Graco Dura-Flo A Series Operation manual

308–360
Rev. A
04143
04140
Model 237–517
Model 237–516
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
STAINLESS STEEL
Dura-Flo 1200 Pumps
With Severe-Duty Rod and Cylinder
Part No. 237–516 Pump, Series A,
21:1 Ratio, with BulldogAir Motor
145 bar (2100 psi) Maximum Fluid Working Pressure
7 bar (100 psi) Maximum Air Input Pressure
Part No. 237–517 Pump, Series A,
13:1 Ratio, with SenatorAir Motor
90 bar (1300 psi) Maximum Fluid Working Pressure
7 bar (100 psi) Maximum Air Input Pressure
Refer to page 2 for T able of Contents.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1995, GRACO INC.

 
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation/Maintenance 8 . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart 11. . . . . . . . . . . . . . . . . . . . . . . . .
Service 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting the Displacement Pump 12. . . . . . .
Reconnecting the Displacement Pump 12. . . . . . .
Displacement Pump Service 14. . . . . . . . . . . . . . . .
Parts Drawings and Parts Lists 18. . . . . . . . . . . . . . . . . .
Pump Assemblies 18. . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 19. . . . . . . . . . . . . . . . . . . . . . .
Technical Data 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 23. . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 24. . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
his 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.
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, call Graco T echnical Assis -
tance at 1–800–543–0339.
 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
T echnical Data on pages 21–22 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).
W
ear hearing protection when operating this equipment.
 Do not lift pressurized equipment.
 Comply with all applicable local, state, and national fire, electrical, and safety regulations.

 
WARNING
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 medi -
cal attention.

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 dif fuser 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 8 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
T ighten 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 P ARTS 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 8 to prevent the
equipment from starting unexpectedly .

4 308-360
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re -
sult in a fire or explosion and serious injury .

Ground the equipment and the object being sprayed. Refer to Grounding on page 5.
 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 be -
ing 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 of f 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 .

308-360 5
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. 305–713 (Senator
Pumps) and Form No. 305–714 (Bulldog 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 4.
1. Pump: use a ground wire and clamp. See Fig. 1.
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.
237–569 Ground Wire and Clamp.
Fig. 1
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.
T o 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. 2 is only a guide for selecting and installing
system components and accessories. Contact your
Graco representative or Graco T echnical Assistance
(1–800–543–0339) 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. 2 illustrates a wall mount system. Pump
dimensions and the mounting hole layout are shown
on page 23.
If you are using a floor stand, refer to its separate
manual for installation and operation instructions.

 
Installation
System Accessories (continued)
WARNING
A bleed-type master air valve (E) and a fluid drain
valve (M) are required in your system. These ac -
cessories help reduce the risk of serious injury , in -
cluding 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 of f. T rapped air can cause the pump to cycle
unexpectedly . Locate the valve close to the pump.
Order Part No. 107–141.
The fluid drain valve assists in relieving fluid pres -
sure in the displacement pump, hose, and gun.
T riggering the gun to relieve pressure may not be
suf ficient. Order Part No. 235–992.
Air Line Accessories
Install the following accessories in the locations shown
in Fig. 2, using adapters as necessary:
An air line lubricator (D) provides automatic air
motor 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 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.
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 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 of f 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. 2, 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. 2 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
T o prevent intake valve damage, always apply T eflon
tape to the female threads of the intake valve before
connecting a suction hose or fitting to the intake.

308-360 7
Installation
04177
Fig. 2
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 Electrically Conductive 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 Electrically Conductive
Fluid Supply Hose
P Fluid Whip Hose
R Gun Swivel
S Airless Spray Gun
T Suction Kit
Y Ground Wire and Clamp
(required; see page 5
for installation instructions)
W Air Line Drain V alve
TYPICAL INSTALLATION
A
B
C
D
E
F
G
H
JK
M
N
P
Y
MAIN
AIR LINE
L
R
S
T
W

 
Operation/Maintenance
Pressure Relief Procedure
WARNING
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 . T o 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 of f 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. 3.
WARNING
T o 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 (100–1 10 ft-lb) using
the supplied wrench (1 10). Do this whenever neces -
sary
. Do not overtighten the packing nut.
04143
Fig. 3
110
2
1
Model
237–516
Shown
1Torque
to 136–149 N.m
(100–1 10 ft-lb)

308-360 9
Operation/Maintenance
Flush the Pump Before First Use
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. See Flushing on page 10.
Starting and Adjusting the Pump
1. See Fig. 2. Connect the suction kit (T) to the
pump’ s fluid inlet. Place the tube into the fluid sup -
ply.
CAUTION
T o prevent intake valve damage, always apply T eflon
tape to the female threads of the intake valve before
connecting a suction hose or fitting to the intake.
2. Close the air regulator (F).
3. Open the pump’ s bleed-type master air valve (E).
4. Hold a metal part of the gun (S) firmly to the side
of a grounded metal pail and hold the trigger open.
5. Slowly open the regulator until the pump starts.
6. Cycle the pump slowly until all air is pushed out
and the pump and hoses are fully primed.
7. Release the gun trigger and lock the trigger safety .
The pump should stall against pressure.
8. If the pump fails to prime properly , open the drain
valve (M). Use the drain valve as a priming valve
until the fluid flows from the valve. Close the valve.
NOTE: When changing fluid containers with the hose
and gun already primed, open the drain valve (M) to
help prime the pump and vent air before it enters the
hose. Close the drain valve when all air is eliminated.
CAUTION
Do not allow the pump to run dry . It will quickly accel -
erate to a high speed, causing damage. If your pump
is running too fast, stop it immediately and check the
fluid supply . If the container is empty and air has
been pumped into the lines, refill the container and
prime the pump and the lines, or flush and leave it
filled with a compatible solvent. Eliminate all air from
the fluid system.
9. With the pump and lines primed, and with ade -
quate air pressure and volume supplied, the pump
will start and stop as you open and close the gun.
In a circulating system, the pump will speed up or
slow down on demand, until the air supply is shut
off.
WARNING
COMPONENT RUPTURE HAZARD
T o 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 T echnical Data, on
pages 21 and 22).
10. Use the air regulator (F) to control pump speed
and fluid pressure. Always use the lowest air pres -
sure necessary to get the desired results. Higher
pressures cause premature tip and pump wear .

10 308-360
Operation/Maintenance
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 8.
For overnight shutdown, stop the pump at the bottom
of its stroke to prevent fluid from drying on the ex -
posed displacement rod and damaging the throat
packings. Relieve the pressure.
Always flush the pump before the fluid dries on the
displacement rod. See Flushing below .
Flushing
WARNING
FIRE AND EXPLOSION HAZARD
Before flushing, read the section FIRE
OR EXPLOSION HAZARD on page 4.
Be sure the entire system and flushing
pails are properly grounded. Refer to
Grounding on page 5.
Flush with a fluid that is compatible with the fluid you
are pumping and with the wetted parts in your system.
Check with your fluid manufacturer or supplier for rec -
ommended flushing fluids and flushing frequency . Al -
ways flush the pump before fluid dries on the displace -
ment rod.
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
1. Relieve the pressure.
2. Remove the spray tip from the gun.
3. Hold a metal part of the gun firmly to the side of a
grounded metal pail.
4. Start the pump. Always use the lowest possible
fluid pressure when flushing.
5. T rigger the gun.
6. Flush the system until clear solvent flows from the
gun.
7.
Relieve the pressure.