Graco Check-Mate 800 Bedienungsanleitung

308352E

Instructions

Check-Mate®800 Pumps

Stainless Steel

Stainless Steel pumps with Priming Piston and Severe-Duty® Rod Cylinder for transferring

common industrial coatings and adhesives. For professional use only.

Model 236462, Series B, 65:1 Ratio

with King®Air Motor and 236612 Displacement Pump

5850 psi (40 MPa, 403 bar) Maximum Working Pressure

90 psi (0.6 MPa, 6.2 bar) Maximum Air Input Pressure

Model 241519, Series B, 65:1 Ratio

with Quiet King®Air Motor and 236612 Displacement Pump

5850 psi (40 MPa, 403 bar) Maximum Working Pressure

90 psi (0.6 MPa, 6.2 bar) Maximum Air Input Pressure

Model 234978, Series A, 31:1 Ratio

with Bulldog®Air Motor and 236612 Displacement Pump

3100 psi (21 MPa, 214 bar) Maximum Working Pressure

100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure

See page 28 for technical specifications.

Important Safety Instructions

Read all warnings and instructions in this

manual before using the equipment.

Save these instructions.

TI03820

2 308352E

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Flush Before Using Equipment . . . . . . . . . . . . . . 6

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 7

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pressure Relief Procedure. . . . . . . . . . . . . . . . . . 8

Packing Nut/Wet Cup. . . . . . . . . . . . . . . . . . . . . . 8

Flush the Equipment . . . . . . . . . . . . . . . . . . . . . . 9

Start and Adjust the Pump . . . . . . . . . . . . . . . . . . 9

Shutdown and Care of the Pump. . . . . . . . . . . . 10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . 13

Disconnect the Displacement Pump . . . . . . . . . 13

Connect the Displacement Pump . . . . . . . . . . . 14

Disassemble the Displacement Pump . . . . . . . . 15

Assemble the Displacement Pump . . . . . . . . . . 18

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Model 236462 Pump, Series B, 65:1 Ratio, with

King Air Motor (shown). . . . . . . . . . . . . . . . . 22

Model 241519 Pump, Series B, 65:1 Ratio, with

Quiet King Air Motor. . . . . . . . . . . . . . . . . . . 22

Model 234978 Pump, Series A, 31:1 Ratio, with

Bulldog Air Motor . . . . . . . . . . . . . . . . . . . . . 22

Part 236612, Series A, Displacement Pump . . . 23

Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 25

Model 23462 and 241519. . . . . . . . . . . . . . . . . . 25

Model 234978. . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Technical Specifications . . . . . . . . . . . . . . . . . . . . 28

Models 236462 and 241519 . . . . . . . . . . . . . . . . 28

Model 234978. . . . . . . . . . . . . . . . . . . . . . . . . . . 29

California Proposition 65 . . . . . . . . . . . . . . . . . . . . 29

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 30

Related Manuals

Manuals are available at www.graco.com

Manual in

English Description

309347 King Air Motor Repair-Instructions

309348 King Quiet Air Motor Repair-Instructions

307049 Bulldog Air Motor Parts-Instructions

Warnings

308352E 3

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The

exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks.

When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.

Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this

manual where applicable.

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This

may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Engage trigger lock when not dispensing.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or

servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or

solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:

• Use equipment only in well-ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop

cloths (potential static sparking).

• Ground all equipment in the work area. See Grounding instructions.

• Never spray or flush solvent at high pressure.

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes

are present.

• Use only grounded hoses.

• Hold dispense valve firmly to side of grounded pail when triggering into pail. Do not use pail liners

unless they are anti-static or conductive.

•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment until

you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

Warnings

4 308352E

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Specifications in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical

Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For

complete information about your material, request Safety Data Sheets (SDSs) from distributor or

retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine

manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create

safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the

Pressure Relief Procedure and disconnect all power sources.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or

swallowed.

• Read Safety Data Sheets (SDSs) to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including

eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not

limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

WARNING

Installation

308352E 5

Installation

Grounding

Pump: use ground wire and clamp (supplied). Remove

the ground screw (Z) and insert through eye of ring

terminal at the end of ground wire (Y). Fasten ground

screw back onto pump and tighten securely. Connect

the other end of the wire to a true earth ground. Order

Part 222011 Ground Wire and Clamp.

Air and fluid hoses: use only electrically conductive

hoses.

Air compressor: follow manufacturer’s

recommendations.

Dispense valve: ground through connection to a

properly grounded fluid hose and pump.

Fluid supply container: follow local code.

Solvent pails used when flushing: follow local code.

Use only conductive metal pails, placed on a grounded

surface. Do not place the pail on a nonconductive

surface, such as paper or cardboard, which interrupts

grounding continuity.

To maintain grounding continuity when flushing or

relieving pressure: hold metal part of the dispense

valve firmly to the side of a grounded metal pail, then

trigger the dispense valve.

Accessories

Install the following accessories in the order shown in

FIG. 2, page 7, using adapters as necessary.

Air and Fluid Hoses

Be sure all air hoses (H) and fluid hoses (N) are properly

sized and pressure-rated for your system. Use only

electrically conductive hoses.

The equipment must be grounded to reduce the risk

of static sparking. Static sparking can cause fumes to

ignite or explode. Grounding provides an escape wire

for the electric current.

FIG. 1

TI1052

A main air bleed valve (C), pump air bleed valve

(E), and fluid drain valve (M) are required. These

accessories help reduce the risk of serious injury,

including fluid injection and splashing of fluid in the

eyes or on the skin, and injury from moving parts if

you are adjusting or repairing the pump.

The main air bleed valve (C) shuts off the air to the

pump and ram. The pump air bleed valve (E)

relieves air trapped between this valve and the

pump after the air is shut off. Trapped air can

cause the pump to cycle unexpectedly. Locate the

valve close to the pump. Order Part 107141.

The fluid drain valve assists in relieving fluid pressure

in the displacement pump, hose, and dispense valve.

Triggering the dispense valve to relieve pressure may

not be sufficient. Order Part 235992.

Installation

6 308352E

Mounting

Mount the pump (A) to suit the type of installation

planned. FIG. 2 on page 7 illustrates a ram-mounted

pump in a multi-valve header system. Pump dimensions

and the mounting hole layout are shown in

Dimensions, page 27.

If you are mounting the pump on a ram, refer to your

separate ram manual for installation and operation

instructions. Mounting Kit 222776 is available to mount

the pump on a 55 gallon (200 liter) ram.

Air Line

•Main air bleed valve (C): is required in your system

to shut off the air supply to the pump and ram.

When closed, the valve will bleed off all air in the

ram and pump, and the ram will slowly lower. Be

sure the valve is easily accessible from the pump,

located upstream from the air manifold (G), and

downstream from the air regulator.

•Air line lubricator (D): provides automatic air

• motor lubrication. Locate in the position shown.

•Pump air bleed valve (E): required in your system,

to relieve air trapped between it and the air motor

when the valve is closed. Be sure the bleed valve is

easily accessible from the pump, and is located

downstream from the air regulator.

•Air Regulator (F): controls pump speed and outlet

pressure by adjusting the air pressure to the pump.

Locate the regulator close to the pump, but

upstream from the pump air bleed valve.

•Air manifold (G): has a swivel air inlet. It mounts to

a ram, and has ports for connecting lines to air

accessories, such as the ram air regulator (T) and

ram director valve (U).

•Air line filter (J): removes harmful dirt and moisture

from the compressed air supply. Also, install a drain

valve (W) at the bottom of each air line drop, to

drain off moisture.

•Air shutoff valve (K): isolates the air line

accessories for servicing. Locate upstream from all

other air line accessories.

•Pump runaway valve (V): senses when the pump

is running too fast and automatically shuts off the air

to the motor. A pump which runs too fast can be

seriously damaged. Locate in the position shown.

Fluid Line

•Fluid drain valve (M): required in your system, to

relieve fluid pressure in the hose and dispense

valve

•Fluid shutoff valve (P): shuts off fluid flow.

•Fluid pressure regulator (L): for more precise

adjustment of the fluid pressure.

•Dispense valve (S): to dispense fluid.

•Fluid line swivel (R): for easier dispense valve

movement.

Flush Before Using Equipment

The equipment was tested with lightweight oil, which is

left in the fluid passages to protect parts. To avoid

contaminating your fluid with oil, flush the equipment

with a compatible solvent before using the equipment.

See Flush the Equipment, page 9.

Trapped air can cause the pump to cycle

unexpectedly, which could result in serious injury from

splashing or moving parts.

Installation

308352E 7

Typical Installation

Accessories are available from Graco. If you supply

your own accessories, be sure they are adequately

sized and pressure-rated to meet the system’s

requirements.

The Typical Installation shown in FIG. 2 is only a guide

for selecting and installing system components and

accessories. Contact your Graco distributor for

assistance in designing a system to suit your particular

needs.

Key:

A Pump

B 200 L (55 gal) Air-Powered Ram

C Main Air Bleed Valve (required, for pump and ram)

D Air Line Lubricator

E Pump Air Bleed Valve (required, for pump)

F Pump Air Regulator

G Air Manifold

H Electrically Conductive Air Supply Hose

J Air Line Filter

K Air Shutoff Valve (for accessories)

L Fluid Regulator

M Fluid Drain Valve (required)

N Electrically Conductive Fluid Hose

P Fluid Shutoff Valve

R Valve Swivel

S Dispense Valve

T Ram Air Regulator

U Ram Director Valve

V Pump Runaway Valve (position only)

W Air Line Drain Valve

Y Ground Wire (required, see Grounding, page 5, for

installation)

FIG. 2: Typical Installation

FLUID HEADER PIPE

(3in. Diameter)

MAIN AIR

LINE

LLP

Operation

8 308352E

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

1. Engage trigger lock.

2. Close all air bleed valves.

3. Disengage the trigger lock.

4. Hold a metal part of the dispense valve firmly to a

grounded metal pail. Trigger the dispense valve to

relieve pressure.

5. Engage the trigger lock.

6. Open all fluid drain valves in the system, having a

waste container ready to catch drainage. Leave

drain valve(s) open until you are ready to dispense

again.

7. If you suspect the nozzle or hose is clogged or that

pressure has not been fully relieved:

a. VERY SLOWLY loosen the tip guard retaining

nut or the hose end coupling to relieve pressure

gradually.

b. Loosen the nut or the coupling completely.

c. Clear the obstruction in the hose or nozzle.

Packing Nut/Wet Cup

Before starting, fill the packing nut (2) 1/3 full with Graco

Throat Seal Liquid (TSL) or compatible solvent.

The packing nut is torqued at the factory and is ready for

operation. If it becomes loose and there is leaking from

the throat packings, relieve pressure, then torque the

nut to 136–149 N•m (100–110 ft-lb) using the supplied

wrench (109). Do this whenever necessary. Do not

overtighten the packing nut.

NOTE: The bleed hole must face down.

This equipment stays pressurized until pressure is

manually relieved. To help prevent serious injury from

pressurized fluid, such as skin injection, splashing

fluid and moving parts, follow the Pressure Relief

Procedure when you stop dispensing and before

cleaning, checking, or servicing the equipment.

FIG. 3

03820

109

Operation

308352E 9

Flush the Equipment

• Flush before fluid can dry in the equipment, at the

end of the day, before storing, and before repairing

equipment.

• Flush at the lowest pressure possible. Check

connectors for leaks and tighten as necessary.

• Flush with a fluid that is compatible with the fluid

being dispensed and the equipment wetted parts.

1. Perform Pressure Relief Procedure, page 8.

2. Remove nozzle and soak in solvent.

3. Set pump to lowest possible fluid pressure, and start

pump.

4. Hold a metal part of the dispense valve (S) firmly to

a grounded metal pail. Trigger the dispense valve

until clean solvent dispenses.

5. Perform Pressure Relief Procedure, page 8.

Start and Adjust the Pump

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

your system.

2. Close the air regulator (F).

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

4. Hold a metal part of the valve (S) firmly to the side of

a grounded metal pail and hold the trigger open.

5. Slowly open the air regulator until the pump starts.

6. Cycle the pump slowly until all air is pushed out and

the pump and hoses are fully primed.

7. Release the valve trigger and lock the trigger safety.

The pump should stall against pressure.

To avoid fire and explosion, always ground equipment

and waste container. To avoid static sparking and

injury from splashing, always flush at the lowest

possible pressure.

Keep hands and fingers away from the priming piston

(21) during operation and whenever the pump is

charged with air. The priming piston extends beyond

the intake housing (19) to pull material into the pump

and can amputate a hand or finger caught between it

and the intake housing. Follow the Pressure Relief

Procedure on page 8, before checking, clearing, or

cleaning the priming piston.

Operation

10 308352E

8. If the pump fails to prime properly, open the bleeder

valve plug (20) slightly. Use the bleed hole, on the

underside of the valve body (29), as a priming valve

until the fluid appears at the hole. See FIG. 3, page

8. Close the plug.

NOTE: When changing fluid containers with the hose

and dispense valve already primed, open the bleeder

valve plug (20), to help prime the pump and vent air

before it enters the hose. Close the plug when all air is

eliminated.

NOTE: With the pump and lines primed, and with

adequate air pressure and volume supplied, the pump

will start and stop as you open and close the dispense

valve. In a circulating system, the pump will speed up or

slow down on demand, until the air supply is shut off.

9. Use the air regulator (F) to control the pump speed

and the fluid pressure.

Shutdown and Care of the Pump

For overnight shutdown, stop the pump at the bottom of

the stroke to prevent fluid from drying on the exposed

displacement rod and damaging the throat packings.

Relieve the pressure according to the Pressure Relief

Procedure, page 8.

Always flush the pump before the fluid dries on the

displacement rod. Refer to Flush the Equipment, page

To reduce the risk of fluid injection, do not use your

hand or fingers to cover the bleed hole on the

underside of the bleeder valve body (29) when

priming the pump. Use a crescent wrench to open

and close the bleeder plug

NOTICE

Do not allow the pump to run dry. It will quickly

accelerate to a high speed, causing damage. If your

pump is running too fast, stop it immediately and

check the fluid supply. If the container is empty and

air has been pumped into the lines, refill the container

and prime the pump and the lines, or flush and

leave it filled with a compatible solvent. Eliminate all

air from the fluid system.

To reduce the risk of overpressurizing your system,

which could cause component rupture and serious

injury, never exceed the Maximum Incoming Air

Pressure to the pump (see the Technical

Specifications on page 28).

NOTICE

Always use the lowest air pressure necessary to get

the desired results. Higher pressures cause

premature nozzle and pump wear.

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