Graco 308152Z1 User Manual

Instructions–Parts List

STAINLESS STEEL

Dura–Flot 2400 Pumps

Severe–Duty rod and cylinder, for abrasive coatings.

Important Safety Instructions

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

See page 2 for Model Numbers, Maximum Working Pressures and Table of Contents.

308152Z1

Part No. 222899 Shown

0566B

List of Models

Pump Part No. and Series Pump Model

222827, Series A

222899, Series A

222898, Series B

222943, Series B

222900, Series B

249157, Series A

249158, Series A

253843 Series A

K This manual also covers displacement pumps 236226, 222994, 236230, and 222993. See pages 34 and 35.

Bulldogr 222803,

Kingt 222803,

Quiet Kingt 222803,

Premiert 222803,

Viscountr 222803,

Premier 249991,

Premier 249991

Displacement Pump Part No. and SeriesK

Series A

Maximum Fluid

Ratio

10:1 7.0 MPa, 69 bar

20:1 13.8 MPa, 138 bar

34:1 23.0 MPa, 234 bar

1.33:1 14.0 MPa, 138 bar

34:1 23.0 MPa, 234 bar

Working Pressure

(1000 psi)

(2000 psi)

(3400 psi)

(2000 psi)

(3400 psi)

Maximum Air/Hydraulic Input Pressure

0.7 MPa, 7 bar (100 psi)

10.0 MPa, 103 bar (1500 psi)

0.7 MPa, 7 bar (100 psi)

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 16. . . . . . . . . . . . . . . . . .

Troubleshooting Chart 18. . . . . . . . . . . . . . . . . . . . . . . . .

Service 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required Tools 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disconnecting the Displacement Pump 19. . . . . . .

Reconnecting the Displacement Pump 20. . . . . . . .

Displacement Pump Service 21. . . . . . . . . . . . . . . .

Parts Drawings and Parts Lists 26. . . . . . . . . . . . . . . . . .

Pump Assemblies 26. . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pumps 30. . . . . . . . . . . . . . . . . . . . . . .

Technical Data 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Hole Layouts 45. . . . . . . . . . . . . . . . . . . . . . . . .

Graco Standard Warranty 46. . . . . . . . . . . . . . . . . . . . . .

Graco Information 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 308152

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 section on page 36 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.

308152 3

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.

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 13 whenever you: are instructed to relieve pres-

sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.

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 308152

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 Eliminate all ignition sources such as pilot lights, cigarettes, and plastic drop cloths (static arc

hazard). Do not plug or unplug power cords or turn lights on or off in the spray area.

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 working 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.

308152 5

Notes

6 308152

Installation

(ALL PUMPS)

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, 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: 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.

Fig. 1

Fig. 2

7. Solvent pails used when flushing: follow your local

TI1052

0864

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.

Optional Fluid Outlet Fitting

Part No. 184470 Fluid Outlet Fitting is available for applications requiring a smaller fluid outlet fitting than the standard 1–1/2 in. npt(m). The 184470 Fitting is 3/4 npt(m) x M42 x 2.0. Contact your Graco distributor to order.

308152 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: Always use Graco Parts and Accessories, available from your Graco distributor. If you supply your own accessories, be sure they are adequately sized and pressure rated for your system.

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. 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)

E F

T 200 LITER (55 GAL.) DRUM

Fig. 3

8 308152

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) for easier gun/valve movement.

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 at left). Be sure the bleed valve is easily accessible from the pump, and is located down- stream from the air regulator.

D 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.

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 222943 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 44 and 45.

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:

D An air line lubricator (D) provides automatic air

motor lubrication.

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 for easier gun movement.

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

from a 200 liter (55 gallon) drum.

308152 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

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 7 for

installation instructions)

AA Hydraulic Return Line Filter

S R

Fig. 4

10 308152

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 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. 4 illustrates a wall-mounted system. Pump dimensions and the mounting hole layout are shown on pages 44 and 45.

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, 19 liter (5 gal.) or Part No. 207428, 3.8 liter (1 gal.). 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.

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. 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 for easier 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 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.

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

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

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 for easier gun movement.

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

from a 200 liter (55 gallon) drum.

308152 11

Notes

12 308152

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 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.

Packing Nut/Wet-Cup

Before starting, fill the packing nut (3) 1/3 full with Graco Throat Seal Liquid (TSL) or compatible solvent. See Fig. 5.

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 to 128–156 NSm (95–115 ft-lb) using the supplied wrench (104). Do this whenever necessary. Do not overtighten the packing nut.

Model 222899

Shown

Bleed hole must

face down

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 (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.

104

Fig. 5

34, 35

308152 13

0566B

Operation/Maintenance

(AIR-POWERED PUMPS)

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 15.

Starting and Adjusting the Pump

1. Refer to the Typical Installation 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 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

CAUTION

Do not allow the pump to run dry. It will quickly accelerate to a high speed, causing damage. If the 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.

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.

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.

SKIN 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 (34) when priming the pump. Use a crescent wrench to open and close the bleeder plug (35). Keep your hands away from the bleed hole.

4. If the pump fails to prime properly, open the bleeder valve plug (35) slightly. Use the bleed hole on the underside of the valve body (34) as a priming valve until the fluid appears at the hole. See Fig. 5. Close the plug (35).

NOTE: When changing fluid containers with the hose and gun already primed, open the bleeder valve plug (35) to help prime the pump and vent air before it enters the hose. Close the plug when all air is eliminated.

WARNING

COMPONENT RUPTURE HAZARD

To reduce the risk of overpressurizing your system, which could cause component rupture and serious injury, never

exceed the specified Maximum Incoming Air Pressure to the pump (see the Technical Data section

on pages 36–41).

14 308152

+ 32 hidden pages