Graco Inc Dura-Flo 1100 User Manual

Instructions – Parts List

74:1 RATIO PREMIERt CARBON STEEL

Cart-Mounted

Airless Package	308415P
WITH DURA-FLOT 1100 DISPLACEMENT PUMP

50.0 MPa, 500 bar (7252 psi) Maximum Working Pressure

0.67 MPa, 6.7 bar (97 psi) Maximum Air Inlet Pressure

Part No. 236489, Series B

With High Pressure Fluid Filter

Part No. 237158, Series B

With High Pressure Fluid Filter, hose and gun

Important Safety Instructions

05899D

Read all warnings and instructions in this manual.

Save these instructions.

See page 2 for model numbers and maximum working pressures.

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

Copyright 1994, Graco Inc. is registered to I.S. EN ISO 9001

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 16

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

WARNING

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

INSTRUCTIONS

DThis equipment is for professional use only.

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

DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

DDo not alter or modify this equipment.

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

DDo not exceed the maximum working pressure of the lowest rated system component. Refer to the Technical Data on page 14 for the maximum working pressure of this equipment.

DUse 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.

DDo not use hoses to pull equipment.

DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 82_C (180_F) or below –40_C(–40_F).

DWear hearing protection when operating this equipment.

DDo not lift pressurized equipment.

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

2 308415

WARNING

SKIN INJECTION HAZARD

Spray from the gun, hose leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed 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 at anyone or at any part of the body.

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

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

DDo not “blow back” fluid; this is not an air spray system.

DAlways have the tip guard and the trigger guard on the gun when spraying.

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

DBe sure the gun trigger safety operates before spraying.

DLock the gun trigger safety when you stop spraying.

DFollow the Pressure Relief Procedure on page 8 if the spray tip 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 or damaged parts immediately. Do not repair high pressure couplings; you must replace the entire hose.

DFluid hoses must have spring guards on both ends, to help protect them from rupture caused by kinks or bends near the couplings.

MOVING PARTS HAZARD

Moving parts, such as the air motor rocker arms, can pinch or amputate your fingers.

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

DBefore servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the equipment from starting unexpectedly.

308415 3

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.

DGround the equipment and the object being sprayed. Refer to Grounding on page 5.

DIf there is any static sparking or you feel an electric shock while using this equipment, stop spraying immediately. Do not use the equipment until you identify and correct the problem.

DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.

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

DElectrically disconnect all equipment in the spray area.

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

DDo not smoke in the spray area.

DDo not turn on or off any light switch in the spray area while operating or if fumes are present.

DDo not operate a gasoline engine in the spray area.

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.

4 308415

Setup

General Information

NOTE: Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing.

NOTE: Always use Genuine Graco Parts and Accessories, available from your Graco distributor. Refer to the Product Data Sheet for your pump, Form No.

305756. If you supply your own accessories, be sure they are adequately sized and pressure rated for your system.

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.

Prepare the Operator

All persons who operate the equipment must be trained in the safe, efficient operation of all system components as well as the proper handling of all fluids. All operators must thoroughly read all instruction manuals, tags, and labels before operating the equipment.

Prepare the Site

Grounding

WARNING

FIRE AND EXPLOSION HAZARD

Before operating the pump, ground the system as explained below. Also read the section FIRE OR EXPLOSION HAZARD on page 4.

1.Pump: use the ground wire and clamp (supplied). See Fig. 1. Loosen the grounding lug locknut (W) and washer (X). Insert one end of the ground wire (57) into the slot in lug (Z) and tighten the locknut securely. Connect the other end of the wire to a true earth ground.

W

X

57

Z

0864

Fig. 1

The Premier pumps require 6.4 m#/min. (230 scfm) of compressed air while operating at 0.67 MPa, 6.7 bar (97 psi) air pressure and 60 cycles per minute. Ensure that you have an adequate compressed air supply.

Refer to Fig. 2. Bring a compressed air supply line (A) from the air compressor to the pump location. Be sure all air hoses (A) are properly sized and pressure-ratedfor your system. Use only electrically conductive hoses. The air hose should have a 3/4 npt(m) thread.

Install a bleed-typeshutoff valve (B) in the air line to isolate the air line components for servicing. Install an air line moisture trap and drain valve (C) to help remove moisture from the compressed air supply.

Keep the site clear of any obstacles or debris that could interfere with the operator’s movement.

Have a grounded, metal pail available for use when flushing the system or draining the fluid filter.

2.Air and fluid hoses: use only electrically conductive hoses.

3.Air compressor: follow manufacturer’s recommendations.

4.Spray gun: ground through connection to a properly grounded fluid hose and pump.

5.Fluid supply container: follow your local code.

6.Object being sprayed: follow your local code.

7.Solvent pails used when flushing: follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts the grounding continuity.

8.To maintain grounding continuity when flushing or relieving pressure, hold a metal part of the spray gun firmly to the side of a grounded metalpail, then trigger the gun.

308415 5

Setup

Supplied Components

Refer to Fig. 2.

WARNING

A red-handledbleed-typemaster air valve (30) and a fluid drain valve (D) are supplied. 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 bleed-typemaster air valve relieves air trapped between this valve and the pump after the valve is closed. Trapped air can cause the pump to cycle unexpectedly. Locate the valve close to the pump.

The fluid drain valve assists in relieving fluid pressure in the displacement pump, hose, and gun. Triggering the gun to relieve pressure may not be sufficient.

DThe red-handledbleed-typemaster air valve

(30)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 locateddownstream from the air regulator (5).

DWith a wrench, loosen and remove the female air line coupler (71). Screw it onto the main air hose

(A). Leave the mating coupler (70) attached to the air manifold (32)

DThe air regulator (5) controls pump speed and outlet pressure by adjusting the air pressure to the pump. Locate the regulator close to the pump, butupstream from thebleed-typemaster air valve.

DThe air manifold (32) provides ports for connecting lines toair-poweredaccessories.

DThe air relief valve (73) opens automatically to prevent overpressurization of the pump.

DThe fluid filter (8) includes a 60 mesh (250 micron) stainless steel element to filter particles from the fluid as it leaves the pump. It includes thefluid drain valve (D), which is required in your system to relieve fluid pressure in the hose and gun (see the

WARNING above).

DThe suction hose (7) and tube (24) allow the pump to draw fluid from a 19 liter (5 gallon) pail (E).

DTwo fluid shutoff valves (69) are supplied at the fluid filter outlets. Attach the fluid hose (103) to one of the valves. Keep the other valve capped and closed at all times unless you are using a second hose and gun.

Connect the Suction Hose

Apply thread sealant to the suction hose (7) and screw it into the bushing (22) at the pump’s fluid intake. Screw the suction tube (24) onto the other end of the hose. Attach the inlet strainer (25) to the tube.

Connect the Fluid Hoses and Gun

NOTE: Model 237158 includes a Hose and Gun Kit (101), which supplies fluid hoses, a spray gun, and connecting parts (ref. nos. 102106). If you supply your own fluid hoses and gun, be sure they are properly sized andpressure-ratedfor your system. Use only electrically conductive hoses.

1.Connect the main fluid hose (103) to one fluid shutoff valve (69) at the fluid filter (8) outlet.

2.Screw the nipple (105) into the other end of the main fluid hose (103).

3.Screw the short whip hose (104) onto the nipple (105).

4.Screw the whip hose (104) onto the fluid inlet of the spray gun (102).

6 308415

Setup

KEY

SUPPLIED WITH ALL MODELS

1 Pump

4Cart

5Pump Air Regulator

7Suction Hose

8Fluid Filter (includes drain valve)

22Pump Intake Bushing

24Suction Tube

30Red-HandledBleed-TypeMaster

Air Valve (required, for pump)

32Air Manifold

57Ground Wire (required; see page 5 for installation instructions)

69Fluid Shutoff Valves

70Air Line Male Coupler

71Air Line Female Coupler

73Air Relief Valve

D Fluid Drain Valve (required)

SUPPLIED WITH MODEL 237158 ONLY	COMPONENTS YOU MUST SUPPLY
102 Airless Spray Gun	A Electrically Conductive Air Supply Hose
103 Electrically Conductive Fluid Supply Hose	B Bleed-TypeMaster Air Valve
104 Electrically Conductive Fluid Whip Hose	(for accessories)
105 Nipple	C Air Line Moisture Trap and Drain Valve
	E Grounded 19 Liter (5 Gallon) Pail

B

Detail of Air Line Connections

Keep this valve capped and closed unless

1	you are using a second hose and gun.

102	57

1

104

105

8

1 69

103

D

22

Fig. 2

30

C

30 5

A 71

70

32 73

4

7

69

24

E

Model 237158 Shown

05901B

308415 7

Operation

Pressure Relief Procedure

WARNING

SKIN INJECTION HAZARD

The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid

under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:

Dare instructed to relieve the pressure,

Dstop spraying,

Dcheck or service any of the system equipment,

Dor install or clean the spray tips.

1.Lock the gun trigger safety.

2.Close the red-handledbleed-typemaster air valve (30, required in your system).

3.Open the fluid shutoff valve (69).

4.Unlock the gun trigger safety.

5.Hold a metal part of the gun firmly to the side of a grounded metal pail, and trigger the gun to relieve pressure.

6.Lock the gun trigger safety.

7.Open the drain valve (D, required in your system), having a container ready to catch the drainage.

8.Leave the drain valve open until you are ready to spray again.

If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip or hose.

Packing Nut/Wet-Cup

Before starting, fill the packing nut (F) 1/3 full with Graco Throat Seal Liquid (TSL) or compatible solvent. See Fig. 3.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure at left.

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 to129–142NSm(95–105ft-lb)using the supplied wrench. Do this whenever necessary. Do not overtighten the packing nut.

Flush the Pump Before First Use

The pump is tested with lightweight oil, which is left in to protect the pump parts. If the fluid you are using may be contaminated by the oil, flush it out with a compatible solvent. See Flushing on page 10.

Using the Airless Spray Gun

Before operating the equipment, read the instruction manual supplied with the gun.

Spray some test patterns before doing any finished work. Refer to the gun manual for detailed information on correct spraying technique.

8 308415

Operation

CAUTION

To avoid tip-over,the cart must be on a flat and level surface. Failure to follow this caution could result in injury or equipment damage.

Prime the Pump

1.See Fig. 3. Remove the tip guard and spray tip from the gun (102). See the gun instruction manual.

2.Close the air regulator (5) and bleed-typeair valves (B, 30).

3.Close the fluid drain valve (D).

4.Engage the air line coupler (71) with the mating coupler (70) attached to the air manifold (32) and twist with a wrench to lock.

5.Check that all fittings throughout the system are tightened securely.

6.Place the suction tube (24) into the fluid supply container.

7.Open the fluid shutoff valve (69).

8.Open the bleed-typeair valves (B, 30).

9.Hold a metal part of the gun (102) firmly to the side of a grounded metal pail and hold the trigger open.

10.Slowly open the air regulator (5) until the pump starts.

11.Cycle the pump slowly until all air is pushed out and the pump and hoses are fully primed.

12.Release the gun trigger and lock the trigger safety. The pump should stall against pressure.

13.If the pump fails to prime properly, open the drain valve (D). Use the drain valve as a priming valve until the fluid flows from the valve. Close the valve.

NOTE: When changing fluid containers with the hose and gun already primed, open the drain valve (D) to help prime the pump and vent air before it enters the hose. Close the drain valve when all air is eliminated.

Set the Air and Fluid Pressure

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 8.

1.Relieve the pressure. Install the tip guard and spray tip in the gun, as explained in the gun manual.

2.Open the air regulator (5) slowly. Use the regulator to control pump speed and fluid pressure. Always use the lowest air pressure necessary to get the desired results. Higher pressures cause premature tip and pump wear.

NOTE: To open the air regulator, turn theT-handlein (clockwise). To close the regulator, turn the handle counterclockwise. To lock the regulator setting, tighten the jam nut.

WARNING

COMPONENT RUPTURE HAZARD

To reduce the risk of overpressurizing your system, which could cause compo-

nent rupture and serious injury, never exceed the specified Maximum Incoming Air Pressure to the pump (see theTechnical Data, on page 14).

3.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 gun.

CAUTION

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.

308415 9

Operation

Shutdown and Care of the Pump

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 8.

For overnight shutdown, stop the pump at the bottom of its stroke to prevent fluid from drying on the exposed displacement rod and damaging the throat packings. Relieve the pressure.

Always flush the pump before the fluid dries on the displacement rod. See Flushing below.

Flushing

WARNING

FIRE AND EXPLOSION HAZARD

Before flushing, read the section FIRE OR EXPLOSION HAZARD on page 4. Be sure the entire system and flushing pails are properly grounded. Refer to

Grounding on page 5.

Flush the pump:

DBefore the first use

DWhen changing colors or fluids

DBefore fluid can dry or settle out in a dormant pump (check the pot life of catalyzed fluids)

DBefore storing the pump.

Flush with a fluid that is compatible with the fluid you are pumping and with the wetted parts in your system. Check with your fluid manufacturer or supplier for recommended flushing fluids and flushing frequency.

CAUTION

Never leave water or water-basefluid in the pump overnight. If you are pumpingwater-basefluid, flush with water first, then with a rust inhibitor such as mineral spirits. Relieve the pressure, but leave the rust inhibitor in the pump to protect the parts from corrosion.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 8.

1.Relieve the pressure.

2.Remove the tip guard and spray tip from the gun. See the gun instruction manual.

3.Remove the filter element from the fluid filter (8). Reinstall the filter bowl.

4.Place the suction tube (24) in a container of solvent.

5.Hold a metal part of the gun firmly to the side of a grounded metal pail.

6.Start the pump. Always use the lowest possible fluid pressure when flushing.

7.Trigger the gun.

8.Flush the system until clear solvent flows from the gun.

9.Relieve the pressure.

10.Clean the tip guard, spray tip, and fluid filter element separately, then reinstall them.

11.Clean the inside and outside of the suction tube (24).

10 308415