Graco Dura-Flo 2400 User manual

INSTRUCTIONS–P ARTS LIST 308–151
Rev B
Supersedes A
This manual contains IMPORT ANT
WARNINGS AND INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
DURA–FLO 2400 PUMPS
Carbon Steel, with Severe–Duty Rod and Cylinder
Model 222–832, Series A
20:1 Ratio King Pump, with Standard Air Motor
126 bar (1800 psi) MAXIMUM FLUID WORKING PRESSURE
6.3 bar (90 psi) MAXIMUM AIR INPUT PRESSURE
Model 222–833, Series A
20:1 Ratio King Pump, with Quiet Air Motor
126 bar (1800 psi) MAXIMUM FLUID WORKING PRESSURE
6.3 bar (90 psi) MAXIMUM AIR INPUT PRESSURE
Model 222–826, Series A
10:1 Ratio Bulldog Pump, with Standard Air Motor
70 bar (1000 psi) MAXIMUM FLUID WORKING PRESSURE
7 bar (100 psi) MAXIMUM AIR INPUT PRESSURE
Model 222–824, Series A
10:1 Ratio Bulldog Pump, with Quiet Air Motor
70 bar (1000 psi) MAXIMUM FLUID WORKING PRESSURE
7 bar (100 psi) MAXIMUM AIR INPUT PRESSURE
Model 222–834, Series A
Viscount Pump, with Quiet Hydraulic Motor
140 bar (2000 psi) MAXIMUM FLUID WORKING PRESSURE
105 bar (1500 psi) MAXIMUM HYDRAULIC INPUT PRESSURE
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
 COPYRIGHT 1991, GRACO INC.
T ABLE OF CONTENTS
Warnings 2, 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terms 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation (Air–Powered Pumps) 4, 5 . . . . . . . . . . . . . . . . . . . . .
Installation (Hydraulic–Powered Pumps) 6, 7 . . . . . . . . . . . . . . .
Operation/Maintenance
All
Models 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air–Powered Models 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic–Powered Models 9. . . . . . . . . . . . . . . . . . . . . . . . .
Service
Troubleshooting
Chart 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required T ools 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting the Displacement Pump 11. . . . . . . . . . . . . .
Reconnecting the Displacement Pump 11. . . . . . . . . . . . . .
Displacement Pump Service 12–14. . . . . . . . . . . . . . . . . . . .
Parts Drawings and Lists
Model 222–832 King Pump 15. . . . . . . . . . . . . . . . . . . . . . . .
Model 222–833 King Pump 16. . . . . . . . . . . . . . . . . . . . . . . .
Model 222–826 Bulldog Pump 17. . . . . . . . . . . . . . . . . . . . .
Model 222–824 Bulldog Pump 18. . . . . . . . . . . . . . . . . . . . .
Model 222–834 V iscount Pump 19. . . . . . . . . . . . . . . . . . . .
Displacement Pumps 222–801 and 222–910 20, 21 . . . . . .
Packing Conversion Kits 21. . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 22, 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data and Performance Charts
Model 222–832 and 222–833 King Pumps 24, 25 . . . . . . . .
Model 222–826 and 222–824 Bulldog Pumps 26, 27 . . . . .
Model 222–834 V iscount Pump 28. . . . . . . . . . . . . . . . . . . .
Dimensional Drawing 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Back Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toll–Free Graco Phone Numbers Back Cover. . . . . . . . . . . . . .

Model 222–832 Shown


308-151
SAFETY W ARNINGS
HIGH PRESSURE FLUID CAN CAUSE SERIOUS INJUR Y . FOR PROFESSIONAL USE ONL Y.
OBSER
VE 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 components can inject fluid
through
your skin and into your body and cause extremely serious bodily
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 spray gun/dispensing valve at anyone or at any part of
the body . NEVER put hand or fingers over the spray tip/nozzle.
ALWA YS have the tip guard in place on the spray 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 A T ONCE. DO NOT TREA T AS A SIMPLE CUT . T ell the doctor
exactly what fluid was injected.
Note to Physician: Injection in the skin is a traumatic injury . It is im -
portant
to treat the injury surgically as soon as possible . Do not
delay treatment to research toxicity . T oxicity is a concern with some ex -
otic
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 spray gun/dispensing 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 bodily injury .
Safety Latch
Whenever you stop spraying/dispensing, even for a moment, always set
the spray gun/dispensing valve safety latch in the closed or “safe” posi -
tion,
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 spray gun/dispensing valve with the trigger guard re -
moved.
This guard helps prevent the gun/valve from triggering acciden -
tally
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 injec -
tion
when the tip is not installed. Check the dif fuser operation regularly .
Follow the Pressure Relief Procedure, to the right, then remove the
spray
tip. Aim the spray gun into a grounded metal pail, holding the spray
gun firmly to the pail. Using the lowest possible pressure, trigger the
spray
gun. If the fluid emitted is not dif fused into an irregular stream, re -
place
the dif fuser immediately .
Tip Guard (only on spray guns)
ALWAYS have the tip guard in place on the spray gun while spraying. The
tip guard alerts you to the fluid injection hazard and helps reduce, but
does
not prevent, the risk of accidentally placing 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 spray tips/nozzles. If the
spray tip/nozzle clogs while spraying/dispensing, engage the spray gun/
dispensing valve safety latch immediately . AL WA YS follow the Pressure
Relief Procedure and then remove the spray tip/nozzle to clean it.
NEVER wipe of f build–up around the spray tip/nozzle until pressure is
fully relieved and the spray gun/dispensing valve safety latch is engaged.
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 sys -
tem,
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 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 sys-
tems,
close the hydraulic supply line valve first , then the return
line valve.
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 pres -
sure.
6. Engage
the gun/valve safety latch.
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/dis -
pense
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, VER Y SLOWL Y loosen the tip guard retaining nut
or hose end coupling and relieve pressure gradually , then loosen
completely. Now clear the tip/nozzle or hose.
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the spray/dispensing equipment or accessories, such as
overpressurizing, modifying parts, using incompatible chemicals and flu -
ids, or using worn or damaged parts, can cause them to rupture and result
in fluid injection, splashing in the eyes or on the skin, or other serious bod -
ily
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 respirator as rec -
ommended
by the fluid and solvent manufacturer .
System Pressure
NEVER exceed the recommended working pressure or the maximum air
or hydraulic inlet pressure stated on your pump or in the TECHNICAL
DATA
on pages 24–28.
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 compatible with
the wetted parts shown in the TECHNICAL DA TA on pages 24–28. Al -
ways
read the manufacturer ’ s literature before using fluid or solvent in
this pump.

308-151 3
HOSE SAFETY
High pressure fluid in the hoses can be very dangerous. If the hose devel -
ops
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 bodily injury or property damage.
ALL FLUID HOSES MUST HA VE 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.
TIGHTEN 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 entire 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 CAREFULL Y . Do not pull on hoses to
move equipment. Do not use fluids which are not compatible with the in -
ner
tube and cover of the hose. DO NOT expose Graco hoses to tem -
peratures
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 resistance of your air , hy -
draulic,
and fluid hoses at least once a week. If your hose does not have a
tag on it which specifies the maximum electrical resistance, contact the
hose supplier or manufacturer for the maximum resistance limits. Use a
resistance meter in the appropriate range for your hose to check the re -
sistance.
If the resistance exceeds the recommended limits, replace it
immediately. An ungrounded or poorly grounded hose can make your
system hazardous. Also, read FIRE OR EXPLOSION HAZARD , below .
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. Sparking 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 flammable sub-
stances,
whether you are spraying/dispensing indoors or outdoors, and
can cause a fire or explosion and serious bodily injury and property dam -
age.
Do not plug in or unplug any power supply cords in the spray/dis -
pensing 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 SPRA YING/DISPENSING IMMEDIATELY.
Check the entire system for proper grounding. Do not use the system
again
until the problem has been identified and corrected.
Grounding
To 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 and hydraulic hoses: use only grounded hoses.
3. Fluid hoses: use only grounded fluid hoses.
4. Air compressor or hydraulic power supply: follow manufacturer ’s
recommendations.
5.
Spray gun or dispensing valve: grounding is obtained through con -
nection
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 relieving pres -
sure
, 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.
To ground the pump:
To ground the 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. See
the ACCESSORIES section for a ground wire and clamp.
Fig 1
W
X
Y
Z
0864
Flushing Safety
Before flushing, be sure the entire system and flushing pails are properly
grounded. Refer to Grounding, above. Follow the Pressure Relief
Procedure
on page 2, and remove the spray tip/nozzle from the spray
gun/dispensing valve. Always use the lowest possible fluid pressure, and
maintain firm metal–to–metal contact between the gun/valve and the pail
during flushing to reduce the risk of fluid injection injury , static sparking
and splashing.
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
2 to prevent the pump from starting accidentally .
On
air–powered pumps, the air motor piston (located behind the air motor
shield ) moves when air is supplied to the motor. NEVER operate the
pump
with the air motor shield removed.
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards – particularly the Gen -
eral
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.

4308-151
TYPICAL INST ALLA TION (AIR–POWERED PUMPS)
0626B
KEY
APump
BWall
Bracket
C Pump Runaway V alve
D
Air Line Lubricator
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
M Fluid Drain V alve (required)
N
Grounded Fluid Supply Hose
P Fluid Whip Hose
RGun/V alve Swivel
S Airless Spray Gun or Dispensing V alve
T
Drum Suction Kit
Y Ground Wire (required)
A
B
C
D
E
F
G
H
JK
M
N
P
Y
MAIN AIR LINE
200 LITER (55 GAL.) DRUM
L
R
S
T

308-151 5
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.
See pages 22 and 23 for accessories available
from
Graco. If you supply your own accessories,
be sure they are adequately sized and pressure–
rated to meet the system’ s requirements.
The T ypical Installation shown on page 4 is only a guide
for selecting and installing system components and ac-
cessories. Contact your Graco representative or Graco
Technical Assistance (see back page) for assistance in
designing
a system to suit your particular needs.
SYSTEM ACCESSORIES
Refer to the T ypical Installation drawing on page 4.
Two accessories are required in your system: a
bleed–type master air valve (E) and a fluid drain
valve
(M). These accessories help 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 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 unex -
pectedly
. Locate the valve close to the pump.
The fluid drain valve assists in relieving fluid pres-
sure
in the displacement pump, hose, and gun. T rig-
gering
the gun to relieve pressure may not be suf fi-
cient.
WARNING
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 of a short whip hose (P) and a
swivel (R) between the main fluid hose (N) and the gun/
valve (S) allows freer gun/valve movement.
Mounting Accessories
Mount the pump (A) to suit the type of installation
planned. The Typical Installation on page 4 illustrates a
wall–mounted
system. Pump dimensions and the mount -
ing
hole layout are shown on pages 30 and 31.
If you are mounting the pump on an elevator or a cart, re -
fer
to the separate manuals supplied with those compo -
nents
for installation and operation instructions.
Air Line Accessories
Install the following accessories in the order shown in the
Typical Installation, using adapters as necessary:
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 serious -
ly
damaged. Install closest to the pump air inlet.
An air line lubricator (D) provides automatic air mo -
tor
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 at
left). Be sure the bleed valve is easily accessible from
the pump, and is located downstream from the air
regulator.
An
air regulator (F) controls pump speed and outlet
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.
An air manifold (G) has a swivel air inlet. It mounts to
a wall bracket or cart, and provides ports for connect -
ing
lines to air–powered accessories.
An air line filter (J) removes harmful dirt and mois-
ture
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.
NOTE: Items E, F , and G are included in the Air Regula -
tion
Kit described in the Accessories section.
Fluid Line Accessories
Install the following accessories in the positions shown in
the T ypical Installation, using adapters as necessary:
A fluid filter (L) includes 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 or valve (S) dispenses the fluid. The gun
shown in the T ypical Installation 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
200 liter (55 gallon) drum.
GROUNDING
WARNING
Before operating the pump, ground the system as
explained under FIRE OR EXPLOSION HAZARD
and
Grounding on page 3.