Graco 308147Y User Manual

Instructions – Parts List

CARBON STEEL

Dura-Flot 1800 Pumps

With Severe–Duty Rod and Cylinder

Important Safety Instructions

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

See page 2 for List of Models and Table of

Contents.

308147Y

ENG

Part No. 222837 Shown

List of Models

Pump Part No. and Series Pump Model Ratio

222837, Series A

222891, Series B

237555, Series B

241490, Series A

233127, Series A

233128, Series A

222892, Series B

Kingt 28:1 19.3 MPa, 193 bar

Quiet Kingt 28:1 19.3 MPa, 193 bar

Premiert 45:1 31 MPa, 310 bar

Viscountr –– 18 MPa, 179 bar

Table of Contents

Maximum Fluid Working Pressure

(2800 psi)

(4500 psi)

(2600 psi)

Symbols

Maximum Air Input Pressure (or Hydraulic Input Pressure*)

0.7 MPa, 7 bar (100 psi)

10 MPa, 103 bar (1500 psi)*

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

Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Assemblies 24. . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pumps 29. . . . . . . . . . . . . . . . . . . . . . .

Packing Conversion Kits 30. . . . . . . . . . . . . . . . . . . .

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

Dimensions 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Hole Layouts 37. . . . . . . . . . . . . . . . . . . . . . . . .

Warranty 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Information NO TAG. . . . . . . . . . . . . . . . . . . . . . .

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.

2 308147

INSTRUCTIONS

WARNING

EQUIPMENT MISUSE HAZARD

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

D This equipment is for professional use only.

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

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

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

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

D Do not exceed the maximum working pressure of the lowest rated system component. Refer to the

Technical Data on pages 32–35 for the maximum working pressure of this equipment.

D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-

nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

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

D Route 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).

D Wear hearing protection when operating this equipment.

D Do not lift pressurized equipment.

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

308147 3

WARNING

SKIN INJECTION HAZARD

Spray from the gun, 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.

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

cal treatment.

D Do not point the gun at anyone or at any part of the body.

D Do not put your hand or fingers over the spray tip.

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

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

D Always have the tip guard and the trigger guard on the gun when spraying.

D Check the gun diffuser operation weekly. Refer to the gun manual.

D Be sure the gun trigger safety operates before spraying.

D Lock the gun trigger safety when you stop spraying.

D Follow the Pressure Relief Procedure on page 12 if the spray tip clogs and before cleaning,

checking or servicing the equipment.

D Tighten all fluid connections before operating the equipment.

D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

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

MOVING PARTS HAZARD

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

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

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

equipment from starting unexpectedly.

4 308147

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.

D Ground the equipment and the object being sprayed. Refer to Grounding on page 6.

D If there is any static sparking or you feel an electric shock while using this equipment, stop spray-

ing immediately. Do not use the equipment until you identify and correct the problem.

D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid

being sprayed.

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

D Electrically disconnect all equipment in the spray area.

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

D Do not smoke in the spray area.

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

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

D 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.

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

D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,

state and national guidelines.

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

solvent manufacturer.

308147 5

Installation

(ALL PUMPS)

Grounding

Fig. 1

WARNING

FIRE AND EXPLOSION HAZARD

Before operating the pump, ground the system as explained below. Also read the section FIRE OR EXPLOSION HAZ- ARD on page 5.

TI1052

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 ground wire to a true earth ground. Order Part No. 222011 Ground Wire and Clamp.

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@ (12 ga) 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.

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

3. Air compressor or hydraulic power supply: follow manufacturer’s recommendations.

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

Fig. 2

5. Fluid supply container: follow your local code.

0864

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 metal pail, then trigger the gun.

6 308147

Notes

308147 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.

Fig. 3 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.

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

Assembling Models 237555, 233127, and 233128

If you have Models 237555, 233127, or 233128 Pumps, assemble the displacement pump (105) to the Premier air motor (101) as instructed on page 18.

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 6

for installation instructions)

E F

T 200 LITER (55 GAL.) DRUM

Fig. 3

8 308147

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.

Air Line Accessories

Install the following accessories in the order shown in Fig. 3, using adapters as necessary:

D An air line lubricator (D) provides automatic air

motor lubrication.

D 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.

D An air regulator (F) controls pump speed and out-

let 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.

D 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.

D 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.

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

moisture from the compressed air supply.

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

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

Mounting Accessories

WARNING

For Model 222939 Premier 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. 3 illustrates a wall-mounted system. Pump dimensions and the mounting hole layout are shown on pages 36 and 37.

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

Fluid Line Accessories

Install the following accessories in the positions shown in Fig. 3, using adapters as necessary:

D 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).

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

shown in Fig. 3 is an airless spray gun for light to medium viscosity fluids.

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

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

from a 200 liter (55 gallon) drum.

308147 9

Installation

(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: 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.

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.

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. Plug 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 stalling the pump.

For optimum pump performance, keep the temperature of the hydraulic oil below 54_C (130_F).

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 POWER SUPPLY

TYPICAL 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 6 for

installation instructions)

AA Hydraulic Return Line Filter

S R

Fig. 4

10 308147

DRAINAGE CONTAINER

200 LITER (55 GAL.) DRUM

0627B

Installation

(HYDRAULIC-POWERED PUMPS)

SYSTEM ACCESSORIES

WARNING

A fluid drain valve (M) is required in your system. This accessory helps reduce the risk of serious bodily 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 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. 4 illustrates a wall-mounted system. Pump dimensions and the mounting hole layout are shown on pages 36 and 37.

D A fluid pressure gauge (F) to monitor hydraulic

oil pressure to the motor and to avoid overpressurizing the motor or displacement pump, and a pres-

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

too fast and possibly damaging itself.

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

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

D An accumulator (J) to reduce the hammering ef-

fect caused by the motor reversing direction.

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

D 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

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. 4, using adapters as necessary:

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

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. 4, using adapters as necessary:

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

D 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.

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

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

from a 200 liter (55 gallon) drum.

308147 11

Operation/Maintenance

(ALL PUMPS)

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:

D are instructed to relieve the pressure, D stop spraying, D check or service any of the system equipment, D or install or clean the spray tips.

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).

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. 5. Using the supplied wrench (104), adjust the packing nut weekly so it is just snug; do not overtighten. Follow the Pressure Relief Procedure at left.

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 or Explosion Hazard on page 5 before flushing, and

follow all recommendations given there.

Model 222837 Shown

In hydraulic-powered systems, close the hydraulic supply line valve first, then the return line valve.

4. Unlock the gun/valve safety latch.

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

6. Lock the gun trigger safety.

7. Open the drain valve (required in your system) and/or the pump bleeder valve, having a container ready to catch the drainage.

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

12 308147

Bleed hole must

face down.

104

Fig. 5

34, 35

0566C

+ 26 hidden pages