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