Graco Dura–Flo, 2400 Instructions-parts List Manual

Instructions–Parts List

CARBON STEEL

Dura–Flo

With Severe–Duty Rod and Cylinder

Important Safety Instructions

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

See page 2 for Model Numbers and Maximum

Working Pressures.

™

2400 Pumps

308151R

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

Part No. 222832 Shown

List of Models

Pump Part No. and Series Pump Model

222826,  Series A

222832,  Series A

222833,  Series B

24Y207,  Series A

222834,  Series B

Bulldog® 222801 10:1 7.0 MPa, 69 bar

TM

King

Quiet King

XL10000

Viscount® 222801 1.33:1 14.0 MPa, 138 bar

TM

Displacement Pump Part No. Ratio

222801 20:1 13.8 MPa, 138 bar

222801 35:1 24.0 MPa, 235 bar

Maximum Fluid Working Pressure

(1000 psi)

(2000 psi)

(3400 psi)

(2000 psi)

Maximum Air/Hydraulic Input Pressure

0.7 MPa, 7 bar (100 psi)

10 MPa, 103 bar (1500 psi)

Table of Contents

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Air-Powered Pumps 8 Hydraulic-Powered Pumps 10

Operation/Maintenance . . . . . . . . . . . . . . . . . . . . .12

ALL PUMPS 12 Air-Powered Pumps 13 Hydraulic-Powered Pumps 14

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . .16

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Required Tools 17 Disconnecting the Displacement Pump 17

Reconnecting the Displacement Pump 18 Displacement Pump Service 20

Parts Drawings and Parts Lists . . . . . . . . . . . . . . 24

Pump Assemblies 24 Displacement Pumps 29 Packing Conversion Kits 31

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Mounting Hole Layouts . . . . . . . . . . . . . . . . . . . . . 40

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 42

2 308151

Symbols

INSTRUCTIONS

Warning Symbol Caution Symbol

WARNING

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

EQUIPMENT MISUSE HAZARD

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

• This equipment is for professional use only.

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

• Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco distributor.

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

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

CAUTION

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

WARNING

• Do not exceed the maximum working pressure of the lowest rated system component. Refer to the Technical Data on pages 32-38 for the maximum working pressure of this equipment.

• 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.

• Do not kink or overbend hoses or use hoses to pull equipment.

• Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 82º C (180º F) or below –40º C (–40º F).

• Wear hearing protection when operating this equipment.

• Do not lift pressurized equipment.

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

Warnings

308151 3

WARNING

INJECTION HAZARD

Spray from the gun/valve, 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.

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

surgical treatment.

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

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

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

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

• Always have the tip guard and the trigger guard on the gun/valve when spraying.

• Be sure the gun/valve trigger safety operates before spraying.

• Lock the gun/valve trigger safety when you stop spraying.

• Follow the Pressure Relief Procedure on page 12 whenever you: are instructed to relieve pressure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip/nozzle.

• Tighten all fluid connections before operating the equipment.

• Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately. Permanently coupled hoses cannot be repaired; replace the entire hose.

• 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.

MOVING PARTS HAZARD

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

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

• Before servicing the equipment, follow the Pressure Relief Procedure on page 12 to prevent

the equipment from starting unexpectedly.

4 308151

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.

• Ground the equipment and the object being sprayed. Refer to Grounding on page 7.

• If 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.

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

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

• Electrically disconnect all equipment in the spray area.

• Extinguish all open flames or pilot lights in the spray area.

• Do not smoke in the spray area.

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

• Do not operate a gasoline engine in the spray area.

• Keep a fire extinguisher in the work 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.

• Know the specific hazards of the fluid you are using.

• Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.

• Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.

308151 5

Notes

___________________________________________________________________________________________

6 308151

Installation

W

X

Z

Y

WLD

*6

8

Grounding

WARNING

FIRE AND EXPLOSION HAZARD

Before operating the pump, ground the system as explained below. Also read the section FIRE AND EXPLOSION HAZARD on page 5.

1. King Pumps: use a ground wire and clamp. See

Fig. 1. 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 No. 222011 Ground Wire and Clamp.

XL10000

ground screw (GS) is attached and tightened securely to the air motor. connect the clamp (U) of the static ground cable (H) to a true earth ground. For a ground wire and clamp, order part No.

244524.

All Other Pumps: use a ground wire and clamp.See Fig. 2. Loosen the grounding lug locknut (W) and washer (X). Insert one end of a 1.5 mm minimum ground wire (Y) into the slot in lug (Z) and tighten the locknut securely. Connect the other end of the wire to a true earth ground. Order Part No. 237569 Ground Wire and Clamp.

TM

Pumps: See figure 3. Verify that the

2

(12 ga)

7. All solvent pails used when flushing, according to

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, 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.

TI1052

Fig. 1

2. Air, fluid, and hydraulic hoses: Use only electrically

conductive hoses with a maximum of 500 feet (150 m) combined hose length to ensure grounding continuity. Check the electrical resistance of your hoses at least once a week. If the total resistance to ground exceeds 29 megohms, replace the hose immediately.

NOTE:

Use a meter that is capable of measuring

resistance at this level.

3. Air compressor or hydraulic power supply: follow

manufacturer’s recommendations.

4. Spray gun/dispensing valve: grounding is obtained

through connection to a properly grounded fluid hose and pump.

5. Fluid supply container: according to your local code.

6. Object being sprayed: according to your local code.

Fig. 2

Fig. 3

0864

308151 7

Installation

(AIR-POWERED PUMPS)

NOTE: Reference numbers and letters in parentheses

in the text refer to the callouts in the figures and the parts drawing.

NOTE: Accessories are available from your Graco distributor. If you supply your own accessories, be sure they are adequately sized and pressure-rated to meet the system’s requirements.

TYPICAL INSTALLATION

KEY A Pump B Wall Bracket C Pump Runaway Valve D Air Line Lubricator E Bleed-Type Master Air Valve

(required, for pump)

F Pump Air Regulator G Air Manifold

H Electrically Conductive Air Supply Hose J Air Line Filter K Bleed-Type Master Air Valve

(for accessories)

L Fluid Filter M Fluid Drain Valve (required) N Electrically Conductive Fluid Supply Hose

MAIN AIR LINE

Fig. 4 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.

P Fluid Whip Hose R Gun/Valve Swivel S Airless Spray Gun

or Dispensing Valve

T Drum Suction Kit Y Ground Wire (required; see page 7 for

installation instructions)

Fig. 4

8 308151

200 LITER (55 GAL.) DRUM

0626C

Installation

(AIR-POWERED PUMPS)

SYSTEM ACCESSORIES

WARNING

A bleed-type master air valve (E) and a fluid drain valve (M) are required in your system. 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-type master air valve 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.

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.

Air and Fluid Hoses

Be sure all air hoses (H) and fluid hoses (N and P) are properly sized and pressure-rated for your system. Use only electrically conductive hoses. Fluid hoses must have spring guards on both ends. Use a whip hose (P) and a swivel (R) between the main fluid hose (N) and the gun/valve (S) to allow freer gun/valve movement.

Mounting Accessories

• An air line lubricator (D) provides automatic air

motor lubrication.

• A bleed-type master air valve (E) 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.

• An 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 bleed-type master air valve.

• A pump runaway valve (C) 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.

• An air manifold (G) has a swivel air inlet. It mounts

to a wall bracket, and provides ports for connecting lines to air-powered accessories.

• An air line filter (J) removes harmful dirt and

moisture from the compressed air supply.

• A second bleed-type air valve (K) isolates the air

line accessories for servicing. Locate upstream from all other air line accessories.

WARNING

For Model 222942 XL10000TM Pump, do not lift the pump by the lift ring when the total weight exceeds 550 lb (250 kg).

Mount the pump (A) to suit the type of installation planned. Fig. 4 illustrates a wall-mounted system. Pump dimensions and the mounting hole layout are shown on pages 40 and 41.

If you are using an elevator or a cart, refer to the separate manuals supplied with those components for installation and operation instructions.

Air Line Accessories

Install the following accessories in the order shown in Fig. 4, using adapters as necessary:

Fluid Line Accessories

Install the following accessories in the positions shown in Fig. 4, using adapters as necessary:

• A fluid filter (L) with a 60 mesh (250 micron)

stainless steel element, to filter particles from the fluid as it leaves the pump. It includes a fluid drain valve (M), which is required in your system to relieve fluid pressure in the hose and gun (see the WARNING at left).

• A gun or valve (S) dispenses the fluid. The gun

shown in Fig. 4 is an airless spray gun for light to medium viscosity fluids.

• A gun swivel (R) allows freer gun movement.

• A suction kit (T) allows the pump to draw fluid from

a 200 liter (55 gallon) drum.

308151 9

Installation

S Airless Spray Gun or Dispensing Valve T Drum Suction Kit U Hydraulic Supply Line Shutoff Valve V Hydraulic Return Line Shutoff Valve Y Ground Wire (required, see page 7 for

installation instructions)

AA Hydraulic Return Line Filter

HYDRAULIC POWER SUPPLY

DRAINAGE

CONTAINER

200 LITER

(55 GAL.) DRUM

KEY

A Pump B Wall Bracket C Hydraulic Supply Line D Hydraulic Return Line E Drain Line (from pressure reducing valve) F Pressure Gauge G Flow Control Valve H Pressure Reducing Valve J Accumulator K Drain Line (from motor drip pan) L Fluid Filter M Fluid Drain Valve (required) N Electrically Conductive Fluid Supply Hose P Fluid Whip Hose R Gun/Valve Swivel

(HYDRAULIC-POWERED PUMPS)

NOTE: Reference numbers and letters in parentheses

in the text refer to the callouts in the figures and the parts drawing.

NOTE: distributor. If you supply your own accessories, be sure they are adequately sized and pressure-rated to meet the system’s requirements.

Fig. 5 is only a guide for selecting and installing components and accessories. Contact your Graco distributor for assistance in designing a system to suit your particular needs.

Accessories are available from your Graco

system

TYPICAL INSTALLATION

CAUTION

It is very important to keep the hydraulic supply system clean at all times. Be sure that all hydraulic fluid lines are absolutely clean. Blow out the lines with air and flush thoroughly with solvent before connecting to the hydraulic motor, to avoid introducing harmful contaminants into the motor. Plus the hydraulic lines immediately when they are disconnected.

Do not exceed 37.8 liter/min (10 gpm) hydraulic oil volume to the motor, to avoid pump stalling.

For optimum pump performance, keep the temperature of the hydraulic oil below 54° C (130° F)

Fig. 5

10 308151

0627B

Installation

(HYDRAULIC-POWERED PUMPS)

SYSTEM ACCESSORIES

WARNING

A fluid drain valve (M) is required in your system to help reduce the risk of serious injury, including fluid injection and splashing of fluid in the eyes or on the skin if you are adjusting or repairing 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.

Mounting Accessories

Mount the pump (A) to suit the type of installation planned. Fig. 5 illustrates a wall-mounted system. Pump dimensions and the mounting hole layout are shown on pages 40 and 41.

Filters

Be sure your hydraulic power supply is equipped with a suction filter to the hydraulic pump and a system return line filter (AA) of 10 micron size.

Carefully follow the manufacturer’s recommendations on reservoir and filter cleaning, and periodic changes of hydraulic fluid. Use only Graco-approved hydraulic oil. Order Part No. 169236, 5 gal. (19 liter) or 207428, 1 gal. (3.8 liter). Do not substitute a lower grade oil or one with a lower flash point.

Hydraulic Lines

The motor has a 3/4 npt(f) hydraulic oil supply fitting, and a 1 in. npt(f) hydraulic oil return fitting. Use a minimum 13 mm (1/2 in.) ID hydraulic supply line, and a minimum 22 mm (7/8 in.) ID return line.

On the hydraulic supply line (C), install the following accessories in the order shown in Fig. 5, using adapters as necessary:

• A pressure reducing valve (H), with a drain line

(E) run directly to the hydraulic return line (D).

• An accumulator (J) to reduce the hammering

effect caused by the motor reversing direction.

On the hydraulic return line (D), install the following accessories in the order shown in Fig. 5, using adapters as necessary:

• A shutoff valve (V) isolates the pump for service.

• A filter (AA) of 10 micron size.

Hydraulic Motor Drip Pan

The hydraulic motor has a drip pan to collect any leakage. Connect a 6 mm (1/4 in.) ID drain line (K) to the barbed fitting on the drip pan, and place the free end in a container to receive the drainage.

Fluid Supply Hoses

Be sure all fluid supply hoses (N and P) are properly sized and pressure-rated for your system. Use only electrically conductive hoses. Fluid hoses must have spring guards on both ends. Use a whip hose (P) and a swivel (R) between the main fluid hose (N) and the gun/valve (S) to allow freer gun/valve movement.

Fluid Line Accessories

Install the following accessories in the positions shown in Fig. 5, using adapters as necessary:

• A fluid filter (L) with a 60 mesh (250 micron)

stainless steel element, to filter particles from the fluid as it leaves the pump. It includes a fluid drain valve (M), which is required in your system to relieve fluid pressure in the hose and gun (see the WARNING at left).

• A shutoff valve (U) isolates the pump for service.

• A fluid pressure gauge (F) to monitor hydraulic oil pressure to the motor and to avoid overpressurizing the motor or displacement pump, and a pressure-

and temperature-compensated flow control valve (G) to prevent the motor from running too fast

and possibly damaging itself.

• A gun or valve (S) dispenses the fluid. The gun shown in Fig. 4 is an airless spray gun for light to medium viscosity fluids.

• A gun swivel (R) allows freer gun movement.

• A suction kit (T) allows the pump to draw fluid from a 200 liter (55 gallon) drum.

308151 11

3

104

Model 222832

Shown

32

33

Bleed hole must face down.

Operation/Maintenance

(ALL PUMPS)

Pressure Relief Procedure

WARNING

INJECTION HAZARD

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:

• are instructed to relieve the pressure,

• stop spraying/dispensing,

• check or service any of the system equipment,

• or install or clean the spray tip/nozzle.

1. Lock the gun/valve trigger safety.

2. Shut off the air or hydraulic supply to the pump

3. In air-powered systems, close the bleed-type master air valve (required in your system). In hydraulic-powered systems, close the hydraulic supply line valve first, then the return line valve.

Flushing the Pump

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 before using the pump.

WARNING

For your safety, read the warning section, FIRE AND EXPLOSION HAZARD on page 5 before flushing, and

follow all recommendations given there.

4. Unlock the gun/valve trigger safety.

5. Hold a metal part of the gun/valve firmly to the side

6. Lock the gun/valve trigger safety.

7. Open the drain valve (required in your system)

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

If you suspect that the spray tip/nozzle 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, nozzle, or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip/nozzle or hose.

Packing Nut/Wet-Cup

Fill the packing nut/wet-cup (3) 1/3 full with Graco Throat Seal Liquid (TSL) or compatible solvent. See Fig. 6. Using the supplied wrench (104), adjust the packing nut weekly so it is just snug; do not overtighten. Follow the Pressure Relief Procedure Warning above before adjusting the packing nut.

of a grounded metal pail, and trigger the gun/valve to relieve pressure.

and/or the pump bleeder valve, having a container ready to catch the drainage.

spray/dispense again.

Fig. 6

12 308151

Operation/Maintenance

(AIR-POWERED PUMPS)

Starting and Adjusting the Pump

1. Refer to Fig. 4 on page 8. Connect the suction kit (T) to the pump’s fluid inlet, and place the tube into the fluid supply.

2. Be sure the air regulator (F) is closed. Then open the pump’s bleed-type master air valve (E). Hold a metal part of the spray gun/dispensing valve (S) firmly to the side of a grounded metal pail and hold the trigger open. Now slowly open the air regulator until the pump starts.

3. Cycle the pump slowly until all air is pushed out and the pump and hoses are fully primed. Release the gun/valve trigger and lock the trigger safety. The pump should stall against pressure when the trigger is released.

WARNING

INJECTION HAZARD

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 (32) when priming the pump. Use a crescent wrench to open and close the bleeder plug (33). Keep your hands away from the bleed hole.

6. Use the air regulator to control the pump speed and the fluid pressure. Always use the lowest air pressure necessary to get the desired results. Higher pressures cause premature tip/nozzle and pump wear.

WARNING

To reduce the risk of overpressurizing your system, which could result in component rupture and cause serious injury, never exceed the specified Maximum Incoming Air Pressure to the pump (see the Technical Data on pages 32–38).

7. Never allow the pump to run dry of the fluid being pumped. A dry pump will quickly accelerate to a high speed, possibly damaging itself. A pump runaway valve (C), which shuts off the air supply to the pump if the pump accelerates beyond the pre-set speed, is available. See Fig. 4 on page 8. If your pump accelerates quickly, or is running too fast, stop it immediately and check the fluid supply. If the supply container is empty and air has been pumped into the lines, refill the container and prime the pump and the lines with fluid, or flush and leave it filled with a compatible solvent. Be sure to eliminate all air from the fluid system.

4. If the pump fails to prime properly, open the bleeder valve plug (33) slightly. Use the bleed hole on the underside of the valve body (32) as a priming valve until the fluid appears at the hole. See Fig. 6. Close the plug (33).

NOTE: When changing fluid containers with the hose and gun already primed, open the bleeder valve plug (33), to assist in priming the pump and venting air before it enters the hose. Close the bleeder valve when all air has been eliminated.

5. With the pump and lines primed, and with adequate air pressure and volume supplied, the pump will start and stop as the gun/valve is opened and closed. In a circulating system, the pump will speed up or slow down on demand, until the air supply is shut off.

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 12.

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

Always flush the pump before the fluid dries on the displacement rod. Never leave water or water-based fluid in the pump overnight. First, flush with water or a compatible solvent, then with mineral spirits. Relieve the pressure, but leave the mineral spirits in the pump to protect the parts from corrosion.

308151 13

Graco Dura–Flo, 2400 Instructions-parts List Manual

Specifications and Main Features

Frequently Asked Questions

User Manual