Graco 918316 Operation manual

200 LITER (55 GALLON) DRUM SIZE

165 MM (6.5 IN.) DUAL POST

Air-Powered

Ram Supply Unit

Instructions–Parts List

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

310524W

Model 918316

Important Safety Instructions

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

See page 2 for Models and Table of Contents.

8934B

2 310524

Table Of Contents

Part Number Air Motor Ratio Pump Wiper Max. Fluid Working Pressure Page

* 918316 Premiert80:1 Check-Mate 1000 EPDM 32.7 MPa, 327 bar (4800 psi) 25

* 918303 Premier 39:1 Check-Matet2100 PVC 27 MPa, 269 bar (3900 psi) 27

687105 Kingt65:1 Check-Mate 800 EPDM 33 MPa, 332 bar (4875 psi) 29

246966 Bulldog 31:1 Check-Mate 800 EPDM 21 MPa, 211 bar (3100 psi) 30

246967 Kingt65:1 Check-Mate 800 EPDM 33 MPa, 332 bar (4875 psi) 32

* 918313 King 65:1 Check-Mate 800{PVC 40 MPa, 403 bar (5850 psi) 35

* 234122 Senator 34:1 Check-Mate 450 EPDM 23 MPa, 234 bar (3400 psi) 35

* 918315 King 50:1 Check-Mate 1000 EPDM 31 MPa, 310 bar (4500 psi) 37

* 918597 King 65:1 Check-Mate 800 EPDM 40 MPa, 403 bar (5850 psi) 39

* 918314 Quiet King 65:1 Check-Mate 800{EPDM 40 MPa, 403 bar (5850 psi) 41

* 918469 Premier 34:1 Dura-Flot2400 PVC 23 MPa, 234 bar (3400 psi) 43

* 918481 Premier 45:1 Dura-Flo 1800 PVC 31 MPa, 310 bar (4500 psi) 45

C59702 Premier 67:1 Dura-Flo 1200{PVC 34 MPa, 345 bar (5000 psi) 47

* 261629 Quiet King 24:1 Check-Mate 800 –16.6 MPa, 166 bar (2400 psi) 9

* These products are CE marked.

Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Pump Selection Chart 6. . . . . . . . . . . . . . . . . . . . . . . . .

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

Selecting a Location for the Ram 8. . . . . . . . . . . . . .

System Accessories and Modules 8. . . . . . . . . . . . .

Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Ram 10. . . . . . . . . . . . . . . . . . . . . . . . . .

Ground The System 10. . . . . . . . . . . . . . . . . . . . . . . .

Starting Up the System 11. . . . . . . . . . . . . . . . . . . . .

Initial Material Loading 12. . . . . . . . . . . . . . . . . . . . . .

Operation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Relief Procedure 13. . . . . . . . . . . . . . . . . .

Raising and Lowering the Ram 14. . . . . . . . . . . . . .

Changing Empty Drums 14. . . . . . . . . . . . . . . . . . . .

Shutdown 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Stop 16. . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing Safety 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ram Pressure Relief Procedure 18. . . . . . . . . . . . .

Removing a Material Drum from

the Supply Unit 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Follower 19. . . . . . . . . . . . . . . . . . . . . .

Removing/Re-installing the King, Senatorr,

or BulldogrPump from the Ram 20. . . . . . . . . . . . .

Removing/Re-installing the Premier Pump

from the Ram 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection Frequency 23. . . . . . . . . . . . . . . . . . . . . .

Parts (see table above) 25. . . . . . . . . . . . . . . . . . . . . . .

Model 918304, Cold Pump Mounting Kit

for Check-Mate Pumps 49. . . . . . . . . . . . . . . . . . . . .

Model 918309, Cold Pump Mounting Kit 50. . . . . .

Model 243785, Ram Air Control Module for

King, Bulldog & Senator 51. . . . . . . . . . . . . . . . . . . .

Model 918306, Ram Air Control Module

for Premier 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model 244072, Air Control Assembly 53. . . . . . . . .

Accessories 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Related Publications 57. . . . . . . . . . . . . . . . . . . . . . . . .

Graco Standard Warranty 58. . . . . . . . . . . . . . . . . . . . .

Graco Information 58. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3310524

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious

injury or death if you do not follow the corresponding

instructions.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to

or destruction of equipment if you do not follow the

corresponding instructions.

WARNING

INSTRUCTIONS

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and

result in serious injury.

DThis equipment is for professional use only.

DRead all instruction manuals, warnings, tags, and labels before operating the equipment.

DUse the equipment only for its intended purpose. If you are uncertain about usage, call the

distributor closest to you.

DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.

DCheck the equipment daily. Repair or replace worn or damaged parts immediately.

DDo not exceed 125 psi (8.8 bar) maximum inbound air pressure to the ram.

DNever exceed the recommended working pressure or the maximum air inlet pressure stated on

your pump or in the Technical Data on page 56.

DBe sure that all spray/dispensing equipment and accessories are rated to withstand the maxi-

mum working pressure of the pump. Do not exceed the maximum working pressure of any

component or accessory used in the system.

DRoute the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces.

DDo not expose Graco hoses to temperatures above 82_C (180_F) or below -40_C (-40_F).

DDo not use the hoses to pull the equipment.

DUse fluids and solvents that are chemically compatible with the equipment wetted parts. See

the Technical Data sections of all the equipment manuals. Always read the material manufac-

turer’s literature before using fluid or solvent in this pump.

DAlways wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid

and solvent manufacturers.

DWear hearing protection when operating this equipment.

DComply with all applicable local, state and national fire, electrical and other safety regulations.

4 310524

WARNING

SKIN INJECTION HAZARD

Spray from the spray gun, hose leaks, or ruptured components can inject fluid into your body and

cause extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on

the skin can also cause serious injury.

DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate

surgical treatment.

DDo not point the gun/valve at anyone or at any part of the body.

DDo not put your hand or fingers over the spray tip/nozzle.

DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.

DAlways have the trigger guard on the gun when dispensing.

DCheck the gun diffuser operation weekly. Refer to the gun manual.

DBe sure the gun/valve trigger safety operates before dispensing

e sure

e gun

gger sa

y opera

ore

spens

ng.

DLock the gun/valve trigger safety when you stop dispensing.

DFollow the Pressure Relief Procedure on page 13 if the nozzle clogs, and before cleaning,

checking or servicing the equipment.

DTighten all fluid connections before operating the equipment.

DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immedi-

ately. Do not repair high pressure couplings; you must replace the entire hose.

DUse only Graco approved hoses. Do not remove the spring guard that is used to help protect

the hose from rupture caused by kinks or bends near the couplings.

FIRE AND EXPLOSION HAZARD

Improper grounding, poor air ventilation, open flames or sparks can cause a hazardous condition

and result in fire or explosion and serious injury.

DGround the equipment and the object being sprayed, and all other electrically conductive

objects in the dispense area. Proper grounding dissipates static electricity generated in the

equipment. See Ground the System on page 10.

DIf there is any static sparking or you feel an electric shock while using the equipment, stop dis-

pensing immediately. Do not use the equipment until you have identified and corrected the

problem.

DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvent or material.

DDo not smoke in the dispense area.

DExtinguish all open flames or pilot lights in the dispense area.

DDo not turn on or off any light switch in the dispense area.

DKeep the dispense area free of debris, including solvent, rags, and gasoline.

5310524

WARNING

MOVING PARTS HAZARD

Moving parts, such as the ram follower plate/pump inlet can pinch or amputate fingers.

DDo not operate the equipment with the guard removed.

DKeep clear of all moving parts when starting or operating the equipment.

DKeep hands and fingers away from the priming piston during operation and whenever the pump

is charged with air.

DKeep clear of the follower plate, pump fluid inlet, and lip of the fluid container when raising or

lowering the ram.

DBefore checking or servicing the ram or pump, follow the Pressure Relief Procedure on

page 13.

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the

skin, inhaled, or swallowed.

DKnow the specific hazards of the fluid you are using.

DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all

local, state and national guidelines.

DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid

and solvent manufacturer.

DProvide adequate ventilation.

6 310524

Pump Selection Chart

Pump Model and Description Maximum Fluid Working

Pressure Maximum Pump Air

Input Pressure Part

Number

34:1 Premier, DF2400, CS Lower

34:1 Premier, DF2400, SST Lower

39:1 Premier, CM2100, CS Lower

39:1 Premier, CM2100, SST Lower

23 MPa, 234 bar (3400 psi)

26.9 MPa, 269 bar (3900 psi)

0.7 MPa, 7 bar (100 psi)

222942

222943

222940

222941

45:1 Premier, DF1800, CS Lower

45:1 Premier, DF1800, SST Lower

80:1 Premier, CM1000, CS Lower

80:1 Premier, CM1000, SST Lower

31 MPa, 310 bar (4500 psi)

40 MPa, 403 bar (5850 psi)

0.7 MPa, 7 bar (100 psi)

0.5 MPa, 5 bar (73 psi)

222938

222939

234667

234824

237518

237520

50:1 King, CM1000, CS Lower

50:1 King, CM1000, SST Lower

65:1 King, CM800, CS Lower

65:1 King, CM800, SST Lower

31 MPa, 310 bar (4500 psi)

40 MPa, 403 bar (5850 psi)

0.6 MPa, 6.2 bar (90 psi)

237707

237708

236471

236462

31:1 Bulldog, CM800, CS Lower

19:1 Senator, CM800, CS Lower

65:1 Reduced Icing Quiet King,

CM800, CS Lower

31:1 Reduced Icing Quiet Bulldog,

CM800, CS Lower

21 MPa, 214 bar (3100 psi)

13 MPa, 131 bar (1900 psi)

40 MPa, 403 bar (5850 psi)

21 MPa, 214 bar (3100 psi)

0.7 MPa, 7 bar (100 psi)

0.6 MPa, 6.2 bar (90 psi)

0.7 MPa, 7 bar (100 psi)

237261

237264

237265

237274

12:1 Bulldog, CM2100, SST Lower

12:1 Quiet Bulldog, CM2100,

SST Lower

24:1 King, CM2100, SST Lower

24:1 Quiet King, CM2100, SST Lower

8 MPa, 83 bar (1200 psi)

14.9 MPa, 149 bar (2160 psi)

0.7 MPa, 7 bar (100 psi)

0.6 MPa, 6.2 bar (90 psi)

222904

222903

222836

222905

67:1 Premier, DF1200, SST Lower 34 MPa, 345 bar (500 psi) 0.5 MPa, 5.2 bar (75 psi) 245171

Viscount Hydraulic Motor, CM2100,

SST Lower

15 MPa, 156 bar (2300 psi) N/A 222906

34:1 Senator, CM4500, CS Lower 23 MPa, 234 bar (3400 psi) 0.7 MPa, 7 bar (100 psi) 222769

7310524

Typical Installation

A Air Line Filter

B Accessory Bleed-Type Master Air Valve

(required)

C Pump Bleed-Type Master Air Valve (required)

D Pump Air Regulator

E Main Air Line Supply

F Air Manifold

G Follower Plate Blowoff Button

H Ram Air Supply Hose

I Air Line Lubricator

J Fluid Drain Valve (required)

K Fluid Regulator

L Applicator Gun or Valve

M Gun Swivel

N Mounting Plate

10 Follower Rod

20 Pump Assembly

30 Ram Hand Valve

40 Ram Module

50 Follower Gasket

60 Follower Plate Assembly

70 Wiper Seals

80 Drum Clamp

90 Grounding Wire (required)

Fig. 1

L M

IAE

8328B

8 310524

Typical Installation

The typical installation discussed below is only a guide

for selecting and installing system components and

accessories. Contact your Graco distributor for help in

designing a system to suit your particular needs.

This air-powered ram extruder forces high viscosity

fluids into the intake valve of the fluid pump. Wiper

rings and other accessory equipment for use with this

ram are listed in the Accessories section on page 54.

Selecting a Location for the Ram

Refer to the Ram Mounting and Clearance Dimensions

drawing (Fig. 14 on page 55) for ram mounting and

clearance dimensions.

When selecting a location for the ram, keep the follow-

ing in mind:

1. There should be sufficient space for installing and

using the equipment.

DMake sure there is sufficient overhead clear-

ance for the pump and ram when the ram is in

the fully raised position.

DMake sure the air regulators for the pump and

ram are fully accessible.

2. Make sure that you will be able to level the base of

the ram using metal shims.

3. When you bolt the ram to the floor, the anchors

should be long enough to prevent the unit from

tipping. Refer to the Dimensional Drawing on page

55 for more information.

System Accessories and Modules

Before you install the system you should be familiar

with the parts discussed below. For more information,

refer to Fig. 1, Typical Installation, on page 7.

Air and Fluid Hoses

When installing a system, make sure:

Dall air and fluid hoses are properly sized for your

system.

Dto use only electrically conductive air and fluid

hoses.

Dto use only Graco approved hoses. Do not remove

the spring guard that is used to help protect the

hose from rupture caused by kinks or bends near

the couplings.

To allow the gun to move more freely, use a short whip

hose between the main fluid hose and the gun.

Air Line Modules

WARNING

PRESSURIZED FLUID HAZARD AND

MOVING PARTS HAZARD

The pump bleed-type master air valve,

to relieve air trapped between this valve

and the pump after the pump air regula-

tor is closed. Trapped air can cause the

pump to cycle unexpectedly, which could

result in serious injury, including splashing in the

eyes or on the skin and injury from moving parts.

3-Regulator Air Control Modules (shown in Fig. 1)

The following components are supplied with your

pump:

DPump Bleed-type Master Air Valve (C) is required in

your system to relieve air trapped between it and

the air motor when the valve is closed (see the

WARNING above). Be sure the bleed valve is

easily accessible from the pump, and is located

downstream from the air regulator.

DPump Air Regulator (D) 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 bleed-type master air valve.

DRam Down Air Regulator (not shown) controls the

air pressure to the ram.

DRam Up Air Regulator (not shown) controls the air

pressure to the ram.

DRam Air Supply Hose (H) connects the ram air

regulator to the air manifold.

DAir Manifold (F) divides the main air supply into

separate lines for the pump and ram.

9310524

Installation

Air Line Accessories

If you have a 3-Regulator Air Control Module, install

the following accessories, using adapters as neces-

sary:

DPump runaway valve senses when the pump is

running too fast and automatically shuts off the air

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

seriously damaged.

DAir line lubricator provides automatic air motor

lubrication (standard on the 4-Regulator Air Control

Module).

DAir line filter removes harmful dirt and moisture

from the compressed air supply (standard on the

4-Regulator Air Control Module).

DAccessory bleed-type air valve isolates the air line

accessories for servicing. Locate upstream from all

other air line accessories. This isolates the acces-

sories for servicing.

Fluid Line Accessories (Fig. 1)

Install the following accessories in the positions shown

in the Typical Installation, using adapters as neces-

sary:

A fluid drain valve (J) is required in your system to

relieve fluid pressure in the hose and gun (see the

WARNING on page 8). When you install the fluid

drain valve:

1. Screw the drain valve into the open branch of a tee

mounted in the fluid line.

2. Install the drain valve pointing down, but so the

handle points up when the valve is opened.

A fluid regulator (K) controls fluid pressure to the

gun/valve, and dampens pressure surges.

A gun or valve (L) dispenses the fluid. The gun shown

in the Typical Installation is a dispensing gun for highly

viscous fluids.

A gun swivel (M) allows the gun to move more freely.

10 310524

Installation

The installation procedure includes:

Dlocating and installing the ram. See Form# 310523

for further information.

Dgrounding the system

Dstarting up the system

Dinitially loading material

Installing the Ram

To install the ram, follow the procedure below. Refer to

the Ram Mounting and Clearance Dimensions drawing

(Fig. 14 on page 55) for ram mounting and clearance

dimensions.

1. Select a convenient location for the equipment.

Check that there is sufficient overhead clearance

for the pump and ram when the ram is in the fully

raised position. Make sure the air regulators for the

pump and ram are fully accessible.

2. Level the base of the ram, using metal shims.

3. Using the holes in the base as a guide, drill holes

for 13 mm. (1/2 in.) anchors. Bolt the ram to the

floor anchors, which are long enough to prevent

the unit from tipping. Refer to the Dimensional

Drawing on page 55.

Ground The System

Ground the supply unit as instructed here and in the

individual component manuals.

WARNING

FIRE AND EXPLOSION HAZARD

When installing the pump, ground the

system as explained below. Also read

the section FIRE AND EXPLOSION

HAZARD on page 4.

To reduce the risk of static sparking, ground the pump,

object being sprayed, and all other spraying/dispensing

equipment used or located in the spraying/dispensing

area. Check your local electrical code for detailed

grounding instructions for your area and type of equip-

ment.

1. Pump: connect a ground wire and clamp to a true

earth ground as shown in Fig. 2.

a. Loosen the grounding lug locknut (W) and

washer (X).

b. Insert one end of a 1.5 mm2(12 ga) minimum

ground wire (Y) into the slot in lug (Z) and

tighten the locknut securely.

c. Connect the other end of the wire to a true

earth ground.

To maintain grounding continuity when flushing or

relieving pressure, always hold a metal part of the

spray gun/dispensing valve firmly to the side of a

grounded metal pail, then trigger the gun/valve.

Fig. 2

2. Fluid and air hoses: use only electrically conduc-

tive materials and air hoses, and fluid hoses.

3. Air compressor: follow the manufacturer’s recom-

mendations.

This manual suits for next models

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