Graco 308357G User Manual

Instructions – Parts List

Parts

CARBON STEEL

Dura–Flot 1100 Pumps

With Severe–Duty Rod and Cylinder

Part No. 236932 Pump, Series A, 74:1 Ratio with Premiert Air Motor and 236478 Displacement Pump

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

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

Important Safety Instructions

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

See page 2 for Table of Contents.

308357G

9589A

GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441

Table of Contents

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

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

Operation/Maintenance 8. . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Chart 11. . . . . . . . . . . . . . . . . . . . . . . . .

Service 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required Tools 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disconnecting the Displacement Pump 12. . . . . . .

Reconnecting the Displacement Pump 12. . . . . . . .

Displacement Pump Service 14. . . . . . . . . . . . . . . .

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.

Parts Drawings and Parts Lists 18. . . . . . . . . . . . . . . . . .

Pump Assembly 18. . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pump 19. . . . . . . . . . . . . . . . . . . . . . . .

Repair Kits 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Hole Layout 23. . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Information 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 page 21 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 exceed the maximum working pressure of the lowest rated system component. This equip-

ment has a 50.0 MPa, 500 bar (7252 psi) maximum working pressure.

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.

D Do not lift the sprayer by the lift ring when the total weight exceeds 550 lb (250 kg).

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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/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 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 8 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 8 to prevent the

equipment from starting unexpectedly.

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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/dispensed. Refer to Grounding on page 5.

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/dispensed.

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

D Electrically disconnect all equipment in the spray/dispense area.

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

D Do not smoke in the spray/dispense area.

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

present.

D Do not operate a gasoline engine in the spray/dispense 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.

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Installation

Grounding

To reduce the risk of static sparking, ground the pump, object being sprayed , and all spray/dispensing equipment used or located in the spray/dispensing area. Check your local electrical code for detailed grounding instructions for your area and type of equipment. Be sure to ground all of this spray/dispensing equipment.

1. Pump: loosen the grounding lug locknut (W) and washer (X). Insert one end of a 1.5 mm2 (12 ga) minimum ground wire (Y) into the slot in lug (Z) and tighten the locknut securely. See Fig. 1. Connect the other end of the wire to a true earth ground. Order Part No. 237569 Ground Wire and Clamp.

2. Air hoses: use only electrically conductive hoses.

3. Fluid hoses: use only electrically conductive fluid hoses.

4. Air compressor: follow manufacturer’s recommendations.

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

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.

5. Spray gun/dispensing valve: grounding is obtained through connection to a properly grounded fluid hose and pump.

0864

Fig. 1

308357 5

Installation

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 representative. 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 Cart C Pump Runaway Valve (location) D Air Line Lubricator (location) 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 (includes drain valve) M Fluid Drain Valve (required)

MAIN AIR LINE

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.

N Grounded Fluid Supply Hose P Fluid Whip Hose R Gun Swivel S Airless Spray Gun T Suction Kit Y Ground Wire (required; see page 5

for installation instructions)

Fig. 2

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Installation

ASSEMBLE THE PUMP

Assemble the displacement pump (105) to the air motor (101) as instructed on pages 12–13.

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. Order Part No. 112730.

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. Order Part No. 224774.

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 at left). Be sure the bleed valve is easily accessible from the pump, and is located down- stream from the air regulator. Order Part No.

112730.

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 1 in. npt air inlet. It

mounts to the pump support 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.

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 (S) to allow freer gun movement.

Mounting Accessories

Mount the pump (A) to suit the type of installation planned. Fig. 2 illustrates a cart-mounted system. Pump dimensions and the mounting hole layout are shown on page 23.

If you are using a floor stand, refer to its separate manual for installation and operation instructions.

Air Line Accessories

Install the following accessories in the locations shown in Fig. 2, using adapters as necessary:

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

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

Fluid Line Accessories

Install the following accessories in the locations shown in Fig. 2, 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 (S) dispenses the fluid. The gun shown in

Fig. 2 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 19 liter (5 gallon) pail.

308357 7

Operation/Maintenance

Pressure Relief Procedure

WARNING

SKIN 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:

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

1. Lock the spray gun/dispensing valve trigger safety.

2. Shut off the air supply to the pump.

3. Close the bleed-type master air valve (required in your system).

4. Unlock the gun/valve trigger safety.

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 4 before

flushing, and follow all recommendations given there.

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

6. Lock the gun/valve 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/dispense again.

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 or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip/nozzle or hose.

Packing Nut/Wet Cup

Before starting, fill the packing nut (2) 1/3 full with Graco Throat Seal Liquid (TSL) or compatible solvent. See Fig. 3.

104

Torque to 129–142 N.m (95–105 ft–lb)

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, you must first follow the Pressure Relief Procedure Warning above, then torque the nut to 129–142 N.m (95–105 ft–lb) using the supplied wrench (104). Do this whenever necessary. Do not overtighten the packing nut.

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9589A

Fig. 3

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