Graco Dura-Flo 1100 User manual

03632
INSTRUCTIONS–P ARTS LIST 308–357
Rev A
CARBON STEEL
Dura-Flo 1 100 Pumps
With Severe-Duty Rod and Cylinder
Part No. 236–932 Pump, Series A,
74:1 Ratio, with Premier Air Motor
510 bar (7400 psi) Maximum Fluid Working Pressure
7 bar (100 psi) Maximum Air Input Pressure
Refer to page 2 for T able of Contents.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1994, GRACO INC.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE

 
Table of Contents
Warnings 3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation/Maintenance 8–9 . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart 11. . . . . . . . . . . . . . . . . . . . . . . . .
Service 12–17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting the Displacement Pump 12, 13 . . . .
Reconnecting the Displacement Pump 12, 13 . . . .
Displacement Pump Service 14–17. . . . . . . . . . . . .
Parts Drawings and Parts Lists 18–20. . . . . . . . . . . . . . .
Pump Assembly 18. . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 19. . . . . . . . . . . . . . . . . . . . . . .
Repair Kits 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 23. . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 24. . . . . . . . . . . . . . . . . . . . . . . . .

 
WARNINGS
High Pressure Spray Can Cause Serious Injury . For Professional Use Only.
Observe All W arnings. Read and understand all instruction manuals before operating equipment.
FLUID INJECTION HAZARD
General Safety
This equipment generates very high fluid pressure. Spray
from the spray gun/dispensing valve, leaks or ruptured com -
ponents can inject fluid through your skin and into your body
and cause extremely serious injury , including the need for
amputation. Also, fluid injected or splashed into the eyes or
on the skin can cause serious damage.
Never point the gun/valve at anyone or at any part of the
body . Never put hand or fingers over the spray tip/nozzle.
Always have the tip guard in place on the gun when spraying.
Always follow the Pressure Relief Procedure , right, before
cleaning or removing the spray tip/nozzle or servicing any
system equipment.
Never try to stop or deflect leaks with your hand or body .
Be sure all equipment safety devices are operating properly
before each use.
Medical Alert – Airless Spray W ounds
If any fluid appears to penetrate your skin, get emergency
medical care at once. Do not treat as a simple cut. T ell the
doctor exactly what fluid was injected.
NOTE TO PHYSICIAN: Injection into the skin is a traumatic
injury. It is important to treat the injury surgically as soon
as possible. Do not delay treatment to research toxicity . T ox-
icity is a concern with some exotic coatings injected directly
into the blood stream. Consultation with a plastic surgeon or
reconstructive hand surgeon may be advisable.
Spray Gun/Dispensing V alve Safety Devices
Be sure all gun/valve safety devices are operating properly
before each use. Do not remove or modify any part of the
gun/valve; this can cause a malfunction and result in serious
injury.
Safety Latch
Whenever you stop spraying/dispensing, even for a moment,
always set the gun/valve safety latch in the closed or “safe”
position, making the gun/valve inoperative. Failure to set the
safety latch can result in accidental triggering of the gun/
valve.
Trigger Guard (if present)
Never operate the gun/valve with the trigger guard removed.
This guard helps prevent the gun/valve from triggering acci -
dentally if it is dropped or bumped.
Diffuser (only on spray guns)
The spray gun dif fuser breaks up spray and reduces the risk
of fluid injection when the tip is not installed. Check the dif -
fuser operation regularly . Follow the Pressure Relief Proce -
dure,
right, then remove the spray tip. Aim the gun into a
grounded metal pail, holding the gun firmly to the pail. Using
the lowest possible pressure, trigger the gun. If the fluid emit -
ted is not dif fused into an irregular stream, replace the dif -
fuser immediately .
Tip Guard (only on spray guns)
Always have the tip guard in place on the gun while spraying.
The tip guard alerts you to the fluid injection hazard and helps
reduce, but does not prevent, the risk of accidentally plac -
ing your fingers or any part of your body close to the spray
tip.
Spray T ip/Nozzle Safety
Use extreme caution when cleaning or changing tips/nozzles.
If the tip/nozzle clogs while spraying/dispensing, engage the
gun/valve safety latch immediately . Always follow the Pres -
sure Relief Procedure and then remove the tip/nozzle to
clean it.
Never wipe of f build-up around the tip/nozzle until pressure is
fully relieved and the gun/valve safety latch is engaged.
Pressure Relief Procedure
To reduce the risk of serious injury , including fluid injection,
splashing in the eyes or on the skin, or injury from moving
parts, always follow this procedure whenever you shut of f the
pump, when checking or servicing any part of the spray/dis -
pensing system, when installing, cleaning or changing spray
tips/nozzles, and whenever you stop spraying/dispensing.
1. Engage the spray gun/dispensing valve safety latch.
2. Shut of f the air supply to the pump.
3. Close the bleed-type master air valve (required in your
system).
4.
Disengage the gun/valve safety latch.
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. Engage the gun/valve safety latch.
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.

4 308-357
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the spray/dispensing equipment or accesso -
ries, such as overpressurizing, modifying parts, using incom -
patible chemicals and fluids, or using worn or damaged parts,
can cause them to rupture and result in fluid injection, splash
-
ing in the eyes or on the skin, or other serious injury , or fire,
explosion or property damage.
Never alter or modify any part of this equipment; doing so
could cause it to malfunction.
Check all spray/dispensing equipment regularly and repair or
replace worn or damaged parts immediately .
Always wear protective eyewear
, gloves, clothing and respi -
rator as recommended by the fluid and solvent manufacturer .
System Pressure
Never exceed the recommended working pressure or the
maximum air inlet pressure stated on your pump or in the
T echnical Data on page 22.
Be sure that all spray/dispensing equipment and accessories
are rated to withstand the maximum working pressure of the
pump. Do not exceed the maximum working pressure of any
component or accessory used in the system.
Fluid Compatibility
Be sure that all fluids and solvents used are chemically com -
patible with the wetted parts shown in the T echnical Data on
page 22. Always read the manufacturer ’ s literature before
using fluid or solvent in the pump.
FIRE OR EXPLOSION HAZARD
Static electricity is created by the high velocity flow of fluid
through the pump and hose. If every part of the spray/
dispensing equipment is not properly grounded, sparking
may occur , and the system may become hazardous. Spark -
ing may also occur when plugging in or unplugging a power
supply cord. Sparks can ignite fumes from solvents and the
fluid being sprayed/dispensed, dust particles and other flam -
mable substances, whether you are spraying/dispensing in -
doors or outdoors, and can cause a fire or explosion and seri -
ous injury and property damage. Do not plug in or unplug any
power supply cords in the spray/dispensing area when there
is any chance of igniting fumes still in the air .
If you experience any static sparking or even a slight shock
while using this equipment, stop spraying/dispensing im -
mediately.
Check the entire system for proper grounding.
Do not use the system again until the problem has been iden -
tified and corrected.
Grounding
T o reduce the risk of static sparking, ground the pump, object
being sprayed, and all other 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: use a ground wire and clamp. See Fig. 1.
2. Air hoses: use only grounded hoses.
3. Fluid hoses: use only grounded fluid hoses.
4. Air compressor: follow manufacturer ’ s recommendations.
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. T o maintain grounding continuity when flushing or reliev -
ing 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
To ground the air motor and pump:
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 .
See Fig. 1. Connect the other end of the wire to a true
earth ground. Order Part No. 222–01 1 Ground Wire and
Clamp.
W
X
Y
Z

Flushing Safety
Before flushing, be sure the entire system and flushing pails
are properly grounded. Refer to Grounding , at left. Follow
the Pressure Relief Procedure on page 3, and remove the
tip/nozzle from the gun/valve. Always use the lowest possible
fluid pressure, and maintain firm metal-to-metal contact be -
tween the gun/valve and the pail during flushing to reduce the
risk of fluid injection injury , static sparking and splashing.

 
HOSE SAFETY
High pressure fluid in the hoses can be very dangerous. If the
hose develops a leak, split or rupture due to any kind of wear ,
damage or misuse, the high pressure spray emitted from it
can cause a fluid injection injury or other serious injury or
property damage.
All fluid hoses must have spring guards on both ends!
The spring guards help protect the hose from kinks or bends
at or close to the coupling which can result in hose rupture.
T ighten all fluid connections securely before each use. High
pressure fluid can dislodge a loose coupling or allow high
pressure spray to be emitted from the coupling.
Never use a damaged hose. Before each use, check the en -
tire hose for cuts, leaks, abrasion, bulging cover , or damage
or movement of the hose couplings. If any of these conditions
exist, replace the hose immediately
. Do not try to recouple
high pressure hose or mend it with tape or any other device.
A repaired hose cannot safely contain the high pressure fluid.
Handle and route hoses carefully . Do not pull on hoses to
move equipment. Do not use fluids which are not compatible
with the inner tube and cover of the hose. Do not expose
Graco hoses to temperatures above 82  C (180  F) or below
–40 C (–40 F).
Hose Grounding Continuity
Proper hose grounding continuity is essential to maintaining a
grounded spray/dispensing system. Check the electrical re -
sistance of your air and fluid hoses at least once a week. If
your hose does not have a tag on it which specifies the maxi
-
mum electrical resistance, contact the hose supplier or manu -
facturer for the maximum resistance limits. Use a resistance
meter in the appropriate range for your hose to check the
resistance. If the resistance exceeds the recommended lim -
its, replace it immediately . An ungrounded or poorly grounded
hose can make your system hazardous. Also, read FIRE OR
EXPLOSION HAZARD
, on page 4.
MOVING P ARTS HAZARD
Moving parts can pinch or amputate your fingers or other
body parts. Keep clear of all moving parts when starting or
operating the pump. Before servicing the pump, follow the
Pressure Relief Procedure on page 3 to prevent the pump
from starting accidentally .
On Premier air-powered pumps, the rocker arms (located
beneath the rocker arm covers) move when air is supplied to
the motor . Never operate the pump with the rocker arm cov -
ers removed.
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards
– particularly the General Standards, Part 1910, and the Construction Standards, Part 1926 – should be consulted.
TERMS
WARNING Alerts user to avoid or correct conditions that
could cause bodily harm.
CAUTION Alerts user to avoid or correct conditions that could
cause damage to or destruction of equipment.
NOTE Identifies essential procedures or helpful information.

6 308-357
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 rep -
resentative. 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
system components and accessories. Contact your
Graco representative or Graco T echnical Assistance
(see back page) for assistance in designing a system
to suit your particular needs.
Fig. 2
KEY
APump
BCart
CPump
Runaway V alve (location)
D Air Line Lubricator (location)
EBleed-T ype Master Air V alve
(required, for pump)
F Pump Air Regulator
G Air Manifold
H Grounded Air Supply Hose
J Air Line Filter
KBleed-T ype Master Air V alve
(for accessories)
L Fluid Filter (includes drain valve)
M Fluid Drain V alve (required)
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 4
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
03760

 
Installation
ASSEMBLE THE PUMP
Assemble the displacement pump (105) to the air mo -
tor (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 seri -
ous bodily 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 of f. T rapped air can cause the
pump to cycle unexpectedly. Locate the valve
close to the pump. Order Part No. 1 12–730.
The fluid drain valve assists in relieving fluid
pressure in the displacement pump, hose, and
gun. T riggering the gun to relieve pressure may
not be sufficient. Order Part No. 224–774.
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 grounded 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:
An air line lubricator (D) provides automatic air
motor lubrication.
 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 eas -
ily accessible from the pump, and is located
downstream from the air regulator . Order Part No.
112–730.
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.
A pump runaway valve (C ) senses when the
pump is running too fast and automatically shuts
of f the air to the motor . A pump which runs too fast
can be seriously damaged.
 An air manifold (G) has a 1” npt air inlet. It
mounts to the pump support bracket, and provides
ports for connecting lines to air-powered accesso -
ries.
An
air line filter (J) removes harmful dirt and
moisture from the compressed air supply .
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:
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).
A gun (S) dispenses the fluid. The gun shown in
Fig. 2 is an airless spray gun for light to medium
viscosity fluids.
 A gun swivel (R) allows freer gun movement.
A suction kit (T) allows the pump to draw fluid
from a 19 liter (5 gallon) pail.
GROUNDING
WARNING
Before operating the pump, ground the system as
explained under Fire or Explosion Hazard and
Grounding on page 4.

 
Operation/Maintenance
Pressure Relief Procedure
T o reduce the risk of serious bodily injury , including
fluid injection, splashing in the eyes or on the skin,
or injury from moving parts, always follow this proce -
dure whenever you shut of f the pump, when check -
ing or servicing any part of the spray/dispensing sys -
tem, when installing, cleaning or changing spray
tips/nozzles, and whenever you stop spraying/dis -
pensing.
1.
Engage the gun/valve safety latch.
2. Shut of f the air supply to the pump.
3. Close the bleed-type master air valve (required
in your system).
4. Disengage the gun/valve safety latch.
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. Engage the gun/valve safety latch.
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, nozzle, or
hose end coupling and relieve pressure gradually
,
then loosen completely. Now clear the tip/nozzle or
hose.
WARNING
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 W arning 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
or Explosion Hazard on page 4 before flushing,
and follow all recommendations given there.
Fig. 3
104
2

Torque
to 129–142 N.m
(95–105 ft–lb)

03632

308-357 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 trig -
ger 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 en -
ters 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 of f.
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
T o reduce the risk of overpressurizing your sys -
tem, which could result in component rupture and
cause serious injury , never exceed the specified
Maximum Incoming Air Pressure to the pump
(see the T echnical Data on page 22).
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 run
-
away valve (C), which shuts of f 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
For overnight shutdown, follow the Pressure Relief
Procedure W arning on page 8. 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.

10 308-357
Notes

308-357 11
Troubleshooting Chart
PROBLEM CAUSE SOLUTION
Pump fails to operate. Restricted line or inadequate air supply;
closed or clogged valves.
Clear; increase air supply .
Check that valves are open.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small.
Open, clear*; use hose with larger ID. Hose must
be rated for 510 bar (7400 psi).
Fluid dried on the displacement rod. Clean; always stop pump at bottom of stroke;
keep wet-cup 1/3 filled with compatible solvent.
Dirty , worn, or damaged motor parts. Clean or repair; see separate motor manual.
Pump operates, but
output low on both
strokes.
Restricted line or inadequate air supply;
closed or clogged valves.
Clear; increase air supply .
Check that valves are open.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small.
Open, clear*; use hose with larger ID. Hose must
be rated for 510 bar (7400 psi).
W orn packings in displacement pump. Replace packings.
Pump operates, but
output low on down-
stroke.
Held open or worn intake valve. Clear valve; service.
Pump operates, but
output low on up-
stroke.
Held open or worn piston valve or pack -
ings.
Clear valve; replace packings.
Erratic or accelerated
pump
speed.
Exhausted fluid supply . Refill and prime.
Held open or worn piston valve or pack -
ings.
Clear valve; replace packings.
Held open or worn intake valve. Clear valve; service.
*To determine if the fluid hose or gun is obstructed, follow the Pressure Relief Procedure W arning below. Disconnect the fluid
hose and place a container at the pump fluid outlet to catch any fluid. T urn on the air just enough to start the pump. If the
pump starts when the air is turned on, the obstruction is in the fluid hose or gun.
NOTE: If you experience air motor icing, call Graco T echnical Assistance (1-800-543-0339).
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including fluid
injection, splashing in the eyes or on the skin, or injury
from moving parts, always follow this procedure whenever
you shut of f the pump, when checking or servicing any part
of the spray/dispensing system, when installing, cleaning
or changing spray tips/nozzles, and whenever you stop
spraying/dispensing.
1.
Engage the gun/valve safety latch.
2. Shut of f the air supply to the pump.
3. Close the bleed-type master air valve (required in your
system).
4.
Disengage the gun/valve safety latch.
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. Engage the gun/valve safety latch.
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 com -
pletely clogged, or that pressure has not been fully re -
lieved after following the steps above, very slowly loosen
the tip guard retaining nut, nozzle, or hose end coupling
and relieve pressure gradually , then loosen completely .
Now clear the tip/nozzle or hose.
WARNING

12 308-357
Service
REQUIRED TOOLS
Set of adjustable wrenches
 15/16 in. (or 23 mm) socket wrench
 Large pipe wrench
T orque wrench
 Rubber mallet
 O-ring pick
 Large vise
 Thread lubricant
 Thread sealant
DISCONNECTING THE DISPLACEMENT
PUMP
1. Flush the pump, if possible. Stop the pump at the
bottom of its stroke. Follow the Pressure Relief
Procedure W
arning on page 1 1.
2.
Disconnect the air hose and fluid hose.
3. Disconnect the displacement pump (105) from the
motor (101) as follows. Be sure to note the relative
position of the pump’ s fluid outlet (U) to the air inlet
(V) of the motor . If the motor does not require
servicing, leave it attached to its mounting.
CAUTION
Be sure to use at least two people when lifting,
moving, or disconnecting the pump. This pump is
too heavy for one person. If you are disconnecting
the displacement pump from a motor which is still
mounted (for example, on a wall bracket), be sure
to support the displacement pump while it is being
disconnected, to prevent it from falling and caus -
ing injury or property damage. Do this by securely
bracing the pump, or by having at least two peo
-
ple hold it while another disconnects it.
If the pump is mounted on a cart, slowly tip the
cart backward until the handle rests on the
ground, then disconnect the displacement pump.
4. Using an adjustable wrench (or hammer and
punch), unscrew the coupling nut (103) from the
connecting rod adapter (102). Remove the cou
-
pling collars (108). T ake care not to lose or drop
them. See Fig. 4.
5. Hold the tie rod flats with a wrench to keep the
rods from turning. Unscrew the nuts (106) from the
tie rods (107). Carefully remove the displacement
pump (105) from the motor (101).
6.
Refer to page 14 for displacement pump service.
T o service the air motor , refer to the separate mo -
tor manual, supplied.
RECONNECTING THE DISPLACEMENT
PUMP
1. Screw the connecting rod adapter (102) into the air
motor shaft. Hold the motor shaft flats with a
wrench to keep it from turning, and torque the
adapter to 312–340 N.m (230–250 ft–lb). See Fig.
4.
2.
Screw the tie rods (107) into the base of the air
motor (101). Using a wrench on the tie rod flats,
torque to 129–142 N.m (95–105 ft–lb).
3. Make sure the coupling nut (103) and the coupling
collars (108) are in place on the displacement rod
(1).
4.
Use at least two people to hold the displacement
pump while another reconnects it to the motor (see
the CAUTION at left). Orient the pump’ s fluid out -
let (U) to the air inlet (V) as was noted in step 3
under Disconnecting the Displacement Pump.
Position the displacement pump (105) on the tie
rods (107).
5. Screw the nuts (106) onto the tie rods (107) and
torque to 129–142 N.m (95–105 ft–lb).
6. Screw the coupling nut (103) onto the connecting
rod adapter (102) loosely . Hold the connecting rod
adapter flats with a wrench to keep it from turning.
Use an adjustable wrench to tighten the coupling
nut. T orque to 312–340 N.m (230–250 ft–lb).
7. Reconnect all hoses. Reconnect the ground wire if
it was disconnected. Fill the packing nut (2) 1/3 full
of Graco Throat Seal Liquid or compatible solvent.
8. T urn on the air supply . Run the pump slowly to en -
sure that it is operating properly .
9.
Before returning the pump to production, follow the
Pressure Relief Procedure W arning on page 1 1.
Retorque the packing nut (2) to 129–142 N.m
(95–105 ft–lb).

308-357 13
Service
Fig. 4
1
2
Torque
to 129–142 N.m (95–105 ft–lb)
T orque to 312–340 N.m (230–250 ft–lb)
101
105
106
108
102
107
103
104
1
2
2
1
1
2
1
V
U
03633

14 308-357
Service
DISPLACEMENT PUMP SERVICE
Disassembly
When disassembling the pump, lay out all the removed
parts in sequence, to ease reassembly
.
NOTE:
Repair Kit 237–166 is available. For the best
results, use all the new parts in the kit. Kit parts are
marked with an asterisk, for example (3*). Kits to con
-
vert the pump to dif ferent packing materials are also
available. Refer to page 20.
1. Place the pump lengthwise in a large vise, with the
jaws on the outlet housing (9) as shown in Fig. 5.
Using the supplied wrench (104), loosen, but do
not remove, the packing nut (2).
2. Using a pipe wrench, unscrew the intake valve
(17) from the intake housing (16). Be careful to
catch the intake ball (15) as you remove the intake
valve, so that it doesn’t fall and suf fer damage.
Remove the o-ring (28) from the intake valve. In -
spect the ball and the seat (D) of the intake valve
for wear or damage. See Fig. 5.
3. Stand the pump upright in the vise. Remove the
six long cap screws (29), using a 15/16” (or 23
mm) socket wrench. See Fig. 8.
4. Lift the outlet housing (9) straight up of f the pump.
Be careful not to scratch the displacement rod (1)
while removing the housing. See Fig. 6.
5. Lift the cylinder (1 1), displacement rod (1), and
piston assembly of f the intake housing (16). Re -
move the ball guide (27) from the intake housing,
and inspect the guide surfaces. See Fig. 6.
6. Using a rubber mallet, drive the displacement rod
(1) and piston assembly out the bottom of the cyl -
inder (1
1) until the piston comes free. Pull the rod
and piston from the cylinder , being careful not to
scratch the parts.
CAUTION
T o reduce the possibility of costly damage to the
rod (1) and cylinder (1 1), always use a rubber mal -
let to drive the rod out of the cylinder. Never use a
hammer to drive the rod.
7. Shine a light into the cylinder (1 1) to inspect the
inner surface for scoring or wear . Remove the
o-rings (10) from the cylinder .
8.
Place the flats of the piston seat housing (14) in a
vise, as shown in Fig. 7. Using an adjustable
wrench, unscrew the piston ball housing (12) from
the piston seat housing. Be careful to catch the
piston ball (13) as you separate the piston seat
housing and ball housing, so that it doesn’t fall and
suf fer damage.
03986
Fig. 5
1
9
11
16
17
Torque
to 522–542 N.m (385–400 ft–lb).

28* 15*
D
2Lubricate.



308-357 15
Service
9. Examine the displacement rod (1) for scratches or
other damage. Only if the rod needs replace -
ment,
unscrew it from the piston ball housing (12),
using an adjustable wrench on the flats of the rod.
10. Remove and inspect the glands and v-packings
(P) from the piston seat housing (14). Inspect the
ball (13), and the seat (E) and guides (F) on the
housing for wear or damage. See Fig. 8.
11. Unscrew the packing nut (2) from the outlet hous -
ing (9). Remove and inspect the glands and
v-packings (T).
12. Clean all parts with a compatible solvent and in -
spect them for wear or damage.
04048
Fig. 6
1
9
11
27
16
03793
Fig. 7

14
12
1
Torque to 386–407 N.m (285–300 ft–lb).




 
Service
Reassembly
1. If it was necessary to remove the piston ball hous -
ing (12) from the displacement rod (1), clean the
threads of the rod and the ball housing, and apply
thread sealant. Screw the ball housing onto the
rod, hand tight. Place the flats of the piston ball
housing in a vise and torque the rod to 386–407
N.m (285–300 ft–lb). See Fig. 8.
2. Place the piston packings on the piston seat hous -
ing (14) in the following order , with the lips of the
v-packings facing up:
the female gland (4*), one
v-packing (3*), four leather
v-packings (5*), and the male gland (6*). See the
Piston Packing Stack Detail in Fig. 8.
NOTE: T o convert the pump to a different packing ma -
terial, see page 20.
3. Place the flats of the piston seat housing (14) in a
vise. Place the ball (13*) on the piston seat (E).
Screw the piston ball housing (12) onto the piston
seat housing hand tight, then torque to 386–407
N.m (285–300 ft–lb). See Fig. 7.
4. Lubricate the throat packings and place them in
the outlet housing (9) in the following order, with
the lips of the v-packings facing down:
the
male gland (6*), four leather v-packings (5*), one
v-packing (3*), and the female gland (4*).
See the Throat Packing Stack Detail in Fig. 8.
NOTE: T o convert the pump to a different packing ma -
terial, see page 20.
5. Lubricate the threads of the packing nut (2), and
loosely install it in the outlet housing (9).
6. Lubricate the piston packings. Slide the displace -
ment rod (1) and piston assembly down into the
cylinder (1 1). The cylinder is symmetrical, so either
end may face up. Use a rubber mallet to drive the
rod into the cylinder , until the piston seat housing
(14) is near the bottom of the cylinder .
7.
Place the intake ball guide (27) in the intake hous -
ing (16). Set the intake housing in the vise, facing
upright. See Fig. 6.
8. Install the o-ring (10*) on the bottom of the cylinder
(1 1). Lubricate the o-ring. Place the cylinder on the
intake housing (16). T ap the top of the displace -
ment rod (1) with a rubber mallet, to seat the cylin -
der.
9.
Install the o-ring (10*) on the top of the cylinder
(1 1). Lubricate the o-ring. Set the outlet housing
(9) on the cylinder .
10.
Apply thread lubricant to the six long cap screws
(29). Install them through the outlet housing (9)
and thread them loosely into the intake housing
(16). T ighten the screws oppositely and evenly
with a socket wrench, then torque to 244–264 N.m
(180–195 ft-lb). See Fig. 8.
11. Place the pump lengthwise in the vise, with the
jaws on the outlet housing (9) as shown in Fig. 5.
12. Install the o-ring (28*) on the intake valve (17). Lu -
bricate the o-ring and the threads of the intake
valve. Place the intake ball (15*) in the intake
housing (16), then screw the intake valve into the
intake housing handtight.
13. Using a pipe wrench, torque the intake valve (17)
to 522–542 N.m (385–400 ft–lb). See Fig. 5.
14. T orque the packing nut (2) to 129–142 N.m
(95–105 ft–lb).
15. Reconnect the displacement pump to the air motor
as explained on page 12.
PTFE
PTFE

308-357 17
Service
03984
Fig. 8
1
2
3
4
Torque
to 129–142 N.m (95–105 ft–lb).
T orque to 522–542 N.m (385–400 ft–lb).
T orque to 386–407 N.m (285–300 ft–lb).
Apply thread sealant.
Lubricate.
5
6
7
8
1
*10
17
15*
14
12
D
E
T
P
2
9
11
*10
*13
16
Lips face up.
Lips face down.
2 (Ref)
*4
*3
*5
*6
9 (Ref)
12 (Ref)
1 1 (Ref)
14 (Ref)
*6
*5
*3
*4
27 (Ref)
*10 (Ref)
4
4
4
4
4
4
5
3
3
2
2
1
See Throat Packing Detail at left.
See Piston Packing Detail at left.
8Throat Packing Stack Detail
Piston Packing Stack Detail
7
7
6
6
F
10 Torque
to 244–264 N.m (180–195 ft–lb).
29
10
*28
4
27
9
9

18 308-357
Parts
Part No. 236–932 Pump, Series A
74:1 Ratio, with Premier Air Motor
Ref.
No. Part No. Description Qty.
101 222–800 AIR MOTOR, Premier
See 308–213 for parts 1
102184–581
ADAPTER, connecting rod 1
103184–098 NUT
, coupling 1
104112–887 WRENCH, spanner 1
105 236–478 PUMP
, displacement
See page 19 for parts 1
106106–166 NUT
, hex; M16 x 2.0 3
107184–382
ROD, tie; 265 mm (10.43”)
shoulder to shoulder 3
108184–129
COLLAR, coupling 2

These parts are included in Connection Kit 235–416.
101
105
106
108
102
107
103104


03983
9
1
17
16
15*
10*
20
*13
12
2
*Throat
Packing
Stack
(see
page 20)
*Piston
Packing
Stack
(see page 20)
14
10*
11
27
28*
29
 
Parts
Displacement Pump 236–478, Series A
Ref Part
No. No. Description Qty
1 189–317 ROD,
displacement; stainless steel 1
2 222–995 PACKING NUT
; carbon steel 1
7Y172–477 T
AG, warning (not shown) 1
8Y172–479 T
AG, warning (not shown) 1
9 237–183
HOUSING, outlet; ductile iron 1
10* 109–499 SEAL; r2
11 190–221 CYLINDER; stainless steel 1
12 184–513
HOUSING, ball, piston; carbon steel 1
13* 100–279
BALL, piston; chrome steel;
0.875” (22.2 mm) dia. 1
Ref Part
No. No. Description Qty
14 222–951 HOUSING, seat, piston valve;
stainless steel w/tungsten carbide seat 1
15* 108–001
BALL, intake; stainless steel;
1.5” (38.1 mm) dia. 1
16 190–218
HOUSING, intake; ductile iron 1
17 237–495 VAL
VE, intake; ductile iron
w/tungsten carbide seat 1
20 101–754
PLUG, pipe, socket hd; 3/8 npt 1
27 190–217
GUIDE, intake ball; carbon steel 1
28* 164–782 O-RING; r1
29 112–921 SCREW
, cap, hex hd; 5/8–11 unc–2a;
10.5” (266.7 mm) long 6
* These parts are included in Standard Repair Kit 237–166
and Conversion Kits 237–167 and 237–168, which may
be purchased separately . See page 20.
Y Replacement Danger and W arning labels, tags and cards
are available at no cost.
PTFE
PTFE

 
Repair Kits
Standard Repair Kit 237–166
(Leather Packings and  Backup)
Ref Part
No. No. Description Qty
3* 109–306 V-PACKING;
2
4* 184–201
GLAND, female; carbon steel 2
5* 184–306 V-P
ACKING; leather 8
6* 184–251
GLAND, male; carbon steel 2
Kit also includes items 10, 13, 15, and 28 (see page 19).
THROAT P ACKINGS:
LIPS F ACE DOWN
PISTON PACKINGS:
LIPS F ACE UP
0805
0806
*5
*4
3*
*4
*5
3*
*6
*6
LUBRICA TE P ACKINGS
Packing Conversion Kit 237–167
( Packings)
Ref Part
No. No. Description Qty
3* 109–306 V-PACKING;
10
4* 184–201
GLAND, female; carbon steel 2
6* 184–251
GLAND, male; carbon steel 2
Kit also includes items 10, 13, 15, and 28 (see page 19).
THROAT P ACKINGS:
LIPS F ACE DOWN
PISTON PACKINGS:
LIPS F ACE UP
0805
0806
*3
*4
*4
*3
*6
*6
LUBRICA TE P ACKINGS
Packing Conversion Kit 237–168
(UHMWPE and Leather Packings)
Ref Part
No. No. Description Qty
3* 109–256 V-PACKING; UHMWPE 6
4* 184–201
GLAND, female; carbon steel 2
5* 184–306 V-P
ACKING; leather 4
6* 184–251
GLAND, male; carbon steel 2
Kit also includes items 10, 13, 15, and 28 (see page 19).
THROAT P ACKINGS:
LIPS F ACE DOWN
PISTON PACKINGS:
LIPS F ACE UP
0805
0806
*4
*4
*3 5*
*6
*6
LUBRICA TE P ACKINGS
*3 5*
PTFE
PTFE
PTFE
PTFE