Instructions-Parts
312374J
Air Controls
EN
Integrated and 2-Button Interlock Air Controls for use with Supply Systems.
For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Integrated Air Controls
L20c Air Controls
r_257302_312376_2e
ti10438a
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Integrated Air Controls
Integrated Air Controls
255650 (shown)
E
1
To reduce the risk of serious injury whenever you are
instructed to relieve the pressure, follow the Pressure
Relief Procedure.
C
Pressure Relief Procedure
1. Close the air motor slider valve (E) and the main air
slider valve (F).
2. Set the ram director valve to DOWN. The ram will
slowly drop.
F
D
3. Jog the director valve up and down to bleed air from
ram cylinders.
r_289105_312375_2a
FIG. 2
Disassembly
1. For Supply Systems with Shrouds: Remove
shrouds. Loosen six captive screws (A) and disas-
semble shrouds (B) from supply system.
255650 (shown)
E
1
B
C
B
F
D
255650 (shown)
r_289105_312375_3a
A
FIG. 3
r_289105_312375_a
FIG. 1
If you are not replacing the manifold (1), you may
prefer to remove the bracket from the ram and
leave it attached to the integrated air controls
2. Disconnect all hoses and tubing from existing air
control.
3. Remove four screws (C) from the mounting bracket
(D) and remove the integrated air controls from the
supply system.
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Integrated Air Controls
4g
4f
4e
4b
4d
4c
4
4a
ti10952a
FIG. 5
r_289105_312375_4a
Replace Air Motor Regulator
FIG. 4
motor regulator not included with 24C824 integrated air
controls.
Replace Director Valve
1. Relieve pressure.
1. Relieve pressure.
2. Disconnect air motor hosing and fittings.
2. Remove screws (4a) and take off director valve.
3. Remove two screws (9) and take off the shutoff
valve (3) at top of module. If your supply system has
an air solenoid, it can remain attached to the shutoff
valve.
3. Remove spring (4c), valve plate (4d), and o-ring
(4b).
Note the orientation of the director valve plate when
you remove it. The opening should be on the oppo-
site side (left) of the lever.
4. Remove two screws (9) and take off the air motor
regulator (6).
5. Attach new regulator to manifold. Orient so the
gauge lines up with the gauge on the ram air regula-
tor and the direction of flow arrow points up. Tighten
screws until snug. Recommend using thread locker
Loctite 220 or equivalent.
4. Remove and discard pin (4g) and four valve seats
(4e) with o-rings (4f).
5. Insert new valve seats (4e) with o-rings (4f) and new
pin.
6. Reattach shutoff valve (3) at top of regulator. Make
sure that o-ring (5) is in place on valve (3).
6. Insert new director valve plate (4d, see Note above)
spring (4c), and o-ring (4b).
7. Attach new director valve with screws (4a). Tighten
screws until snug.
4
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Integrated Air Controls
Replace Ram Air Regulator
1. Relieve pressure.
2. Remove four screws (7a) and take off the ram air
regulator (7).
3. Replace o-rings (7b) on back side of regulator.
4. Attach new air regulator to manifold. Use index pin
for correct orientation. Tighten screws until snug.
Reassembly
1. Using four screws, attach the integrated air controls
2. Attach the ram up, ram down, and blowoff air lines
255650 (shown)
Not included
with 24C824
}
Ram up
Blowoff
Ram down
Auxiliary
air supply port
ti10778a
FIG. 6
3. Attach all other hoses and replace shrouds.
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2-Button Interlock
2-Button Interlock
3. Raise platen to top of drum.
4. Attach actuator bracket.
a. For D200 and D200s supply systems: Attach
actuator bracket (138) near bottom of lift rod so
it engages the roller switch when the platen
reaches the top of the drum.
To reduce the risk of serious injury whenever you are
instructed to relieve the pressure, follow the Pressure
Attach Roller Switch and
Actuator
1. Attach roller switch (133) to bracket (132). Position
roller switch to far back position on the bracket and
leave mounting screws (144) loose.
139
140
2. Attach bracket (132) to ram with screws (105) and
washers (106). Leave screws loose. See FIG. 7 and
138
144
133
105
ti10848a
ti10847a
FIG. 9
b. For D60 supply systems: Loosen one screw
(151a) and remove one screw (152b). Align
actuator rod (151) on piston rod so it touches
the air motor mounting bracket. Tighten actua-
tor rod to piston rod with four screws (140).
106
132
151b
ti10844a
FIG. 7: D200 and D200s Bracket
151a
150
105
151
144
106
132
138
139
152
153
133
r_289105_312375_5a
140
r_289105_312375_5a
FIG. 8: D60 Bracket
FIG. 10
6
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2-Button Interlock
5. Tighten actuator bracket to rod using 4 screws (140)
and bracket clamps (139).
6. Adjust the roller switch (133) out so it contacts actu-
ator bracket (138), then tighten screws (144).
130
7. Tighten bracket (132) to ram with screws (105) and
washers (106).
8. Connect main air (S1) to port (S1) on roller switch
(133) with 15 in. of tubing (146).
9. Connect switch signal air (S2) to port (S2) on roller
switch (133) with 15 in. of tubing (146).
10. For D60 supply systems: Install two fittings (150)
into (S1) and (S2).
S2
S1
145
ti10843a
FIG. 12
133
7. Reattach integrated air controls. See Reassembly,
ti10844a2
page 5.
FIG. 11:
8. Insert cap screw (145) through integrated air con-
Attach 2-Button Interlock
Assembly
1. Relieve pressure.
3. Disconnect air lines.
4. Remove integrated air controls from bracket. See
5. Remove back cover from 2-button interlock assem-
bly (130).
6. Position 2-button interlock assembly between air
control bracket and air controls. The screws that
attach the integrated air controls to the supply sys-
tem also attach the 2-button interlock assembly.
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2-Button Interlock
12. Connect tubing (147) from ram up fitting on back of
air controls to fitting (U1) on right side of top pilot
9. Inside 2-button interlock module, disconnect elbow
fitting (6) and push fittings (7) from tee fitting (5).
Remove plug (8) from auxiliary air supply port on
back of integrated air controls. Install tee fitting (5)
through into the port and through the opening in the
bracket. Reconnect elbow fitting (6) and push fit-
tings (7). Reinstall plug (8) at top of tee fitting (5).
13. Connect tubing from ram up fitting near bottom of
ram cylinder to fitting (U2) on left side of top sole-
noid.
14. Connect blowoff air (B1) to blowoff air connector on
platen.
10. Connect tubing (147) from ram down fitting on back
of air controls to fitting (D1) on right side of bottom
15. Replace cover on 2-button interlock assembly.
It may be necessary to rearrange tubing so cover
will fit back on assembly.
11. Connect tubing from ram down fitting near top of
ram cylinder to fitting (D2) on left side of bottom pilot
16. Attach all other hoses and replace shrouds.
S1
U2
U1
D2
B1
(blowoff)
D1
7
S2
6
D1
(ram down)
8
5
U1
(ram up)
FIG. 13
8
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L20c Air Controls
L20c Air Controls
Replace Air Motor Shutoff Valve
and Ram Shutoff Valve
To reduce the risk of serious injury whenever you are
instructed to relieve the pressure, follow the Pressure
Relief Procedure.
1. Remove two screws (211) from air motor shutoff
valve and two screws (209) from ram shutoff valve.
Pressure Relief Procedure
2. Remove valve assemblies from panel.
1. Close the air motor shutoff valve (E) and remove air
line from air control coupling (x).
Remove Blowoff Push Button
2. Set the elevator director valve to DOWN. The ram
will slowly drop.
1. Hold button in place and remove screw.
Disassembly
1. Remove two screws that attach air control panel to
elevator.
2. Remove nut underneath button and push button
from panel (201).
Reassembly
1. Replace parts as needed and reassemble them in
the reverse order of disassembly.
2. Disconnect all hoses and tubing from existing air
control.
Replace Air Motor Regulator
2. Connect all hoses and tubing.
1. Loosen swivel fitting (205) between regulator (206)
and air motor shutoff valve (203).
3. Install air controls on elevator with two screws and
lockwashers from kit 257613. See manual 313527.
2. Remove nut (218) from front of regulator and pull
regulator out of panel (201).
206
218
205
201
203
r_289105_312375_8a
FIG. 14
312374J
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Parts
Parts
L20c Air Controls, 257613
Front View
218
212
Back View
201
213
216
202
206, 218
207
215
209
205
204
211
r_289105_312375_9a
208
217
219
214
203
r_289105_312375_9a2
210
Ref. Part
Description
Qty.
201
PANEL
1
1
2
1
1
1
1
1
2
1
2
1
1
2
3
1
1
1
1
202 517313 VALVE, 3 way
203 114362 VALVE, ball, air
204
205
FITTING, adapter
FITTING, 90° swivel
206 110318 REGULATOR
207
208
209
210
211
FITTING, tee
FITTING, line, air
SCREW, cap; 10-24 x 0.375 in.
FITTING, elbow
SCREW, cap; 10-24 x 0.625 in.
212 15T500 GAUGE
213
214
215
216
217
218
219
FITTING, 90° swivel
FITTING, elbow
FITTING, elbow
FITTING, elbow
FITTING, swivel
NUT, regulator
SAFETY, valve
Mounting screws and lockwashers are included with
kit 257613. See manual 313527.
10
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Parts
Model 255650; D200s, D200, and D60
Model 257612; S20
Integrated Air Controls
3
Ref.
Part
Description
Qty.
1
3
MANIFOLD
★ 121108 VALVE, shutoff (includes o-rings
and screws)
1
2
5
◆ 121793 VALVE, shutoff (includes o-rings
and screws)
2
1
4
121107 VALVE, director (includes 4a and
SCREW
6
9
4a
4b
5
4
1
3
2
1
O-RING
★ 121110 O-RING, buna
◆ 102620 O-RING, buna
★ 255651 REGULATOR, air motor (includes
regulator, o-ring, and screws)
◆ 257614 REGULATOR, air motor (includes
regulator, o-ring, and screws)
121106 REGULATOR, ram (includes 7a
and 7b)
5★
14◆
6
1
1
13
1
7
10
11
4b
7a
7b
8
SCREWS
O-RING
4
2
1
4
9
121109 VALVE, blowoff (includes valve
and push button)
9
★ 121112 SCREW, cap, socket head
1/4-20 x 5/8
◆ 120039 SCREW, cap, socket head
10-32 x 1/2
6
6
8
13
4a
10
11
517449 MUFFLER
100721 PLUG, pipe, auxiliary air supply
1
1
2
13 ★ 101689 GAUGE, air pressure, 0-200 psi
(0-1.4 MPa, 0-14 bar)
7a
5
◆ 113911 GAUGE, air pressure, 0-160 psi
(0-1.1 MPa, 0-11 bar)
2
1
7b
7
ti10774a
3
14 ◆ 107204 O-RING, buna
9
★ For D200s, D200, and D60 supply systems only.
◆ ForS20 supply systems only.
312374J
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Parts
Model 24C824; D200s and D200
Integrated Air Controls
Ref. Part
Description
Qty.
1
MANIFOLD
121108 VALVE, shutoff (includes o-rings
and screws)
1
1
1
3
10
11
4
121107 VALVE, director (includes 4a and
SCREW
1
4b
4
4a
4b
5
4
1
1
1
O-RING
121110 O-RING, buna
121106 REGULATOR, ram (includes 7a
and 7b)
8
7
7a
7b
8
SCREWS
O-RING
4
2
1
13
4a
121109 VALVE, blowoff (includes valve
and push button)
9
121112 SCREW, cap, socket head
1/4-20 x 5/8
2
7a
5
7b
7
10 517449 MUFFLER
1
1
1
ti10774a
11 100721 PLUG, pipe, auxiliary air supply
13 101689 GAUGE, air pressure, 0-200 psi
(0-1.4 MPa, 0-14 bar)
3
9
12
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Parts
2-Button Interlock Kit
144
133
Model 255719
(For D200 3-in., 55 gallon (200 liter) supply systems with
NXT 2200, 3400 and 6500 Air Motors only)
105
106
Model 255720
(For D200s 6.5-in., 55 gallon (200 liter) supply systems
with NXT 2200, 3400 and 6500 Air Motors only)
132
1
Model 257615
(For D60 3-in., 16 gallon (60 liter) supply systems)
135
136
137
ti10844a1
Ref. Part
Description
SCREW, cap, 1/4-20 x 5/8
WASHER, lock, 1/4
AIR CONTROL, 2-button interlock
BRACKET, switch, mounting
BRACKET, switch, mounting
VALVE, roller operated
WASHER, no. 8
WASHER, lock, no. 8
NUT, hex, 8-32
BRACKET, actuator
BRACKET, actuator, mounting
SCREW, cap, 1/4-20 x 1 1/4
SCREW, cap, 8/32 x 1
SCREW, panhead, 8-32 x 1 1/2
SCREW, cap, 1/4-20 x 2 1/2
TUBING, nylon, 5/32 in. (not shown) 30
Qty.
1
Flip mounting bracket 132 on D60 supply systems.
105
106
130
132
✿
133
135
136
137
138
139
140
✿
144
145
146
147
150✿
151✿
152✿
153✿
2
2
1
1
1
1
2
2
2
1
2
4
4
2
1
130
145
TUBING, nylon, 1/4 in. (not shown
ELBOW, 90°; 5/32 tube x 5/32 OD
ACTUATOR, weldment
WASHER, plain-
30
2
1
4
ti10843a1
NUT, hex; 8/32
4
Actuator Bracket (138) for 255719 and 255720
✿ For D60 2-button interlock kit 257615 only.
Actuator Bracket (138) for 257615
151
138
139
140
138
139
152
153
ti10848a
140
r_289105_312375_5a
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Pneumatic Schematic
Pneumatic Schematic
Integrated Air Control Module
INTEGRATED AIR
CONTROL MODULE
Pump Pressure
Regulator
Air Motor
Shutoff
Pump Air
Motor
MAIN
AIR IN
Ram Pressure
Regulator
Ram Directional
Control Valve
Ram Down
Blow Off
Valve
UP
Air Pressure
Relief Valve
Platen
DOWN
Ram Up
14
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Pneumatic Schematic
Integrated Air Control Module with Optional 2-Button Interlock
INTEGRATED AIR
CONTROL MODULE
Air Motor
Shutoff
Pump Pressure
Regulator
Pump Air
Motor
MAIN
AIR IN
Blow Off
Valve
Ram Pressure
Regulator
Ram Directional
Control Valve
UP
Platen
Air Pressure
Relief Valve
DOWN
Ram Interlock
Roller Valve
OPTIONAL 2-BUTTON
INTERLOCK
Ram Down Pilot
Interlock Valve
Ram Down
Ram Up Pilot
Interlock Valve
Ram Up
Interlock
Push buttons
P
A
B
S
Synchronous
Input
Safety Valve
312374J
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Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs
will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
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.
This manual contains English. MM 312374
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2008, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Revision J, January 2015
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