Graco Dura-Flo 1100 Datasheet

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
CARBON STEEL
Dura–Flot1100 Pumps
With Severe–Duty Rod and Cylinder
Part No. 236932 Pump, Series A, 74:1 Ratio
with PremiertAir 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
308357G
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Table of Contents.
9589A
Parts

2 308357
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. . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo 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.
DUse 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.
DDo 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.
DDo not kink or overbend hoses or use hoses to pull equipment.
DRoute 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).
DWear hearing protection when operating this equipment.
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
DDo not lift the sprayer by the lift ring when the total weight exceeds 550 lb (250 kg).

308357 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.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi-
cal treatment.
DDo not point the gun/valve at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip/nozzle.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DDo not “blow back” fluid; this is not an air spray system.
DAlways have the tip guard and the trigger guard on the gun when spraying.
DBe sure the gun/valve trigger safety operates before spraying.
DLock the gun/valve trigger safety when you stop spraying.
DFollow 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.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
DUse 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.
DKeep clear of all moving parts when starting or operating the pump.
DBefore servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the
equipment from starting unexpectedly.

4 308357
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.
DGround the equipment and the object being sprayed/dispensed. Refer to Grounding on page 5.
DIf 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.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed/dispensed.
DKeep the spray/dispense area free of debris, including solvent, rags, and gasoline.
DElectrically disconnect all equipment in the spray/dispense area.
DExtinguish all open flames or pilot lights in the spray/dispense area.
DDo not smoke in the spray/dispense area.
DDo not turn on or off any light switch in the spray/dispense area while operating or if fumes are
present.
DDo not operate a gasoline engine in the spray/dispense area.
DKeep 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.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

308357 5
Installation
Grounding
To reduce the risk of static sparking, ground the pump,
object being sprayed , and all spray/dispensing equip-
ment 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. Con-
nect 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 recommen-
dations.
5. Spray gun/dispensing valve: grounding is obtained
through connection to a properly grounded fluid
hose and pump.
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.
Fig. 1
W
X
Y
Z
0864

6 308357
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.
Fig. 2 is only a guide for selecting and installing sys-
tem components and accessories. Contact your Graco
distributor for assistance in designing a system to suit
your particular needs.
Fig. 2
KEY
APump
BCart
CPump Runaway Valve (location)
DAir Line Lubricator (location)
EBleed-Type Master Air Valve
(required, for pump)
FPump Air Regulator
GAir Manifold
HElectrically Conductive Air Supply Hose
JAir Line Filter
KBleed-Type Master Air Valve
(for accessories)
LFluid Filter (includes drain valve)
MFluid Drain Valve (required)
NGrounded Fluid Supply Hose
PFluid Whip Hose
RGun Swivel
SAirless Spray Gun
TSuction Kit
YGround Wire (required; see page 5
for installation instructions)
A
B
C
D
E
F
G
H
JK
M
N
P
Y
MAIN AIR LINE
L
R
S
T
TYPICAL INSTALLATION

308357 7
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 pres-
sure in the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may not be
sufficient. Order Part No. 224774.
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:
DAn air line lubricator (D) provides automatic air
motor lubrication.
DA 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 easi-
ly accessible from the pump, and is located down-
stream from the air regulator. Order Part No.
112730.
DAn 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.
DApump 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.
DAn 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 accesso-
ries.
DAn air line filter (J) removes harmful dirt and
moisture from the compressed air supply.
DA 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:
DA 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).
DA gun (S) dispenses the fluid. The gun shown in
Fig. 2 is an airless spray gun for light to medium
viscosity fluids.
DA gun swivel (R) allows freer gun movement.
DA suction kit (T) allows the pump to draw fluid
from a 19 liter (5 gallon) pail.

8 308357
Operation/Maintenance
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
Fluid under high pressure can be in-
jected 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:
Dare instructed to relieve the pressure,
Dstop spraying/dispensing,
Dcheck or service any of the system equipment,
Dor 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.
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.
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.
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.
9589A
Fig. 3
104
2
1Torque to 129–142 N.m
(95–105 ft–lb)
1

308357 9
Operation/Maintenance
Starting and Adjusting the Pump
1. Refer to Fig. 2 on page 6. 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 (S) 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 trigger and engage the safety latch. The
pump should stall against pressure when the
trigger is released.
4. If the pump fails to prime properly, open the drain
valve (M). Use the drain valve as a priming valve
until the fluid flows from the valve. See Fig. 2.
Close the drain valve.
NOTE: When changing fluid containers with the hose
and gun already primed, open the drain valve (M), to
assist in priming the pump and venting air before it
enters the hose. Close the drain valve when all air has
been eliminated.
5. With the pump and lines primed, and with ade-
quate air pressure and volume supplied, the pump
will start and stop as the gun 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 and pump
wear.
WARNING
To reduce the risk of overpressurizing your system,
which could result in component rupture and cause
serious injury, never exceed the specified Maxi-
mum Incoming Air Pressure to the pump (see the
Technical Data on page 21).
7. Never allow the pump to run dry of the fluid being
pumped. A dry pump will quickly accelerate to a
high speed, possibly damaging itself. A pump
runaway valve (C), which shuts off the air supply to
the pump if the pump accelerates beyond the
pre-set speed, is available. See Fig. 2 on page 6.
If your pump accelerates quickly, or is running too
fast, stop it immediately and check the fluid supply.
If the supply container is empty and air has been
pumped into the lines, refill the container and
prime the pump and the lines with fluid, or flush
and leave it filled with a compatible solvent. Be
sure to eliminate all air from the fluid system.
Shutdown and Care of the Pump
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
For overnight shutdown, relieve the pressure. Stop
the pump at the bottom of its stroke to prevent fluid
from drying on the exposed displacement rod and
damaging the throat packings.
Always flush the pump before the fluid dries on the
displacement rod. Never leave water or water-based
fluid in the pump overnight. First, flush with water or a
compatible solvent, then with mineral spirits. Relieve
the pressure, but leave the mineral spirits in the pump
to protect the parts from corrosion.

10 308357
Notes