Graco Dura-Flo 1800 Series Operation manual

Instructions – Parts List
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for List of Models and Table of
Contents.
Part No. 222837 Shown
308147Y
ENG
CARBON STEEL
Dura-Flot1800 Pumps
With Severe–Duty Rod and Cylinder

2 308147
List of Models
Pump Part No.
and Series Pump Model Ratio Maximum Fluid Working Pressure Maximum Air Input Pressure (or
Hydraulic Input
Pressure*)
222837,
Series A Kingt28:1 19.3 MPa, 193 bar (2800 psi) 0.7 MPa, 7 bar (100 psi)
222891,
Series B Quiet Kingt28:1 19.3 MPa, 193 bar (2800 psi) 0.7 MPa, 7 bar (100 psi)
237555,
Series B Premiert45:1 31 MPa, 310 bar (4500 psi) 0.7 MPa, 7 bar (100 psi)
241490,
Series A Premiert45:1 31 MPa, 310 bar (4500 psi) 0.7 MPa, 7 bar (100 psi)
233127,
Series A Premiert45:1 31 MPa, 310 bar (4500 psi) 0.7 MPa, 7 bar (100 psi)
233128,
Series A Premiert45:1 31 MPa, 310 bar (4500 psi) 0.7 MPa, 7 bar (100 psi)
222892,
Series B Viscountr–– 18 MPa, 179 bar (2600 psi) 10 MPa, 103 bar (1500 psi)*
Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air-Powered Pumps 8. . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic-Powered Pumps 10. . . . . . . . . . . . . . . . . .
Operation/Maintenance 12. . . . . . . . . . . . . . . . . . . . . . . .
All Pumps 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air-Powered Pumps 13. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic-Powered Pumps 14. . . . . . . . . . . . . . . . . .
Troubleshooting Chart 16. . . . . . . . . . . . . . . . . . . . . . . . .
Service 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting the Displacement Pump 17. . . . . . .
Reconnecting the Displacement Pump 18. . . . . . . .
Displacement Pump Service 20. . . . . . . . . . . . . . . .
Parts 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Assemblies 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pumps 29. . . . . . . . . . . . . . . . . . . . . . .
Packing Conversion Kits 30. . . . . . . . . . . . . . . . . . . .
Technical Data 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layouts 37. . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information NO TAG. . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.

308147 3
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 not sure, 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 pages 32–35 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 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.

4 308147
WARNING
SKIN INJECTION HAZARD
Spray from the gun, 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 at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip.
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.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DBe sure the gun trigger safety operates before spraying.
DLock the gun trigger safety when you stop spraying.
DFollow the Pressure Relief Procedure on page 12 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
Do not repair high pressure couplings; you must replace the entire hose.
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 12 to prevent the
equipment from starting unexpectedly.

308147 5
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. Refer to Grounding on page 6.
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.
DKeep the spray area free of debris, including solvent, rags, and gasoline.
DElectrically disconnect all equipment in the spray area.
DExtinguish all open flames or pilot lights in the spray area.
DDo not smoke in the spray area.
DDo not turn on or off any light switch in the spray area while operating or if fumes are present.
DDo not operate a gasoline engine in the spray 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.

6 308147
Installation
(ALL PUMPS)
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE OR EXPLOSION HAZ-
ARD on page 5.
Fig. 1 TI1052
Y
Z
Fig. 2
W
X
Y
Z
0864
1. King Pumps: use a ground wire and clamp. See
Fig. 1. Remove the ground screw (Z) and insert
through eye of ring terminal at the end of ground
wire (Y). Fasten ground screw back onto pump
and tighten securely. Connect the other end of
ground wire to a true earth ground. Order Part No.
222011 Ground Wire and Clamp.
All Other Pumps: use a ground wire and clamp.
See Fig. 2. 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. Connect the other
end of the wire to a true earth ground. Order Part
No. 237569 Ground Wire and Clamp.
2. Air, hydraulic, and fluid hoses: use only electrically
conductive hoses.
3. Air compressor or hydraulic power supply: follow
manufacturer’s recommendations.
4. Spray gun: ground through connection to a prop-
erly grounded fluid hose and pump.
5. Fluid supply container: follow your local code.
6. Object being sprayed: follow your local code.
7. Solvent pails used when flushing: follow 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 continu-
ity.
8. To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray
gun firmly to the side of a grounded metal pail,
then trigger the gun.

308147 7
Notes

8 308147
Installation
(AIR-POWERED PUMPS)
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
Fig. 3 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.
Assembling Models 237555, 233127, and
233128
If you have Models 237555, 233127, or 233128
Pumps, assemble the displacement pump (105) to the
Premier air motor (101) as instructed on page 18.
Fig. 3
KEY
APump
BWall Bracket
CPump Runaway Valve
DAir Line Lubricator
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
MFluid Drain Valve (required)
NElectrically Conductive Fluid Supply Hose
PFluid Whip Hose
RGun/Valve Swivel
SAirless Spray Gun
or Dispensing Valve
TDrum Suction Kit
YGround Wire (required; see page 6
for installation instructions)
A
B
C
D
E
F
G
H
JK
MN
P
Y
MAIN AIR LINE
200 LITER (55 GAL.) DRUM
L
R
S
T
TYPICAL INSTALLATION
0626C

308147 9
Installation
(AIR-POWERED PUMPS)
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.
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.
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/valve (S) to allow freer gun/valve
movement.
Mounting Accessories
WARNING
For Model 222939 Premier Pump, do not lift the
pump by the lift ring when the total weight exceeds
550 lb (250 kg).
Mount the pump (A) to suit the type of installation
planned. Fig. 3 illustrates a wall-mounted system.
Pump dimensions and the mounting hole layout are
shown on pages 36 and 37.
If you are using an elevator or a cart, refer to the
separate manuals supplied with those components for
installation and operation instructions.
Air Line Accessories
Install the following accessories in the order shown in
Fig. 3, 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 above). Be sure the bleed valve is eas-
ily accessible from the pump, and is located
downstream from the air regulator.
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 swivel air inlet. It
mounts to a wall bracket, and provides ports for
connecting lines to air-powered accessories.
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 positions shown
in Fig. 3, 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 or valve (S) dispenses the fluid. The gun
shown in Fig. 3 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 200 liter (55 gallon) drum.

10 308147
Installation
(HYDRAULIC-POWERED PUMPS)
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
distributor. If you supply your own accessories, be sure
they are adequately sized and pressure-rated to meet
the system’s requirements.
Fig. 4 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.
CAUTION
It is very important to keep the hydraulic supply
system clean at all times. Be sure that all hydraulic
fluid lines are absolutely clean. Blow out the lines
with air and flush thoroughly with solvent before
connecting to the hydraulic motor, to avoid introduc-
ing harmful contaminants into the motor. Plug the
hydraulic lines immediately when they are discon-
nected.
Do not exceed 37.8 liter/min (10 gpm) hydraulic oil
volume to the motor, to avoid stalling the pump.
For optimum pump performance, keep the tempera-
ture of the hydraulic oil below 54_C (130_F).
Fig. 4 0627B
KEY
APump
BWall Bracket
CHydraulic Supply Line
DHydraulic Return Line
EDrain Line (from pressure reducing valve)
FPressure Gauge
GFlow Control Valve
HPressure Reducing Valve
JAccumulator
KDrain Line (from motor drip pan)
LFluid Filter
MFluid Drain Valve (required)
NElectrically Conductive Fluid
Supply Hose
PFluid Whip Hose
RGun/Valve Swivel
SAirless Spray Gun or Dispensing Valve
TDrum Suction Kit
UHydraulic Supply Line Shutoff Valve
VHydraulic Return Line Shutoff Valve
YGround Wire (required, see page 6 for
installation instructions)
AA Hydraulic Return Line Filter
A
B
D
E
F
G
HJ
K
M
N
P
Y
200 LITER
(55 GAL.)
DRUM
L
R
S
T
U
C
V
HYDRAULIC
POWER SUPPLY
DRAINAGE
CONTAINER
AA
TYPICAL INSTALLATION

308147 11
Installation
(HYDRAULIC-POWERED PUMPS)
SYSTEM ACCESSORIES
WARNING
A fluid drain valve (M) is required in your system.
This accessory helps reduce the risk of serious
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 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.
Mounting Accessories
Mount the pump (A) to suit the type of installation
planned. Fig. 4 illustrates a wall-mounted system.
Pump dimensions and the mounting hole layout are
shown on pages 36 and 37.
Filters
Be sure your hydraulic power supply is equipped with a
suction filter to the hydraulic pump and a system return
line filter (AA) of 10 micron size.
Carefully follow the manufacturer’s recommendations
on reservoir and filter cleaning, and periodic changes
of hydraulic fluid. Use only Graco-approved hydraulic
oil. Order Part No. 169236, 5 gal. (19 liter) or 207428,
1 gal. (3.8 liter). Do not substitute a lower grade oil or
one with a lower flash point.
Hydraulic Lines
The motor has a 3/4 npt(f) hydraulic oil supply fitting,
and a 1 in. npt(f) hydraulic oil return fitting. Use a
minimum 13 mm (1/2 in.) ID hydraulic supply line, and
a minimum 22 mm (7/8 in.) ID return line.
On the hydraulic supply line (C), install the following
accessories in the order shown in Fig. 4, using adapt-
ers as necessary:
DAshutoff valve (U) isolates the pump for service.
DA fluid pressure gauge (F) to monitor hydraulic
oil pressure to the motor and to avoid overpressur-
izing the motor or displacement pump, and a pres-
sure- and temperature-compensated flow con-
trol valve (G) to prevent the motor from running
too fast and possibly damaging itself.
DA pressure reducing valve (H), with a drain line
(E) run directly to the hydraulic return line (D).
DAn accumulator (J) to reduce the hammering ef-
fect caused by the motor reversing direction.
DAshutoff valve (V) isolates the pump for service.
DAfilter (AA) of 10 micron size.
Hydraulic Motor Drip Pan
The hydraulic motor has a drip pan to collect any
leakage. Connect a 6 mm (1/4 in.) ID drain line (K) to
the barbed fitting on the drip pan, and place the free
end in a container to receive the drainage.
Fluid Supply Hoses
Be sure all fluid supply 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/valve (S) to allow freer gun/valve movement.
Fluid Line Accessories
Install the following accessories in the positions shown
in Fig. 4, 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 or valve (S) dispenses the fluid. The gun
shown in Fig. 4 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 200 liter (55 gallon) drum.

12 308147
Operation/Maintenance
(ALL PUMPS)
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. 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:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray tips.
1. Lock the gun/valve trigger safety.
2. Shut off the air or hydraulic supply to the pump.
3. In air-powered systems, close the bleed-type
master air valve (required in your system).
In hydraulic-powered systems, close the hydraulic
supply line valve first, then the return line valve.
4. Unlock the gun/valve safety latch.
5. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and trigger the gun/valve to
relieve pressure.
6. Lock the gun trigger safety.
7. Open the drain valve (required in your system)
and/or the pump bleeder valve, 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 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 or hose.
Packing Nut/Wet-Cup
Fill the packing nut/wet-cup (3) 1/3 full with Graco
Throat Seal Liquid (TSL) or compatible solvent. See
Fig. 5. Using the supplied wrench (104), adjust the
packing nut weekly so it is just snug; do not overtigh-
ten. Follow the Pressure Relief Procedure at left.
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 5 before flushing, and
follow all recommendations given there.
Fig. 5
0566C
3
34, 35
104
Model 222837
Shown
1Bleed hole must
face down.
1

308147 13
Operation/Maintenance
(AIR-POWERED PUMPS)
Starting and Adjusting the Pump
1. Refer to Fig. 3 on page 8. 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/dispensing valve (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/valve trigger and lock the trigger safety
latch. The pump should stall against pressure
when the trigger is released.
WARNING
SKIN INJECTION HAZARD
To reduce the risk of fluid injection, do not use your
hand or fingers to cover the bleed hole on the
underside of the bleeder valve body (34) when
priming the pump. Use a crescent wrench to open
and close the bleeder plug (35). Keep your hands
away from the bleed hole.
4. If the pump fails to prime properly, open the
bleeder valve (35) slightly. Use the bleed hole on
the underside of the valve body (34) as a priming
valve until the fluid appears at the hole. See Fig. 5.
Close the plug (35).
NOTE: When changing fluid containers with the hose
and gun already primed, open the bleeder valve plug
(35), to assist in priming the pump and venting air
before it enters the hose. Close the bleeder 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/valve 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/nozzle and
pump wear.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of overpressurizing
your system, which could cause compo-
nent rupture and serious injury, never
exceed the specified Maximum Incoming Air Pres-
sure to the pump (see the Technical Data on
pages 32–35).
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. 3 on page 8.
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 12.
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.

14 308147
Operation/Maintenance
(HYDRAULIC-POWERED PUMPS)
Starting and Adjusting the Pump
1. Refer to Fig. 4 on page 10. Connect the suction kit
(T) to the pump’s fluid inlet, and place the tube into
the fluid supply.
2. Check the hydraulic fluid level before each use,
and add fluid as necessary.
3. Make certain that the supply line shutoff valve (U)
and the return line shutoff valve (V) are closed.
4. Start the hydraulic power supply.
5. Hold a metal part of the gun/valve (S) firmly to the
side of a grounded metal pail and hold the trigger
open.
6. Open the return line shutoff valve (V) first, then
slowly open the supply line shutoff valve (U).
7. Cycle the pump slowly until all air is pushed out
and the pump and hoses are fully primed. Release
the gun/valve trigger and engage the safety latch.
The pump should stall against pressure when the
trigger is released.
WARNING
SKIN INJECTION HAZARD
To reduce the risk of fluid injection, do not use your
hand or fingers to cover the bleed hole on the
underside of the bleeder valve body (34) when
priming the pump. Use a crescent wrench to open
and close the bleeder plug (35). Keep your hands
away from the bleed hole.
8. If the pump fails to prime properly, open the
bleeder valve (35) slightly. Use the bleed hole, on
the underside of the body (34), as a priming valve
until the fluid appears at the hole. See Fig. 5.
Close the plug (35).
NOTE: When changing fluid containers with the hose
and gun already primed, open the bleeder valve plug
(35), to assist in priming the pump and venting air
before it enters the hose. Close the bleeder valve
when all air has been eliminated.
9. With the pump and lines primed, and with ade-
quate hydraulic volume supplied, the pump will
start and stop as the gun/valve is opened and
closed. In a circulating system, the pump will
speed up or slow down on demand, until the
hydraulic power supply is shut off.
10. Use the fluid pressure gauge (F) and flow control
valve (G) to control the pump speed and the fluid
outlet pressure. Always use the lowest hydraulic
flow and pressure necessary to get the desired
results. Higher pressures cause premature tip/noz-
zle and pump wear.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of overpressurizing
your system, which could cause compo-
nent rupture and serious injury, never
exceed 10 MPa, 103 bar (1500 psi) Maximum Hy-
draulic Input Pressure to the pump, or 140 bar
(2000 psi) Maximum Fluid Working Pressure (see
the Technical Data on page 35).
To prevent overpressurizing the hydraulic motor or
its seals, always shut off the supply line valve (U)
first, then shut off the return line valve (V).
CAUTION
Do not allow the hydraulic oil temperature to exceed
54_C (130_F). The pump seals will wear faster and
leakage may occur if the pump is operated at higher
oil temperatures.
11. 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. 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.

308147 15
Operation/Maintenance
(HYDRAULIC-POWERED PUMPS)
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 12.
For overnight shutdown, relieve the pressure on page
12. Stop the pump at the bottom of the 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.

16 308147
Troubleshooting Chart
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
1. Relieve the pressure.
2. Check all possible causes and problems before
disassembling the pump.
PROBLEM CAUSE SOLUTION
Pump fails to operate Restricted line or inadequate air/hydraulic
supply; closed or clogged valves Clear; increase air/hydraulic 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.
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 out-
put low on both strokes Restricted line or inadequate air/hydraulic supply; closed or clogged valves Clear; increase air/hydraulic 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.
Bleeder valve open Close.
Fluid too heavy for pump priming Use bleeder valve (see pages 13 and 14); use ram.
Worn packings in displacement pump Replace packings.
Pump operates, but out-
put low on downstroke Held open or worn intake valve Clear valve; service.
Fluid too heavy for pump priming Use bleeder valve (see pages 13 and 14); use ram.
Pump operates, but out-
put low on upstroke Held open or worn piston valve or packings. Clear valve; replace packings.
Erratic or accelerated
pump speed Exhausted fluid supply Refill and prime.
Fluid too heavy for pump priming Use bleeder valve (see pages 13 and 14); use ram.
Held open or worn piston valve or packings. Clear valve; replace packings.
Held open or worn intake valve Clear valve; service.
*To determine if the fluid hose or gun is obstructed, relieve the pressure. Disconnect the fluid hose and place a
container at the pump fluid outlet to catch any fluid. Turn on the air/hydraulic power just enough to start the pump. If
the pump starts when the air/hydraulic power is turned on, the obstruction is in the fluid hose or gun.

308147 17
Service
Required Tools
DSet of socket wrenches
DSet of adjustable wrenches
D24 in. adjustable wrench
DTorque wrench
DRubber mallet
DArbor press
DSoft wooden block (approx. 1 square foot in size)
DLarge vise, with soft jaws
DThread lubricant
DAnti-seize lubricant 222955
DLoctiteR2760tor equivalent
NOTE: Service Tool 109507 is available as an acces-
sory. The tool fits over the top of the displacement rod,
making it easier to apply a 24 inch adjustable wrench
or 3/4 in. drive socket when connecting or disconnect-
ing the rod from the piston assembly.
Disconnecting the Displacement Pump
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
1. Flush the pump, if possible. Stop the pump at the
bottom of its stroke. Relieve the pressure.
2. Disconnect the air or hydraulic hose. Plug all
hydraulic hoses immediately, to prevent contami-
nation of the hydraulic system. Hold the fluid outlet
fitting (4) with a wrench to keep it from being
loosened while you disconnect the fluid hose.
WARNING
For Model 222939 Premier Pump, do not lift the
pump by the lift ring when the total weight exceeds
550 lb (250 kg).
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 to the air or
hydraulic inlet 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 causing
injury or property damage. Do this by securely brac-
ing the pump, or by having at least two people hold it
while another disconnects it.
4. Using adjustable wrenches, unscrew the coupling
nut (103) from the connecting rod adapter (102).
Remove the coupling collars (108). Take care not
to lose or drop them. See Fig. 6.
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 20 for displacement pump service.
To service the air or hydraulic motor, refer to the
separate motor manual, supplied.

18 308147
Service
Reconnecting the Displacement Pump
WARNING
To reduce the risk of pinching or injuring hands or
fingers caught between the hydraulic motor drip
pan and the coupling nut, always use connecting
rod adapter 184595 and tie rods 184596 on
Model 222892 Viscount Pump. Never use con-
necting rod adapter 184451 and tie rods 184452
on Model 222892; those parts do not allow
sufficient clearance between the drip pan and
coupling nut.
NOTE: On Premier models, ensure that the rod adapt-
er (102) has not loosened during maintenance. Proper
torque is necessary to prevent the rod adapter from
loosening during the pump operation.
If the rod adapter (102) has loosened during mainte-
nance, remove the adapter and apply LoctiteR2760t
(or equivalent) to the rod adapter and air motor piston
threads, and then torque as specified in Fig. 6.
1. Screw the connecting rod adapter (102) to the air
motor shaft. Torque as specified in Fig. 6.
2. Screw the tie rods (107) into the air motor (101).
Using a wrench on the tie rod flats, torque as
specified.
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
outlet to the air or hydraulic inlet 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 as noted in Fig. 6.
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. Torque as noted in Fig. 6.
7. Torque the packing nut (3) to 135–169 NSm
(100–125 ft-lb).
8. Reconnect all hoses. Reconnect the ground wire if
it was disconnected. Fill the wet-cup (3) 1/3 full of
Graco Throat Seal Liquid or compatible solvent.
9. Turn on the air or hydraulic power supply. On
hydraulic pumps, open the hydraulic return line
valve first, then the supply line valve. Run the
pump slowly to ensure that it operates properly.

308147 19
Service
Fig. 6
3
108
101
106
1
0567C
105
4
104
107
102
King, Bulldog, and Viscount Pumps
(Model 222837 Shown)
103
1
2
3
4
Torque to 196–210 NSm (145–155 ft-lb)
Torque to 135–169 NSm (100–125 ft-lb)
Torque to 129–142 NSm (95–105 ft-lb)
1
1
2
3
3
Square hole is for use with torque wrench.
4
Premier Pumps
(Model 237555 Shown)
105
104
106
108
102
107
103
01397C
Torque to 129–142 NSm (95–105 ft-lb)
Torque to 312–340 NSm (230–250 ft-lb)
5
6
4
3 2
5
5
6
6
4
101
1
Apply LoctiteR2760t(or equivalent) to threads.
7
7

20 308147
Service
DISPLACEMENT PUMP SERVICE
Disassembly
When disassembling the pump, lay out all the removed
parts in sequence, to ease reassembly. Clean all parts
with a compatible solvent and inspect them for wear or
damage. Refer to Fig. 7.
NOTE: Repair Kits are available to replace the throat
(T) and piston (P) packings, and to replace the o-rings
and cylinder seals. For the best results, use all the new
parts in the kit. Kit parts are marked with an asterisk,
for example (11*). These kits can also be used to
convert the pump to different packing materials. Refer
to pages 29 and 30.
1. Stand the displacement pump upright in a large
vise. Loosen, but do not remove, the packing nut
(3). Remove the six long cap screws (20), using a
socket wrench.
2. Lift the outlet housing (19) straight up off the
pump. Be careful not to scratch the displacement
rod (1) while removing the housing.
3. Lift the cylinder (7), displacement rod (1), and
piston assembly off the intake housing (17).
4. Remove the seal (6), ball guide (14), intake ball
(16), intake seat housing (15), and o-ring (27) from
the intake housing (17). Inspect the ball (16) and
the ball seat (A) on the housing (15) for wear or
damage.
5. Remove the seal (6) from the bottom of the outlet
housing (19). Unscrew the packing nut (3). Re-
move the glands and v-packings (T) from the
housing. Do not remove the outlet fitting (4) and
o-ring (5) unless they need replacement.
6. Unscrew the handle of the bleeder valve plug (35)
completely from the valve body (34). Clean the
valve threads and the bleed hole. It is not neces-
sary to remove the valve housing from the pump
outlet housing (19).
7. Stand the cylinder (7) upright on a wooden block.
Using a rubber mallet or an arbor press, drive the
displacement rod (1) and piston assembly down
into the cylinder as far as possible, then place the
cylinder on its side and continue to drive the rod
out the bottom until the piston comes free. Pull the
rod and piston from the cylinder, being careful not
to scratch the rod or cylinder.
CAUTION
To reduce the possibility of costly damage to the rod
(1) and cylinder (7), always use a rubber mallet or an
arbor press to drive the rod out of the cylinder. Be
sure to place the cylinder on a soft block of wood.
Never use a hammer to drive the rod.
NOTE: Service Tool 109507 is available as an acces-
sory. The tool fits over the top of the displacement rod
(1), making it easier to apply a 24 inch adjustable
wrench or 3/4 in. drive socket when disconnecting the
rod from the piston assembly.
8. Put the flats of the piston seat housing (12) in a
vise. Unscrew the rod (1) from the housing (12),
leaving the ball guide (9) assembled to the rod. Be
careful to catch the piston ball (10) as you sepa-
rate the housing (12) and ball guide (9), so that it
doesn’t fall and suffer damage.
9. Remove the glands and v-packings (P) from the
piston seat housing (12). Inspect the ball (10) and
ball seat (B) on the housing (12) for wear or dam-
age.
10. Inspect the outer surface of the displacement rod
(1) and the inner surface of the cylinder (7) for
scoring or wear; replace either part if necessary. If
the rod is being replaced, remove the ball guide (9)
as explained in step 11.
NOTE: Do not remove the ball guide (9) from the
displacement rod (1) unless either part is damaged.
11. Place the flats of the ball guide (9) in a vise. Using
a 24 in. adjustable wrench or 3/4 in. drive socket,
unscrew the rod (1) from the ball guide.