Graco Dura-Flo XL 1000cc Guide

3A4100D
EN
Operation and Parts
Dura-Flo™XL 1000cc Pumps
For use with bulk supply of medium to high viscosity sealant and adhesive materials.
For professional use only.
Not approved for use with group 1 fluids as defined by Directive 2014/68/EU (Pressure
Equipment Directive).
Not approved for use in European explosive atmosphere location.
See Technical Specifications page on page 19 for maximum allowable ambient temperature information.
See Page 2 for model information and
maximum working pressure.
Important Safety Instructions
Read all warnings and instructions in this and all
related manuals. Save all instructions.
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2 3A4100D
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification / Pump Assembly . . . . 5
Motor Component Identification . . . . . . . . . . . . . 6
Grounding the System . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 9
For the Supply System . . . . . . . . . . . . . . . . . . . . 9
For the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Packing Nut / Wet-Cup . . . . . . . . . . . . . . . . . . . 10
Flushing the Pump . . . . . . . . . . . . . . . . . . . . . . 10
Disconnecting the Displacement Pump . . . . . . 10
Lower Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
25A447, 25A448, 25A449, 25A450 . . . . . . . . . . 11
Lower Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 12
Air Motor 25A455 . . . . . . . . . . . . . . . . . . . . . . . . 13
Air Motor Parts List . . . . . . . . . . . . . . . . . . . . . . 14
Dura-Flo 1000cc Pumps with Xtreme and XL Motors
15
Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Kits and Accessories . . . . . . . . . . . . . . . . . . . . . 17
Dimensions and Mounting Hole Layouts . . . . . . 18
Technical Specifications . . . . . . . . . . . . . . . . . . . . 19
California Proposition 65 . . . . . . . . . . . . . . . . . . . 19
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 20
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 20
Models
Related Manuals
Pump Part
and Series
Pump Style Motor Pump Lower Ratio Maximum Fluid
Working Pressure
Maximum Air
Input Pressure
25A451,
Series A
XL 1000cc,
Severe Duty,
Carbon Steel
25A455
XL 24000
25A447
Dura-Flo 1800
(1000cc)
47:1 4500 psi
(31 MPa, 310 bar)
100 psi
(0.7 MPa, 7 bar)
25A452,
Series A
XL 1000cc,
MaxLife,
Carbon Steel
25A455
XL 24000
25A448
Dura-Flo 1800
(1000cc)
47:1 4500 psi
(31 MPa, 310 bar)
100 psi
(0.7 MPa, 7 bar)
25A453,
Series A
XL 1000cc,
Severe Duty,
Stainless Steel
25A455
XL 24000
25A449
Dura-Flo 1800
(1000cc)
47:1 4500 psi
(31 MPa, 310 bar)
100 psi
(0.7 MPa, 7 bar)
25A454,
Series A
XL 1000cc,
MaxLife,
Stainless Steel
25A455
XL 24000
25A450
Dura-Flo 1800
(1000cc)
47:1 4500 psi
(31 MPa, 310 bar)
100 psi
(0.7 MPa, 7 bar)
Manual Description
309169 Uni-Drum™Supply System for 1200 Liter (300 gallon) Containers
309028 Uni-Drum™Supply System for 1200 Liter (300 gallon) Containers
3A2510 Uni-Drum™Supply System for 1000 Liter (265 gallon) Containers
332499 Uni-Drum™Supply System for 1000 Liter (265 gallon) Containers

Warnings
3A4100D 3
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 symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNINGWARNINGWARNING
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, 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 surgi-
cal treatment.
•Engage trigger lock when not dispensing.
•Do not point dispensing device at anyone or at any part of the body.
•Do not put your hand over the fluid outlet.
•Do not stop or deflect leaks with your hand, body, glove, or rag.
•Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking,
or servicing equipment.
•Tighten all fluid connections before operating the equipment.
•Check hoses and couplings daily. Replace worn or damaged parts immediately.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or sol-
vent flowing through the equipment can cause static sparking. 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 sparking).
•Ground all equipment in the work area. See Grounding instructions.
•Never spray or flush solvent at high pressure.
•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.
•Use only grounded hoses.
•Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
•Keep a working fire extinguisher in the work area.

Warnings
4 3A4100D
MOVING PARTS HAZARD
Moving parts can pinch, cut 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 equip-
ment, Relieve Pressure and disconnect all power sources.
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 Safety Data Sheet (SDS) from distributor or retailer.
•Do not leave the work area while equipment is energized or under pressure.
•Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine man-
ufacturer’s replacement parts only.
•Do not alter or modify equipment. Alterations or modifications may void agency approvals and cre-
ate safety hazards.
•Make sure all equipment is rated and approved for the environment in which you are using it.
•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.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, includ-
ing eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is
not limited to:
•Protective eyewear, and hearing protection.
•Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
WARNINGWARNINGWARNING

Component Identification / Pump Assembly
3A4100D 5
Component Identification / Pump Assembly
* Included with this system.
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Typical Installation
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6
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Torque to 129-142 N•m
(95-105 ft-lb).
Apply sealant to
threads (102969).
Torque to 312-340 N•m
(230-250 ft-lb).
1
2
3
3
3
2
1
1
Pump Assembly Instructions:
1. Assemble (H) to (F).
Apply sealant and torque.
2. Assemble (L) to (F) and torque.
3. Assemble (G) to (L)
and hand-tighten (N).
4. Assemble (K) and
torque (J) to (H).
5. Torque (N) to (L).
Ref. Description
A Pump
B Supply System
C Main Air Inlet
D Supply System Control Panel
E Bleed-Type Shutoff Valve
F* Motor, XL
G* Displacement Pump
H* Coupling Adapter
J* Coupling Nut
K* Coupling Collar
L* Tie Rod with Extension
N* Hex Nut
P* Packing Nut / Wet Cup
Q* Packing Nut Wrench
S* Pump Bleed Valve
Ref. Description

Component Identification / Pump Assembly
6 3A4100D
Motor Component Identification
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Ref. Description
AA Directional Air Valve
BB Air Inlet 1 in. npt(f)
CC Muffler
DD Pilot Valve
EE Manifold
FF Manual Shuttle Override Button
GG Ground Screw
HH Static Ground Cable
JJ Plug for Optional Solenoid
KK Optional Reed Switch Mount
LL External Pilot Lines
MM De-ice Bleed Air Valve
NN Lift Ring - 500 lb (363 kg) Maximum
PP Pump Drive Rod
Ref. Description

Grounding the System
3A4100D 7
Grounding the System
Pump: Use a ground wire and clamp (supplied). Verify
that the ground screw (GG) is attached and tightened
securely to the air motor. Connect the clamp (U) of the
static ground cable (HH) to a true earth ground. For a
replacement ground wire and clamp, order part 244524.
NOTE: Have qualified personnel check the resistance
between each pump and the true earth ground.
Air and fluid hoses: Use only electrically conductive
hoses with a maximum of 500 ft (150 m) combined hose
length to ensure grounding continuity. Check electrical
resistance of hoses. If total resistance to ground
exceeds 29 megohms, replace the hose immediately.
Air compressor: Follow manufacturer recommendations.
Spray gun or dispensing valve: Ground through connec-
tion to a properly grounded fluid hose and pump.
NOTE: See system manual for additional grounding
information.
NOTE: Use a meter that is capable of measuring resis-
tance at this level.
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes
to ignite or explode. Grounding provides an escape
wire for the electric current.
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Installation
8 3A4100D
Installation
1. Remove the air motor and pump from the system.
See the system manual for instructions.
2. Assemble ground wire (HH) to the ground screw
location on the air motor (F).
3. Remove the 45° 1 in. NPT fitting and replace it with
elbow (BB) and swivel (6) as needed. Assemble
with pipe sealant.
4. Install mounts (3) and gaskets (4). Torque to 15-18
ft-lb (20-24 N•m).
5. Install air motor (F) onto the system. See system
manual for further instructions.
NOTE: For Uni-Drum™systems, position the left and
right pumps as shown below.
Keep hands and fingers away from the follower plate,
pump inlets, and the drum when raising and lowering
the follower plate to reduce the risk of pinching or
amputating hands or fingers.
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Pressure Relief Procedure
3A4100D 9
Pressure Relief Procedure
For the Supply System
See the system manual.
For the Pump
1. Disable any dispense equipment on the system.
See the system manual.
2. Close the bleed-type shutoff valve (E)
3. Open any downstream forward valves, such as the
ball seat applicators on ram assemblies that may be
part of the system. Have a container ready to catch
the drainage.
4. Open the pump bleed valve (S). NOTE: Have a con-
tainer ready.
5. Leave the bleed valve open until you are ready to
spray/dispense again.
Follow the Pressure Relief Procedure
whenever you see this symbol.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing fluid
and moving parts, follow the Pressure Relief Proce-
dure when you stop dispensing and before cleaning,
checking, or servicing the equipment.

Maintenance
10 3A4100D
Maintenance
Packing Nut / Wet-Cup
1. Fill the packing nut/wet cup (P) 1/3 full with Graco
Throat Seal Liquid (TSL).
2. Use the supplied wrench (Q) to adjust the packing
nut weekly so that it is just snug. Do NOT
over-tighten.
Flushing the Pump
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
flush material before using the pump.
•Flush at the lowest pressure possible. check
connectors for leaks and tighten as necessary.
•Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted
parts.
1. Perform the Pressure Relief Procedure on page 9.
2. Set pump to lowest possible fluid pressure, and then
start the pump.
3. Dispense fluid into a grounded metal pail.
Disconnecting the Displacement
Pump
1. Flush the pump if you are using flushable material.
2. Stop the pump at the bottom of its stroke.
3. Perform the Pressure Relief Procedure on page 9.
4. Disconnect the air or the hydraulic hose. Plug all
hydraulic hoses immediately to prevent the contami-
nation of the hydraulic system. Hold the fluid outlet
fitting with a wrench to keep it from being loosened
while you disconnect the fluid hose.
5. Disconnect the displacement pump (G) from the
motor (F) as follows. Make sure to note the relative
position of the pump fluid outlet to the air or hydrau-
lic inlet of the motor due to orientation restrictions on
the system. If the motor does not require servicing,
leave it attached to its mounting.
6. Using adjustable wrenches to unscrew the coupling
nut (J) from the coupling adapter (H). Remove the
coupling collars (K). Take care not to lose or drop
the collars.
7. Hold the tie rod (L) flats with a wrench to keep the
rods from turning. Unscrew the hex nuts (N) from
the tie rods extensions. Carefully remove the dis-
placement pump (G) from the motor (F).
To reduce the risk of serious injury, do not flush pump
with group 1 fluids as defined by Directive 2014/68/EU
(Pressure Equipment Directive).
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4
3
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pres-
sure Relief Procedure on page 9.
Be sure to use at least two people when lifting, moving,
or disconnecting the pump. This pump is too heavy for
one person. If you are disconnecting the displacement
pump from a motor which is still mounted (for example,
on a wall bracket), be sure to support the displacement
pump while it is being disconnected. Failure to do so
may result in the pump falling and causing injury or
property damage. Do this by securely bracing the
pump, or by having at least two people hold the pump
while another person disconnects it.