Graco Dura-Flo 1200 User manual

308360D
EN
Instructions
Dura-Flo®1200 Pumps
Stainless Steel
For dispensing non-corrosive and non-abrasive oils and lubricants only. For professional
use only.
237516 Pump, Series A, 21:1 Ratio,
with Bulldog®Air Motor
2100 psi (14.5 MPa, 145 bar) Maximum Fluid Working
Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Input Working
Pressure
237517 Pump, Series A, 13:1 Ratio,
with Senator®Air Motor
1300 psi (9 MPa, 90 bar) Maximum Fluid Working
Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Working
Pressure
See page 24 for model information, including maximum
working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.
04140
04143
Model 237517
Model 237516
II 2 G

2 308360D
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Flush Before Using Equipment . . . . . . . . . . . . . . 6
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure. . . . . . . . . . . . . . . . . . 8
Flush the Equipment . . . . . . . . . . . . . . . . . . . . . . 8
Packing Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Start and Adjust the Pump . . . . . . . . . . . . . . . . . . 9
Shutdown and Care for the Pump . . . . . . . . . . . 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disconnect the Displacement Pump. . . . . . . . . . 12
Connect the Displacement Pump . . . . . . . . . . . . 12
Disassemble the Displacement Pump . . . . . . . . 14
Assemble the Displacement Pump. . . . . . . . . . . 16
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Packing Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 22
Model 237516 Bulldog Pump . . . . . . . . . . . . . . . 22
Model 237517 Senator Pump. . . . . . . . . . . . . . . 22
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Mounting Hole Layout. . . . . . . . . . . . . . . . . . . . . 23
Technical Specifications . . . . . . . . . . . . . . . . . . . . 24
California Proposition 65 . . . . . . . . . . . . . . . . . . . . 25
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 26
Related Manuals
Manual in
English Description
311827 Dura-Flo Lowers
307049 Bulldog Air Motor
307592 Senator and Quiet Senator Air Motors

Warnings
308360D 3
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.
WARNING
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 Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) 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
manufacturer’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.
SKIN INJECTION HAZARD
High-pressure fluid from gun, 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 surgical treatment.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying 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.

Warnings
4 308360D
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.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
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.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read Safety Data Sheets (SDSs) to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
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.
WARNING

Installation
308360D 5
Installation
Grounding
Pump: use ground wire and clamp (supplied). Loosen
grounding lug locknut (LL) and washer (LW). Insert one
end of a 1.5 mm2(12 ga) minimum ground wire end
(GW) into lug (LS) slot and tighten locknut securely.
Connect ground clamp to a true earth ground. Order
part 237569 ground wire and clamp.
Air and fluid hoses: use only electrically conductive
hoses. Check electrical resistance of hoses. If total
resistance to ground exceeds 29 megaohms, replace
hose immediately.
Air compressor: follow manufacturer’s
recommendations.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Fluid supply container: follow local code.
Object being sprayed: follow local code.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a nonconductive
surface, such as paper or cardboard, which interrupts
grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray
gun/dispense valve firmly to the side of a grounded
metal pail, then trigger the gun/valve.
Accessories
Install the following accessories in the order shown in
FIG. 1, page 7, using adapters as necessary. Contact
your Graco representative or Graco Technical
Assistance for assistance in designing a system to suit
your needs.
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. 1, page 7, illustrates a wall mount system.
See Dimensions and Mounting Hole Layout, page 23.
If you are using a floor stand, refer to its separate
manual for installation and operation instructions.
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes to
ignite or explode. Grounding provides an escape wire
for the electric current.
LW
LS
LL
GE

Installation
6 308360D
Air Line
•Air line lubricator (D): provides automatic air
motor lubrication.
•Bleed-type master air valve (E): required in your
system to relieve air trapped between it and the air
motor when the valve is closed.
NOTE: Be sure the valve is easily accessible from the
pump and located downstream from the air regulator.
•Air regulator (F): controls pump speed and outlet
pressure by adjusting the air pressure to the pump.
NOTE: Locate the regulator close to the pump, but
upstream from the bleed-type master air valve.
•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.
•Air manifold (G): has a 3/4 npsm(f) swivel air inlet.
It mounts to the pump support bracket, and provides
ports for connecting lines to air-powered
accessories.
•Air line filter (J): removes harmful dirt and moisture
from the compressed air supply. Also, install a drain
valve (W) at the bottom of each air line drop, to
drain off moisture.
•Second bleed-type air valve (K): isolates the air
line accessories for servicing.
NOTE: Locate upstream from all other air line
accessories.
Fluid Line
•Fluid filter (L): with a 60 mesh (250 micron)
stainless steel element to filter particles from the
fluid as it leaves the pump.
•Fluid drain valve (M): required in your system, to
relieve fluid pressure in the hose and gun.
•Gun (S): to dispense fluid.
NOTE: The gun shown in FIG. 1, page 7, is an airless
spray gun for light to medium viscosity fluids.
•Fluid line swivel (R): for easier gun movement.
•Suction kit (T): enables the pump to draw fluid from
a container.
Flush Before Using Equipment
The equipment was tested with lightweight oil, which is
left in the fluid passages to protect parts. To avoid
contaminating your fluid with oil, flush the equipment
with a compatible solvent before using the equipment.
See Flush the Equipment, page 8.
Trapped air can cause the pump to cycle
unexpectedly, which could result in serious injury from
splashing or moving parts.
NOTICE
To prevent intake valve damage, always apply PTFE
tape to the female threads of the intake valve before
connecting a suction hose or fitting to the intake.

Installation
308360D 7
Typical Installation
FIG. 1: Typical Installation
K
J
Main Air Line
Y
A
B
L
N
M
T
W
S
R
P
H
CG
F
E
D
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
P Fluid whip hose
R Gun swivel
S Airless spray gun
T Suction kit
Y Ground wire and clamp (required, see
Grounding, page 5, for installation instructions)
W Air line drain valve
Key:

Operation
8 308360D
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Engage trigger lock.
2. Shut off the air supply to the pump.
3. Close the bleed-type master air valve.
4. Disengage the trigger lock.
5. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
6. Engage the trigger lock.
7. Open all fluid drain valves in the system, having a
waste container ready to catch drainage. Leave
drain valve(s) open until you are ready to spray
again.
8. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved:
a. VERY SLOWLY loosen the tip guard retaining
nut or the hose end coupling to relieve pressure
gradually.
b. Loosen the nut or the coupling completely.
c. Clear the obstruction in the hose or tip.
Flush the Equipment
• Flush before fluid can dry in the equipment, at the
end of the day, before storing, and before repairing
equipment.
• Flush at the lowest pressure possible. Check
connectors for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted parts.
1. Perform Pressure Relief Procedure, page 8.
2. Remove spray tip from the gun.
3. Hold a metal part of the gun firmly to a grounded
metal pail.
4. Start the pump.
5. Trigger the gun until clean solvent dispenses.
6. Perform Pressure Relief Procedure, page 8.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
To avoid fire and explosion, always ground equipment
and waste container. To avoid static sparking and
injury from splashing, always flush at the lowest
possible pressure.

Operation
308360D 9
Packing Nut
Before starting, fill the packing nut (2) 1/3 full with Graco
Throat Seal Liquid (TSLTM) or compatible solvent.
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:
1. Perform the Pressure Relief Procedure, page 8.
2. Torque the packing nut (2) to 136-149 N•m
(100-110 ft-lb) with the supplied wrench (110).
NOTE: Do not overtighten the packing nut.
Start and Adjust the Pump
1. Connect the suction kit (T) to the pump fluid inlet.
Place the tube into the fluid supply.
2. Close the air regulator (F).
3. Open the pump bleed-type master air valve (E).
4. Hold a metal part of the gun (S) firmly to the side of
a grounded metal pail and hold the trigger open.
5. Slowly open the regulator until the pump starts.
6. Cycle the pump slowly until all air is pushed out and
the pump and hoses are fully primed.
7. Release the gun trigger, engage the trigger safety
lock. The pump should stall against pressure.
8. 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. Close the valve.
NOTE: When changing fluid containers with the hose
and gun already primed, open the drain valve (M) to
help prime the pump and vent air before it enters the
hose. Close the drain valve when all air is eliminated.
9. With the pump and lines primed, and with adequate
air pressure and volume supplied, the pump will
start and stop as you open and close the gun. In a
04143
Model 237516
Shown
110
2
Torque to
136-149 N•m
(100-110 ft-lb)
1
1
NOTICE
To prevent intake valve damage, always apply PTFE
tape to the female threads of the intake valve before
connecting a suction hose or fitting to the intake.
To reduce the risk of over-pressurizing your system,
which could cause rupture and serious injury, never
exceed the specified Maximum Air Input Pressure to
the pump (see Technical Specifications, pages
24-25).
NOTICE
Do not allow the pump to run dry. It will quickly
accelerate to a high speed, causing damage. If your
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.

Operation
10 308360D
circulating system, the pump will speed up or slow
down on demand, until the air supply is shut off.
10. Use the air regulator (F) to control pump speed and
fluid pressure.
Shutdown and Care for the
Pump
1. Follow the Pressure Relief Procedure, page 8.
2. Follow Flush the Equipment, page 8.
NOTICE
Always use the lowest air pressure necessary to get
the desired results. Higher pressures cause
premature tip and pump wear.
NOTICE
Always flush the pump before the fluid dries on the
displacement rod and causes damage.
NOTICE
For overnight shutdown, stop the pump at the bottom
of its stroke to prevent fluid from drying on the
exposed displacement rod and damaging the throat
packings.