Graco Dura-Flo 900 Series Operation manual

Instructions – Parts List
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
STAINLESS STEEL
Dura–Flo 900tPumps
With Severe–Duty Rod and Cylinder
U.S. Patent No. 5,456,583
Foreign Patents Pending
308354H
04275B
Model 237286
04143B
Model 237287
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for model numbers and maximum
working pressures.

2 308354
List of Models
Pump Part No.
and Series Pump Model Ratio Maximum Fluid Working Pressure Maximum Air Input Pressure
237286,
Series B Reduced Icing Quiet King56:1 38.6 MPa, 386 bar (5600 psi) 0.7 MPa, 7 bar (100 psi)
237287,
Series A Bulldog28:1 19.3 MPa, 193 bar (2800 psi) 0.7 MPa, 7 bar (100 psi)
237280,
Series A Senator17:1 11.7 MPa, 117 bar (1700 psi) 0.7 MPa, 7 bar (100 psi)
245172,
Series A King56:1 38.6 MPa, 386 bar (5600 psi) 0.7 MPa, 7 bar (100 psi)
245173,
Series B Quiet King56:1 38.6 MPa, 386 bar (5600 psi) 0.7 MPa, 7 bar (100 psi)
237290,
Series A Viscount II (hydraulic) 3.5:1 34 MPa, 345 bar (5000 psi) 9.9 MPa, 99 bar (1428 psi)
hydraulic pressure
248817,
Series A Viscount II (hydraulic) 3.5:1 34 MPa, 345 bar (5000 psi) 9.9 MPa, 99 bar (1428 psi)
hydraulic pressure
Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation/Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart 15. . . . . . . . . . . . . . . . . . . . . . . . .
Service 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting the Displacement Pump 16. . . . . . .
Reconnecting the Displacement Pump 16. . . . . . . .
Displacement Pump Service 18. . . . . . . . . . . . . . . .
Parts Drawings and Parts Lists 22. . . . . . . . . . . . . . . . . .
Pump Assemblies 22. . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 26. . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 33. . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

308354 3
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, contact your Graco distributor.
Do not alter or modify this equipment.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on pages 28–30 for the maximum working pressure of this equipment.
Use 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.
Do not use hoses to pull equipment.
Route 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).
Wear hearing protection when operating this equipment.
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.

4 308354
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.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi-
cal treatment.
Do not point the gun at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip.
Do not stop or deflect leaks with your hand, body, glove or rag.
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the gun when spraying.
Check the gun diffuser operation weekly. Refer to the gun manual.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 10 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
Do not repair high pressure couplings; you must replace the entire hose.
Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
MOVING PARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the Pressure Relief Procedure on page 10 to prevent the
equipment from starting unexpectedly.

308354 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.
Ground the equipment and the object being sprayed. Refer to Grounding on page 6.
If 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.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not operate a gasoline engine in the spray 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.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

6 308354
Installation
General Information
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
NOTE: Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor. Refer to
Product Data Sheet, Form No. 305715 (Senator
Pumps), Form No. 305716 (Bulldog Pumps), and Form
No. 305717 (King Pumps). If you supply your own
accessories, be sure they are adequately sized and
pressure rated for your system.
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.
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.
Fig. 1 TI1052
Y
Z
Fig. 2
W
X
Y
Z
0864
2. Air and fluid hoses: use only electrically conductive
hoses.
3. Air compressor: follow manufacturer’s recommen-
dations.
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.
System Accessories
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.
Air and Fluid Hoses
Be sure all air hoses (H) and fluid hoses (N and P) are
properly sized and pressure-rated for your system.
Use only electrically conductive hoses. Fluid hoses
must have spring guards on both ends. Use a whip
hose (P) and a swivel (R) between the main fluid hose
(N) and the gun (S) to allow freer gun movement.
Mounting Accessories
Mount the pump (A) to suit the type of installation
planned. Fig. 3 illustrates a wall mount system. Pump
dimensions and the mounting hole layout are shown
on page 33.
If you are using a floor stand, refer to its separate
manual for installation and operation instructions.

308354 7
Installation
System Accessories (continued)
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.
Order Part No. 107141.
A fluid drain valve (M) 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. Order Part No. 210658.
Air Line Accessories
Install the following accessories in the locations shown
in Fig. 3, using adapters as necessary:
An air line lubricator (D) provides automatic air
motor lubrication.
Ableed-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.
An 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.
Apump 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.
An air manifold (G) has a 3/4 npsm(f) swivel air
inlet. It mounts to the pump support bracket, and
provides ports for connecting lines to air-powered
accessories.
An air line filter (J) removes harmful dirt and
moisture from the compressed air supply. Also,
install a drain valve (W) at the bottom of each air
line drop, to drain off moisture.
A 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 locations shown
in Fig. 3, using adapters as necessary:
A fluid filter (L) with a 60 mesh (250 micron)
stainless steel element, to filter particles from the
fluid as it leaves the pump.
A fluid drain valve (M), which is required in your
system, helps relieve fluid pressure in the hose
and gun (see the WARNING at left).
A gun (S) dispenses the fluid. The gun shown in
Fig. 3 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 supply container.
CAUTION
To prevent intake valve damage, always apply PTFE
tape to the female threads of the intake valve before
connecting a suction hose or fitting to the intake.

8 308354
Installation
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 Swivel
SAirless Spray Gun
TSuction Kit
YGround Wire and Clamp
(required; see page 6
for installation instructions)
WAir Line Drain Valve
TYPICAL INSTALLATION
A
B
C
D
E
F
G
H
JK
M
N
P
Y
MAIN AIR LINE
L
R
S
T
W
04177B

308354 9
Installation
(HYDRAULIC-POWERED PUMPS)
Fluid Line Accessories
Install the following accessories in the locations shown
in Fig. 4, using adapters as necessary:
A fluid filter (L) with a 60 mesh (250 micron)
stainless steel element, to filter particles from the
fluid as it leaves the pump.
A fluid drain valve (M), which is required in your
system, helps relieve fluid pressure in the hose
and gun (see the WARNING on page 7).
A gun (S) dispenses the fluid. The gun shown in
Fig. 4 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 supply container.
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 Swivel
SAirless Spray Gun
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
04582B
Fig. 4
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 HYDRAULIC-POWERED INSTALLATION

10 308354
Operation/Maintenance
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:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tips.
1. Lock the gun/valve trigger safety.
2. Shut off the air supply to the pump.
3. Close the bleed-type master air valve (required in
your system).
4. Unlock the gun/valve trigger safety.
5. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and trigger the gun to relieve
pressure.
6. Lock the gun/valve trigger safety.
7. Open the drain valve (required in your system),
having a container ready to catch the drainage.
8. Leave the drain valve open until you are ready to
spray 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
Before starting, fill the packing nut (2) 1/3 full with
Graco Throat Seal Liquid (TSL) or compatible solvent.
See Fig. 5.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
The packing nut is torqued at the factory and is ready
for operation. If it becomes loose and there is leaking
from the throat packings, relieve the pressure, then
torque the nut to 136–149 N.m (100–110 ft-lb) using
the supplied wrench (110). Do this whenever neces-
sary. Do not overtighten the packing nut.
Fig. 5
110
21
Model
237287
Shown
1Torque to 136–149
(100–110 ft-lb)
04143B