Graco Dura-Flo 1800 Technical reference manual

Instructions - Parts
Dura-Flo™Lowers
Carbon Steel or Stainless Steel Lowers, with Severe-Duty Rod and Cylinder. For use on
Graco pumps, sprayers and fluid handling systems. For professional use only.
Dura-Flo 1800 (430 cc) Lowers
Dura-Flo 2400 (580 cc) Lowers
See page 3 for model information, including maximum working pressure.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
TI8341a
311825L
EN

2311825L
Contents
Models ...................................3
Warnings .................................4
Repair ....................................6
Pressure Relief Procedure .................6
Required Tools ..........................6
Disassembly ............................7
Reassembly ............................8
Parts ....................................11
Dura-Flo 1800 (430 cc) Lowers .............12
Dura-Flo 2400 (580 cc) Lowers .............14
Repair Kits ...............................16
UHMWPE and PTFE Packings .............16
PTFE and Leather Packings ...............17
PTFE Packings .........................18
UHMWPE and Leather Packings ...........19
Dimensions ..............................21
Technical Data ............................21
Graco Standard Warranty ...................22
GracoInformation .........................22

Models
311825L 3
Models
Lower Part
No. and
Series Description Packings
Maximum Fluid
Working Pressure
222796, A Dura-Flo 1800 (430 cc) carbon steel 3 PTFE/2 leather 32 MPa (324 bar, 4700 psi)
24W644 Dura-Flo 1800 (430 cc) carbon steel 3 UHMWPE/2 PTFE 32 MPa (324 bar, 4700 psi)
222988, A Dura-Flo 1800 (430 cc) carbon steel 5 PTFE 32 MPa (324 bar, 4700 psi)
222805, A Dura-Flo 1800 (430 cc) stainless steel 3 UHMWPE/2 PTFE 32 MPa (324 bar, 4700 psi)
241956, A Dura-Flo 1800 (430 cc) stainless steel 3 UHMWPE/2 PTFE 32 MPa (324 bar, 4700 psi)
246925, A Dura-Flo 1800 (430 cc) stainless steel 3 UHMWPE/2 leather 32 MPa (324 bar, 4700 psi)
246987, A Dura-Flo 1800 (430 cc) stainless steel 4 leather, 3 UHMWPE throat/
3 UHMWPE, 2 leather piston
32 MPa (324 bar, 4700 psi)
246988, A Dura-Flo 1800 (430 cc) stainless steel 4 leather, 3 UHMWPE throat/
3 UHMWPE, 2 leather piston
32 MPa (324 bar, 4700 psi)
249992, A Dura-Flo 1800 (430 cc) stainless steel 4 leather, 3 UHMWPE throat/
3 UHMWPE, 2 UHMWPE piston
32 MPa (324 bar, 4700 psi)
687055, A Dura-Flo 1800 (430 cc) stainless steel 3 UHMWPE/2 carbon-filled PTFE 32 MPa (324 bar, 4700 psi)
C59703, A Dura-Flo 1800 (430 cc) stainless steel 3 UHMWPE/2 PTFE 32 MPa (324 bar, 4700 psi)
L430CM Dura-Flo 1800 (430 cc) carbon steel 4 leather, 3 UHMWPE throat/
3UHMWPE, 2 leather piston
32 MPa (324 bar, 4700 psi)
L430CS, A Dura-Flo 1800 (430 cc) carbon steel 3 UHMWPE/2 PTFE 32 MPa (324 bar, 4700 psi)
L430SS, A Dura-Flo 1800 (430 cc) stainless steel 3 UHMWPE/2 PTFE 32 MPa (324 bar, 4700 psi)
L430SM, A Dura-Flo 1800 (430 cc) stainless steel 4 leather, 3 UHMWPE throat/
3 UHMWPE, 2 leather piston
32 MPa (324 bar, 4700 psi)
222801, A Dura-Flo 2400 (580 cc) carbon steel 3 PTFE/2 leather 24 MPa (235 bar, 3400 psi)
222991, A Dura-Flo 2400 (580 cc) carbon steel 4 leather/1 PTFE backup 24 MPa (235 bar, 3400 psi)
222992, A Dura-Flo 2400 (580 cc) carbon steel 5 PTFE 24 MPa (235 bar, 3400 psi)
C59798, B Dura-Flo 2400 (580 cc) carbon steel 3 PTFE/2 leather 24 MPa (235 bar, 3400 psi)
222803, A Dura-Flo 2400 (580 cc) stainless steel 3 UHMWPE/2 PTFE 24 MPa (235 bar, 3400 psi)
222993, A Dura-Flo 2400 (580 cc) stainless steel 3 PTFE/2 leather 24 MPa (235 bar, 3400 psi)
222994, A Dura-Flo 2400 (580 cc) stainless steel 5 PTFE 24 MPa (235 bar, 3400 psi)
236226, A Dura-Flo 2400 (580 cc) stainless steel 3 UHMWPE/2 PTFE 24 MPa (235 bar, 3400 psi)
236230, A Dura-Flo 2400 (580 cc) stainless steel 4 leather/1 PTFE backup 24 MPa (235 bar, 3400 psi)
241648, A Dura-Flo 2400 (580 cc) stainless steel 3 UHMWPE/2 carbon-filled PTFE 24 MPa (235 bar, 3400 psi)
249991, A Dura-Flo 2400 (580 cc) stainless steel 4 leather, 3 UHMWPE throat/
3 UHMWPE, 2 UHMWPE piston
24 MPa (235 bar, 3400 psi)
15F298, A Dura-Flo 2400 (580 cc) stainless steel 4 leather, 3 UHMWPE throat/
3 UHMWPE, 2 leather piston
24 MPa (235 bar, 3400 psi)
L580CS, A Dura-Flo 2400 (580 cc) carbon steel 3 UHMWPE/2 PTFE 24 MPa (235 bar, 3400 psi)
L580SS, A Dura-Flo 2400 (580 cc) stainless steel 3 UHMWPE/2 PTFE 24 MPa (235 bar, 3400 psi)
L580SM, A Dura-Flo 2400 (580 cc) stainless steel 4 leather, 3 UHMWPE throat/
3 UHMWPE, 2 leather piston
24 MPa (235 bar, 3400 psi)

Warnings
4311825L
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. 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 arc).
• 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.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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 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.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
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 Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• 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.

Warnings
311825L 5
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
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 MSDS’s 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.
• Always wear impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing protection
WARNING

Repair
6311825L
Repair
Pressure Relief Procedure
1. Engage trigger lock.
2. Shutoff the pump:
a. For air-powered pumps, close the bleed-type
master air valve.
b. For hydraulic-powered pumps, close the supply
line shutoff valve (U) first, then close the return
line shutoff valve (V).
3. Disengage the trigger lock.
4. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
5. Engage the trigger lock.
6. 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.
7. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved after follow-
ing the steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Clear
hose or tip obstruction.
Required Tools
• Set of socket wrenches
• Set of adjustable wrenches
• 24 in. adjustable wrench
• Torque wrench
• Rubber mallet
• Arbor press
• Soft wooden block (approx. 1 square foot in size)
• Large vise, with soft jaws
• Thread lubricant
• Anti-seize lubricant 222955
• Loctite®2760™or equivalent
Trapped air can cause the pump to cycle unexpect-
edly, which could result in serious injury from splashing
or moving parts.
Accessory Service Tools are available which fit
over the top of the displacement rod, making it eas-
ier to use a 24 in. adjustable wrench or 3/4 in. drive
socket when disassembling/assembling the rod
and piston.
• For Dura-Flo 1800 (430 cc) Lowers, order Part
No. 109507 Tool.
• For Dura-Flo 2400 (580 cc) Lowers, order Part
No. 109508 Tool.

Repair
311825L 7
Disassembly
Lay out all the removed parts in sequence, to ease reas-
sembly. Clean all parts with a compatible solvent and
inspect them for wear or damage. Refer to FIG.1.
1. Flush the pump, if possible. Stop the pump at the
bottom of its stroke. Relieve the pressure, page 6.
2. Disconnect the lower from the motor. See your sep-
arate pump assembly manual.
3. Stand the lower upright in a large vise. Loosen, but
do not remove, the packing nut (3). Remove the six
long cap screws (20).
4. Lift the outlet housing (19) straight up off the lower.
Be careful not to scratch the displacement rod (1)
while removing the housing.
5. Lift the cylinder (7), displacement rod (1), and piston
assembly off the intake housing (17).
6. 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 dam-
age.
7. Remove the seal (6) from the bottom of the outlet
housing (19). Unscrew the packing nut (3). Remove
the glands and v-packings (T) from the housing. Do
not remove the outlet fitting (4) and o-ring (5) unless
they need replacement.
8. Unscrew the bleeder valve plug (35) completely
from the valve body (34). Clean the valve threads
and the bleed hole. It is not necessary to remove the
valve body.
9. 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 cylin-
der 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.
10. 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
that the piston ball (10) doesn't fall as you separate
the housing (12) and ball guide (9).
11. Remove the glands and v-packings (P) from the pis-
ton seat housing (12). Inspect the ball (10) and ball
seat (B) on the housing (12) for wear or damage.
12. Inspect the outer surface of the displacement rod (1)
and the inner surface of the cylinder (7) for scoring
or wear; replace if damaged. If replacing the rod,
remove the ball guide (9) (see step 13).
13. 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.
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 also can be
used to convert the lower to different packing mate-
rials. Refer to pages 16-20.
CAUTION
To reduce the possibility of costly damage to the rod
(1) and cylinder (7), first place the cylinder on a soft
block of wood. Always use a rubber mallet or an arbor
press to drive the rod (1) out of the cylinder (7). Never
use a hammer to drive the rod.
Accessory Service Tools are available which fit
over the top of the displacement rod, making it eas-
ier to use a 24 in. adjustable wrench or 3/4 in. drive
socket when disassembling/assembling the rod
and piston.
• For Dura-Flo 1800 (430 cc) Lowers, order Part
No. 109507 Tool.
• For Dura-Flo 2400 (580 cc) Lowers, order Part
No. 109508 Tool.
Do not remove the ball guide (9) from the displace-
ment rod (1) unless either part needs replacement.

Repair
8311825L
Reassembly
1. If the ball guide (9) was removed, place the flats of
the displacement rod (1) in a vise. Apply anti-seize
lubricant 222955 to the threads and mating faces of
the rod and the ball guide. Screw the ball guide onto
the rod, hand tight. Remove from the vise. See FIG.
1.
2. Install the piston packings (P) on the piston (12) in
the correct order for your lower, see Repair Kits,
pages 16-20. Install the v-packings one at a time
with the lips facing up.
3. Apply anti-seize lubricant 222955 to the threads and
mating faces of the ball guide (9) and piston seat
housing (12). Place the flats of the piston seat hous-
ing in a vise. Place the ball (10) on the piston seat.
Screw the assembled rod (1) and ball guide (9) onto
the piston assembly hand tight, then torque to
459-481 N•m (338-354 ft-lb).
4. Use an arbor press to reinstall the rod (1) into the
cylinder (7), as follows. (The cylinder is symmetrical,
so either end may face up.) Lubricate the piston
packings (P). With the piston end facing down,
lower the rod into the cylinder. Start the piston into
the cylinder as much as possible, then drive the rod
and piston the rest of the way into the cylinder with
the arbor press.
5. Lubricate the o-ring (27*) and seal (6*). Install the
o-ring on the intake seat housing (15). Install the
intake seat housing (15), intake ball (16), ball guide
(14), and seal (6*) in the intake housing (17). Set the
intake housing all the way into the vise.
6. Place the cylinder (7) on the intake housing (17).
Tap on the top of the displacement rod (1) with a
rubber mallet, to seat the cylinder.
7. Lubricate the throat packings (T). Install the throat
packings (T) in the outlet housing (19) in the correct
order for your lower, see Repair Kits, pages 16-20.
Install the v-packings one at a time with the lips fac-
ing down.
8. Lubricate the threads of the packing nut (3), and
loosely install it in the outlet housing (19).
9. Lubricate the seal (6*) and install it in the bottom of
the outlet housing (19). Set the outlet housing on
top of the cylinder (7). Apply thread lubricant to the
six long cap screws (20). Install the cap screws
through the outlet housing (19) and thread them
loosely by hand into the intake housing (17). Tighten
the cap screws oppositely and evenly, then torque
to 244-264 N•m (180-195 ft-lb).
10. Install the bleeder valve plug (35). The plug has two
sets of threads. Be sure to screw the plug fully into
the valve body (34). Torque the plug to 30-38 N•m
(22-28 ft-lb).
11. Reconnect the lower to the motor as explained in
your separate pump assembly manual.
To convert the lower to a different packing material,
see pages 16-20.
Accessory Service Tools are available which fit
over the top of the displacement rod, making it eas-
ier to use a 24 in. adjustable wrench or 3/4 in. drive
socket when disassembling/assembling the rod
and piston.
• For Dura-Flo 1800 (430 cc) Lowers, order Part
No. 109507 Tool.
• For Dura-Flo 2400 (580 cc) Lowers, order Part
No. 109508 Tool.
CAUTION
To reduce the possibility of costly damage to the rod
(1) and cylinder (7), first place the cylinder on a soft
block of wood. Always use a rubber mallet or an arbor
press to drive the rod (1) into the cylinder (7). Never
use a hammer to drive the rod.
To convert the lower to a different packing material,
see pages 16-20.
It is not ordinarily necessary to remove the outlet fit-
ting (4) and o-ring (5*). However, if they were
replaced because of damage, lubricate the o-ring
and place it on the fitting. Screw the fitting into the
outlet housing (19). Torque to 156-171 N•m
(115-126 ft-lb).

Repair
311825L 9
FIG. 1. Cutaway View
1
1
T*
*P
3
*6
6*
7
910
12
14
15
16
17
19
27*A
B
20
34
35
4
*5
Torque to 156-171 N•m (115-126 ft-lb).
Torque to 135-169 N•m (100-125 ft-lb).
For 241648, 249991, and 15F298, limit torque to 27-40 N•m
(20-30 ft-lb).
Torque to 459-481 N•m (338-354 ft-lb).
Torque oppositely and evenly to 244-264 N•m (180-195 ft-lb).
Apply anti-seize lubricant to threads and mating faces.
Lubricate.
Apply thread lubricant.
Use arbor press to drive into cylinder (7).
Unscrew plug from valve housing
and clean.
Torque to 30-38 N•m (22-28 ft-lb).
Used on lowers with stainless steel
capscrews only.
1
2
3
4
5
6
7
8
9
10
11
2
3
4
5
6
7
8
9
10
6
6
5
3
6
33 11
TI8392a

Repair
10 311825L