originally defective item purchaser all of its rights under any original of sale. Ground Force Mfg. shall in no way be liable manufacturers warranty covering such for any losses, costs, forfeiture or damages (including component parts, and agrees to assist the loss of profits, liabilities of the purchaser, purchaser in making such contacts with the or its customers, or third persons, and all other manufacturer of such component parts as may consequential damages), whether direct or indirect, be necessary to protect its right under the and whether or not resulting from or contributed to by warranty covering them. the default or negligence of Ground Force Mfg., itsC. In case of defects in materials or workmanship agents, employees and subcontractors, which might or defects arising from the selection of material be claimed as a result of the defect, use or failure of or processes of manufacture, such defects the item delivered. must become apparent in the machine, Except as stated, there is no warranty, express or accessory, equipment or part within six months implied, in connection with the design, manufacture, or 1,000 hours of operations, whichever shall sale or use of the machinery, accessories, equipment first expire after delivery of the machine to the and parts sold by Ground Force Mfg. Ground Force original purchaser. Mfg.’s liability on its warranty shall in no eventThe extent of Ground Force Mfg.’s liability under this exceed the cost of the item of sale.warranty as to defects in material or workmanship and
  • 6. 2. OPERATION
  • 7. PON1a Operation such as hydraulic oil tanks, gear boxes,IMPORTANT!!! compressor crankcase oil or “Lubricoolant” tanks, etc. If the unit involves oil-pumpingPRE-OPERATION NOTE equipment (such as lubrication trucks or skids),Because of strict regulations which govern the a minimal amount of product oil must be loadedoverseas shipment of equipment, any fluids or oils, into each particular tank to immerse the suctionwhich are not pertinent to or necessary for movement stand pipe. This will guarantee that when theof this unit, have most likely been removed or drained. oil product pumps are initially started, there willThis process may have been performed either at be enough oil to prevent running the pumpGround Force Mfg.s facility or prior to loading for dry.shipment. ♦ Remove stretch-wrap or shrink film fromAny and all gate valves or ball valves pertaining to equipment or assemblies. Many times if athe hydraulic oil tank have been closed to help particular component needs protection duringeliminate any interior contamination to the tank. shipment against rough handling, abrasions, or overall abusive contact, it will be protected byAny and all valves MUST BE OPENED prior to means of a wrapping compound or film. Thisoperation of this unit or severe damage to hydraulic film, either by itself or accompanied by “bubbleoil pump and hydraulic oil filters WILL occur. Gate wrap,” cardboard or wood should be removedvalves must be turned fully CCW to open and ball prior to operation, but not before the finalvalves are clearly marked on the handles as to which stage of commissioning of the equipment.position is open or closed.All other fluids and oils must be checked for proper NUB35 Operationlevels prior to operation. IMPORTANT!!! New Unit Break-InPSP1 Operation 1. Check hydraulic pump drive shaft set screws toIMPORTANT!!! be sure shipping vibration has not loosened them.POST-SHIPMENT PREPARATIONThis unit has been specially prepared to eliminate the 2. Check pump and air compressor drive shaftdetrimental effects, which occur to equipment in the coupling set screws daily until they set and noenvironment of ocean transport. There are a few longer loosen with operation.procedures that may need to be addressed prior tooperation of this unit. 3. Tighten any hydraulic fittings, which may loosen. Fittings will commonly loosen and drip♦ Remove any shipping film that has been the first few weeks of operation. applied to surfaces. This film is typically applied by means of a paint spray gun. This is 4. Check oil level on compressor daily. meant to provide protection directly on non- painted, machined surfaces such as control valves, shafts, couplings, cylinder piston rods, POC15 Operation etc. The film may be removed by simply wiping down the surface with a rag soaked with PRE-OPERATION CHECK LIST lacquer thinner or strong grade rubbing 1. Check hydraulic oil level. alcohol. 2. Check hydraulic oil tank outlet to be sure it is Because this film is very tacky and is not open. soluble with water or most oils, all surfaces must be cleaned thoroughly to prevent the 3. Check product oil tank outlets to be sure they malfunction of moving parts such as valve are open. spools. 4. Check general condition of truck.♦ Check all fluids pertaining to the operation of not only the truck chassis (if applicable), but 5. Check motor drive couplings. also the on-board system tanks or reservoirs
  • 8. 6. Check charge on fire extinguishers. Both methods of mounting incorporate an operating speed of 1400-1800 rpm engine speed. Consult the7. Be sure all operating controls are "OFF" "Operating Instructions" in section 2 of this manual before starting truck. for your particular application. ESO1c Operation8. Check compressor crankcase oil level. EMERGENCY SHUT -OFFPOC15 Operation(Continued) PRODUCT PUMPS9. Check product levels in tanks - make certain This unit is equipped with an emergency shut-off that there is enough oil or product in tank to valve which enables the operator to disengage the immerse the pump suction if tank is not in use. low volume product oil product pumps (by pushing one valve knob) but ONLY in the case of anDO NOT RUN PRODUCT PUMPS DRY!!! emergency. Such emergencies would include a low volume oil product delivery hose failing, or if equipment tank being filled was not monitored andHPU1a Operation allowed to overflow. In many cases, the emergencyENGAGING THE HYDRAULIC shut-off is easier and quicker to push than trying to figure out in a split second which product control toPUMP shut off. Keep in mind that the purpose of this valveThis unit is equipped with a variable volume hydraulic IS NOT for daily operation and MUST not be used aspump. There are two distinct methods which Ground (what some operators have, in the past, beenForce Mfg. uses to mount and couple these pumps to considering) a main On/Off control.the chassis or drive system. These two methods alsodetermine the procedure to engage the pump. WARNING!!!Direct Front MountThe first mounting method is pump installation ahead This Emergency Valve has been installed ONLY forof radiator (front mount) between the chassis frame the above mentioned reason in an EMERGENCYrails. The pump is then connected to the engine situation. This valve does not turn Off all systemscrankshaft dampener via a flexible u-joint driveline. on the unit. If used as a main shut-off during dailyThis driveline also includes a slip-spline for any operations, the potential for damage to otherextreme movement of engine due to torque. Since the pumping systems is extremely high. This damagedirect drive line connection means that the pump is will NOT be covered under warranty.turning continuously with the engine or power unit, aball valve has been installed within the pumpdischarge line to disengage the pump. By closing this This emergency shut-off system is operated with aball valve and stopping the flow of oil from the pump, single valve and needs simply to be pushed in to thethe pump will remain in a "neutral state". When "off" position IF NECESSARY. The valve is installedhydraulic pressure is needed to run systems, simply in the hose reel compartment and is clearly marked.turn on the ball valve. Operators must familiarize themselves with not only this but all controls.IMPORTANT!!!Note: At no time should this vehicle be operated at IMPORTANT!!!higher than 1500 rpm with hydraulic pump engaged. Note: This valve does not effect the diesel deliveryThe pump is designed to run with no load system or any high volume oil product delivery(disengaged) at speeds up to 2400 rpm without system. Each of these systems have their owndamage. The ball valve must be turned off while unit separate on-off controls.is being operated at these higher speeds. OPW1 OperationPTO or Direct-Couple PTOThe second mounting method consists of a P.T.O. WARNING!!!using either a drive line or a direct coupled Oil Product Pumpconfiguration to drive the pump. Typically the pump The oil product pumps on this unit utilize a selfis mounted separate from the P.T.O. on a heavy contained hydraulic control system. This system willmount which is suspended from truck frame or main automatically control the hydraulic circuit that turnsstructure of carriage. the pump/motor on and off. The system relies on a series of sensing lines and check valves to sendTo engage this system is simply to flip the P.T.O. proper signals which determine the demand of anyswitch to "Engage" position. one product delivery system.
  • 9. The most danger to these systems occurs when the 10. If so equipped, using appropriate reel controlsupply tanks are run low on product. Once the valve, pull out knob to "UNWIND" positionproduct pump looses its prime, the product line is not and pull hose from appropriate reel. (See alsoOPW1 Operation "Ground Force Hose Reel Operating(Continued) Instructions".)allowed to build pressure and will not properly signalthe hydraulic control system. Without signal, the 11. Dispense required amount of product.pump will continue to run dry and will eventually bedamaged. 12. Return hoses to reel by pushing in on the knob of the appropriate rewind control valve.At NO time should these pumps be allowed to rundry. Damage due to dry-running is typically self- 13. When dispensing of product is complete, turnevident and is not covered by warranty. Operators the appropriate pump control off.must be aware of product levels in tanks to preventthis type of damage. 14. When delivery processes are completed allow truck engine to idle. Disengage hydraulicIn the case of a product tank being inadvertently run pump.dry during oiling procedures, the “Emergency PumpShut-Off” may be utilized to turn off the dry pump. Oil Delivery SystemTank must be immediately refilled before engaging the The oil pumping systems on your new lube truck“Emergency Pump Shut-Off” again and running the utilize a self-contained hydraulic control system. Thisproduct pump. system automatically turns the pump hydraulics on and off as the truck operator opens the oil dischargeOI237 Operation nozzle. The truck operator is not required to manually turn the oil pump systems on. Once the dischargeOPERATING INSTRUCTIONS nozzle is attached to the receiving equipment, theFuel/Lube Truck operator simply needs to turn on the control valve at1. Do pre-operation checklist. the end of the delivery hose.2. Be sure all operating controls are in The oil pump delivery rates depend on whether the oil "OFF" position before starting truck. system is equipped for low volume, fixed delivery, or for high volume delivery. The high volume system3. Start truck engine and allow to idle. Make has a variable output rate with which the truck certain that parking brakes are set. operator can adjust from minimum flow to maximum flow (approx. 20-30 gpm). The delivery speed control4. Engage the hydraulic pump. Engine must run is affected by moving the pump speed control lever at approximately 1500 RPM. CW to decrease flow, CCW to increase flow. The output rate of the low volume system is a fixed rate5. If compressed air is needed, locate (not adjustable). Pump delivery can be throttled back compressor control, turn on compressor however, by partially opening the hose-end delivery and allow it to charge tank(s) fully. control valve.6. Product delivery functions may be operated from rear compartment. Grease Pumps Pull out the appropriate control valve for grease reel7. Reset product totalizer or meter. to engage either the high or low volume grease pumps. Grease hoses will be charged until the control8. Engage selected product by pulling valves are turned off (pushed in). appropriate selector valve handle out to "ON" position. Waste Oil Pump Pull out the appropriate control valve to engage theNote: Low volume oil product pumps have no waste oil pump. If so equipped, a selector valve isselector valve (see “Emergency Shut-Off Product included in the waste oil plumbing system to allowPumps” instructions). both on-loading and offloading. The selector valve is clearly marked for flow position.9. All product delivery rates on this truck have been preset to the maximum allowable, so no adjusting of pump speeds will be necessary.
  • 10. Coolant Pump gravity) until control valve is moved to anotherPull out the appropriate control valve to engage the function position.coolant pump. The coolant pump will run as long asthe control valve is in the “ON” position. This 2. Lock: this function is accomplished bycoolant system will deliver new coolant. “bumping” the control valve handle slightly from the unwind position to the “center” position. In this position, the valve will closeOI237 Operation off the flow of hydraulic fluid to the reel drive(Continued) motor and create a “lock” in the hydraulicDiesel Fuel Pump circuit, which will allow virtually no reelPull out the appropriate control valve to engage the movement.diesel pump. The pump will run as long as the controlvalve is in the “ON” position. DO NOT let this pump This position may also be used after rewinding byrun continually!! Run the pump only as long as simply allowing control valve handle/spool to returndelivery is required. Damage to pump may occur if to the center (lock) position.allowed to run indefinitely. 3. Rewind: this function is accomplished by using the control valve handle to the fully “in” CAUTION!!! position. This is a spring loaded valve position which when released will return to the Any time the pump control valves are pulled out, “lock” position. In the “rewind” position, the the product hoses will be pressurized. DO NOT hydraulic valve controls the powered rewind open the discharge nozzle or valve unless you are function of the reel. The hydraulic fluid which ready to have product pumped out!!! drives the reel motor is regulated both in pressure and flow. Even though this function is regulated, during this function the operator must maintain a moderate tension on the product hose (by physically holding the hose)OI164 Operation to eliminate the “freewheeling” effect that willOPERATING INSTRUCTIONS occur if hose is left unattended.Ground Force Hose Reels “Freewheeling” can cause serious personalThis unit is equipped with Ground Force hydraulically injury and/or equipment damage if notcontrolled product hose reels. Each hydraulic control monitored. Damage encountered because offor these reels consist of one single spool directional this freewheeling is considered misuse and iscontrol valve and one hydraulic drive motor which not covered by warranty.also acts as the live center for the drum (sheave) ofthe reel. When the rewinding procedure is completed, simply release the valve handle, allowing valve to return toThe control valve has three positions being: 1) the “lock” position.unwind, 2) lock, and 3) rewind. Each of these threepositions will determine the function of the reel. Hose Reels Each of the Ground Force hydraulic rewind reelsNote: The hydraulic systems on Ground Force includes the use of a specific size and type of hose,equipment are typically of the load sensing type and which has been installed to accommodate the typein order for proper operation of the reel controls, one and flow requirements of that particular productor more product delivery functions may need to be delivery system. Many different fluid flow rates andengaged. The easiest system to accomplish this is working pressures may be present, so mixing of hosesthe diesel delivery. By engaging this system the main from one reel to another may have detrimental affects.hydraulic system will maintain its maximum pressure If servicing of reels or replacement of reel hoses isand provide more control for hose reel circuits. required, make certain that the hoses installed on reels are of original size and type.1. Unwind: this function is accomplished by pulling out on the control valve handle. When engaged in this position the reel will be allowed Hose Stops to “float” or coast so that the operator may pull Each Ground Force reel is equipped with a hose stop any desired amount of hose from the reel. to alleviate the problem of pulling the product hose Although having a slight tension, this function through the reel fair lead during rewinding does not allow hose to be held in position by procedures. This hose stop should be occasionally itself. Hose will continue to feed off of reel (by checked for tightness and positioning, and should be replaced immediately if any damage shows evident. If
  • 11. the hose stop is missing or damaged, extreme caution To Operateshould be exercised during reel use, until hose stop After initial warm-up procedures have been followed,can be replaced. the hydraulic pump must be engaged (see also “Engaging the Hydraulic Pump” section) and thePressure and Flow Regulation “compressor” switch must be turned On.The hydraulic circuits which control the functions ofthe Ground Force hose reels have incorporated relief Note: Compressor switch is sometimes accompaniedOI164 Operation by an On indicator light. If compressor indicator light(Continued) does not illuminate when switch is turned on, do notvalves and flow controls which have been factory set assume that the compressor is not functioning, checkto accommodate the needs of this particular unit. for faulty bulb.These controls must not be tampered with. Allow the compressor to run long enough to fully charge the receiver tanks (until system shuts down to CAUTION!!! “standby” mode). Air system is now ready for use. Severe damage to equipment and/or personal injury Drain tank condensation with each use (see below). could result if relief valves and flow controls are readjusted by anyone other than a qualified IMPORTANT!!! Ground Force technician. This damage will not be covered as a part of the warranty. SAFETY NOTE!!!OI87d Operation Do not assume that the compressor is turned offOPERATING INSTRUCTIONS simply because it is not running. This system will intermittently start and stop without warning.Air Compressor Keep hands and loose clothing clear of all movingThis truck is equipped with an on-board hydraulic- parts and make certain that all guards and shieldsdrive air compressor. This compressor develops an are properly in place at all times.air supply which may be used to fill tires, drive airtools and remote pumps or motors, etc. Included withthis air compressor is one or more receiver tanks, an After use of compressor is complete, turn off“F.R.L.” package (explained later), and a supply of ½” “compressor” switch (located either in truck cab or ator ¾” I.D. hose which is loaded on a hose reel. control console). This system should never be left “on” while not in use. During any “Down-Time” ofThe loading of this compressed air supply is an “on- this truck (whether it be for a short period, shiftdemand” system. Once the “compressor” switch change, or for prolonged service or maintenance) the(located either in truck cab or rear control panel) is air compressor as well as all system controls shouldturned on, the hydraulic system will drive the be in the “Off” position. Any functions left in “On”compressor which will run until a pre-set air pressure position could cause potential dangers whenis reached, and then the system will shut down hydraulic system or air system is re-engaged.leaving the compressor in a “standby” mode. Thecompressor will then stay idle until additional air is Air Tank Drainneeded to replenish the supply, or until the Most air receiver tanks for these air systems are“compressor” switch is turned off. equipped with a drain valve for bleeding residual condensation. This valve should be opened dailyF.R.L. (Optional) and should be considered part of the normalInstalled within the airline system is a “filter-regulator- maintenance for this unit.lubricator” assembly. This assembly is used to filterand trap airline contaminants, regulate the airlinepressure, and automatically lubricate the dischargeline air.The filter must be cleaned and drained on a regularbasis and the lubricator kept relatively full with a highquality, moisture repelling air system lubricant. Donot allow lubricator to run dry.
  • 12. 3. MAINTENANCE / TROUBLE SHOOTING
  • 13. M16 MaintenanceINTRODUCTIONYour lube truck was constructed with care and withquality materials. Simple routine maintenance willassure that it will continue to operate with minimalproblems. This section of this manual will help youestablish a routine maintenance schedule and willdetail components which may need service at sometime.Note: This section of the manual has the suggestedschedule of maintenance operations for your newtruck body. Some or all of the schedules will apply toyour individual truck. These schedules are intendedas a guideline only. As long as attention is paid tolubrication and maintenance a minimum of times asrecommended, your own mine maintenance schedulecan supersede the recommended schedule.SP1 MaintenanceSAFETY PROCEDURES1. THINK!!2. Use EXTREME CAUTION when working on or servicing any machinery.3. Before doing any work on equipment, follow three easy steps: A. Lock It Out B. Tag It Out C. Put The Keys In Your Pocket4. Before starting equipment after servicing, check to see that all personnel are clear. When you are positive all are clear, check again!HS11 MaintenanceHYDRAULIC SYSTEMInspectionInspect your truck daily for worn hoses or loosefittings. When hoses appear worn (especially if wirewrappings are showing through), replace the hosebefore a failure occurs. Tighten any loose fittings.Note: When equipment is new, leaks will frequentlyoccur. This is normal and will cease after the unit hasbeen in operation for a while when fittings aretightened and seated.
  • 14. Hint: When re-sealing pipe thread fittings, use $30 filter is an inexpensive preventative maintenanceanaerobic hydraulic thread sealant (Felpro #51452). for a $6,000.00 hydraulic system.Do not use Teflon tape (its use voids somecomponent manufacturers warranties). Suction Filter This filter is included to capture any large particlesGeneral Fitting Sizes: which may get into the oil reservoir. This filter is theo 1/4" hose - JIC #4 (37o) screw-on canister filter which is plumbed to the hydraulic oil tank in the suction oil line.o 3/8" hose - JIC #8 (37o)o 1/2" hose - JIC #10 (37o) CAUTION!!!o 3/4" hose - JIC #12 (37o) Your hydraulic reservoir is equipped with a pressure holding vent cap. This pressurizes theo 1" hose - JIC #16 (37o) reservoir to approximately 3 psi to assure adequate oil feed to the hydraulic pump. DO NOT replaceHydraulic Oil this cap with a non-pressurized model!!!Your new truck has been shipped without hydraulicoil. Utilize preferably a premium grade AW46hydraulic oil.Return Oil FilterThese filters are the screw-on canister filters whichare plumbed to the hydraulic oil tank in the return oilline. Ground Force replacement filters MUST be usedto maintain the factory warranty.We recommend changing the hydraulic system returnoil filters monthly if your truck is used frequently. AMS60 Maintenance MAINTENANCE SCHEDULE DESCRIPTION DAILY WEEKLY MONTHLY ANNUALLY Lubricate reel fair lead rollers X Lubricate hydraulic valves and actuators X Change hydraulic oil X Change hydraulic oil filter X Clean in-tank suction strainer (with oil change) X Check hydraulic oil level X Check chassis motor oil X Check hydraulic control valves X Check hydraulic hoses and fittings X Check drive couplings and inserts X Check body mounting bolts X Check hydraulic pump driveshaft bolts/coupling X set screws
  • 15. Check hydraulic pump mount bolts XCheck compressor crankcase oil level XCheck compressor drive couplings XChange compressor crankcase oil See Compressor “Maintenance Schedule”Clean compressor air filter element See Compressor “Maintenance Schedule”FRL package - drain condensation fromfilter/separator - add lubricant oil to lubricator asneeded XClean coolant suction strainer (if applicable) XReplace diesel fuel filters (if applicable) XDrain condensation from air receiver tanks X
  • 16. TSG10 Trouble Shooting system, simple tests will narrow down potentialINTRODUCTION problems.Periodically some problem may occur with your lube Test instruments which are needed to diagnose yourtruck. Most problems are minor and can be easily truck are:solved. This section of this manual is provided tohelp you in diagnosing and solving problems you o High pressure and flow test meter.may encounter. o Digital electronic multi-meter (Must be digitalNote: Before replacing any major components, isolate with 0-10 amp DC current range).the problem! As with any hydraulic or electricalTS11a Trouble Shooting TROUBLE SHOOTING GUIDE PROBLEM PROBABLE CAUSE ITEMS TO CHECK Hydraulic system PTO not engaged or main Cable Shift PTOs: Check cable. will not operate. pump ball valve not turned on. Air Shift PTOs: Adequate air pressure to shift? Air Tank Emergency Valve: Valve functioning? Control valve working properly? Shift cylinder on PTO operating? Check position of ball valve on pump (direct mount only). Hydraulic pump not Check PTO-pump driveshaft. running. Check keyways in pump, PTO driveshaft. Check pump shaft. Check if pump is free or "frozen up." Hydraulic pump turning, no Check oil level in hydraulic tank. apparent oil output. Check pump driveshaft. Hydraulic pump turning, oil Check pressure build when a circuit is used. output apparently O.K. a. No/low Pressure: Check circuit or main relief valve. b. High Pressure Relieving: Check to be sure the operating system is not "frozen up." (Pressure Compensated Check pressure compensator, reset to 1800 psi. Pumps Only) Pump output pressure too low. Check relief valves.
  • 17. TS11a Trouble Shooting TROUBLE SHOOTING GUIDE (Continued) PROBLEM PROBABLE CAUSE ITEMS TO CHECK Product pump will Motor flow control closed. Check inlet flow control to motor; closed, reset for not run. desired output. No hydraulic oil at drive Check main hydraulic pump ball valve to be sure it motor or low oil pressure. is fully opened. High pressure in system, Pump binding: Check oil flow to be sure pump pump will not turn. turns with hydraulic motor uncoupled. Motor turns, pump will not. Check drive coupling. Hydraulic motor bad. Check motor. Hose reel will not PTO not engaged. Check PTO. function. No hydraulic oil or low Check hydraulic pump. pressure to control valve. Relief valve on valve block Check system pressure, if OK and hose reel does set too low. not develop pressure when running, reset reel control valve relief. Hydraulic motor getting oil, Replace motor. but not functioning.
  • 18. TS44 Trouble Shooting HYDRAULIC LOAD SENSING SYSTEM TROUBLE SHOOTING GUIDE PROBLEM PROBABLE CAUSE ITEMS TO CHECK Hydraulic system will not Plugged load sense bleed valve Remove cartridge, check for debris return to a standby cartridge. creating obstruction of orifice. Clean pressure of 300-500 psi and reinstall. after all circuits have been disengaged. Faulty pump compensator. Replace compensator block. Hydraulic circuit(s) not totally Perform single circuit diagnostics to disengaged - load sense circuit still determine which circuit remains receiving signal pressure. open. Repair circuit components. Hydraulic system will not Plugged signal port on pump Remove load sense signal line from develop high pressure (will compensator control block. compensator block. Engage one not raise above typical 300- circuit (such as “product delivery,” 500 psi standby pressure). compressor, or down riggers). Signal hose should discharge a steady stream of oil. Remove compensator block and thoroughly clean (see pump service instructions). Wrong sized orifice in load sense Check for proper load sense bleed bleed valve cartridge. Pressure is valve cartridge. If questionable, not being allowed to build in load replace with 0.1 g.p.m. cartridge. sense signal circuit. Leak in load sense signal line Check for leaks, repair as needed. circuit. Circuit control valve not being Check for mechanical failure such engaged properly. as pneumatic pilot not actuating a hydraulic valve. Faulty load sense check valve or Systematically run each separate possible plug. circuit. Determine which circuit does not bring pump up to pressure. Replace or repair load sense check valve on that circuit. Faulty pump compensator. Replace compensator block. Hydraulic system pressure Too high of volume of load sense Check for leaks, repair as needed. will not increase even with circuit signal pressure lost by bleed all system and circuit relief to tank or by line leaks. Check for proper load sense bleed valves set. valve cartridge. If questionable, replace with 0.1 g.p.m. cartridge.
  • 19. 4. HYDRAULICS / PNUEMATICS / ELECTRICAL
  • 20. VVH5 Hydraulics out with the compensator/pump set at high pressure,VARIABLE VOLUME or system damage could occur if the compensator setting is too high.HYDRAULIC PUMPADJUSTMENT For further information, see the adjustmentFor Part #3286PM3XX, 3286PM4XX, procedures in the appropriate “Overhaul Manual.”3286PM6XX, Series PumpsThis Ground Force hydraulic system is designed to HSP4 Hydraulicsoperate at less than 1800 psi hydraulic pressure.Therefore, it is important that the pressure HYDRAULIC SYSTEMcompensator (which sets the maximum available Pressure Relief Adjustmenthydraulic pressure of the hydraulic pumps) be set Procedures (With Hydraulic Pumpproperly or damage to the hydraulic system could Series 3286 PM 3XX, 4XX, andpotentially occur. 6XX/Without Spool Valve Relief)The pressure compensator is a cast housing which isattached to the main body of the hydraulic pump. Reference Drawing No. 96019/B32This cast housing includes two adjustment screws.One being the load sense pressure adjustment, and Prior to adjusting any relief valves, please verifythe other being the load pressure limiter adjustment. which particular valves are involved with thisThe load pressure limiter should be the only procedure. Follow directions precisely and carefully.adjustment immediately necessary. A= Main Hydraulic Pump - Flow and PressureSome portions of Ground Force hydraulic systems are Compensateddesigned to "overdrive" the hydraulic pressure B= Load Sense Adjustment Screwneeded to operate the system, i.e. on air compressors. C= Pressure Compensator AdjustmentThis means that when that function of the truck is Screwengaged, the hydraulic pump will automaticallydeliver its maximum pressure rather than just the D= Main System Relief Valve (only one)pressure needed to operate the system. This aids in E= Cap, Adjustment Screw Coveradjusting the compensator. Follow the listed F= Adjustment Screwprocedures to adjust the compensator. G= Cartridge, Relief Adjustment Note: Do not start engine or engage hydraulicBulk Explosive Trucks With Variable system(s) until called for!!!Volume PumpEngage the auger delivery circuit to bring the truck to Adjustment Preparationmaximum pressure. It will be O.K. to leave the product 1. Locate "A" (Hydraulic Pump) and controlselector (ANFO or Blend) off and run the truck as block which includes “B” (Load Sensethough it is in a "clean out" mode; this will still bring Adjustment Screw) and “C” (Pressurethe truck up to full operating pressure. When the Compensator Adjustment Screw).system is turned on, adjust the pressure limiteradjusting screw on the pressure compensator control 2. Using a 1/2" wrench, loosen the jam nuts onup to the desired 1800 psi, and set the lock nut. “B” and “C,” making sure that “B” and “C” do not turn in the process. A 5/32" Allen wrenchService Trucks (Mechanics, Lube, may be used to hold “B” and “C” in place.etc.)The air compressor on all Ground Force service trucks 3. Using a 5/32" Allen wrench, turn “C” (Pressureis designed to overdrive the hydraulic system. Turn Compensator Adjustment Screw) CCW untilon the compressor controls, and while the air spring pressure is no longer observed. Thencompressor is running adjust pressure to 1800 psi and turn the same “C” screw CW approximately 2set the lock nut. full turns. This will adjust the pump output to a fairly low pressure.On All UnitsWhen replacing the main hydraulic pump or the 4. Locate "D" (Main System Relief Valve) andcompensator; be sure to back off the pressure associated components "E", "F", and "G".compensator adjustment counter clockwise when firstinstalling the part. Engage the hydraulics and bringthe pressure up and set at 1800 psi. DO NOT start
  • 21. HSP4 Hydraulics(Continued) 7. Turn "F" slowly CW until "squealing" stops.5. Use a 1" wrench to hold "G" (Relief Valve Cartridge) in place while using a 15/16" wrench 8. Replace "E" (Cap). Do not over tighten, needs to loosen and remove "E" (Adjustment Screw only to be slightly more than hand tight. Main Cap). Make certain that during this procedure System Relief Valve is now set and should the Relief Valve Cartridge "G" does not loosen need no further adjustments. from its seated position within the main block of the relief valve (assembly). Place "E" in a 9. Return to main pump and while monitoring the safe location (to be reinstalled later). pressure gauge, turn "Pump Compensator Pressure Adjustment Screw" CCW slowly until6. Make certain ALL controls are "OFF" or in pressure gauge reads 1800 psi pressure. "NEUTRAL" position, including the "Product Delivery" control. 10. While holding the adjustment screw with a 5/32" Allen wrench, tighten the jam nut with aAdjustment Procedures ½" wrench.Note: Do not attempt any adjustments without firstfollowing steps 1 through 6 of "Adjustment 11. Recheck pressure at gauge. If pressure hasPreparation." changed, pump compensator must be readjusted.1. Start engine, engage hydraulic pump, raise to approximately 1000 rpm. Note: Please keep in 12. Disengage the main hydraulic circuit which had mind that even the slightest adjustments made been engaged for pressure adjustments. must be monitored visually on the "Hydraulic System Pressure Gauge." 13. Locate “B” (Load Sense Pressure Adjustment). While monitoring the system pressure gauge,2. Making sure that ALL other operating controls use a 5/32" Allen wrench and adjust the are "OFF" or in "NEUTRAL" position, turn “Standby” pressure to 400-500 psi. "ON" one of the main hydraulic circuits: CW = Increase Pressure u Stemming/ANFO Trucks = CCW = Decrease Pressure Product Delivery Note: After releasing all of the function circuits to u Mechanic/Service/Lubrication “Neutral” on this system, the “Standby” pressure Units = Air Compressor or Fuel Pump should drop to 400-500 psi within 30-45 seconds maximum. If the system does not react in this manner,3. Locate "C” (Pressure Compensator see the “Load Sense Trouble Shooting” section in Adjustment) on main pump control block. this manual.4. Turn “C” (Adjustment Screw) CW while 14. Once the “Standby” pressure has been monitoring the pressure gauge. Continue to adjusted and rechecked (by engaging and turn until pressure reads 2000 psi or until "D" disengaging a hydraulic circuit) tighten the jam (Main System Relief Valve) starts to make a nut on “B” to secure in place. whistling or squealing sound, whichever comes first. 15. Disengage the hydraulic pump.3. If 2000 psi cannot be obtained without the main 16. Allow engine to idle for "cool down" period system relief valve making noise (which signifies and then stop engine. that the oil is relieving), then "F" (Relief Valve Adjustment Screw) must be turned CW no more than ½ (one-half) turn at a time, along with continued CW adjustment of the "Pressure Compensator Adjustment Screw," until a 2000 psi pressure is reached. Once the pressure gauge reads 2000 psi, locate "D" and turn "F" (Adjustment Screw) CCW until the valve begins to "squeal."
  • 22. HP22 Parts HYDRAULIC SYSTEM PARTS UNIT SERIAL NUMBERS 145-04-001 & 145-04-002 REFERENCE HYDRAULIC DIAGRAM145-02-001_2/H ITEM PART # DESCRIPTION QTY 1 3286PM604 MAIN HYDRAULIC PUMP 1 2 1227HY301 MAIN RELIEF VALVE 1 3 9475FI010 SUCTION STRAINER, IN TANK 1 4 9475HY003 FILLER/BREATHER CAP - 3 PSI 1 5 9475FI011 FILTER HOUSING, RETURN OIL 1 6 9777FI004 FILTER ELEMENT DO NOT SUBSTITUTE 2 7 9400HY003 CARTRIDGE, LOAD SENSE BLEED VALVE 1 7A 9400HY004 BODY, FLOW CONTROL 1 8 3400VA008 GATE VALVE, 2-1/2" TANK SUCTION 1 9 3451VA054 CHECK VALVE, 3/4" BRONZE 1 10 1812HY001 SIGHT GLASS 2 11 9400HY031 BODY FLOW CONTROL 5 12 9400HY078 CARTRIDGE, FLOW CONTROL - 2.0 GPM 1 13 9400HY007 PRESSURE REDUCING VALVE 1 14 9414HY257 MOTOR, HYDRAULIC - REELS 8 14A 9414HY253 MOTOR, HYDRAULIC - REEL 2 15 9411HY001 VALVE, SINGLE SPOOL - REELS 10 16 6156GG001 PRESSURE GAUGE - 3000 PSI 1 17 2519HY351 VALVE, SELECTOR - 1/2" 3 18 9400HY070 CARTRIDGE, FLOW CONTROL 2 19 9400HY074 CARTRIDGE, RELIEF VALVE 2 20 9424HY001 CHECK VALVE, LOAD SENSE 3 21 9900HY131 MANIFOLD, COMPRESSOR CONTROL 1 22 9400HY083 SOLENOID CARTRIDGE 1 23 9400HY084 SOLENOID COIL - 12 VDC 1 24 9500HY063 CARTRIDGE, LOAD SENSE CHECK 1 25 9400HY052 CARTRIDGE, FLOW CONTROL - 25 GPM 1
  • 23. HP22 Parts HYDRAULIC SYSTEM PARTS UNIT SERIAL NUMBERS 145-04-001 & 145-04-002 REFERENCE HYDRAULIC DIAGRAM (Continued) 26 9414HY247 MOTOR, HYDRAULIC 1 27 9400HY078 CARTRIDGE, FLOW CONTROL 1 28 9400HY078 CARTRIDGE, FLOW CONTROL 1 29 9414HY272 MOTOR, HYDRAULIC - COMPRESSOR COOLING FAN 1 30 10082PM301 MOTOR, HYDRAULIC - GREASE PUMP 2 31 10082PM303 PUMP TUBE, GREASE - HIGH PRESSURE 1 32 10082PM302 PUMP TUBE, GREASE - HIGH VOLUME 1 33 9900HY130 MANIFOLD, PRODUCT PUMP - SEE ALSO DRAWING NO. 94080/B91 5 34 9400HY013 CARTRIDGE, FLOW CONTROL 5 35 9424HY004 CHECK VALVE, PRODUCT OIL 5 36 2617PM303 PUMP/MOTOR COMBO - SEE ALSO DRAWING NO. 94080/B91 5 37 2519HY352 SELECTOR VAVLE, 3/4" 1 38 9400HY012 CARTRIDGE, FLOW CONTROL 1 39 9400HY016 BODY, FLOW CONTROL 1 40 9414HY209 MOTOR, HYDRAULIC - WATER PUMP 1
  • 24. 5. PARTS
  • 25. Parts Parts WARRANTY PARTS TO PURCHASE PARTS:When Ground Force manufactures Order ALL parts for the items shown inmachinery, we utilize parts and supplies this book through Ground Force not themade by many vendors. It is an part manufacturer!!!unfortunate fact of life that a percentage ofthese parts that we purchase to assemble Ground Force is a master distributor allour machinery will be bad. Component the components used to build yourparts all have their respective equipment and can furnish them cheapermanufacturers warranties. Since youve and faster than the componentpurchased Ground Force manufactured manufacturer.machinery, we will do everything in ourpower to assure you that your equipment When ordering, use the Ground Forcestays in top operating condition and will Part Number to assure receiving the rightback you in any warranty claims. part quickly!Should any parts on your new unit prove Ground Force maintains an inventory ofto become defective, we can usually ship the common parts which are part of thea replacement part from our stock normal maintenance and repair of yourovernight if you so desire. What we need equipment.to do at Ground Force to receive ourwarranty credit for parts proven to bedefective is to have parts returned by you,the owner of the machine, to us, so thatwe may apply to parts suppliers forwarranty credit. To do this, it isimperative that we receive the faulty partwhen you replace it with a new one.Our warranty procedure at Ground Forceis that when we ship a replacement partfor your unit, either on warranty orstandard replacement, we will send aninvoice with that part. When we receivethe defective part back from you, we willsubmit that to our suppliers for a warrantycredit. As soon as warranty credit isreceived for that part, we will issue acredit invoice for the amount charged onyour replacement. (Freight charges arenot covered under warranty).If you have any questions about GroundForces warranty system, please contactChad Wilson at (208) 664-9291.
  • 26. DP4a DOOR PARTS CATCHGAS SPRING LATCH LEVERSIDE COMPARTMENTS PART # 13500WH501(LIFT-UP DOORS) (INCLUDES CATCH)PART # 15088HW1252 EACH PER DOOR EDGE TRIM PART # 4200WH015 (PER FOOT)(SIDE-SWING DOORS)PART # 15088HW0351 EACH PER DOOR "D" DOOR SEAL (SELF BONDING) PART # 10600WH939 (ORDER PER FOOT)
  • 27. ITEM DIM ARESCO DESCRIPTION QTY A PART # 1266DC401 COUPLING HALF, 1-1/4 x 5/16 AR 1266DC402 COUPLING HALF, 1-1/2 x 3/8 AR 1 4.0 1266DC404 1266DC405 COUPLING HALF, 50 mm x 14 mm COUPLING HALF, 1 x 1/4 AR AR 1 1266DC407 COUPLING HALF, 1-7/8 x 1/2 AR 1266DC408 COUPLING HALF, 1-3/4 x 3/8 AR 1266DC412 COUPLING HALF, 1-1/4 AR 14 TOOTH SPLINED 2 1266DC403 INSERT, HYTREL AR 1266DC503 COUPLING HALF, 1-1/4 x 5/16 AR 1266DC504 COUPLING HALF, 2-3/8 x 5/8 AR 1266DC505 COUPLING HALF, 2-1/8 x 1/2 AR AR 2 1266DC506 COUPLING HALF, 2-1/2 x 5/8 1 1266DC507 COUPLING HALF, 1-1/2 x 3/8 AR 4.8 1266DC508 COUPLING HALF, 1-7/8 x 1/2 AR 1266DC509 COUPLING HALF, 1-15/16 x 1/2 AR 1266DC510 COUPLING HALF, 2-1/4 x 5/8 AR 1 1266DC511 COUPLING HALF, 55 mm x 16 mm AR 1266DC512 COUPLING HALF, 50 mm x 14 mm AR 1266DC513 COUPLING HALF, 2-1/4 X 3/8 AR 1266DC501 INSERT, HYTREL AR2 1266DC502 INSERT, NEOPRENE AR 1266DC301 COUPLING HALF, 1 6 TOOTH SL E PI D N AR 1266DC302 COUPLING HALF, 1-1/4 x 5/16 AR DIM A 1266DC304 COUPLING HALF, 3/4 x 3/16 AR OUTSIDE DIAMETER 1266DC306 COUPLING HALF, 1 x 1/4 AR 1266DC307 COUPLING HALF, 1-1/8 x 1/4 AR 1266DC308 COUPLING HALF, 1-1/2 x 3/8 AR 1266DC309 COUPLING HALF, 1-5/8 x 3/8 AR 1266DC310 COUPLING HALF, 38 mm x 10 mm AR 1 3.45 1266DC311 COUPLING HALF, 28 mm x 8 mm AR 1266DC312 COUPLING HALF, 35 mm x 10 mm AR 1266DC313 COUPLING HALF, 42 mm x 12 mm AR NOTE : PART NUMBERS 1266DC314 COUPLING HALF, 7/8 x 1/4 AR HIGHLIGHTED ARE 1266DC315 COUPLING HALF, 1-3/8 x 5/16 AR APPLICABLE TO 1266DC316 COUPLING HALF, 9/16 x 1/8 AR YOUR TRUCK. 1266DC317 COUPLING HALF, 7/8 13 TOOTH SPLINED AR 2 1266DC303 INSERT, HYTREL AR 1266DC102 COUPLING HALF, 1 x 1/4 AR 1266DC105 COUPLING HALF, 3/4 x 3/16 AR 1266DC109 COUPLING HALF, 16.5 mm x 5 mm AR1 2.6 1266DC111 COUPLING HALF, 7/8 x 1/4 AR 1266DC112 COUPLING HALF, 5/8 x 3/16 AR 1266DC113 COUPLING HALF, 1/2 x # 404 WOODRUFF AR G o n r u d F r e Mg o c f . 1266DC114 COUPLING HALF, 3/8 BORE AR DRAWING NUMBER : 9-1 2- 3 2 0-5 B 1266DC115 COUPLING HALF, 24 mm x 8 mm AR 1266DC116 COUPLING HALF, 5/16 BORE AR DRIVE COUPLING 2 1266DC104 INSERT, HYTREL AR S RE 1 0 3 0 4 0 & 5 0 E I S 0 , 0 , 0 0 . O V
  • 28. JB1 JUNCTION BOX ITEM PART# DESCRIPTION 1 7813LT012 JUNCTION BOX/COMPLETE
  • 29. L1 TRUCK LIGHTS ITEM PART # DESCRIPTION 1 7813LT012 JUNCTION BOX 2 7813LT007 LAMP, CLEARANCE, AMBER 3 7813LT006 LAMP, CLEARANCE, RED 4 7813LT005 IDENTIFICATION BAR 5 7813LT009 LAMP, STOP, OR TURN
  • 30. L2 TRUCK LIGHTS 1 2 ITEM PART # DESCRIPTION 7813LT009 LAMP, STOP OR TURN/COMPLETE 1 1156 BULB 2 7813LT025 LENS, REPLACEMENT - RED
  • 31. L4 ICC LIGHTS ITEM PART # DESCRIPTION 1 7813LT005 IDENTIFICATION BAR 2 7813LT001 LENS 3 T-67 BULB
  • 32. L5b FLOOD LIGHT ASSEMBLY ITEM PART # DESCRIPTION 7813LT014 FLOOD LIGHT, AMBER/COMPLETE 7813LT008 FLOOD LIGHT, CLEAR/COMPLETE 7813LT013 FLOOD LIGHT, HALOGEN/COMPLETE 1 7813LT017 BULB, HALOGEN 2 7813LT018 BULB, CLEAR FLOOD 3 7813LT022 BULB, AMBER
  • 33. L7a CLEARANCE LIGHT ASSEMBLY ITEM. PART # DESCRIPTION 1 7813LT006 LAMP,CLEARANCE RED/COMPLETE 2 7813LT007 LAMP, CLEARANCE AMBER/COMPLETE 3 7813LT002 LENS, AMBER 4 7813LT003 LENS, RED 5 56 GROMMET 6 T67 BULB
  • 34. WIRING LOOM AND FITTINGS 90 ELBOW (3/8" - 635-053) (1/2" - 635-065) 3/8" TUBING - PT24006 1/2" TUBING - PT24008 STRAIGHT FITTING (3/8" - 600-053 (1/2" - 600-063)WIRING JUNCTION BOX (BOX - #4900EL125) (PANEL - #4900EL126)
  • 35. 1615AP002 PART # 6500-04-02 1615AP001 PART # 6500-04-02 PART # 6500-04-02 PART # 6500-04-02PART # 6500-04-04PART # 6500-04-04 PART # 222P-4-4PART # 6500-04-04PART # 6500-04-04 PART # 6500-04-04 3936AP006 PART # 222P-4-4PART # 6500-04-04 3936AP007Ground Force Mfg. PLUMBING AIR VALVESDRAWING NUMBER : 3 9 3 6 A P ( 6 5 P 0 ,1 1 A 0 2 9 6 P 0 / 0 ) 1 1 A 0 1 6 5P 0 , 3 A 0 6 0 7 3 ov
  • 36. G3 G5 2 1 8 7 4 4 5 10 3 6 9 ITEM PART # DESCRIPTION QTY 1 9483HY028 STACKING BOLT, G3 AR 2 9483HY029 CLAMP BOLT, G3 AR 3 9483HY030 CLAMP WELD PLATE, G3 AR 4 9483HY031 CLAMP INSERT, G3 AR 5 9483HY032 CLAMP, 1/4 TUBING, G3 AR 9483HY033 CLAMP, 1/2 TUBING, G3 AR 9483HY035 CLAMP, 5/8 TUBING, G3 AR 9483HY037 CLAMP, 3/4 TUBING, G3 AR 9483HY038 CLAMP, 7/8 TUBING, G3 AR 9483HY039 CLAMP, 1 TUBING, G3 AR 6 9483HY040 CLAMP, RAIL WELD PLATE, G3 AR 7 9483HY048 STACKING BOLT, G5 AR 8 9483HY049 CLAMP BOLT, G5 AR 9 9483HY050 CLAMP WELD PLATE, G5 AR 10 9483HY054 CLAMP 1 PIPE, G5 AR 9483HY056 CLAMP 1-1/4 PIPE, G5 ARGround Force Mfg. RIGID HYDR. TUBE MOUNTINGDRAWING NUMBER : 9-1 2- 1 2 0-4 B PARTS
  • 37. DL25dc DRIVELINE - COMPLETE 1 2 3 4 5 7 6 6 7 Highlighted Items Apply to This Unit Note: Quanity "A/R" = As Required LENGTH USED IN INCHES ITEM PART # DESCRIPTION ITEM PART # QUANTITY DESCRIPTION 4 2-40-1701DS SPLINE STUB 1 2-2-329 1 FLANGE YOKE 2-40-1711DS SPLINE STUB 2-2-479 1 FLANGE YOKE 5 2-3-5221KX SLIP YOKE 3-2-119 1 FLANGE YOKE 3-3-1501KX SLIP YOKE 2 2-28-1757 TUBE YOKE 1 6 1-0153HD U-JOINT ASSEMBLY 3-28-47 TUBE YOKE 2 2-0053 U-JOINT ASSEMBLY 3 DOM 2 X .120 DRIVELINE TUBING 2 5-280X U-JOINT ASSEMBLY DOM 2-1/2 X .083 DRIVELINE TUBING 2 7 2-4-433 END YOKE, 3/4" X 3/16" KEY A/R 2-4-473 END YOKE, 1" X 1/4" KEY A/R 2-4-1741 END YOKE, SPLINED A/R 2-4-533 END YOKE, 1-1/4" X 5/16" KEY A/R 2-4-1233 END YOKE, 1-1-/2" X 3/8" KEY A/R 2-4-3331 END YOKE, 7/8" SPLINED A/R 8 50-2502 SET SCREW A/R NOT SHOWN 1-0099 U-BOLT KIT FOR 2-0053 A/R 3-4-24 YOKE, TAPER A/R 6-4-7541X YOKE A/R 6-4-7561X YOKE A/R
  • 38. Instructions – Parts List PartsALUMINUM AND STAINLESS STEELHuskyt 1040 Air-OperatedDiaphragm Pumps 308479ADAluminum Model Shown120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure*Model No. D73____ Aluminum Pumps*Model No. D83____ Aluminum Pumps, Remote*Model No. D74____ Stainless Steel Pumps*Model No. D84____ Stainless Steel Pumps, Remote*Model No. D7C____ Aluminum BSPT Pumps*Model No. D8C____ Aluminum BSPT Pumps, Remote*Model No. D7D____ Stainless Steel BSPT Pumps*Model No. D8D____ Stainless Steel BSPT Pumps, Remote*Model No. DR4____ Stainless Steel Plus Pumps*Model No. DS4____ Stainless Steel Plus Pumps, Remote*Model No. DRD____ Stainless Steel BSPT Plus Pumps*Model No. DSD____ Stainless Steel BSPT Plus Pumps, RemoteModel No. 232501 Private–Label Aluminum 1040 Pump (See page 24.) (not certified )Model No. 234124 Private–Label Aluminum 1040 Pump (See page 24.)*NOTE: Refer to the Pump Matrix on page 24 to determinethe Model No. of your pump.NOTE: Plus models include stainless steel center sections.US and Foreign Patents Pending Read warnings and instructions. See page 2 for table of contents 02632CGRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441Copyright 1994, Graco Inc. is registered to I.S. EN ISO 9001
  • 39. Table of Contents SymbolsSafety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warning SymbolSymbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 WARNINGOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 This symbol alerts you to the possibility of seriousTroubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 injury or death if you do not follow the instructions.Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Caution SymbolRepair Kit Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CAUTIONDimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 31Technical Data and Performance Chart . . . . . . . . . . . 32 This symbol alerts you to the possibility of damage toGraco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 34 or destruction of equipment if you do not follow theGraco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 instructions. WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury. INSTRUCTIONS D This equipment is for professional use only. D Read all instruction manuals, tags, and labels before operating the equipment. D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor. D Do not alter or modify this equipment. Use only genuine Graco parts and accessories. D Check equipment daily. Repair or replace worn or damaged parts immediately. D Do not exceed the maximum working pressure of the lowest rated component in your system. This equipment has a 120 psi (0.8 MPa, 8 bar) maximum working pressure at 120 psi (0.8 MPa, 8 bar) maximum incoming air pressure. D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings. D Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use could result in a chemical reaction, with the possibility of explosion. D Do not use hoses to pull equipment. D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex- pose Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F). D Do not lift pressurized equipment. D Comply with all applicable local, state, and national fire, electrical, and safety regulations.2 308479
  • 40. WARNINGTOXIC FLUID HAZARDHazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on theskin, inhaled, or swallowed.D Know the specific hazards of the fluid you are using.D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.D Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas. If the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 9.FIRE AND EXPLOSION HAZARDImproper grounding, poor ventilation, open flames or sparks can cause a hazardous condition andresult in a fire or explosion and serious injury.D Ground the equipment. Refer to Grounding on page 4.D If there is any static sparking or you feel an electric shock while using this equipment, stop pumping immediately. Do not use the equipment until you identify and correct the problem.D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.D Pipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 9.D Keep the work area free of debris, including solvent, rags, and gasoline.D Electrically disconnect all equipment in the work area.D Extinguish all open flames or pilot lights in the work area.D Do not smoke in the work area.D Do not turn on or off any light switch in the work area while operating or if fumes are present.D Do not operate a gasoline engine in the work area. 308479 3
  • 41. InstallationGeneral Information GroundingD The Typical Installations shown in Figs. 2–4 are only guides for selecting and installing system WARNING components. Contact your Graco distributor for FIRE AND EXPLOSION HAZARD assistance in planning a system to suit your needs. This pump must be grounded. Before operating the pump, ground the system as explained below. Also, read the sec-D Always use Genuine Graco Parts and Accessories. tion FIRE AND EXPLOSION HAZARD, Refer to Product Data Sheet 305588. on page 3.D Reference numbers and letters in parentheses refer To reduce the risk of static sparking, ground the pump to the callouts in the figures and the parts lists on and all other equipment used or located in the pumping pages 26–28. area. Check your local electrical code for detailed grounding instructions for your area and type of equip-D Aluminum Husky 1040 Pump Model No. 239823, ment. Ground all of this equipment. with straight-thread manifolds, is available and can be ordered separately. D Pump: Connect a ground wire and clamp as shown in Fig. 1. Loosen the grounding screw (W). Insert one end of a 12 ga (1.5 mm@) minimum ground wire (Y) behind the grounding screw and tighten the screw securely. Connect the clamp end of the WARNING ground wire to a true earth ground. Order Part TOXIC FLUID HAZARD No. 222011 Ground Wire and Clamp. Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed. Y 1. Read TOXIC FLUID HAZARD on page 3. 2. Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data section of all equipment manu- als. Read the fluid and solvent manufacturer’s warnings. W 02646B Fig. 1Tightening Screws Before First Use D Air and fluid hoses: Use only grounded hoses withAfter you unpack the pump, and before you use it for a maximum of 500 ft (150 m) combined hosethe first time, check and retorque external fasteners. length to ensure grounding continuity.Retorque the fluid cover screws first, then the manifoldscrews. This keeps the manifolds from interfering with D Air compressor: Follow the manufacturer’s recom-tightening the fluid covers. See the Service section for mendations.torque specifications. D All solvent pails used when flushing: Follow the local code. Use only metal pails, which are conduc-After the first day of operation, check and retorque the tive. Do not place the pail on a non-conductivefasteners again. Although the recommended fre- surface, such as paper or cardboard, which inter-quency for retorquing fasteners varies with pump rupts the grounding continuity.usage, a general guideline is to retorque fastenersevery two months. D Fluid supply container: Follow the local code.4 308479
  • 42. InstallationMountings c. The air line filter (F) removes harmful dirt and moisture from the compressed air supply. CAUTION 2. Install a grounded, flexible air hose (A) between The pump exhaust air may contain contaminants. the accessories and the 1/2 npt(f) pump air inlet Ventilate to a remote area if the contaminants (N). See Fig. 5. Use a minimum 3/8” (9.5 mm) ID could affect your fluid supply. See Air Exhaust air hose. Screw an air line quick disconnect cou- Ventilation on page 9. pler (D) onto the end of the air hose (A), and screw the mating fitting into the pump air inlet snugly. Do not connect the coupler (D) to the fitting until youD Be sure the mounting surface can support the are ready to operate the pump. weight of the pump, hoses, and accessories, as well as the stress caused during operation. Installation of Remote Pilot Air LinesD For all mountings, be sure the pump is bolted directly to the mounting surface. 1. Refer to Parts Drawings. Connect air line to pump as in preceding steps.D For ease of operation and service, mount the pump so the air valve cover (2), air inlet, and fluid inlet and outlet ports are easily accessible. 2. Connect 1/4 in. O.D. tubing to push type connec- tors (14) on air motor of pump.D Rubber Foot Mounting Kit 236452 is available to reduce noise and vibration during operation. NOTE: by replacing the push type connectors, other sizes or types of fittings may be used. The new fittingsAir Line will require 1/8 in. npt threads. 3. Connect remaining ends of tubes to external air WARNING signal, such as Graco’s Cycleflo (P/N 195264) or A bleed-type master air valve (B) is required in Cycleflo II (P/N195265) controllers. your system to relieve air trapped between this valve and the pump. Trapped air can cause the NOTE: the air pressure at the connectors must be at pump to cycle unexpectedly, which could result in least 30% of the air pressure to the air motor for the serious injury, including splashing in the eyes or on pump to operate. the skin, injury from moving parts, or contamination from hazardous fluids. See Fig. 3. Fluid Suction Line 1. Use grounded fluid hoses. The pump fluid inlet (R)1. Install the air line accessories as shown in Figs. is 1” npt(f). See Fig. 5. Screw the fluid fitting into 2–4 on pages 7 and 8. Mount these accessories the pump inlet securely. on the wall or on a bracket. Be sure the air line supplying the accessories is grounded. 2. If the fluid inlet pressure to the pump is more than a. Install an air regulator (C) and gauge to control 25% of the outlet working pressure, the ball check the fluid pressure. The fluid outlet pressure will valves will not close fast enough, resulting in be the same as the setting of the air regulator. inefficient pump operation. b. Locate one bleed-type master air valve (B) 3. At inlet fluid pressures greater than 15 psi (0.1 close to the pump and use it to relieve trapped MPa, 1 bar), diaphragm life will be shortened. air. See the WARNING above. Locate the other master air valve (E) upstream from all air line accessories and use it to isolate them 4. See the Technical Data on page 32 for maximum during cleaning and repair. suction lift (wet and dry). 308479 5
  • 43. InstallationFluid Outlet Line 1. Use grounded fluid hoses (L). The pump fluid outlet (S) is 1” npt(f). See Fig. 5. Screw the fluid fitting into the pump outlet securely. WARNING A fluid drain valve (J) is required to relieve pres- 2. Install a fluid drain valve (J) near the fluid outlet. sure in the hose if it is plugged. The drain valve See the WARNING above, and Figs. 2–4 on reduces the risk of serious injury, including splash- pages 7 and 8. ing in the eyes or on the skin, or contamination from hazardous fluids when relieving pressure. 3. Install a shutoff valve (K) in the fluid outlet line. Install the valve close to the pump fluid outlet. See Fig. 3.6 308479
  • 44. InstallationKEY FOR FIG. 2A Air supply line TYPICAL BUNG-MOUNT INSTALLATIONB Bleed-type master air valve (required for pump)C Air regulatorD Air line quick disconnect E F C BE Master air valve (for accessories)F Air line filter AG Fluid suction lineH Bung adapterJ Fluid drain valve (required) K LK Fluid shutoff valveL Fluid lineY Ground wire (required; see page 4 D for installation instructions) J Y H G 02648BFig. 2 TYPICAL FLOOR-MOUNT INSTALLATION KEY FOR FIG. 3 A Air supply line E F C B B Bleed-type master air valve (required for pump) A C Air regulator D Air line quick disconnect E Master air valve (for accessories) K F Air line filter L G Fluid suction line J Fluid drain valve (required) D K Fluid shutoff valve L Fluid line Y Ground wire (required; see page 4 J for installation instructions) G Y 02651BFig. 3 308479 7
  • 45. InstallationKEY FOR FIG. 4A Air supply lineB Bleed-type master air valve TYPICAL WALL-MOUNT INSTALLATION (required for pump)C Air regulator E F BD Air line quick disconnect CE Master air valve (for accessories) A K LF Air line filterG Fluid suction lineJ Fluid drain valve (required)K Fluid shutoff valve DL Fluid lineM Wall mounting bracketY Ground wire (required; see page 4 J for installation instructions) Y G M 02649BFig. 4Changing the Orientation of the Fluid Inlet KEY N 1/2 npt(f) air inlet portand Outlet Ports P Muffler. Air exhaust port is 3/4 npt(f) R 1 npt(f) fluid inlet port Apply medium-strengthOn aluminum pumps, the fluid inlet and outlet man- S 1 npt(f) fluid outlet port 1 (blue) LoctiteR or equiv-ifolds have threaded ports on both ends. The pump is 106 Manifold and cover screws alent to the threads, andshipped with a plug installed in one end of each man- 3 Air valve screws torque to 120–150 in-lbifold, and the opposite end open. See Fig. 5. To (14–17 N.m).change the orientation of the inlet and/or outlet port, Torque to 50–60 in-lb 2 (5.6–6.8 NSm).remove the plug from one end of a manifold and installit in the opposite end. 106 1On stainless steel pumps, the fluid inlet and outlet 2 S 3manifolds have threaded ports on one end only. Thepump is shipped with the ports facing the same direc- Ntion. To reverse the orientation of the ports: 106 11. Remove the screws and nuts holding the inlet and/or outlet manifold to the covers.2. Reverse the manifold and reattach. Install the screws and torque to 120–150 in-lb (14–17 N.m). P R 02632C Fig. 58 308479
  • 46. InstallationAir Exhaust Ventilation The air exhaust port is 3/4 npt(f). Do not restrict the air exhaust port. Excessive exhaust restriction can cause erratic pump operation. WARNING FIRE AND EXPLOSION HAZARD To provide a remote exhaust: Be sure to read and follow the warnings and precautions regarding TOXIC FLUID HAZARD, and FIRE OR EXPLO- 1. Remove the muffler (P) from the pump air exhaust SION HAZARD on page 3, before op- port. erating this pump. Be sure the system is properly ventilated for your 2. Install a grounded air exhaust hose (T) and con- type of installation. You must vent the exhaust to a nect the muffler (P) to the other end of the hose. safe place, away from people, animals, food handl- The minimum size for the air exhaust hose is 3/4 ing areas, and all sources of ignition when pumping in. (19 mm) ID. If a hose longer than 15 ft (4.57 m) flammable or hazardous fluids. is required, use a larger diameter hose. Avoid sharp bends or kinks in the hose. Diaphragm failure will cause the fluid being pumped to exhaust with the air. Place an appropri- ate container at the end of the air exhaust line to 3. Place a container (U) at the end of the air exhaust catch the fluid. See Fig. 6. line to catch fluid in case a diaphragm ruptures. See Fig. 6. VENTING EXHAUST AIR KEY A Air supply line B Bleed-type master air valve (required for pump) C Air regulator D Air line quick disconnect E Master air valve (for accessories) F Air line filter P Muffler T Grounded air exhaust hose E F C B U Container for remote air exhaust A T D U P 02650Fig. 6 308479 9
  • 47. InstallationFluid Pressure Relief Kit CAUTION Pressure Relief Kit 235409 (V) is available for Aluminum Pumps, to prevent overpressurization and rupture of the pump or hose. See Fig. 7. The kit includes instructions. 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. 3 SKEYR 1 npt(f) optional fluid inlet portS 1 npt(f) optional fluid outlet portV Pressure relief kit1 Install kit between fluid inlet and outlet manifolds.2 Connect fluid inlet line here.3 Connect fluid outlet line here. 2 R V 1 02653CFig. 710 308479
  • 48. OperationPressure Relief Procedure 5. Close the fluid drain valve (J). WARNING 6. Back out the air regulator (C) knob, and open all PRESSURIZED EQUIPMENT HAZARD bleed-type master air valves (B, E). The equipment stays pressurized until pressure is manually relieved. To reduce the risk of serious 7. If the fluid hose has a dispensing device, hold it injury from pressurized fluid, accidental spray from open while continuing with the following step. the gun or splashing fluid, follow this procedure whenever you 8. Slowly increase air pressure with the air regulator (C) until the pump starts to cycle. Allow the pump D Are instructed to relieve pressure to cycle slowly until all air is pushed out of the lines D Stop pumping and the pump is primed. D Check, clean or service any system equipment D Install or clean fluid nozzles If you are flushing, run the pump long enough to thoroughly clean the pump and hoses. Close the1. Shut off the air to the pump. air regulator. Remove the suction tube from the2. Open the dispensing valve, if used. solvent and place it in the fluid to be pumped.3. Open the fluid drain valve to relieve fluid pressure, having a container ready to catch the drainage. Operation of Remote Piloted PumpsFlush the Pump Before First Use 1. Follow preceding steps 1 through 7 of StartingThe pump was tested in water. If the water could and Adjusting Pump.contaminate the fluid you are pumping, flush the pumpthoroughly with a compatible solvent. Follow the steps 2. Open air regulator (C).under Starting and Adjusting the Pump.Starting and Adjusting the Pump WARNING The pump may cycle once before the external sig- WARNING nal is applied. Injury is possible. If pump cycles, TOXIC FLUID HAZARD wait until end before proceeding. To reduce the risk of serious injury, splashing in the eyes or on the skin, and 3. Pump will operate when air pressure is alternately toxic fluid spills, never move or lift a applied and relieved to push type connectors (14). pump under pressure. If dropped, the fluid section may rupture. Always follow the Pressure Relief NOTE: Leaving air pressure applied to the air motor for Procedure Warning above before lifting the pump. extended periods when the pump is not running may shorten the diaphragm life. Using a 3–way solenoid1. Be sure the pump is properly grounded. Refer to valve to automatically relieve the pressure on the air Grounding on page 4. motor when the metering cycle is complete prevents2. Check fittings to be sure they are tight. Use a this from occurring. compatible liquid thread sealant on male threads. Tighten fluid inlet and outlet fittings securely. Pump Shutdown3. Place the suction tube (if used) in fluid to be pumped. WARNINGNOTE: If fluid inlet pressure to the pump is more than25% of outlet working pressure, the ball check valves To reduce the risk of serious injury whenever youwill not close fast enough, resulting in inefficient pump are instructed to relieve pressure, always follow theoperation. Pressure Relief Procedure at left.4. Place the end of fluid hose (L) into an appropriate container. At the end of the work shift, relieve the pressure. 308479 11
  • 49. MaintenanceLubrication Tightening Threaded ConnectionsThe air valve is designed to operate unlubricated, Before each use, check all hoses for wear or damage,however if lubrication is desired, every 500 hours of and replace as necessary. Check to be sure alloperation (or monthly) remove the hose from the pump threaded connections are tight and leak-free. Checkair inlet and add two drops of machine oil to the air and retorque all threaded connections at least everyinlet. two months. Retorque the fluid cover screws first, followed by the manifold screws. CAUTION The recommended frequency for retorquing of fasten- Do not over-lubricate the pump. Oil is exhausted ers varies with pump usage; a general guideline is to through the muffler, which could contaminate your retorque fasteners every two months. fluid supply or other equipment. Excessive lubrica- tion can also cause the pump to malfunction. Preventive Maintenance Schedule Establish a preventive maintenance schedule, basedFlushing and Storage on the pump’s service history. This is especially impor- tant for prevention of spills or leakage due to dia- WARNING phragm failure. To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11.Flush the pump often enough to prevent the fluid youare pumping from drying or freezing in the pump anddamaging it. Use a compatible solvent.Always flush the pump and relieve the pressure beforestoring it for any length of time.12 308479
  • 50. Notes 308479 13
  • 51. Troubleshooting D Relieve the pressure before checking or servicing WARNING the equipment. To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11. D Check all possible problems and causes before disassembling the pump.PROBLEM CAUSE SOLUTIONPump cycles at stall or fails to hold Worn check valve balls (301), seats Replace. See page 18.pressure at stall. (201) or o-rings (202).Pump will not cycle, or cycles once Air valve is stuck or dirty. Disassemble and clean air valve.and stops. See page 16. Use filtered air. Check valve ball (301) severely Replace ball and seat. See page worn and wedged in seat (201) or 18. manifold (102 or 103). Check valve ball (301) is wedged Install Pressure Relief Valve into seat (201), due to overpressur- (see page 10). ization. Dispensing valve clogged. Relieve pressure and clear valve.Pump operates erratically. Clogged suction line. Inspect; clear. Sticky or leaking balls (301). Clean or replace. See page 18. Diaphragm ruptured. Replace. See pages 19–21. Restricted exhaust. Remove restriction.Air bubbles in fluid. Suction line is loose. Tighten. Diaphragm ruptured. Replace. See pages 19–21. Loose inlet manifold (102), dam- Tighten manifold bolts (106) or re- aged seal between manifold and place seats (201) or o-rings (202). seat (201), damaged o-rings (202). See page 18. Loose diaphragm shaft bolt (107). Tighten or replace (pages 19–21). Damaged o-ring (108). Replace. See pages 19–21.14 308479
  • 52. TroubleshootingPROBLEM CAUSE SOLUTIONFluid in exhaust air. Diaphragm ruptured. Replace. See pages 19–21. Loose diaphragm shaft bolt (107). Tighten or replace (pages 19–21). Damaged o-ring (108). Replace. See pages 19–21.Pump exhausts excessive air at Worn air valve block (7), o-ring (6), Repair or replace. See page 16.stall. plate (8), pilot block (18), u-cups (10), or pilot pin o-rings (17). Worn shaft seals (402). Replace. See pages 19–21.Pump leaks air externally. Air valve cover (2) or air valve cover Tighten screws. See page 16. screws (3) are loose. Air valve gasket (4) or air cover Inspect; replace. See pages 16, gasket (22) is damaged. 22–23. Air cover screws (25) are loose. Tighten screws. See pages 22–23.Pump leaks fluid externally from ball Loose manifolds (102, 103), dam- Tighten manifold bolts (106) or re-check valves. aged seal between manifold and place seats (201) or o-rings (202). seat (201), damaged o-rings (202). See page 18. 308479 15
  • 53. ServiceRepairing the Air Valve ReassemblyTools Required 1. If you replaced the bearings (12, 15), reinstall as explained on page 22. Reassemble the fluid sec-D Torque wrench tion.D Torx (T20) screwdriver or 7 mm (9/32”) socket wrenchD Needle-nose pliers 2. Install the valve plate seal (9{) into the groove at the bottom of the valve cavity. The rounded side ofD O-ring pick the seal must face down into the groove. SeeD Lithium base grease Fig. 11.NOTE: Air Valve Repair Kit 236273 is available. Referto page 25. Parts included in the kit are marked with a 3. Install the valve plate (8) in the cavity. The plate issymbol, for example (4{). Use all the parts in the kit for reversible, so either side can face up. Install thethe best results. three screws (3), using a Torx (T20) screwdriver or 7 mm (9/32”) socket wrench. Tighten until theDisassembly screws bottom out on the housing. See Fig. 11. WARNING 4. Install an o-ring (17{) on each pilot pin (16). To reduce the risk of serious injury whenever you Grease the pins and o-rings. Insert the pins into are instructed to relieve pressure, always follow the the bearings (15), narrow end first. See Fig. 10. Pressure Relief Procedure on page 11.1. Relieve the pressure. 5. Install a u-cup packing (10{) on each actuator piston (11), so the lips of the packings face the2. With a Torx (T20) screwdriver or 7 mm (9/32”) narrow end of the pistons. See Fig. 10. socket wrench, remove the six screws (3), air valve cover (2), and gasket (4). See Fig. 8. 6. Lubricate the u-cup packings (10{) and actuator3. Move the valve carriage (5) to the center position pistons (11). Insert the actuator pistons in the and pull it out of the cavity. Remove the valve bearings (12), wide end first. Leave the narrow block (7) and o-ring (6) from the carriage. Using a end of the pistons exposed. See Fig. 10. needle-nose pliers, pull the pilot block (18) straight up and out of the cavity. See Fig. 9. 7. Grease the lower face of the pilot block (18{) and4. Pull the two actuator pistons (11) out of the bear- install so its tabs snap into the grooves on the ings (12). Remove the u-cup packings (10) from ends of the pilot pins (16). See Fig. 9. the pistons. Pull the pilot pins (16) out of the bearings (15). Remove the o-rings (17) from the push pins. See Fig. 10. 8. Grease the o-ring (6{) and install it in the valve block (7{). Push the block onto the valve carriage5. Inspect the valve plate (8) in place. If damaged, (5). Grease the lower face of the valve block. See use a Torx (T20) screwdriver or 7 mm (9/32”) Fig. 9. socket wrench to remove the three screws (3). Remove the valve plate (8) and seal (9). See Fig. 11. 9. Install the valve carriage (5) so its tabs slip into the grooves on the narrow end of the actuator pistons6. Inspect the bearings (12, 15) in place. See Fig. 10. (11). See Fig. 9. The bearings are tapered and, if damaged, must be removed from the outside. This requires disas- sembly of the fluid section. See page 22. 10. Align the valve gasket (4{) and cover (2) with the six holes in the center housing (1). Secure with six7. Clean all parts and inspect for wear or damage. screws (3), using a Torx (T20) screwdriver or 7 Replace as needed. Reassemble as explained on mm (9/32”) socket wrench. Torque to 50–60 in-lb page 16. (5.6–6.8 N.m). See Fig. 8.16 308479
  • 54. Service Torque to 50–60 in-lb 2 3 2 1 Insert narrow end first. (5.6–6.8 NSm). 2 2 Grease. 3 Install with lips facing narrow end of piston (11). 4{ 4 Insert wide end first. 10{ 2 3 11 4 12 2 17{ 15 16 1 02644B 02643Fig. 8 Fig. 10 1 Rounded side must face down. 3 2 Detail 2 Tighten screws until 1 5 they bottom out on See Detail at right. the housing. 8 2 Grease. 2 {6 3 Grease lower face. 3 {7 1 {9 18{ 3 5 1 02642 02645Fig. 9 Fig. 11 308479 17
  • 55. ServiceBall Check Valve Repair 1 Apply medium-strength (blue) LoctiteR or equivalent to the threads, and torque to 120–150 in-lb (14–17 N.m).Tools Required 2 Arrow (A) must point toward outlet manifold (103).D Torque wrench 3 Beveled seating surface must face the ball (301).D 10 mm socket wrench 4 Not used on some models.D O-ring pick Aluminum Model ShownDisassemblyNOTE: A Fluid Section Repair Kit is available. Refer to 1 106page 25 to order the correct kit for your pump. Partsincluded in the kit are marked with an asterisk, forexample (201*). Use all the parts in the kit for the bestresults. 103NOTE: To ensure proper seating of the balls (301),always replace the seats (201) when replacing theballs. Also, on some models, replace the o-rings (202). 301* 201* 3 WARNING To reduce the risk of serious injury whenever you 202* 4 are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11. 1011. Relieve the pressure. Disconnect all hoses. A 22. Remove the pump from its mounting.3. Using a 10 mm socket wrench, remove the four bolts (106) and nuts (114, used on stainless steel pumps only) holding the outlet manifold (103) to the fluid covers (101). See Fig. 12.4. Remove the o-rings (202, not used on some 301* models), seats (201), and balls (301) from the manifold (103). 201* 35. Turn the pump over and remove the inlet manifold 202* 4 (102). Remove the o-rings (202, not used on some models), seats (201), and balls (301) from the fluid covers (101). 102Reassembly1. Clean all parts and inspect for wear or damage. Replace parts as needed. 106 12. Reassemble in the reverse order, following all 02647C notes in Fig. 12. Be sure the ball checks and Fig. 12 manifolds are assembled exactly as shown. The arrows (A) on the fluid covers (101) must point toward the outlet manifold (103).18 308479
  • 56. ServiceDiaphragm Repair WARNINGTools RequiredD Torque wrench To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow theD 10 mm socket wrench Pressure Relief Procedure on page 11.D 15 mm socket wrench (aluminum models) or 1” socket wrench (stainless steel models)D 19 mm socket wrench 1. Relieve the pressure.D O-ring pickD Lithium-base grease 2. Remove the manifolds and disassemble the ball check valves as explained on page 18.DisassemblyNOTE: A Fluid Section Repair Kit is available. Refer topage 25 to order the correct kit for your pump. Parts 3. Using a 10 mm socket wrench, remove the screwsincluded in the kit are marked with an asterisk, for (106) holding the fluid covers (101) to the airexample (401*). Use all the parts in the kit for the best covers (23). Pull the fluid covers (101) off theresults. pump. See Fig. 13. 1 Apply medium-strength (blue) LoctiteR or equivalent to the threads, and torque to 120–150 in-lb (14–17 N.m). 2 Arrow (A) must point toward air valve (B). B 23 101 A 2 106 1 02635BFig. 13 308479 19
  • 57. Service4. Loosen but do not remove the diaphragm shaft NOTE: On stainless steel pumps only, the fluid side bolts (107), using a 15 mm socket wrench (1” on diaphragm plate (105) is stainless steel. This plate is stainless steel models) on both bolts. not stamped with its part number. Be sure to install this plate on the fluid side of the diaphragm.5. Unscrew one bolt from the diaphragm shaft (24) and remove the o-ring (108), fluid side diaphragm c. On TeflonR models only, install the TeflonR plate (105), TeflonR diaphragm (403, used on diaphragm (403*). Make certain the side TeflonR models only), diaphragm (401), and air marked AIR SIDE faces the center hous- side diaphragm plate (104). See Fig. 14. ing (1). d. Install the diaphragm (401*) on the bolt. Make6. Pull the other diaphragm assembly and the dia- certain the side marked AIR SIDE faces the phragm shaft (24) out of the center housing (1). center housing (1). Hold the shaft flats with a 19 mm socket wrench, and remove the bolt (107) from the shaft. Disas- e. Install the air side diaphragm plate (104) so semble the remaining diaphragm assembly. the rounded side faces the diaphragm (401). This plate is used on all models, and is7. Inspect the diaphragm shaft (24) for wear or stamped with its part number. scratches. If it is damaged, inspect the bearings (19) in place. If the bearings are damaged, refer to f. Apply medium-strength (blue) LoctiteR or page 22. equivalent to the bolt (107) threads. Screw the bolt into the shaft (24) hand tight.8. Reach into the center housing (1) with an o-ring pick and hook the u-cup packings (402), then pull 3. Grease the length and ends of the diaphragm shaft them out of the housing. This can be done with the (24), and slide it through the housing (1). bearings (19) in place. 4. Assemble the other diaphragm assembly to the9. Clean all parts and inspect for wear or damage. shaft as explained in step 2. Replace parts as needed. 5. Hold one shaft bolt (107) with a wrench and torque the other bolt to 20–25 ft-lb (27–34 N.m) at 100Reassembly rpm maximum.1. Install the shaft u-cup packings (402*) so the lips face out of the housing (1). Lubricate the pack- 6. Align the fluid covers (101) and the center housing ings. See Fig. 14. (1) so the arrows (A) on the covers face the same direction as the air valve (B). Apply medium-2. Install the diaphragm assembly on one end of the strength (blue) LoctiteR or equivalent to the shaft (24) as follows: threads of the screws (106). Secure the covers with the screws handtight. See Fig. 13. Using a 10 a. Install the o-ring (108*) on the shaft bolt (107). mm socket wrench, torque the screws oppositely and evenly to 120–150 in-lb (14–17 N.m). b. Install the fluid side diaphragm plate (105) on the bolt so the rounded side faces the dia- 7. Reassemble the ball check valves and manifolds phragm (401). as explained on page 18.20 308479
  • 58. Service 19 402* 1 105 2 107 5 403* 1 24 104 401* 3 6 1 4 2 3 02638A 02637A Cutaway View, with Diaphragms in Place Cutaway View, with Diaphragms Removed 24 4 104 2 401* 3 403* 3 6 105 2 108* 1 107 5 24 4 1 Lips face out of housing (1). 2 Rounded side faces diaphragm (401). 3 Air Side must face center housing (1). 4 Grease. 5 Apply medium-strength (blue) LoctiteR or equivalent. Torque to 20–25 ft-lb (27–34 N-m) at 100 rpm maximum. 6 Used on pumps with TeflonR diaphragms only.Fig. 14 02636B 308479 21
  • 59. ServiceBearing and Air Gasket RemovalTools Required ReassemblyD Torque wrench 1. If removed, install the shaft u-cup packings (402*) so the lips face out of the housing (1).D 10 mm socket wrenchD Bearing puller 2. The bearings (12, 15, and 19) are tapered and can only be installed one way. Insert the bearings intoD O-ring pick the center housing (1), tapered end first. Using aD Press, or block and mallet press or a block and rubber mallet, press-fit the bearing so it is flush with the surface of the centerDisassembly housing.NOTE: Do not remove undamaged bearings. 3. Reassemble the air valve as explained on page WARNING 16. To reduce the risk of serious injury whenever you 4. Align the new air cover gasket (22) so the pilot pin are instructed to relieve pressure, always follow the (16) protruding from the center housing (1) fits Pressure Relief Procedure on page 11. through the proper hole (H) in the gasket.1. Relieve the pressure. 5. Align the air cover (23) so the pilot pin (16) fits in the middle hole (M) of the three small holes near2. Remove the manifolds and disassemble the ball the center of the cover. Install the screws (25), check valves as explained on page 18. handtight. Apply medium-strength (blue) LoctiteR3. Remove the fluid covers and diaphragm assem- or equivalent to the threads of the screws (25). blies as explained on page 19. See Fig. 15. Using a 10 mm socket wrench, torque the screws oppositely and evenly to 130–150 in-lbNOTE: If you are removing only the diaphragm shaft (15–17 N.m).bearing (19), skip step 4.4. Disassemble the air valve as explained on page 6. Install the diaphragm assemblies and fluid covers 16. as explained on page 19.5. Using a 10 mm socket wrench, remove the screws 7. Reassemble the ball check valves and manifolds (25) holding the air covers (23) to the center as explained on page 18. housing (1). See Fig. 15.6. Remove the air cover gaskets (22). Always replace the gaskets with new ones.7. Use a bearing puller to remove the diaphragm shaft bearings (19), air valve bearings (12) or pilot pin bearings (15). Do not remove undamaged bearings.8. If you removed the diaphragm shaft bearings (19) reach into the center housing (1) with an o-ring pick and hook the u-cup packings (402), then pull them out of the housing. Inspect the packings. See Fig. 14.22 308479
  • 60. Service 12 1 21 Insert bearings tapered end first.2 Press-fit bearings flush with surface of center housing (1).3 Apply medium-strength (blue) LoctiteR or equivalent. Torque to 130–150 in-lb (15–17 N.m). 15 1 2 02640 Detail of Air Valve Bearings 1 16 19 2 1 22 H M 23 25 3 02639BFig. 15 308479 23
  • 61. Pump MatrixHusky 1040 Aluminum and Stainless Steel Pumps, Series AYour Model No. is marked on the pump’s serial plate. To determine the Model No. of your pump from the followingmatrix, select the six digits which describe your pump, working from left to right. The first digit is always D,designating Husky diaphragm pumps. The remaining five digits define the materials of construction. For example, apump with an aluminum air motor, aluminum fluid section, polypropylene seats, Teflonr balls, and Teflonrdiaphragms is Model D 7 3 9 1 1. To order replacement parts, refer to the part lists on pages 26–28. The digits inthe matrix do not correspond to the ref. nos. in the parts drawing and lists. Diaphragm Pump Air Motor Fluid Section – Seats Balls Diaphragms 232501* aluminum aluminum – Hytrelr acetal Hytrelr D (for all pumps) 7 Aluminum 1 (not used) – 1 (not used) 1 (Teflonr) 1 (Teflonr) (Standard) 234124* 8 Aluminum 2 (not used) 2 (acetal) 2 (acetal) 2 (not used) (Remote) R sst (standard) 3 (aluminum) – 3 (316 sst) 3 (316 sst) 3 (not used) S sst (remote) 4 (sst) – 4 (17–4 PH sst) 4 (440C sst) 4 (not used) 5 (not used) – 5 (Hytrelr) 5 (Hytrelr) 5 (Hytrelr) C (aluminum 6 (Santoprener) 6 (Santoprener) 6 (Santoprener) BSPT) D (sst BSPT) – 7 (buna–N) 7 (buna-N) 7 (buna-N) – 8 (Vitonr) 8 (Vitonr) 8 (Vitonr) – 9 (polypropylene) 9 (not used) 9 (not used) – A (Kynarr) A (not used) A (not used) – G (Geolastr) G (Geolastr) G (Geolastr)* 232501, Aluminum 1040 Pump, Series AModel No. 232501 is a private-label aluminum 1040 pump. This pump is the same as Model No. D73525 except forthe label and:Reference #10 is 115666 Packing, U–cup, VitonReference #17 is 168518 O–ring, VitonUse 243492 as the Air Valve Repair Kit* 234124, Aluminum 1040 Pump, Series AModel No. 234124 is a private-label aluminum 1040 pump. This pump is the same as Model No. D73GGG exceptfor the label and:Reference #10 is 115666 Packing, U–cup, VitonReference #17 is 168518 O–ring, VitonUse 243492 as the Air Valve Repair Kit246450 Stainless Steel Air Motor Conversion KitUse kit 246450 and refer to manual 309643 (included in kit) to convert from aluminum air motor to stainless steel airmotor.24 308479
  • 62. Repair Kit MatrixFor Husky 1040 Aluminum and Stainless Steel Pumps, Series ARepair Kits may be ordered separately. To repair the air valve, order Part No. 236273 (see page 28). Parts includedin the Air Valve Repair Kit are marked with a symbol in the parts list, for example (4{).To repair your pump, select the six digits which describe your pump from the following matrix, working from left toright. The first digit is always D, the second digit is always 0 (zero), and the third is always 7. The remaining threedigits define the materials of construction. Parts included in the kit are marked with an asterisk in the parts list, forexample (201*). For example, if your pump has polypropylene seats, Teflonr balls, and Teflonr diaphragms, orderRepair Kit D 0 7 9 1 1. If you only need to repair certain parts (for example, the diaphragms), use the 0 (null)digits for the seats and balls, and order Repair Kit D 0 7 0 0 1. The digits in the matrix do not correspond to theref. nos. in the parts drawing and lists on pages 26–28. Diaphragm Pump Null Shaft O-ring – Seats Balls Diaphragms D (for all pumps) 0 (for all pumps) 7 (Teflonr) – 0 (null) 0 (null) 0 (null) – 1 (not used) 1 (Teflonr) 1 (Teflonr) – 2 (acetal) 2 (acetal) 2 (not used) – 3 (316 sst) 3 (316 sst) 3 (not used) – 4 (17–4 PH sst) 4 (440C sst) 4 (not used) – 5 (Hytrelr) 5 (Hytrelr) 5 (Hytrelr) – 6 (Santoprener) 6 (Santoprener) 6 (Santoprener) – 7 (buna–N) 7 (buna-N) 7 (buna-N) – 8 (Vitonr) 8 (Vitonr) 8 (Vitonr) – 9 (polypropylene) 9 (not used) 9 (not used) – A (Kynarr) A (not used) A (not used) – G (Geolastr) G (Geolastr) G (Geolastr) 308479 25
  • 63. PartsAir Motor Parts List (Matrix Column 2) Ref. Ref.Digit No. Part No. Description Qty Digit No. Part No. Description Qty7 1 188838 HOUSING, center; alumi- 1 8 Same as 7 with the following exceptions num 1 195921 HOUSING, center; alumi- 1 2 188854 COVER, air valve; alum. 1 num, remote 3 116344 SCREW, mach, hex 9 23 195917 COVER, air; remote 2 flange hd; M5 x 0.8; 12 mm (0.47 in.) R Same as 7 with the following exceptions 4{ 188618 GASKET, molded Santo- 1 1 15A734 HOUSING, center; 1 prene stainless steel 5 188855 CARRIAGE; aluminum 1 2 15A735 COVER, air valve; 1 stainless steel 6{ 108730 O-RING; nitrile 1 23 15A736 COVER, air; stainless 2 7{ 188616 BLOCK, air valve; acetal 1 steel 8 188615 PLATE, air valve; sst 1 S Same as 7 with the following exceptions 9{ 188617 SEAL, valve plate;buna-N 1 1 15B835 HOUSING, center; 1 remote, stainless steel 10{ 112181 PACKING, u-cup; nitrile 2 2 15A735 COVER, air valve; 1 11 188612 PISTON, actuator; acetal 2 stainless steel 12 188613 BEARING, piston; acetal 2 23 15B794 COVER, air; remote, 2 13} 104765 PLUG, pipe; headless 2 stainless steel 14} 115671 FITTING, connector; male 2 15 188611 BEARING, pin; acetal 2 16 188610 PIN, pilot; stainless steel 2 17{ 157628 O-RING; buna-N 2 18{ 188614 BLOCK, pilot; acetal 1 19 188609 BEARING, shaft; acetal 2 20 116343 SCREW, grounding 1 22 188603 GASKET, air cover; foam 2 23 188839 COVER, air; aluminum 2 24 188608 SHAFT, diaphragm; sst 1 25 115643 SCREW; M8 x 1.25; 12 25 mm (1 in.)26 308479
  • 64. PartsFluid Section Parts List (Matrix Column 3) Ref. Ref.Digit No. Part No. Description Qty Digit No. Part No. Description Qty3 101 188840 COVER, fluid; aluminum 2 4 101 188860 COVER, fluid; sst 2 102 188841 MANIFOLD, inlet; 1 102 188862 MANIFOLD, inlet; sst 1 aluminum 103 188842 MANIFOLD, outlet; 1 103 188861 MANIFOLD, outlet; sst 1 aluminum 104 188607 PLATE, air side; alum. 2 104 188607 PLATE, air side; alum. 2 105 188960 PLATE, fluid side; sst 2 105 188607 PLATE, fluid side; 2 106 112178 SCREW; M8 x 1.25; 24 aluminum 25 mm (1 in.) 106 115643 SCREW; M8 x 1.25; 24 107 189044 BOLT; M12 x 1.75; 2 25 mm (1 in.) 35 mm (1.38 in.); sst 107 189044 BOLT; M12 x 1.75; 2 108* 104319 O-RING; Teflonr 2 35 mm (1.38 in.); sst 110 188621 LABEL, warning 1 108* 104319 O-RING; Teflonr 2 Y 110 188970 LABEL, warning 1 111 112182 MUFFLER 1 Y 113 None Not Used 0 111 112182 MUFFLER 1 114 112257 NUT, hex; M8 x 1.25; sst 8 113 112183 PLUG: 1” npt; cst 4 114 None Not Used 0 continued 308479 27
  • 65. Parts 3 2 11 10{ 4{ {17 5 16 6{ {18 3 7{ 8 9{ 2 113 16 17{ 12 Y110 106 10{ 14} 11 22 23 103 25 15 24 2 113 *402 20 1 19 104 401* 301* 403* 1 202* 4 111 13} 105 201* 108* 107 202* 4Aluminum Model Shown 1061 Used on pumps with Teflonr diaphragms only.2 Not used on stainless steel pumps. 114 33 Not used on aluminum pumps. 1014 Not used on all models. 2 113 *301* These parts are included in the Pump Repair Kit, 202* 4 which may be purchased separately. Refer to the Repair Kit Matrix on page 25 to *201 determine the correct kit for your pump. 202* 4{ These parts are included in Air Valve Repair Kit 236273, which may be purchased separately. 102Y Replacement Danger and Warning labels, tags and cards are available at no cost.} These parts are unique to remote piloted air motor, D8–––– and DS–––– 106 2 113 02633E28 308479
  • 66. PartsFluid Section Parts List (Matrix Column 3) Seat Parts List (Matrix Column 4)(continued) Ref. Ref. Digit No. Part No. Description QtyDigit No. Part No. Description Qty 2 201* 188604 SEAT; acetal 4C 101 188840 COVER, fluid; aluminum 2 202* 109205 O-RING; Teflonr 8 102 192070 MANIFOLD, inlet; 1 aluminum; BSPT 3 201* 188707 SEAT; 316 stainless steel 4 103 192071 MANIFOLD, outlet; 1 202* 109205 O-RING; TeflonR 8 aluminum; BSPT 4 201* 188708 SEAT; 17-4 stainless steel 4 104 188607 PLATE, air side; 2 aluminum 202* 109205 O-RING; Teflonr 8 105 188607 PLATE, fluid side; 2 5 201* 188711 SEAT; Hytrelr 4 aluminum 202 None Not Used 0 106 115643 SCREW; M8 x 1.25; 24 25 mm (1 in.) 6 201* 191595 SEAT; Santoprene 4 107 189044 BOLT; M12 x 1.75; 2 202* 109205 O-RING; Teflonr 8 35 mm (1.38 in.); sst 7 201* 15B275 SEAT; Buna–N 4 108* 104319 O-RING; Teflonr 2 202* None Not used 0 110 188970 LABEL, warning 1 8 201* 15B633 SEAT; Viton 4 Y 202 None Not Used 0 111 112182 MUFFLER 1 9 201* 189722 SEAT; polypropylene 4 113 113991 PLUG: 1” BSPT; cst 4 114 None Not Used 0 202* 109205 O-RING; Teflonr 8D 101 188860 COVER, fluid; sst 2 A 201* 189723 SEAT; Kynar 4 102 192068 MANIFOLD, inlet; sst; 1 202* 109205 O-RING; Teflonr 8 BSPT G 201* 194211 SEAT; Geolast 4 103 192069 MANIFOLD, outlet; sst; 1 BSPT 202* 109205 O-RING; Teflonr 8 104 188607 PLATE, air side; 2 aluminum 105 188960 PLATE, fluid side; sst 2 106 112178 SCREW; M8 x 1.25; 24 25 mm (1 in.) 107 189044 BOLT; M12 x 1.75; 2 35 mm (1.38 in.); sst 108* 104319 O-RING; Teflonr 2 110 188621 LABEL, warning 1 Y 111 112182 MUFFLER 1 113 None Not Used 0 114 112257 NUT, hex; M8 x 1.25; sst 8 308479 29
  • 67. PartsBall Parts List (Matrix Column 5) Diaphragm Parts List (Matrix Column 6) Ref. Ref.Digit No. Part No. Description Qty Digit No. Part No. Description Qty1 301* 112088 BALL; Teflonr 4 1 401* 188606 DIAPHRAGM, backup; 2 Hytrelr2 301* 112254 BALL; acetal 4 402* 112181 PACKING, u-cup; nitrile 23 301* 103869 BALL; 316 stainless steel 4 403* 188605 DIAPHRAGM; Teflonr 24 301* 102973 BALL; 440C stainless 4 steel 5 401* 188606 DIAPHRAGM; Hytrelr 25 301* 112089 BALL; Hytrelr 4 402* 112181 PACKING, u-cup; nitrile 26 301* 112092 BALL; Santoprene 4 6 401* 188857 DIAPHRAGM; Santo- 2 prene7 301* 15B488 BALL; buna-N 4 402* 112181 PACKING, u-cup; nitrile 28 301* 15B487 BALL; Vitonr 4 7 401* 15B499 DIAPHRAGM; buna-N 2G 301* 114751 BALL; Geolastr 4 402* 112181 PACKING, u-cup; nitrile 2 8 401* 15B500 DIAPHRAGM; Vitonr 2 402* 112181 PACKING, u-cup; nitrile 2 G 401* 194212 DIAPHRAGM; Geolastr 2 402* 112181 PACKING, u-cup; nitrile 230 308479
  • 68. Dimensional Drawings FRONT VIEW 12.0 in. PUMP MOUNTING (305 mm) HOLE PATTERN 6.0 in. (152 mm) 5.0 in. Four 0.5 in. (127 mm) (12.5 mm) 1 1/2 npt(f) diameter holes Air Inlet 1 npt(f) Optional Fluid Outlet 5.5 in. (139.5 mm) A B C 9.1 in. (231.1 mm) 1 On aluminum pumps only. 1.0 in. 1 3/4 npt(f) 5.5 in. (25.5 mm)1 npt(f) Air Exhaust (139.5 mm)Optional (mufflerFluid Inlet included) 7437A 3.95 in. 1 npt(f) (100 mm) Fluid Outlet SIDE VIEW 45° Dim. Alum. Pumps SST Pumps A 12.58 in. (319.5 mm) 12.31 in. (312.7 mm) 5.0 in. B 13.58 in. (345.0 mm) 13.31 in. (338.1 mm) (127 mm) 1 npt(f) Fluid Inlet C 14.48 in. (367.8 mm) 14.21 in. (360.9 mm) 9.25 in. (235 mm) 308479 31
  • 69. Technical DataMaximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 psi (0.8 MPa, 8 bar)Air pressure operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–120 psi (0.14–0.8 MPa, 1.4–8 bar)Maximum air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 scfmAir consumption at 70 psi/20 gpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 scfm (see chart)Maximum free-flow delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 gpm (159 l/min)Maximum pump speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 cpmGallons (Liters) per cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 (0.57)Maximum suction lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ft (5.48 m) wet or dryMaximum size pumpable solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/8 in. (3.2 mm)* Maximum Noise Level at 100 psi, full flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 dBa* Sound Power Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 dBa* Noise Level at 70 psi and 50 cpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 dBaMaximum operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150_F (65.5_C); 200_F (93.3_C) for models with Teflonr diaphragmsAir inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt(f)Fluid inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1” npt(f)Fluid outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1” npt(f)Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vary by Model. See pages 26–28.Non-wetted external parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aluminum, 302, 316 stainless steel, polyester (labels)Weight Aluminum pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 lb (8.2 kg) Stainless steel pumps with aluminum center section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 lb (15.0 kg) Stainless steel pumps with stainless steel center section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 lb (22kg)Teflonr, Vitonr, and Hytrelr are registered trademarks of the DuPont Co.Geolastr and Santoprener are registered trademarks of the Monsanto Co.Kynarr is a registered trademark of Atochem North America, Inc.Loctiter is a registered trademark of the Loctite Corporation.* Noise levels measured with the pump mounted on the floor, using Rubber Foot Kit 236452. Sound power measured per ISO Standard 9614–1.32 308479
  • 70. Performance Chart Test Conditions: Pump tested in water with inlet submerged. FLUID OUTLET PRESSURE––psi (MPa, bar) Fluid Pressure Curves 120A at 120 psi (0.7 MPa, 7 bar) air pressure (0.84, 8.4) AB at 100 psi (0.7 MPa, 7 bar) air pressure 100C at 70 psi (0.48 MPa, 4.8 bar) air pressure (0.7, 7) BD at 40 psi (0.28 MPa, 2.8 bar) air pressure 80 (0.55, 5.5)To find Fluid Outlet Pressure C(psi/MPa/bar) at a specific fluid flow 60(gpm/lpm) and operating air pressure (0.41, 4.1)(psi/MPa/bar): 401. Locate fluid flow rate along bottom of D (0.28, 2.8) chart.2. Follow vertical line up to intersection 20 with selected fluid outlet pressure curve. (0.14, 1.4)3. Follow left to scale to read fluid outlet 0 pressure. 0 5 10 15 20 25 30 35 40 (19) (38) (57) (76) (95) (114) (133) (152) FLUID FLOW--gpm (lpm) AIR CONSUMPTION––scfm (cubic meters/min) Air Consumption Curves 60 (1.68) A at 120 psi (0.7 MPa, 7 bar) air pressure B at 100 psi (0.7 MPa, 7 bar) air pressure 50 (1.40) C at 70 psi (0.48 MPa, 4.8 bar) air pressure D at 40 psi (0.28 MPa, 2.8 bar) air pressure 40 A (1.12) B To find Pump Air Consumption (scfm or 30 m#/min) at a specific fluid flow (gpm/lpm) and (0.84) air pressure (psi/MPa/bar): C 1. Locate fluid flow rate along bottom of chart. 20 (0.56) 2. Read vertical line up to intersection with selected air consumption curve. D 10 3. Follow left to scale to read air consumption. (0.28) 0 0 5 10 15 20 25 30 35 40 (19) (38) (57) (76) (95) (114) (133) (152) FLUID FLOW--gpm (lpm) 308479 33
  • 71. Graco WarrantiesGraco Standard Husky Pump WarrantyGraco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on thedate of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limitedwarranty published by Graco, Graco will, for a period of five years from the date of sale, repair or replace any part of the equipmentdetermined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accor-dance 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 byfaulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-stitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility ofGraco 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 forverification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. Theequipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defectin material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, andtransportation.THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUTNOT 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 otherremedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or anyother incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within six years of the dateof sale.Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connectionwith accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufacturedby Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will providepurchaser 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 equipmenthereunder, 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 CUSTOMERSThe parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedingsentered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciairesexécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.Extended Product WarrantyGraco warrants all Husky 205, 307, 515, 716, 1040, 1590, 2150, and 3275 air valve center sections to be free from defects in materialand workmanship for a period of fifteen years from date installed in service by the original purchaser. Normal wear of items such aspackings or seals are not considered to be defects in material and workmanship.Five years Graco will provide parts and labor.Six to Fifteen years Graco will replace defective parts only. Graco InformationTO PLACE AN ORDER, contact your Graco distributor, or call this number 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 308479 11/1994, Revised 05/200334 308479
  • 72. Catalog 0600P-6/USA Prep-Air ® II, 07F SeriesStandard 07F Series 3/8", 1/2", 3/4" – Basic 1/2" Body 07F Filters – Standard A Twist Automatic Features Drain Drain • Excellent water removal efficiency. B • Unique deflector plate and shroud creates a swirling of the air stream ensuring maximum water and dirt separation. C • Large filter element surface guarantees low pressure drop and increased element life. • Optional Push ‘N’ Drain requires only fingertip E touch to drain. Optional automatic float drain D available. • Shown with recommended metal bowl guard. • High Flow: 3/8" – 100 SCFM § Distance Required 1/2" – 130 SCFM § F To Remove All Bowls 3/4" – 145 SCFM § Regardless Of Drain Option Port NPT BSPP 07F Filter Dimensions Size Twist Drain Automatic Float Drain Twist Drain Automatic Float Drain A B C Poly Bowl ‡ / Metal Guard 3.24 3.25 .70 (82) (83) (18) 3/8" 07F22AC 07F26AC 07F22AC1 07F26AC1 D D† E 1/2" 07F32AC 07F36AC 07F32AC1 07F36AC1 6.97 7.00 7.67 3/4" 07F42AC 07F46AC 07F42AC1 07F46AC1 (177) (178) (195) E† F Metal Bowl / Sight Gauge 7.70 2.75 3/8" 07F24AC 07F28AC 07F24AC1 07F28AC1 (196) (70) 1/2" 07F34AC 07F38AC 07F34AC1 07F38AC1 Inches (mm) † With Automatic Float Drain 3/4" 07F44AC 07F48AC 07F44AC1 07F48AC1Standard part numbers shown, for other models refer to ordering information below.‡ For polycarbonate bowl see Caution on page 2.§ SCFM = Standard cubic feet per minute at 90 PSIG inlet and 5 PSIG pressure drop.Ordering Information 07F 3 2 A C — — Engineering Port Size Bowl Options Elements Level Options Port Type 2. 3/8 Inch Polycarbonate Bowl Metal Bowl A. 40 Micron C. Current Blank. None Blank. NPT 3. 1/2 Inch 1. Twist Drain 3. Twist Drain B. 5 Micron P. Differential 1. BSPP 4. 3/4 Inch 2. Metal Bowl Guard / 4. Sight Gauge / Z. Adsorber Pressure 2. BSPT Twist Drain Twist Drain Indicator 5. Auto Float Drain 7. Auto Float Drain 6. Metal Bowl Guard / 8. Sight Gauge / Auto Float Drain Auto Float Drain E. Push ‘N’ Drain G. Push ‘N’ Drain F. Metal Bowl Guard / H. Sight Gauge / Push ‘N’ Drain Push ‘N’ Drain J. Semi-Auto Drain L. Semi-Auto Drain K. Metal Bowl Guard / M. Sight Gauge / Semi-Auto Drain Semi-Auto DrainNOTE: BOLD OPTIONS ARE STANDARD. 14 Parker Hannifin Corporation Pneumatic Division Pneumatic Richland, Michigan www.parker.com/pneumatic
  • 73. Catalog 0600P-6/USA Prep-Air ® II, 07F SeriesTechnical Specifications – 07F Air Line FiltersTechnical Information Primary Pressure - bar Primary Pressure - bar 2.4 bar 6.2 bar 10.3 bar 2.4 bar 6.2 bar 10.3 bar Primary Pressure - PSIG Primary Pressure - PSIG 35 PSIG 90 PSIG 150 PSIG 35 PSIG 90 PSIG 150 PSIG 7 7 .4 6 6 .4 Pressure Drop - PSIG Pressure Drop - PSIG Pressure Drop - bar Pressure Drop - bar 5 5 .3 .3 4 4 .2 3 .2 3 2 2 .1 .1 1 Flow Characteristics 1 Flow Characteristics 07F22A 07F32A 3/8 Inch Ports 1/2 Inch Ports 0 0 0 0 0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160 180 200 220 Flow - SCFM Flow - SCFM 0 10 20 30 40 50 60 70 0 10 20 30 40 50 60 70 80 90 100 3 3 Flow - dm /s Flow - dm /s n n Primary Pressure - bar 2.4 bar 6.2 bar 10.3 bar Primary Pressure - PSIG 35 PSIG 90 PSIG 150 PSIG 7 .4 6 Pressure Drop - PSIG Pressure Drop - bar 5 .3 4 .2 3 2 .1 1 Flow Characteristics 07F42A 3/4 Inch Ports 0 0 0 20 40 60 80 100 120 140 160 180 200 220 240 260 Flow - SCFM 0 10 20 30 40 50 60 70 80 90 100 110 120 Flow - dm3 /s n07F Filter Kits & Accessories Port Threads ......................................................... 3/8, 1/2, 3/4 Inch Pressure & Temperature Ratings –Bowl Guard Kit .................................................................. PS805P Without Differential Pressure Indicator:Bowl Kits – Polycarbonate Bowl – 0 to 150 PSIG (0 to 10.3 bar) Poly Bowl – Automatic Float Drain ................................. PS822P 32°F to 125°F (0°C to 52°C) Semi-Auto Drain .......................................... PS892P Metal Bowl – 0 to 250 PSIG (0 to 17.2 bar) Twist Drain .................................................. PS832P Push ‘N’ Drain ............................................. PS804P 32°F to 175°F (0°C to 80°C) Metal Bowl –Automatic Float Drain ................................. PS826P With Differential Pressure Indicator –0 to 150 PSIG (0 to 10.3 bar) Semi-Auto Drain .......................................... PS894P 32°F to 125°F (0°C to 52°C) Twist Drain .................................................. PS834P Automatic Float Drain – 10 to 250 PSIG (0.7 to 17.2 bar) Push ‘N’ Drain ............................................. PS825P at 125°F (52°C) or less Sight Gauge / Automatic Drain ................... PS823P Weight ....................................................................... 2.2 lb. (1.0 kg) Sight Gauge / Semi-Auto Drain .................. PS893P Sight Gauge / Twist Drain ........................... PS835P Materials of Construction Sight Gauge / Push ‘N’ Drain ...................... PS806P Body ........................................................................................... ZincDPI Replacement Kit .......................................................... PS781P Bowls .................................................... Transparent PolycarbonateDrain Kits – Automatic Float Drain ................................. PS506P Metal (Zinc) With or Without Sight Gauge Semi-Auto Drain .......................................... PS511P Bowl Guards ........................................................................... Steel Twist Drain .................................................. PS512P Push ‘N’ Drain ............................................. PS513P Collar ....................................................................... Plastic or Metal Deflector, Shroud & Baffle ................................................. Plastic Drains – Twist Drain – Body & Nut ....................................... Plastic XFilter Element Kits –40 Micron .......................................... PS801P 5 Micron ............................................ PS802P Push ‘N’ Drain – Body .............................................. Nitrile Adsorber ........................................... PS831P Stem ............................................. BrassMounting Bracket Kit ........................................................ PS843P Automatic Float Drain – Housing, Float ................. PlasticSight Gauge Kit ................................................................. PS814P Seals ............................................. Nitrile Springs, Push Rod ........ Stainless Steel Filter Elements –40 Micron (Standard) ................................ PlasticSpecifications 5 Micron (Optional) ................................... PlasticBowl Capacity .............................................................. 7.2 Ounces Adsorber (Optional) .............. Activated CharcoalSump Capacity ............................................................ 2.8 Ounces Seals ........................................................................................ Nitrile Sight Gauge ................................................................... Polyamide 15 Parker Hannifin Corporation Pneumatic Division Pneumatic Richland, Michigan www.parker.com/pneumatic
  • 74. Catalog 0600P-6/USA Prep-Air ® II, 07R SeriesStandard 07R Series 3/8", 1/2", 3/4" – Basic 1/2" Body 07R Regulators – Standard A Features • Secondary aspiration plus balanced poppet provides B PUS CK H O quick response and accurate pressure regulation. TO L • Rolling diaphragm for extended life. • Two high flow 1/4" gauge ports can be used as additional outlets. • Easily serviced. C • Removable non-rising knob for panel mounting E and tamper resistance. • High Flow: 3/8" – 70 SCFM § 1/2" – 90 SCFM § D 3/4" – 90 SCFM § Port Size NPT BSPP 07R Regulator Dimensions Without Gauge A B C 3.24 2.74 4.79 3/8" 07R213AC 07R213AC1 (82) (70) (122) 1/2" 07R313AC 07R313AC1 D E 3/4" 07R413AC 07R413AC1 1.61 6.40 (41) (163) With 160 PSI Gauge Inches (mm) 3/8" 07R218AC 07R218AC1 1/2" 07R318AC 07R318AC1 3/4" 07R418AC 07R418AC1Standard part numbers shown, for other models refer to ordering information below.NOTE: 2.00 Dia. (51mm) hole required for panel mounting.§ ! WARNING SCFM = Standard cubic feet per minute at 100 PSIG inlet, 90 PSIG no flow secondary setting and 10 PSIG pressure drop. Product rupture can cause serious injury. Do not connect regulator to bottled gas. Do not exceed maximum primary pressure rating.Ordering Information 07R 3 13 A C — — --- Engineering Port Size Pressure Range Relief Level Port Type Options Preset 2. 3/8 Inch Without Gauge A. Relieving C. Current Blank. NPT Blank. No Options Blank. None 3. 1/2 Inch 10. 30 PSIG L. Non-Relieving 1. BSPP L.† Preset XXX* Preset 4. 3/4 Inch 11. 60 PSIG 2. BSPT Non-Adjustable Pressure 13. 125 PSIG P.† Preset * Available Preset 15. 250 PSIG Adjustable Range, 10 to 90 PSIG in 5 PSIG With Gauge R. Reverse Flow increments. For 17. 30 PSIG † Inlet Pressure is 100 PSIG. higher pressures, For other pressures, contact contact factory. 16. 60 PSIG (Example: 18. 125 PSIG factory. 065 = 65 PSIG) 21. 250 PSIGNOTE: BOLD OPTIONS ARE STANDARD. 54 Parker Hannifin Corporation Pneumatic Division Pneumatic Richland, Michigan www.parker.com/pneumatic
  • 75. Catalog 0600P-6/USA Prep-Air ® II, 07R SeriesTechnical Specifications – 07R Air Line RegulatorsTechnical Information Relief And Flow Characteristics Relief And Flow Characteristics 07R213A 07R313A 100 100 Secondary Pressure - PSIG Secondary Pressure - PSIG 6Secondary Pressure - bar 6 Secondary Pressure - bar 80 80 5 5 4 60 60 4 3 3 40 40 2 2 20 20 1 3/8 Inch Ports 1 1/2 Inch Ports 100 PSIG (6.9 bar) Primary Pressure 100 PSIG (6.9 bar) Primary Pressure 0 0 0 0 10 0 10 30 50 70 90 110 130 10 0 10 30 50 70 90 110 130 Rated Flow - SCFM Rated Flow - SCFM 5 0 5 15 25 35 45 55 5 0 5 15 25 35 45 55 3 3 Flow - dm /s Flow - dm /s n n Relief And Flow Characteristics 07R413A 100 Secondary Pressure - PSIG 6 Secondary Pressure - bar 80 5 4 60 3 40 2 20 1 3/4 Inch Ports 100 PSIG (6.9 bar) Primary Pressure 0 0 10 0 10 30 50 70 90 110 130 150 170 Rated Flow - SCFM 5 0 5 15 25 35 45 55 65 75 3 Flow - dm /s n07R Regulator Kits & Accessories SpecificationsBonnet Assembly Kit ........................................................ PS715P Gauge Ports (2) .................................................................. 1/4 InchControl Knob ................................................................... P04069B (Can be used as additional High Flow 1/4 Inch Outlet Ports)Gauges – 60 PSIG (0 to 400 kPa) ..................................... P781641 Port Threads ......................................................... 3/8, 1/2, 3/4 Inch 160 PSIG (0 to 1100 kPa) ................................. P781642 Primary Pressure Rating – 300 PSIG (0 to 2000 kPa) ................................. P781643 Maximum Primary Pressure ........................ 250 PSIG (1725 kPa)Mounting Bracket Kit (Includes Panel Mount Nut) ........... PS807P Secondary Pressure Ranges –Panel Mount Nut – Plastic .................................................. P04082 Standard Pressure ......................... 2 to 125 PSIG (14 to 863 kPa) Metal ................................................. P04079B Low Pressure .................................. 1 to 60 PSIG (6.9 to 414 kPa) High Pressure .............................. 5 to 250 PSIG (35 to 1725 kPa)Reverse Flow Service Conversion Kit – Relieving ................................................... PS808RP Non-Relieving ........................................... PS809RP Temperature Rating ........................... 32°F to 175°F (0°C to 80°C) Weight ........................................................................ 2.5 lb. (1.1 kg) XService Kit – Relieving (Includes Poppet) ......................... PS808P Materials of Construction Non-Relieving (Includes Poppet) ................. PS809P Adjusting Stem ....................................................................... SteelSprings – 1-30 PSIG Range ................................................. P01698 1-60 PSIG Range ................................................. P04062 Body .......................................................................................... Zinc 2-125 PSIG Range ............................................... P04063 Bonnet, Piston Stem, Valve Poppet & Cap ......................... Plastic 5-250 PSIG Range ............................................... P04064 Collar, Knob ........................................................................... PlasticTamperproof Kit .................................................................. PS737P Diaphragm .............................................................................. Nitrile Seals ........................................................................................ Nitrile Springs – Poppet ............................................................... Stainless Control ...................................................................... Steel 55 Parker Hannifin Corporation Pneumatic Division Pneumatic Richland, Michigan www.parker.com/pneumatic
  • 76. Catalog 0600P-6/USA Prep-Air ® II, 17L SeriesStandard 17L Series 3/8", 1/2", 3/4" – Basic 1/2" Body 17L Micro-Mist Lubricators – Standard Features A • Proportional oil delivery over a wide range of air flows. B • Generates oil particles of 5 micron or smaller downstream to lubricate systems having complex piping arrangements. C • Precision needle valve assures repeatable oil delivery and provides simple adjustment of delivery rate. • Ideal for low and high flow applications with changing E air flow. D • Transparent sight dome for 360° visibility. • Yellow fill cap identifies Micro-Mist Lubricator. • High Flow: 3/8" – 60 SCFM § Distance Required 1/2" – 90 SCFM § F To Remove All Bowls 3/4" – 90 SCFM § Regardless Of Drain Option Port NPT BSPP 17L Lubricator Dimensions Size Twist Drain No Drain Twist Drain No Drain A B C Poly Bowl ‡ / Metal Guard 3.24 3.25 2.41 (82) (83) (61) 3/8" — 17L22BE — 17L22BE1 D D† E 1/2" — 17L32BE — 17L32BE1 6.86 6.95 9.27 3/4" — 17L42BE — 17L42BE1 (174) (177) (235) E† F Metal Bowl / Sight Gauge 7.93 2.75 3/8" 17L24BE — 17L24BE1 — (201) (70) 1/2" 17L34BE — 17L34BE1 — Inches (mm) † With Twist Drain 3/4" 17L44BE — 17L44BE1 —Standard part numbers shown, for other models refer to ordering information below.‡ For polycarbonate bowl see Caution on page 2.§ SCFM = Standard cubic feet per minute at 90 PSIG inlet and 5 PSIG pressure drop.Ordering Information 17L 2 2 B E — Engineering Port Port Size Bowl Options Options Level Type 2. 3/8 Inch Polycarbonate Bowl Metal Bowl B. With Fill Plug E. Current Blank. NPT 3. 1/2 Inch 1. No Drain 4. Sight Gauge/ C. With Fill Plug/Nylon 1. BSPP 4. 3/4 Inch 2. Metal Bowl Guard/ Twist Drain Sight Dome 2. BSPT No Drain 8. Sight Gauge/ F. With Body Pressure Fill 5. Pressure Fill Pressure Fill G. With Body Pressure Fill/ 6. Metal Bowl Guard/ M. Sight Gauge/ Nylon Sight Dome Pressure Fill Auto Fill Device J. Auto Fill Device K. Metal Bowl Guard/ Auto Fill Device R. Twist Drain N. Metal Bowl Guard/ Twist DrainNOTE: BOLD OPTIONS ARE STANDARD. 106 Parker Hannifin Corporation Pneumatic Division Pneumatic Richland, Michigan www.parker.com/pneumatic
  • 77. Catalog 0600P-6/USA Prep-Air ® II, 17L SeriesTechnical Specifications – 17L Air Line Micro-Mist LubricatorsTechnical Information Primary Pressure - bar 2.4 bar 6.2 bar 10.3 bar Primary Pressure - PSIG 35 PSIG 90 PSIG 150 PSIG 7 .4 6 Pressure Drop - PSIG Pressure Drop - bar 5 .3 4 .2 3 2 .1 1 Flow Characteristics 17L22B 3/8 Inch Ports 0 0 0 10 20 30 40 50 60 70 80 90 100 Flow - SCFM 0 5 10 15 20 25 30 35 40 45 3 Flow - dm /s n Primary Pressure - bar 2.4 bar 6.2 bar 10.3 bar Primary Pressure - PSIG 35 PSIG 90 PSIG 150 PSIG 7 .4 6 Pressure Drop - PSIG Pressure Drop - bar 5 .3 4 .2 3 2 .1 Flow Characteristics 17L32B 1/2 Inch Ports 1 & 17L42B 3/4 Inch Ports 0 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Flow - SCFM 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 3 Flow - dm /s n17L Micro-Mist Lubricator Kits & SpecificationsAccessories Bowl Capacity .............................................................. 4.9 OuncesAdjustment Knob ............................................................... P04121 Minimum Flow for Lubrication ................... 1 SCFM At 100 PSIGBowl Guard Kit .................................................................. PS805P Port Threads ......................................................... 3/8, 1/2, 3/4 InchBowl Kits – Pressure & Temperature Rating – Polycarbonate Bowl – 0 to 150 PSIG (0 to 10.3 bar) Poly Bowl – No Drain ...................................................... PS846P 32°F to 125°F (0°C to 52°C) Twist Drain .................................................. PS817P Metal Bowl – 0 to 250 PSIG (0 to 17.2 bar) Pressure Fill ................................................ PS819P 32°F to 175°F (0°C to 80°C) Remote Fill .................................................. PS828P Suggested Lubricant ......................................................... F442 Oil Metal Bowl –Sight Gauge / Twist Drain ........................... PS829P Petroleum based oil of 100 to 200 SSU viscosity Sight Gauge / Pressure Fill ........................ PS820P at 100°F and an aniline point greater than 200°FDrain Kit – Twist Drain ......................................................... PS512P (DO NOT USE OILS WITH ADDITIVES,Fill Cap Kit ........................................................................... PS742P COMPOUNDED OILS CONTAINING SOLVENTS,Lubricator Service Kit ........................................................ PS748P GRAPHITE, DETERGENTS, OR SYNTHETIC OILS.)Mounting Bracket Kit ......................................................... PS843P Weight ......................................................................... 1.9 lb. (.9 kg)Oil – 1 Gal. .......................................................................... F442002 12 Quart Case ............................................................ F442003 Materials of Construction Body .......................................................................................... Zinc X 4 Gallon Case ............................................................ F442005Pressure Fill Adapter Kit ................................................... PS716P Bowls – Transparent .................................................. Polycarbonate Metal (With Sight Gauge) ............................................ ZincPressure Fill Button ........................................................... P11912 Bowl Guard ............................................................................. SteelRemote Auto-Fill Device ................................................. PS505CP Collar ....................................................................... Plastic or MetalSight Dome / Fill Cap Kit .................................................. PS739P Drain – Twist – Body & Nut .................................................... PlasticSight Dome Kit ................................................................... PS740P Injector Meter Block & Base Assembly ............................ PlasticNylon Sight Dome Kit ...................................................... PS740N Seals ....................................................................................... NitrileSight Gauge Kit .................................................................. PS814P Sight Dome ............................................................... Polycarbonate Sight Gauge ...................................................... Polyamide (Nylon) 107 Parker Hannifin Corporation Pneumatic Division Pneumatic Richland, Michigan www.parker.com/pneumatic
  • 78. 1 8 9 7 4 1618 17 2 3a 6 16 5 16 16 16 3 DRAWING NUMBER
  • 79. CONTROL VALVE 7 & PLUMBING SEE DWG.# 99063/B19 98038/B19 98041/B19 6 10 8 ROLLER KIT DETAIL 1 5 13 9 2b3a 2a 2 DRAWING NUMBER
  • 80. Parts INSTRUCTIONS-PARTS LIST 308156 This manual contains important Rev. K warnings and information. First choice when READ AND KEEP FOR REFERENCE. quality counts.t INSTRUCTIONS Dyna-Start HYDRAULIC RECIPROCATOR AND PUMP 1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure 7500 psi (51 MPa, 517 bar) Maximum Fluid Outlet Pressure FOR LUBRICATING FLUIDS ONLY 5:1 Ratio Universal Pump and Reciprocator Model 224912, Series C, 35 lb. pail size Model 224751, Series C, 120 lb. drum size Model 224752, Series C, 400 lb. drum size Model 239883, Series A, reciprocator only Patent No. 4,383,475 Foreign Patents Pending Patent 1984 Canada Brevete 1984 Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Replacing Throat Seals . . . . . . . . . . . . . . . . . . . . . . 11 Disconnecting the Reciprocator and Displacement Pump . . . . . . . . . . . . . . . . . . . . 12 Reciprocator Repair . . . . . . . . . . . . . . . . . . . . . . . . . 13 Displacement Pump Repair . . . . . . . . . . . . . . . . . . . 17 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . 19 Reciprocator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Pump Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Dimensions and Mounting Hole Layout . . . . . . . . . . . 23 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 24 06151B Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . 24 GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 ECOPYRIGHT 1991, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001
  • 81. SymbolsWarning Symbol Caution Symbol WARNING CAUTIONThis symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage toinjury or death if you do not follow the corresponding or destruction of equipment if you do not follow theinstructions. corresponding instructions. WARNING WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury. D This equipment is for professional use only. D Read all instruction manuals, tags, and labels before operating the equipment. D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor. D Do not alter or modify this equipment. Use only genuine Graco parts and accessories. D Check equipment daily. Repair or replace worn or damaged parts immediately. D Do not exceed the maximum working pressure of the lowest rated component in your system. This equipment has a 1500 psi (10 MPa, 102 bar) maximum hydraulic input pressure and 7500 psi (51 MPa, 517 bar) maximum fluid outlet pressure. D Use fluids and solvents that are compatible with the equipment wetted parts. Refer to the Techni- cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings. D Handle hoses carefully. Do not pull on hoses to move equipment. D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex- pose Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F). D Do not lift pressurized equipment. D Comply with all applicable local, state, and national fire, electrical, and safety regulations.2 308156
  • 82. WARNING WARNINGFLUID INJECTION HAZARDFluid from the dispensing valve, leaks or ruptured components can inject fluid into your body andcause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or onthe skin can also cause serious injury.D Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medical attention.D Do not point the dispensing valve at anyone or at any part of the body.D Do not put your hand or fingers over the end of the dispensing valve.D Do not stop or deflect leaks with your hand, body, glove or rag.D Use only extensions and couplers that are designed for use with your dispensing valve.D Do not use a low pressure flexible nozzle with this equipment.D Follow the Pressure Relief Procedure on page 8 if the grease fitting coupler clogs and before cleaning, checking or servicing the equipment.D Tighten all fluid connections before operating the equipment.D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not repair high pressure couplings; you must replace the entire hose.D Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by kinks or bends near the couplings.TOXIC FLUID HAZARDHazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on theskin, inhaled, or swallowed.D Know the specific hazards of the fluid you are using.D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer. 308156 3
  • 83. WARNING WARNING FIRE AND EXPLOSION HAZARD Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and result in a fire or explosion and serious injury. D Ground the equipment and the object being dispensed to. Refer to Grounding on page 7. D If there is any static sparking or you feel an electric shock while using this equipment, stop dispensing immediately. Do not use the equipment until you identify and correct the problem. D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being dispensed. D Keep the dispense area free of debris, including solvent, rags, and gasoline. D Do not smoke in the dispense area. D Do not turn on or off any light switch in the dispense area while dispensing or while operating if fumes are present. MOVING PARTS HAZARD Moving parts can pinch or amputate your fingers. D Keep clear of all moving parts when starting or operating the pump. D Before servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the equipment from starting unexpectedly.4 308156
  • 84. InstallationTypical Installation of a L M N Suction Feed System J K F G H P E D Q C B A R U T S W KEY A Follower plate J Hydraulic inlet, 1/2 npt Q* Flow control valve B Weep tube K Tee, 3/4 npt (required in systems over 3 gpm C Fluid outlet line (to gun) L* Supply line shut-off valve [11 lpm]) D Drain valve (required) M* Pressure gauge R Hydraulic supply line E Ground wire N* Pressure reducing valve S Check valve F Hydraulic return line, minimum (required in systems over 1500 psi T Variable volume pressure 3/4” I.D. (required) [10 MPa, 102 bar]) compensated pump G Hydraulic outlet, 1/2 npt P Accumulator U Hydraulic power supply H Return line shut-off valve, W Drain line, accumulator minimum 3/4” (required) * Included in Hydraulic Fluid Control Kit 236864, which can be ordered separately.Fig. 1 04477AAlthough the installation shown in Fig. 1 is only a guide Pump Accessoriesfor selecting and installing system components andaccessories, some of the equipment is required, as D Follower plate (A) ensures a good prime.noted in the key. For assistance in designing a system Place the plate on the grease and rotate whileto suit your needs, contact your Graco distributor. pressing firmly to level the material.Mount the pump to suit the type of installation planned. D Pump outlet drain valve (D) helps relieve fluid pressure in the pump when the pump is shut off. Install the valve close to the pump WARNING fluid outlet. Order Part No. 111229, valve. Maximum Working Pressure of Accessories To reduce the risk of serious injury including fluid WARNING injection and splashing in the eyes or on the skin, which may be caused if a component ruptures, all Pump Outlet Drain Valve accessories added to the reciprocator power sup- A pump outlet drain valve (D) is required in your ply side must have at least a 1500 psi (10 MPa, system. This valve helps relieve pressure in the 102 bar) maximum working pressure. displacement pump and hose when shutting down the system and in case of a clogged outlet hose. All accessories added to the pump fluid outlet side Install the valve close to the pump outlet. must have at least a 7500 psi (51 MPa, 517 bar) maximum working pressure. 308156 5
  • 85. Installation Hydraulic Lines WARNING D Shut-off valves (H and L) are installed in the Mount the pump securely so that it cannot move hydraulic supply and return lines. Order Part around during operation. Failure to do so could No. 108537. result in personal injury or equipment damage. D Drain Line: Remove the plug (59) from theNOTE: Refer to Fig. 1 to locate the parts mentioned pump adapter and install a 1/8” diameter weepbelow. tube (B), ending in a waste container. Monitor the weepage of hydraulic fluid. If it seems excessive or increases suddenly, the CAUTION reciprocator/pump seals may need to be changed. See Fig. 2. Keep the Hydraulic System Clean The hydraulic supply system must be kept clean at all times to reduce the risk of damaging the recip- rocator hydraulic power supply. Blow out all hy- draulic lines with air, flush thoroughly with solvent, and then blow out with air again before connecting the lines to the reciprocator. Always plug the hydraulic inlets, outlets and lines when disconnecting them for any reason to avoid introducing dirt and other contaminants into the system. Carefully follow the manufacturer’s recommenda- tions on reservoir and filter cleaning, and periodic 59 changes of hydraulic fluid.Hydraulic Power Supply WARNING Fig. 2 06146B Limit Fluid Flow to Reciprocator D Hoses: Use a minimum 1/2” supply line (R) To reduce the risk of overpressurizing the hydraulic and minimum 3/4” return line (F) on the reciprocator, which could cause a rupture and reciprocator. Contact your Graco serious injury, including fluid injection, the hydraulic representative for details of line sizing. system must have a means to limit the incoming fluid flow to the reciprocator to a maximum of 3 D A pressure reducing valve (N) circulates gpm (11 lpm) and 1500 psi (10 MPa, 102 bar). See excess hydraulic fluid pressure back to the the description below. hydraulic power supply. Install this valve (N) in the hydraulic supply line with a drain hose (W) teed into the hydraulic return line (F). LimitThe hydraulic power supply system (U) must have a supply pressure to a maximum of 1500 psipressure reducing valve and a pressure-compensated (10 MPa, 102 bar).flow control. A flow control valve (Q) is required to limit D An accumulator (P) reduces the hammeringthe incoming flow to the reciprocator to a maximum of effect caused by the motor when it reverses3 gpm (11 lpm). direction.NOTE: A supply line shut-off valve (L), pressure D A fluid-filled pressure gauge (M), Part No.gauge (M), pressure reducing valve (N), and a flow 112567, monitors hydraulic pressure to thecontrol valve (Q) are included in the Hydraulic Fluid reciprocator during startup. See Fig. 1. UseControl Kit 236864, which can be ordered separately. the gauge for initial adjustment of the reciprocator. It can be removed after adjustment is made.6 308156
  • 86. InstallationGroundingTo reduce the risk of static sparking, ground the pump. To ground the pump, remove the ground screw (Z)Check your local electrical code for detailed grounding and insert through the eye of the ring terminal at end ofinstructions for your area and type of equipment. ground wire (Y). Fasten the ground screw back onto the pump and tighten securely. Connect the other endD Pump: Use ground wire and clamp as shown in of the wire to a true earth ground. Fig. 3. To order a Grounding Wire and Clamp Kit, order Part No. 222011.D Hydraulic Hoses and Fluid Outlet Hoses: Use only electrically conductive hoses. ZD Hydraulic Power Supply: Follow manufacturer’s recommendations.D Any pails used when flushing: Use only metal, grounded pails when flushing. Make firm metal to metal contact between the a metal part of the dispense valve and the pail. Use the lowest possible pressure. Y 06147B Fig. 3 308156 7
  • 87. OperationPressure Relief Procedure To start the pump 1. Turn on the hydraulic power supply. WARNING 2. Open the return line shut-off valve (H) first and INJECTION HAZARD slowly open the hydraulic supply shut-off valve (L). The system pressure must be manually relieved to prevent the system from 3. Adjust the flow control valve (Q) to limit the starting or dispensing accidentally. Fluid hydraulic flow to no more than 3 gpm (11 lpm), under high pressure can be injected through the which is approximately 60 cycles per minute. skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving NOTE: If Graco Part No. 236864 hydraulic fluid parts, follow the Pressure Relief Procedure control is used, no adjustment is necessary. whenever you 4. By adjusting the pressure reducing valve (N), D Are instructed to relieve the pressure increase the hydraulic inlet pressure from 50 to D Check or service any of the system equipment 1500 psi (0.34 to 10 MPa, 3.4 to 103 bar). D Install or clean the nozzle Increasing the inlet pressure increases the outlet pressure. Decreasing the inlet pressure decreases the outlet pressure.1. Shut off the hydraulic power supply. 5. Open the drain valve while priming the pump;2. Close the supply line shut-off valve (L in Fig. 1). close it when the pump is primed.3. Open the dispensing valve to relieve pressure. 6. Always use the lowest pressure possible to obtain the desired results. This reduces pump wear.4. Open the pump outlet drain valve, and have a container ready to catch the drainage. CAUTION5. Close the return line shut-off valve (H). Never allow a pump to run dry of the fluid beingNOTE: Leave the drain valve open until you are ready pumped. A dry pump quickly speeds up and canto dispense again. damage itself. If it speeds up, shut off the power supply to the reciprocator immediately. Refill theIf you suspect that the nozzle or hose is completely supply container, and prime the pump to eliminateclogged, or that pressure has not been fully relieved air.after following the steps above, very slowly loosen thehose end coupling to relieve pressure, then clear theobstruction. CAUTIONBefore You Start the Pump Maximum Working Temperature1. Check the hydraulic fluid level in the hydraulic Do not exceed 130_ F (54_ C) hydraulic oil tem- power supply before each use, and add fluid as perature. The reciprocator seals will wear faster necessary to fill the lines. and leakage may occur if the pump is operated at higher oil temperatures. CAUTION Always use Graco approved hydraulic oil or equiv- alent, Part Numbers 169236 (5 gallon) or 207428 (1 gallon). Do not substitute lower grade oil.2. Flush the pump before using it for the first time to remove the light oil that was left in after factory testing to protect the pump from corrosion. Be sure the solvent used is compatible with the fluid to be pumped and the pump wetted parts. See Technical Data, page 23. Flush until clean solvent comes from the outlet hose.8 308156
  • 88. Operation If the Pump Leaks at the Fluid Fittings WARNING Tighten the fittings (1, 5, 58), which are self-sealing MAXIMUM WORKING PRESSURES and have replaceable o-rings. If leaking persists, change the o-rings.To reduce the risk of serious injury, includingfluid injection and splashing in the eyes or on theskin, which may be caused if a component self-sealingruptures: fitting (1,5,58)Never exceed 1500 psi (10 MPa, 102 bar) Maxi-mum Hydraulic Pressure to the reciprocator. reciprocatorNever exceed 7500 psi (51 MPa, 517 bar) Maxi-mum Outlet Pressure from the displacement pump.Be sure all accessories added to the reciprocatorpower supply side have at least a 1500 psi o-ring(10 MPa, 102 bar) Maximum Working Pressure. (1a,5a,58a)Accessories added to the pump fluid outlet side 04478should have at least a 7500 psi (51 MPa, 517 bar) Fig. 4Maximum Working Pressure.The working pressure of the displacement pump Shutdownhas a 5:1 ratio to the pressure at which the recipro-cator is operated. Therefore, if the fluid supplied to Relieve the pressure whenever you shut down.the reciprocator is 1000 psi (7 MPa, 69 bar), thepump fluid outlet pressure will be 5 times the hy-draulic pressure, or 5000 psi (34 MPa, 345 bar). WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 8. 308156 9
  • 89. TroubleshootingProblem Cause SolutionPump does not run. Closed dispense valve. Pump only runs with valve open. Pressure too low. Increase supply pressure using a pressure adjusting valve. Insufficient hydraulic fluid supply. Check hydraulic supply. Adjust to a maximum of 3 gpm (11 lpm) flow. Clogged fluid outlet line, intake valve, Relieve pressure. Check; clear dispense valve, suction line. obstructions. Reciprocator damaged. Repair. See page 13.Pump speeds up or runs erratically. Pump piston and/or intake Relieve pressure. Check and repair. valve worn. See pages 17 and 18. Empty supply container. Refill and reprime. Do not allow pump to run dry. Monitor closely or use a low-level cutoff valve.Pump runs, but output low on up Pump piston and/or intake valve Relieve pressure. Check and repair.and/or down stroke. worn. See page 17 and 18.Pump runs but output low on both Insufficient hydraulic fluid supply. Check hydraulic supply. Adjust tostrokes. maximum 3 gpm (11 lpm) flow. Pressure too low. Increase supply pressure using a pressure adjusting valve. Clogged fluid outlet line, intake valve, Relieve pressure. Check; clear dispense valve, suction line. obstructions.Excessive weepage from weep Worn throat packings. Repair. See page 11.tube (B).Hydraulic oil leaks from fittings in the Fittings (1,5,58) are loose, or their Tighten the self-sealing fittings. Ifupper or lower reciprocator blocks o-rings are worn or damaged. leaking persists, change the o-rings.(31,32).10 308156
  • 90. ServiceReplacing the Throat SealsSee Fig. 5. 32 16* 2NOTE: Replace these seals if fluid leaks excessivelythrough the weep tube (B). This procedure can be 19 4done without disassembling the entire reciprocator. 44* WARNING To reduce the risk of serious injury whenever you 16* 3 are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 8. 431. Relieve the pressure. 1 462. Disconnect the reciprocator from the pump. See the procedure on page 12.3. Remove the four capscrews (46) from the bottom 33 of the adapter (43). Tap the adapter to loosen it and pull it off the bottom cap (32).4. Remove the seals (16*,44*) and guide (19) from the top of the adapter (43).NOTE: Items 16 and 44 are included in the 1 Torque to 28 to 32 ft-lb (38 to 43 N-m).Reciprocator Repair Kit, 223426. 2 Lips face up. 3 Lips face down.5. Lubricate the guide (19) and install the seals and guide in the adapter (43), one at a time in the 4 Lubricate. order shown in Fig. 5. 016606. Reassemble. Torque the capscrews (46) to 28 to Fig. 5 32 ft-lb (38 to 43 N-m). Install the displacement pump. Follow Step 24, page 16. 308156 11
  • 91. ServiceDisconnecting the Reciprocator andDisplacement Pump CAUTION Keep The Hydraulic System CleanSee Fig. 6. It is essential to keep the hydraulic oil system cleanNOTE: When displacement pump 224914 is and free of contaminants to reduce the risk of dam-purchased separately, it comes with the priming piston aging the hydraulic reciprocator. Always install a(112) and priming cylinder (111) unassembled. plug in each tube fitting and on each hose endConnect the displacement pump to the hydraulic whenever fluid lines are disconnected to preventreciprocator before assembling the priming piston and contamination.cylinder. Torque the priming piston to 35 ft-lb (47 N-m). 3 1. Flush the pump if possible and stop it with the displacement rod in the lowest position. 36,37 WARNING 32 To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the 43 Pressure Relief Procedure on page 8. 46 (hidden from view) 2. Relieve the pressure. 3. Disconnect the outlet hose from the displacement 33 pump. 4. Slowly loosen the hydraulic supply (58) and return (5) fittings to relieve any pressure, and then 35 remove the hoses. Install plugs on the tube fittings 204 and in the hose ends. Check the o-rings (5a, 58a) 202* on the fittings and replace them if they are worn or 101 203* damaged. See Fig. 4 and the Parts Drawing. 103 5. Using a strap wrench on the displacement cylinder (108), screw it out of the pump adapter (43), and 01682 slide it down as far is it will go. 06151B 6. Pull the connecting rod (35) down as far as it will Fig. 6 go. Remove the cotter pin (204). NOTE: For the 35 lb. length pump, the priming cylinder (111) and the priming piston (112) must be completely removed before you can pull down the displacement cylinder (108) far enough to remove the cotter pin (204). 7. Unscrew the piston coupling (103) to remove the pump.12 308156
  • 92. Reciprocator RepairReciprocator RepairNOTES See Fig. 9 for Steps 4 to 20, except where noted.D Clean and inspect all parts for wear or damage. 4. Tap on the bottom of the displacement rod (34) Replace parts as needed. For the best results, with a plastic mallet to loosen the cylinder (25). always replace all the o-rings and seals when you disassemble the pump. Repair Kit 223426 is 5. Grasp the valve spool (31) and pull it off the available. Parts included in the kit are marked with cylinder and tie rods (38). Pull the cylinder and one asterisk, for example (23*), in the text and piston off the bottom cap (32). It is not necessary drawings. Always replace the seals (23*,24*) and to remove the tie rods from the bottom cap. the seals (16*, 44*) together.D Assembly Tool 189305 is required for 6. Lay the assembly on its side. Place a clean rag reassembling the reciprocator. around the yoke (9) to prevent losing the detent balls. Slide the yoke (9) sideways off the valveD Loctiter 242 thread sealant and Loctiter Primer T sleeve (29) while holding the balls (7) and spring or Perma-Locr 115 thread sealant and (6) in place. Perma-Bondr Surface Conditioner I are required. Be sure their shelf life is within the manufacturer’s 7. Slide the cylinder (25) off the displacement rod recommendations. (34). Hold the hex end of the displacement rod in a vise and use a spanner wrench in the pin holes ofBefore you begin, drain the oil out of the reciprocator the piston (22) to screw it off the rod.as follows: Place the reciprocator in a drain pan, pushthe piston all the way up/in, then all the way down/out.1. Place the adapter (43) in a vise. Remove the four CAUTION capscrews (46) and the base (33). Pull the bottom Be careful not to scratch the outside of the dis- cap (32) off of the adapter (43). See Fig. 7. If placement rod or the inside of the cylinder. needed, replace the seals as described on page 11. 8. Visually inspect the spring (21). If there is wear or2. Loosen both nuts on the fluid tube (45). Use a damage, remove the nut (18), spring (21) and wrench to rotate the tube fittings (1,58) to the side, retainers (20) from the trip rod (12). Reassemble and then remove the tube (45). Check the o-rings with a retainer (20) on each end of the new spring (1a,58a) on the fittings and replace them if they (21). You must thread the nut onto the rod until it are worn or damaged. Install plugs in the fittings to runs out of thread, so that it bottoms out on the prevent contamination. See Fig. 4 and the Parts shoulder of the rod. See Fig. 8. Drawing. 123. Remove the capscrew (3), nuts (36) and lockwashers (37) on top of the reciprocator. See 20 Fig. 7. 3,39,2 21 36,37 20 Fig. 8 18 01664 32 43 46 hidden from view 33 06146B Fig. 7 308156 13
  • 93. Reciprocator Repair NOTE: If you are re-using or reassembling any parts, 3,39,2 use a surface cleaner such as chlorinated solvent on 36,37 the threads, and blow with compressed air. A 1/4–28 UNF–2A tap can be used to remove adhesive from the 30 internal threads of the yoke (9). 31 NOTE: Thread sealant and primer are required. See the third bulleted note on page 13 for specifications. *13 9. Apply fresh thread sealant to the first two or three internal threads of the yoke (9). Apply primer to the external thread of the rod (12). Let dry for three or four minutes. Assemble, torquing the screw to 54 29 to 56 in-lb (6.1 to 6.3 N-m). Remove excess sealant. Allow 24 hours to cure before operating the reciprocator. 26 6,7 10. Clean all sealant from the threads of any part you are reusing, and apply thread sealant to the first 9 51 2 two or three internal threads of the valve assembly (31). If you removed the capscrew (51), apply 1 22 thread sealant to the first two or three internal 12 threads of the valve stop (26). Apply primer to the external threads of the valve sleeve (29). Let dry 25 for three or four minutes, assemble, and remove *24 excess sealant. Allow 24 hours to cure before operating the reciprocator. 23*,49* 11. Remove the o-ring (13*) from the bottom of the 17 spool valve (31) and replace it with a new o-ring. 20 38 12. Use a spanner wrench to screw the piston (22) 21 onto the displacement rod (34). Torque to 30 to 40 ft-lb (41 to 54 N-m). 32 34 CAUTION 13* When inserting the piston into the cylinder, care- SeeFig. 8 fully guide the piston seal (23*) and bearing (24*) to prevent damaging these parts. 20 18 13. Lay Assembly A and Assembly B on the workbench. 14. Slide Assembly B into the center of the tool (D), Part No. 189305. Align the upper detent holes (C) of the yoke (9) with the center line of the tool (D). See Fig. 10. 17 1 Torque to 30 to 40 ft-lb (41 to 54 N-m) 2 Torque to 42 to 45 in-lb (4.7 to 5.1 N-m) 06153 Fig. 914 308156
  • 94. Reciprocator Repair 31 ASSEMBLY A 29 26 6 7 12 D C ASSEMBLY B 9 06148 Fig. 1015. Insert the spring (6) and one ball (7) into the valve 18. If the tie rods (38) were removed, reinstall them stop (26) of Assembly A. Tilt the valve stop and with the short threaded end up. The other end start guiding it into the tool (D), making sure the should be screwed about 9/16” into the bottom ball is sliding into the rounded slot in the tool (D). cylinder cap (32). Place the other ball at the other end of the spring and push it in with your thumb while rotating the NOTE: When reinstalling the cylinder (25) (Step 19), valve stop (26) until the spring is horizontal and the be sure the “P” port in the valve spool (31) and the port balls are in place. Continue holding this assembly in the bottom cylinder cap (32) are in line with each together. See Fig. 10. other. Be sure the o-rings (13*) are in place in the valve spool and cylinder cap.16. Slide the valve stop assembly down into the tool. Make sure the balls (7) snap into the upper set of 19. Place the cylinder (25) on the cylinder cap (32). holes (C) in the yoke (9), and the curved ends of Install the piston (22) and valve assembly (31). the guide clamp have engaged the valve sleeve 20. Install the o-ring (49*) in the deep lower groove of (29) groove. See Fig. 10. Slide the tool (D) back the piston (22) and install the seal (23*) over the over the rod (12) to remove it. o-ring. Install the piston bearing (24*) around theRefer to Fig. 11 for Steps 17 to 24. upper groove of the piston. Holding the piston bearing in place to avoid damage, slide the17. Place the adapter (43) in a vise, and install the cylinder over the piston and press it down. seals as described on page 11. Install the cylinder cap (32). 308156 15
  • 95. Reciprocator Repair21. Install the capscrew (3), o-ring (39) and washer (2). Install the lockwashers (37) and nuts (36). 3,39,2 Torque the nuts to 28 to 32 ft-lb (36 to 43 N-m). 1 36,37 CAUTION 31 Never install the fluid tube (45) before torquing the tie rods. Doing so could cause misalignment and damage the reciprocator when it is operated. *1322. Reinstall the fluid tube (45) and fittings (1). Torque the fittings to 25 to 35 ft-lb (34 to 48 N-m). See the Parts Drawing on page 20. 2523. Pull the displacement rod (34) in and out to be sure it moves easily with only a little resistance from the rod seal. 3824. To reconnect the reciprocator and pump, install the o-ring (17). Screw the connecting rod (35) into the displacement rod (34). Install the cotter pin (204). Install a new copper gasket (202*). Make sure the seal (203*) in the bottom of the adapter (43) is in good condition. Push the cylinder up into the 32 adapter and engage the threads. Screw in the pump, using a strap wrench for the final tightening. 13* See Fig. 12. 4325. Connect the hydraulic supply and return hoses to the fittings (5, 60). WARNING To reduce the risk of static sparking be sure to re- connect the ground wire before operating the pump. 35 1 Torque to 28 to 32 ft-lb (36 to 43 N-m) 06153 Fig. 11 *202 35 204 43 203* 103 118 1 1 Torque to 150 to 160 ft-lb (205 to 220 N-m) 01682 Fig. 1216 308156
  • 96. Displacement Pump RepairDisassembly WARNING 116 To reduce the risk of serious injury whenever you 101 102 are instructed to relieve pressure, always follow the 103 115 Pressure Relief Procedure on page 8. 104*1. If possible, flush the pump. Relieve the pressure. 107 105*2. Follow Disconnecting the Reciprocator and 117 106 Displacement Pump procedure on page 12. 1023. Place the pump in a vise. Unscrew the priming 115 cylinder (111). 1164. Push the priming piston (112) into the pump until 118 109 the hex of the piston coupling (103) is exposed. 114* 1085. Hold the piston coupling (103), and unscrew the piston rod (119). 110 113*6. Unscrew the packing housing (110) and remove all 1 119 parts. 27. Pull the piston (107) and the priming tube (108) assembly out of the pump housing.8. Unscrew the priming tube (108), and remove all parts. 1119. Unscrew the piston (107), and remove all parts. 11210. Clean all parts thoroughly with a compatible solvent. Inspect the parts for wear, and replace as needed. Scoring or irregular surfaces on the priming tube (108), or inside the cylinder (118) causes premature packing wear and leaking. 1 Only used on Models 223513 and 223514. 2 Insert 1/4” dia. rod through hole to hold priming tube (108) when removing or installing parts connected to it. 01684A Fig. 13 308156 17
  • 97. Displacement Pump RepairReassemblyNOTE: Repair Kit 223427 is available. Referencenumbers marked with an asterisk are included in the 116kit. 101 102NOTE: The balls (116) cannot be reseated on the 103 115hardened seats (102). However, the seats can be 104*reversed and used a second time. 1 107 105*NOTE: Lubricate all parts with a light, waterproofgrease. 117 1061. Insert the pin (101) into the piston coupling (103), 102 and insert the pin (117) into the pump piston (107). 1152. Put the pump piston (107) in a vise, and stack the 116 spacer (106), seal (105*), packing (104*), gasket (115), seat (102), and ball (116) on it in the order 118 109 shown in Fig. 14. Thread the piston coupling (103) 1 108 114* onto the pump piston (107), and torque it to 60 ft-lb (80 N-m). 1 110 113*3. Turn the pump piston (107) over in the vise, and insert the ball (116), seat (102), and gasket (115). 2 3 1194. Assemble the seal (113), packing (114) and 4 bearing (109) on the packing housing (110). Screw the packing housing into the cylinder (118), and torque to 60 ft-lb (80 N-m).5. Slide the assembly into the cylinder from the top. 111 Use your finger to guide the assembly through the lower seals. 2 1126. Models 223513, 223514 only: Screw the piston rod (119) onto the priming tube (108). Torque to 35 ft-lb (47 N-m).7. Place the gasket (202*) in the base of the reciprocator. Place the o-ring (203*) into the groove of the pump adapter (43). Screw the cylinder into the pump adapter. 1 Torque to 60 ft-lb (80 N-m).8. Firmly screw the priming piston (112) onto the 2 Torque to 35 ft-lb (47 N-m). piston rod (119). Torque to 35 ft-lb (47 N-m). 3 Only used on Models 223513 and 223514. 4 Insert 1/4” dia. rod through hole to hold priming9. Firmly screw the priming cylinder (111) onto the tube (108) when removing or installing parts cylinder (118). connected to it. 01684A Fig. 1410. Reconnect the ground wire to the reciprocator if it is disconnected.18 308156
  • 98. Displacement Pump PartsModel 223513, Series A, 120 lb.Includes items 101 to 119 103 109Model 223514, Series A, 400 lb. 101 116 *114Includes items 101 to 119 102 *113 115Model 224914, Series A, 35 lb. 104*Includes items 101 to 118 105* 110 106Ref.No. Part No. Description Qty.101 108992 PIN, spring 1 107102 162559 SEAT, valve 2 116 119103 183670 COUPLING, piston 1 117104* 108990 PACKING, block 1 102105* 108989 SEAL, backup 1 115106 183669 SPACER, piston 1107 183676 PISTON, pump 1108 183677 TUBE, priming 1 108109 183668 BEARING, priming 1110 183675 HOUSING, packing 1 112111 CYLINDER, priming 1 183673 Model 223513 185999 Model 223514 111 187312 Model 224914112 183672 PISTON, priming 1 118113* 108988 SEAL, backup 1114* 108987 PACKING, block 1115 150451 GASKET, copper 2116 100170 BALL 2117 108991 PIN, spring 1118 183678 CYLINDER, pump 1119 ROD, piston 1 186002 Model 223513 185998 Model 223514 None Model 224914* These parts and items 202, 203 on page 22, are included in Repair Kit 223427, which may be purchased separately. 01685 Fig. 15 308156 19
  • 99. Reciprocator Parts Model 239883, Series A Includes items 1 to 60 3 NOTE: See pages 11 to 18 for impor- 39 tant assembly procedures 2 and torque values. 36 37 24* 30 22 5 49* 23* 16* *4 31 17 58a 5a 20 19 58 29 21 44* 9 20 7 18 16* 660 7 26 45 59 51 34 46 43 1a 12 1 17 *13 38 25 35 14 33 40 52 Label 46 32 *13 06154B 20 308156
  • 100. Reciprocator PartsModel 239883, Series AIncludes items 1 to 60Ref. Ref.No. Part No. Description Qty. No. Part No. Description Qty.1 106470 ELBOW, straight thread, 30 178181 PLATE, cap 1 3/4–16 unf–2a x 31 239874 SPOOL, valve assembly 3/4–16 unf–2a, 37_ flare 3/4–16 unf –2b(f) 1 includes item 1a 1 32 186225 CAP, cylinder, bottom, cs 11a 110987 .O-RING 1 33 183833 BASE, aluminum 12 178179 WASHER, sealing 1 34 188078 ROD, displacement, cs 13 106276 CAPSCREW, hex hd, 35 183671 CONNECTING ROD 1 3/8–24 x 5/8” 1 36 100307 NUT, full, hex; 3/8–16 unc–2b 44 104093 O-RING 1 37 100133 LOCKWASHER, 3/8” 45 112568 ADAPTER, pipe,3/4 unf(m) 38 187405 ROD, tie, 8.5” shoulder to 1/2 npt(f), steel shoulder, 3/8–16 unc–2a,cs 4 includes item 5a 1 39 155685 O-RING 15a 110987 .O-RING 1 40Y 179885 LABEL, Warning 16 108437 SPRING, compression, steel 1 43 183533 ADAPTER, pump, cs 17 100069 BALL, 1/4” dia. steel 2 44* 108951 SEAL, polyester elastomer 19 189077 YOKE, valve 1 45 217221 TUBE, inlet 112 192657 ROD, stop, cs 1 46 108986 CAPSCREW, sch, 3/18–1613* 106274 O-RING, buna–N 2 unc–2a x 4.5” 414 116343 SCREW, grounding 1 49* 108014 O-RING, buna–N 116* 108952 PACKING, v-block 2 51 104092 CAPSCREW, sch; 10–2417 105765 O-RING 2 unrc–3a x 5/8” 218 114231 LOCKNUT, hex, 1/4–28 unf–3b 52 106115 LOCKWASHER, spring; 3/8” 4 steel and nylon 1 58 107197 TEE includes item 58a 119 183531 GUIDE, rod, bronze 1 58a 110987 .O-RING 120 192655 RETAINER, spring, cs 2 59 110064 PLUG, pipe, vented, 1/8–27 nptf 121 178189 SPRING, compression, steel 1 60 112569 UNION, swivel; steel 122 192656 PISTON, CS 123* 178226 SEAL, piston * These parts and items 202, 203 on page 22 are glass-filled Teflon 1 included in Repair Kit 223426, which may be24* 178207 BEARING, piston purchased separately. bronze-filled Teflon 125 178229 CYLINDER, motor, cs 1 Y Replacement Danger and Warning labels, tags and26 192654 STOP, valve, cs 1 cards are available at no cost.29 189072 SLEEVE, valve, steel 1 Assembly Tool 189305 required for repairing the reciprocator. 308156 21
  • 101. Pump PartsModel 224752, Series C400 pound drum size 201Ref.No. Part No. Description Qty.201 239883 RECIPROCATOR, see page 21 1202* 183715 GASKET, copper 1203* 108993 O-RING 1204 108992 PIN 1 206 label205 223514 DISPLACEMENT PUMP see page 19 1 202206 183741 LABEL, identification 1 203*Model 224751, Series C 204120 pound drum sizeRef.No. Part No. Description Qty. 205201 239883 RECIPROCATOR, see page 21 1202* 183715 GASKET, copper 1203* 108993 O-RING 1204 108992 PIN 1205 223513 DISPLACEMENT PUMP see page 19 1206 183741 LABEL 1Model 224912, Series C35 pound drum sizeRef.No. Part No. Description Qty.201 239883 RECIPROCATOR, see page 21 1 06155B202* 183715 GASKET, copper 1203* 108993 O-RING 1204 108992 PIN 1205 224914 DISPLACEMENT PUMP see page 19 1206 183741 LABEL 1* These parts are included in Repair Kits 223426 and 223427, which may be purchased separately.22 308156
  • 102. Technical Data Max. grease output pressure . . . . . . . . . . . . . . . . . . . . . . 7500 psi (51 MPa, 517 bar) Max. hydraulic fluid input pressure . . . . . . . . . . . . . . . . . . 1500 psi (10 MPa, 102 bar) Max. hydraulic fluid input volume . . . . . . . . . . . . . . . . . . . . 3 gpm (11.7 lpm), 60 cpm Hydraulic fluid consumption rate . . . . . . . . . . . . . . 6.5 ounces (0.195 liter) per cycle or 1 gallon per 19.5 cycles Maximum fluid temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130_ F (55_ C) Effective piston area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.48 sq in. (9.55 cm2) Piston rod diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3/8 in. (34.9 mm) Output per cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with No. 2 grease at 60 cpm free flow: 5 lb/min (2.25 kg/min) at 3000 psi (21 MPa, 207 bar): 4 lb/min (1.8 kg/min) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 in. (101.6 mm) Thrust at 1000 psi (7 MPa, 69 bar) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1480 lb (673 kg) Maximum suction lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 feet (4 m) Displacement pump wetted parts . . . . . . . . . . . . . . . . . . . steel, copper, polyurethane, buna–N, polyester elastomer Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model 224752: 42 lb (18.9 kg) Model 224751: 37.5 lb (16.9 kg) Model 224912: 32.5 (17.7 kg) Sound pressure* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 dB(A) * Sound pressure reading taken with pump operating at 66 cycles per minute. Sound pressure measured per CAGI-PNEUROP, 1971. LoctiteR is a registered trademark of Loctite Corporation. Dimensions and Mounting Hole Layout3/8 npt Hydraulic Inlet 3 in (76.2 mm) 3/4 npt Hydraulic Outlet minimum diameter clearance hole 14.75 in. (375 mm) Reciprocator Model 239883 3.536 in. (90.424 mm) 29.75 in. (756 mm) Model 224912 41.5 in. (1054 mm) 3.536 in. (90.424 mm) clearance for, or Model 224751 tap 5/16–18, typical 4 places 48.5 in.1/2 npt(f) (1232 mm)fluid Model 224752 NOTE: Pump body orientation is squareoutlet with mounting holes. 15 in. (381 mm) Model 224914 26.75 in. (679 mm) Model 223513 33.75 in. (857 mm) Model 223514 06151 308156 23
  • 103. Graco Standard WarrantyGraco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on thedate of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limitedwarranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipmentdetermined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained inaccordance 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 byfaulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, orsubstitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility ofGraco 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 forverification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. Theequipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defectin material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, andtransportation.THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUTNOT 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 otherremedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or anyother incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of thedate of sale.Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connectionwith accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufacturedby Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will providepurchaser 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 equipmenthereunder, 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 CUSTOMERSThe parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedingsentered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les partiesreconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procéduresjudiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées. Graco Phone Numbers TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers to identify the distributor closest to you: 1–800–533–9655 Toll Free 612–623–6928 612–378–3590 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 GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 www.graco.com PRINTED IN U.S.A. 308156 December 1991, Revised August 200124 308156
  • 104. Parts INSTRUCTIONS–PARTS LIST 308642 Rev. L This manual contains important warnings and information. First choice when READ AND KEEP FOR REFERENCE. quality counts.t INSTRUCTIONS WITH OR WITHOUT ELECTRONIC METERS V5t V12t EM6t and EM12t Dispense Valves 1500 psi (10 MPa, 102 bar) Maximum Working Pressure CAUTION EM12 These dispense valves are designed to dispense Model 238641 petroleum-based lubricants only. Notes D See the list on page 3 for Model Numbers and 06294A configurations. D See manual 307965 for information on electronic meters 244075 and 244076. V12 Model 238644 Table of Contents 06292A Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Bare Valve Model 238646 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Parts — EM12 and V12 Dispense Valves . . . . . . . . . 12 8537A Parts — EM6 Dispense Valves . . . . . . . . . . . . . . . . . . 13 Parts — V5 Dispense Valves . . . . . . . . . . . . . . . . . . . . 14 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 16 Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . 16 EM6 Model 243599 TI0407 GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 ECOPYRIGHT 1997, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001
  • 105. Notes2 308642
  • 106. ModelsNon-Metered Valves Metered Valves EM12 – with trigger lockV12 – with trigger lock English MeterWith Extension 238636 3/4” swivel, rigid extension238644 3/4” swivel, rigid extension 238637 3/4” swivel, flex extension 238640 1/2” swivel, rigid extension238645 3/4” swivel, flex extension 238641 1/2” swivel, flex extension238651 1/2” swivel, rigid extension238652 1/2” swivel, flex extension Metric Meter 238638 3/4” swivel, rigid extension 238639 3/4” swivel, flex extensionV5 – with trigger lock 238642 1/2” swivel, rigid extension 238643 1/2” swivel, flex extensionWith Extension222411, Series C, 1/2” swivel, oil nozzle/extension222412, Series C, 1/2” swivel, gear lube extension222413, Series C, 1/2” swivel, ATF nozzle/extension EM6 – without trigger lock English Meter 243599 1/2” swivel, rigid extension 243600 1/2” swivel, gear lube 243601 1/2” swivel, flex extensionBare Valves Metric Meter238646 3/4” swivel, no extension, with trigger lock 243602 1/2” swivel, rigid extension238647 1/2” swivel, no extension, with trigger lock 243603 1/2” swivel, gear lube243992 1/2” swivel, no extension, without trigger lock 243604 1/2” swivel, flex extension 308642 3
  • 107. WarningsWarning Symbol Caution Symbol WARNING CAUTIONThis symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage toinjury or death if you do not follow the instructions. or destruction of equipment if you do not follow the instructions. WARNING WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury. INSTRUCTIONS D This equipment is for professional use only. D Read all instruction manuals, tags, and labels before you operate this equipment. D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor. D Do not alter or modify this equipment. Use only genuine Graco parts and accessories. D Check equipment daily. Repair or replace worn or damaged parts immediately. D Do not exceed the maximum working pressure of the lowest rated system component. Refer to the Technical Data on page 15 for the maximum working pressure of this component. D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings. D Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids that contain such solvents in pressurized aluminum equipment. Such use could result in a chemical reaction, with the possibility of explosion. D Do not use hoses to pull equipment. D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 180_ F (82_ C) or below –40_ F (–40_ C). D Do not lift pressurized equipment. D Comply with all applicable local, state, and national fire, electrical, and safety regulations.4 308642
  • 108. WARNING WARNINGINJECTION HAZARDFluid from the dispensing valve, leaks, or ruptured components can inject fluid into your body andcause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or onthe skin can also cause serious injury.D Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediate medical attention.D Do not point the dispensing valve at anyone or at any part of the body.D Do not put your hand or fingers over the end of the dispensing valve.D Do not stop or deflect leaks with your hand, body, glove or rag.D Use only extensions and nozzles that are designed for use with your dispensing valve.D Do not use a low-pressure flexible extension with this equipment.D Follow the Pressure Relief Procedure on page 9 before you clean, check, or service the equipment.D Tighten all fluid connections before you operate the equipment.D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not repair high pressure couplings; you must replace the entire hose. 308642 5
  • 109. InstallationSee manual 307965 for electronic meters installation, operation, parts, and cautions and warnings.NOTE: Numbers in parenthesis, for example (7), and in the Parts Drawings are reference numbersin the Parts List on page12.Typical InstallationFig. 1 shows a typical installation. Additionally, these KEY DESCRIPTIONdispense valves can be installed on a console. H Thermal relief kit (required) Part No. 237904 Install downstream from pump. CAUTION J Fluid shut-off valve Do not use this electronic metered dispense K Hose valve on non-Graco consoles. Such use could L Hose reel fluid inlet hose result in the trigger becoming inadvertently pressed while the dispense valve is stowed. M Hose reel N Metered dispense valve The installation shown in Fig. 1 is only a guide. The J components shown are typical; however, it is not a complete system design. Contact your Graco distribu- L tor for assistance in designing a system to suit your H particular needs. M CAUTION To prevent line contamination, which can cause equipment malfunction or damage, flush the lines before you install the equipment in the system. K WARNING FIRE AND EXPLOSION HAZARD N The movement of fluids through the dispensing system generates static electricity. The static electricity can cause volatile fumes to ignite, resulting in explosion and fire. The dispensing system must always be grounded. See Grounding on page 8. 04472AFig. 16 308642
  • 110. InstallationPre-Installation Procedure Existing Installation1. Relieve the pressure. 1. Relieve the pressure. WARNING WARNING To reduce the risk of serious injury, whenever you To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 9. Pressure Relief Procedure on page 9. 2. Loosen and disconnect the hose from the old2. Close the fluid shut-off valve (item J in Fig. 1). dispense valve (the one that you are replacing).3. Ground the hose and reel or console. See For steps 3 to 5, see Fig. 2. Grounding on page 8. Do not use TeflonR tape on the pipe joints; it may cause a loss of ground 3. Thread the extension (26a) into the outlet of the across the pipe joint. dispense valve, and tighten firmly.Installation Procedure NOTE: Do not over tighten the extension tube assembly by using the nozzle adapter to hand turn the CAUTION nozzel. For rigid extensions, thread the extension in at least three full turns, position the extension If this is a new installation, or if the oil in the for proper alignment, and tighten the sealing lines is contaminated, flush the lines before you nut (7). The TeflonR seal on the sealing nut must install the dispensing valve. face the valve housing.New Installation 4. Apply thread sealant to the male threads of the1. Relieve the pressure. hose fitting, thread the hose fitting into the swivel (20), and tighten firmly. WARNING 5. Thread the new nozzle (8) or nozzle adapter onto To reduce the risk of serious injury, whenever you the extension, and tighten firmly. are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 9. 6. Open all dispense position shut-off valves, and start the pump to pressurize the system. See theSteps 2 to 6 are the Flushing Procedure. Operation section for proper operation.2. Close the fluid shut-off valve (J) at each dispense 7. For metered dispense valves, to ensure dispens- position. ing accuracy, purge all air from the fluid lines and dispense valves before you use them.3. Make sure the main fluid outlet valve at the pump is closed, the air pressure to the pump motor is adjusted, and the air valve is open. Slowly open Model shown is a V12 with main fluid valve. a 75_ bend rigid extension. 74. Place the hose end (with no dispense valve con- nected) into a container for waste oil. Secure the hose in the container so it will not come out during flushing. If you have multiple dispense positions, 26a first flush the dispense position farthest from the 8 pump, and work your way toward the pump.5. Slowly open the shut-off valve (J) at the dispense position. Flush out a sufficient amount of oil to ensure that the entire system is clean, and close the valve. 20 06292A Fig. 26. Repeat step 5 at all other dispense positions. 308642 7
  • 111. InstallationGroundingProper grounding is an essential part of maintaining a D Pump: Follow manufacturer’s recommendations.safe system. D Air and Fluid hoses: Use only grounded hoses. D Air compressor: Follow manufacturer’s recommen-To reduce the risk of static sparking, ground all system dations.components per local and national electrical codes. D Fluid supply container: Follow your local code.Refer to the user manuals for the pump and othersystem components to ground the following: D To maintain grounding continuity when flushing or relieving pressure, always hold a metal part of the valve firmly to the side of a grounded metal pail, then trigger the valve.8 308642
  • 112. OperationPressure Relief Procedure WARNING WARNING To reduce the risk of a serious bodily injury, includ- ing fluid injection, never exceed the maximum PRESSURIZED EQUIPMENT HAZARD working pressure of the valve you are using or of The equipment stays pressurized until the lowest rated component in your system. pressure is manually relieved. To reduce the risk of serious injury from pressurized fluid, accidental spray from the dispenser or splashing fluid, follow the Pressure Dispensing Procedure Relief Procedure whenever you D Are instructed to relieve pressure See instruction manual 307965 for electronic meter D Check, clean, or service any system equipment operation. D Install or clean fluid nozzles NOTE: Before you begin, make sure you understand how to unlock the trigger. Model EM6 does not have1. Turn off the power supply to the pump. a trigger lock.2. Trigger the valve into a waste container to relieve pressure. 1. Pull the trigger toward the valve body to open the valve and begin dispensing.3. Open any bleed-type master air valves and fluid drain valves in the system. 2. Lock the valve open by keeping the trigger squeezed and depressing the trigger lock button4. Leave the drain valve open until you are ready to (25 in the Parts Drawing). Then release the pressurize the system. trigger, releasing your forefinger from the trigger lock last.If you suspect that the dispensing valve, extension, ornozzle is clogged or that pressure has not been fullyrelieved after following the steps above, very slowly 3. Pull the trigger toward the valve body to releaseloosen a fitting on the fluid line to relieve pressure the trigger lock. The trigger lock disengages.gradually, then loosen it completely, then clear theclog. 4. Release the trigger to stop dispensing. 308642 9
  • 113. TroubleshootingRelieve the pressure before you check or repair thedispensing valve. Be sure all other valves and controls WARNINGand the pump are operating properly. To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 9. Problem Cause Solution Display does not activate or is Electronic control is malfunctioning. Replace the electronic control. showing unintelligent See instruction manual 307965. characters. Slow or no fluid flow Filter is clogged, or 1. Relieve the pressure. Pump pressure is low, or 2. Clean or replace the filter (10). Shutoff valve is not fully open, or See Filter Replacement on page 11. Foreign material is jammed in the metering element. 3. If the problem remains, contact your Graco distributor for repair or replacement. Oil leaks from swivel. Swivel is loose. Torque the swivel (20) to 15 to 20 ft-lb (20 to 27 N-m). If the problem remains, contact your Graco distributor for repair or replacement. O-ring is worn or damaged. Replace the o-ring (6), and torque the swivel (20) to 15 to 20 ft-lb (20 to 27 N-m). If the problem remains, contact your Graco distributor for repair or replacement. Oil drips from nozzle. * Nozzle is damaged or obstructed. Inspect the nozzle for damage or obstructions, and replace if damaged. Valve leaks. O-rings or valve seat are worn or Replace the o-rings (15) and/or the damaged. valve seat (29). See Valve Handle Repair on page 11.* Some fluid weepage is possible in applications where thermal expansion of fluid is possible.10 308642
  • 114. ServiceNOTE: See instruction manual 307965 for electronic meter service instructions.Valve Handle Repair 6. Lubricate the cam, and slide it into the valveSee Fig. 3. handle, making sure the notch is oriented as shown in Fig. 3. Ensure that the large end of theNOTE: The large end of the pushrod (30) fits into a pushrod is resting in the notch of the cam.notch in the cam (21), which is part of the triggerassembly. It is important that you know this before you 7. Replace the screws (14) and washers (28), andremove or install parts. torque the screws to 15 to 25 in-lb (1.7 to 2.8 N-m).1. Relieve the pressure. 8. Replace the swivel (20), and torque to 15 to 20 ft-lb (20 to 27 N-m). WARNING Filter Replacement To reduce the risk of serious injury, when you are See Fig. 3. instructed to relieve pressure, always follow the Pressure Relief Procedure on page 9. 1. Relieve the pressure.2. If you are replacing the o-rings (15), or the cam (21), or the push rod (30), remove the swivel (20), WARNING and remove the internal pieces. You must To reduce the risk of serious injury, when you are remove the cam in order to get the push rod instructed to relieve pressure, always follow the out of the outlet end of the valve handle. Pressure Relief Procedure on page 9.3. Remove the screws (14) and washers (28), and 2. Unscrew the hose fitting from the swivel (20). remove the trigger (24). Push the cam (21) out of the valve handle (18). Replace the o-rings (15) 3. Remove and replace the filter (10), which is inside and/or the cam. the valve handle (18). Make sure the filter is oriented as shown in Fig. 3.4. Replace any worn or broken parts. 4. Thread the hose fitting into the swivel (20), and5. Reassemble the internal pieces. The push rod tighten. Make sure the swivel (20) is torqued to (30) must be inserted through the outlet end of 15 to 20 ft-lb (20 to 27 N-m). the valve handle before the cam (21) is installed. 14 30 28 NOTE: For torque specifications and lubrication instructions, see the service notes in the Parts 15 Drawings on pages 12, 13 and 14. EM6 models do not have trigger lock parts 11, 25, and 27. 15 27 11 notch 28 18 25 14 21 10 20 24 308642 11 7854BFig. 3
  • 115. Parts — EM12 and V12 Dispense ValvesEM12 Models: 238636 to 238643 – with trigger lock (with electronic meter and extension)V12 Models: 238644, 238645, 238651, 7 26a and 238652 – with trigger lock (no meter, includes extension) 36Bare Valves: 238646 and 238647 – with trigger lock (no meter, no extension) Includes items 6, 10–25, and 27–30 8 1 5 35 26b 2 14 30 28 15 4 18 21 29 15 4 28 8 1 12 27 16 11 14 2 06293C 10 25 1 Torque to 15 to 20 ft-lb (20 to 27 N-m). 2 Torque to 15 to 25 in-lb (1.7 to 2.8 N-m). 3 Apply lubricant to threads when reassembling. 6 4 4 Apply lubricant to packings and sealing 20 1 3 24 surfaces when reassembling. 5 Apply thread sealant when reassembling.Ref RefNo. Part No. Description Qty No. Part No. Description Qty6 111137 O–RING, valve/swivel 21 191315 CAM 1 For Models 238636 to 238645, 24 191320 TRIGGER 1 238651, and 238652 2 25 191321 TRIGGER LOCK 1 For Models 238646 and 238647 1 26a 191403 TUBE, 75_ bend; 1/2 npt7 112841 NUT, seal; 1/2–14 npt For Models 238636, 238638, For Models 238636, 238638, 238640, 238642, 238644, and 238640, 238642, 238644, and 238651 1 238651 1 26b 238401 HOSE, flexible; 1/2 npt8 238400 NOZZLE, oil For Models 238637, 238639, For Models 238636 to 238645, 238641, 238643, 238645, 238651, and 238652 1 and 238652 110 185416 FILTER 1 27 192106 GUIDE, spring 111 113924 SPRING, compression 1 28 191552 WASHER, flat 212 113493 SPRING, compression 1 29 191313 SEAT, valve 114 110637 SCREW, machine 2 30 192501 ROD, push 115 113574 SEAL, o-ring 2 35 158491 NIPPLE16 113627 WASHER, plain 1 For Models 238636 to 238643 118 191074 HANDLE, valve 1 36 244075 METER, electronic; English20 238398 SWIVEL; 3/4–14 npt For Models 238636, 238637, For Models 238636 to 238639 238640, and 238641 1 and 238644 to 238646 1 244076 METER, electronic; metric 238399 SWIVEL; 1/2–14 npt For Models 238638, 238639, For Models 238640 to 238643, 238642, and 238643 1 238647, 238651 and 238652 112 308642
  • 116. Parts — EM6 Dispense ValvesEM6 Models: 243599 to 243604 – without trigger lock (with electronic meter and extension) 28cBare Valve: 243992 bare valve – without trigger lock 28b (no meter, no extension) Includes items 6, 10–23, and 25–27 7 28a 29c 33 29b 5 32 29a 2 13 27 25 14 4 20 17 14 4 30a 25 30b 26 11 13 2 TI0408 15 10 1 Torque to 15 to 20 ft-lb (20 to 27 N-m). 2 Torque to 15 to 25 in-lb (1.7 to 2.8 N-m). 3 Apply lubricant to threads when reassembling. 4 Apply lubricant to packings and sealing 6 4 23 surfaces when reassembling. 5 Apply thread sealant when reassembling. 18 1 3 Ref Ref No. Part No. Description Qty No. Part No. Description Qty 6 111137 O–RING, valve/swivel 29 201701 NOZZLE, gear lube For Models 243599 to 243604, 2 For Models 243600 and 243603 For Model 243992 1 Includes items 29a–29c 1 7 112841 NUT, seal; 1/2–14 npt 29a 100206 . BUSHING; 1/2 npt(m) x 1/4 npt(f) 1 For Models 243599 to 243604, 1 29b 187046 . TUBE, nozzle 1 10 185416 FILTER 1 29c 201540 . NOZZLE, non–drip 11 113493 SPRING, compression 1 30 203687 NOZZLE, flexible extension 13 110637 SCREW, machine 2 For Models 243601 and 243604 14 113574 SEAL, quad ring 2 Includes items 30a–30b 1 15 113627 WASHER, plain 1 30a 109160 . HOSE, coupled; 1 ft (0.3 m); 17 191074 HANDLE, valve 1 1/2–14 npt(m) x 1/4–18 npt(f) 1 18 238399 SWIVEL; 1/2–14 npt 1 30b 203655 . NOZZLE, non–drip 1 20 191315 CAM 1 25 191552 WASHER, flat 1 23 191320 TRIGGER 1 26 191313 SEAT, valve 1 28 203265 NOZZLE, rigid extension 27 192501 ROD, push 1 For Models 243599, and 243602 32 158491 NIPPLE Includes items 28a–28c 1 For Models 243599 to 243604 1 28a 100081 . BUSHING; 1/2 npt(m) x 3/8 npt(f) 1 33 244075 METER, electronic; English 28b 159246 . TUBE, nozzle 1 For Models 243599, 243600, 28c 203655 . NOZZLE, non–drip 1 and 243601 1 244076 METER, electronic; metric For Models 243602, 243603, and 243604 1 308642 13
  • 117. Parts — V5 Dispense Valves 2 Model 238647 –– Bare Valve Ref No. Part No. Description Qty 1* 238647 VALVE 1 Model 222411, Series C –– For Oil 3 Ref No. Part No. Description Qty 1* 238647 VALVE 1 2 203265 NOZZLE, oil 1 1 See parts list on page 13. 4 Model 222412, Series C –– For Gear Lube Ref No. Part No. Description Qty 1* 238647 VALVE 1 3 201701 NOZZLE, gear lube 1 See parts list on page 13. Model 222413, Series C –– For A.T.F. 7853A Ref No. Part No. Description Qty 1* 238647 VALVE 1 4 203687 NOZZLE, A.T.F. 1 See parts list on page 13. * See parts below. Model 238647 –– Bare Valve, with trigger lock Ref No. Part No. Description Qty 1 Torque to 15 to 20 ft-lb (20 to 27 N-m). 6 111137 O-RING, valve/swivel 1 2 Torque to 15 to 25 in-lb (1.7 to 2.8 N-m). 10 185416 FILTER 1 11 113924 SPRING, compression 1 3 Apply lubricant to threads when reassembling. 12 113493 SPRING, compression 1 14 110637 SCREW, machine 2 4 Apply lubricant to packings and sealing surfaces when reassembling. 15 113574 SEAL, o-ring 2 16 113627 WASHER, plain 1 18 191074 HANDLE, valve 1 14 2 20 238399 SWIVEL; 1/2–14 npt 1 30 21 191315 CAM 1 28 24 191320 TRIGGER 1 25 191321 TRIGGER LOCK 1 27 192106 GUIDE, spring 1 15 4 28 191552 WASHER, flat 2 29 191313 SEAT, valve 1 21 30 192501 ROD, push 1 15 4 29 27 28 12 11 16 25 18 14 2 10 20 1 3 24 7854B 6 414 308642
  • 118. Technical Data NOTE: See instruction manual 307965 for electronic meter Technical Data.Recommended maximum flow rate*V5 dispense valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 gpm (18.9 lpm)EM6 dispense valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 gpm (23.0 lpm)V12 and EM12 dispense valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.0 gpm (45.4 lpm)Maximum operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 psi (10 MPa, 102 bar)Weight (without meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 lb (0.18 kg)Operating temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . –40_ to 180_ F (–40_ to 82_ C)Inlet sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt and 3/4 npt See page 3 for model numbers and configurations.Outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 nptWetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aluminum, stainless steel, carbon steel, acetal, nitrile rubber, Geolastt* Under normal operating conditionsTeflonr is a registered trademark of the DuPont Company.Geolastt is a trademark of Advanced Elastomer Systems. 308642 15
  • 119. Graco Standard WarrantyGraco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on thedate of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limitedwarranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipmentdetermined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accor-dance 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 byfaulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-stitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility ofGraco 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 forverification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. Theequipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defectin material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, andtransportation.THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUTNOT 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 otherremedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or anyother incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of thedate of sale.Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connectionwith accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufacturedby Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will providepurchaser 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 equipmenthereunder, 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 CUSTOMERSThe parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedingsentered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciairesexécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées. Graco Phone Numbers TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers to identify the distributor closest to you: 1–800–533–9655 Toll Free 612–623–6928 612–378–3590 Fax All written and visual data contained in this document reflect 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 GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 www.graco.com PRINTED IN USA 308642 February 1997, Revised September 200116 308642