Graco XL 1000cc, 3A4100E, Dura-Flo Operation Manual

Operation and Parts

™

Dura-Flo

For use with bulk supply of medium to high viscosity sealant and adhesive materials. For professional use only. Not approved for use with group 1 fluids as defined by Directive 2014/68/EU (Pressure Equipment Directive). Not approved for use in European explosive atmosphere location.

See Technical Specifications page on page 20 for maximum allowable ambient temperature information.

See Page 2 for model information and maximum working pressure.

Important Safety Instructions

Read all warnings and instructions in this and all related manuals. Save all instructions.

XL 1000cc Pumps

3A4100E

WLD

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

Component Identification / Pump Assembly . . . . 5

Motor Component Identification . . . . . . . . . . . . . 6

Grounding the System . . . . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 9

For the Supply System . . . . . . . . . . . . . . . . . . . . 9

For the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Packing Nut / Wet-Cup . . . . . . . . . . . . . . . . . . . 10

Flushing the Pump . . . . . . . . . . . . . . . . . . . . . . 10

Disconnecting the Displacement Pump . . . . . . 10

Models

Pump Part and Series

25A451, Series A

25A452, Series A

25A453, Series A

25A454, Series A

Pump Style Motor Pump Lower Ratio Maximum Fluid

XL 1000cc, Severe Duty, Carbon Steel

XL 1000cc, MaxLife, Carbon Steel

XL 1000cc, Severe Duty, Stainless Steel

XL 1000cc, MaxLife, Stainless Steel

*25A455 XL 24000

*25A447 Dura-Flo 1800 (1000cc)

*25A448 Dura-Flo 1800 (1000cc)

*25A449 Dura-Flo 1800 (1000cc)

*25A450 Dura-Flo 1800 (1000cc)

Lower Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

25A447, 25A448, 25A449, 25A450 . . . . . . . . . . 11

Lower Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 12

Air Motor 25A455 . . . . . . . . . . . . . . . . . . . . . . . . 13

Air Motor Parts List . . . . . . . . . . . . . . . . . . . . . . 14

Dura-Flo 1000cc Pumps with Xtreme and XL Motors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Kits and Accessories . . . . . . . . . . . . . . . . . . . . . 17

Dimensions and Mounting Hole Layouts . . . . . . 18

Technical Specifications . . . . . . . . . . . . . . . . . . . . 19

California Proposition 65 . . . . . . . . . . . . . . . . . . . . 19

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 20

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 20

Maximum Air

47:1

Working Pressure

4500 psi (31 MPa, 310 bar)

Input Pressure

100 psi (0.7 MPa, 7 bar)

* Items are part of a kit, See Kits and Accessories on page 17.

Related Manuals

Manual Description

309169

309028

3A2510

332499

2 3A4100E

Uni-Drum™ Supply System for 1200 Liter (300 gallon) Containers

Uni-Drum™ Supply System for 1000 Liter (265 gallon) Containers

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNINGWARNINGWARNING

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgi-

cal treatment.

• Engage trigger lock when not dispensing.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

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

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking,

or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic

drop cloths (potential static sparking).

• Ground all equipment in the work area. See Grounding instructions.

• Never spray or flush solvent at high pressure.

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

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes

are present.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they

are anti-static or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

3A4100E 3

Warnings

WARNINGWARNINGWARNING

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equip- ment, Relieve Pressure and disconnect all power sources.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in

all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheet (SDS) from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine man-

ufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent

manufacturer.

4 3A4100E

Component Identification / Pump Assembly

Pump Assembly Instructions:

1. Assemble (H) to (F). Apply sealant and torque.

2. Assemble (L) to (F) and torque.

3. Assemble (G) to (L) and hand-tighten (N).

4. Assemble (K) and torque (J) to (H).

5. Torque (N) to (L).

&

(

)

WLD

Torque to 129-142 N•m

(95-105 ft-lb).

Apply sealant to

threads (102969).

Torque to 312-340 N•m

(230-250 ft-lb).

Ref. Description

A Pump

B Supply System

C Main Air Inlet

D Supply System Control Panel

E Bleed-Type Shutoff Valve

F* Motor, XL

G* Displacement Pump

H* Coupling Adapter

WLD

Typical Installation

Ref. Description

J* Coupling Nut

K* Coupling Collar

L* Tie Rod with Extension

N* Hex Nut

P* Packing Nut / Wet Cup

Q* Packing Nut Wrench

S* Pump Bleed Valve

* Included with this system.

3A4100E 5

Component Identification / Pump Assembly

Motor Component Identification

Ref. Description

AA Directional Air Valve

BB Air Inlet 1 in. npt(f)

CC Muffler

DD Pilot Valve

EE Manifold

FF Manual Shuttle Override Button

GG Ground Screw

((

///

)

))

Ref. Description

HH Static Ground Cable

JJ Plug for Optional Solenoid

KK Optional Reed Switch Mount

LL External Pilot Lines

MM De-ice Bleed Air Valve

NN Lift Ring - 500 lb (363 kg) Maximum

PP Pump Drive Rod

WLD

6 3A4100E

+ 14 hidden pages