Graco 308148ZAA User Manual
Instructions – Parts List
STAINLESS STEEL
Dura–Flot 1800 Pumps
With Severe–Duty Rod and Cylinder
Part Nos. 222895 Pump, Series B, and 253377, Series A
28:1 Ratio, with Quiet Kingt Air Motor
19.3 MPa, 193 bar (2800 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure
Part No. 222897 Pump, Series B,
with Viscountr Hydraulic Motor
18 MPa, 179 bar (2600 psi) Maximum Fluid Working Pressure
10 MPa, 103 bar (1500 psi) Maximum Hydraulic Input Pressure
308148ZAA
ENG
Part Nos. C59792 and 222939 Pumps, Series B,
Part Nos. 233069}, 233070}, 234667}, 234824},
241957, 243689, 246923, 246924, 246989{,
246990{, 246991{, 246992{, 253842, Pumps, Series A,
45:1 Ratio, with Premiert Air Motor
31 MPa, 310 bar (4500 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure
{
Not certified
}
Not
nor certified
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Table of Contents.
Part No. 222895 Shown
0566C
Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air-Powered Pumps 8. . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic-Powered Pumps 10. . . . . . . . . . . . . . . . . .
Operation/Maintenance 13. . . . . . . . . . . . . . . . . . . . . . . .
All Pumps 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air-Powered Pumps 14. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic-Powered Pumps 15. . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . .
Pump Assemblies 25. . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pumps 28. . . . . . . . . . . . . . . . . . . . . . .
Packing Conversion Kits 32. . . . . . . . . . . . . . . . . . . .
Technical Data 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layouts 39. . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 308148
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death 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
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 uncertain about usage, 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.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
D Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on pages 33–37 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.
308148 3
WARNING
SKIN 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.
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/valve at anyone or at any part of the body.
D Do not put your hand or fingers over the spray tip/nozzle.
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/valve when spraying.
D Be sure the gun/valve trigger safety operates before spraying.
D Lock the gun/valve trigger safety when you stop spraying.
D Follow the Pressure Relief Procedure on page 13 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip/
nozzle.
D Tighten all fluid connections before operating the equipment.
D Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
D Use only Graco approved hoses. Do not remove any 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.
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 13 to prevent the
equipment from starting unexpectedly.
4 308148
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 7.
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.
308148 5
Notes
6 308148
Installation
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.
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 and hydraulic hoses: use only electrically
conductive hoses.
3. Fluid hoses: use only grounded fluid hoses.
4. Air compressor or hydraulic power supply: follow
manufacturer’s recommendations.
5. Spray gun/dispensing valve: grounding is obtained
through connection to a properly grounded fluid
hose and pump.
7. Object being sprayed: according to your local
code.
8. 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.
9. 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.
Z
Fig. 1
W
Y
Y
TI1052
X
Z
6. Fluid supply container: according to your local
code.
Fig. 2
0864
308148 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
JK
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. 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.
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)
D
Y
A
H
E
F
C
G
R
S
L
P
B
M
N
T
200 LITER (55 GAL.) DRUM
Fig. 3
8 308148
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 skin 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.
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 Models 222939 and C59792 Premier Pumps,
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 38 and 39.
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. 3, using adapters as necessary:
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.
308148 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. 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)
10 308148
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
E
C
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 7 for
installation instructions)
AA Hydraulic Return Line Filter
F
HJ
G
V
U
A
Y
S
R
L
B
P
N
Fig. 4
AA
DRAINAGE
CONTAINER
M
D
K
T
200 LITER
(55 GAL.) DRUM
0627B
308148 11
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 skin
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. 4 illustrates a wall-mounted system.
Pump dimensions and the mounting hole layout are
shown on pages 38 and 39.
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
On the hydraulic return line (D), install the following
accessories in the order shown in Fig. 4, using adapters as necessary:
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
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
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.
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.
12 308148
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)
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.
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