Graco Dura-Flo Operation manual

308151R
Instructions–Parts List
Dura–Flo ™ 2400 Pumps
With Severe–Duty Rod and Cylinder
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Model Numbers and Maximum
Working Pressures.
Part No. 222832 Shown
GRACO INC. P.O BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 1991, Graco Inc. is registered to I.S. EN ISO 9001
CARBON STEEL

2 308151
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Air-Powered Pumps 8
Hydraulic-Powered Pumps 10
Operation/Maintenance . . . . . . . . . . . . . . . . . . . . .12
ALL PUMPS 12
Air-Powered Pumps 13
Hydraulic-Powered Pumps 14
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . .16
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Required Tools 17
Disconnecting the Displacement Pump 17
Reconnecting the Displacement Pump 18
Displacement Pump Service 20
Parts Drawings and Parts Lists . . . . . . . . . . . . . . 24
Pump Assemblies 24
Displacement Pumps 29
Packing Conversion Kits 31
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Mounting Hole Layouts . . . . . . . . . . . . . . . . . . . . . 40
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 42
List of Models
Pump Part No.
and Series Pump Model
Displacement
Pump Part No. Ratio
Maximum Fluid
Working Pressure
Maximum Air/Hydraulic
Input Pressure
222826, 
Series A
Bulldog® 222801 10:1 7.0 MPa, 69 bar
(1000 psi)
0.7 MPa, 7 bar
(100 psi)
222832, 
Series A
KingTM 222801 20:1 13.8 MPa, 138 bar
(2000 psi)
0.7 MPa, 7 bar
(100 psi)
222833, 
Series B
Quiet KingTM 222801 20:1 13.8 MPa, 138 bar
(2000 psi)
0.7 MPa, 7 bar
(100 psi)
24Y207, 
Series A
XL10000TM 222801 35:1 24.0 MPa, 235 bar
(3400 psi)
0.7 MPa, 7 bar
(100 psi)
222834, 
Series B
Viscount® 222801 1.33:1 14.0 MPa, 138 bar
(2000 psi)
10 MPa, 103 bar
(1500 psi)

308151 3
Symbols
Warning Symbol Caution Symbol
Warnings
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
CAUTION
This symbol alerts you to the possibility of damage
to or destruction of equipment if you do not follow
the instructions.
WARNING
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 uncertain about usage, call your
Graco distributor.
• Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
• 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 32-38 for the maximum working pressure of this equipment.
• Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
• Do not kink or overbend hoses or 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 82º C (180º F) or below –40º C (–40º 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.
INSTRUCTIONS

4 308151
WARNING
INJECTION HAZARD
Spray from the gun/valve, hose 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
surgical treatment.
• Do not point the gun/valve at anyone or at any part of the body.
• Do not put your hand or fingers over the spray tip/nozzle.
• 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/valve when spraying.
• Be sure the gun/valve trigger safety operates before spraying.
• Lock the gun/valve trigger safety when you stop spraying.
• Follow the Pressure Relief Procedure on page 12 whenever you: are instructed to relieve
pressure; stop spraying; clean, check, or service the equipment; and install or clean the spray
tip/nozzle.
• Tighten all fluid connections before operating the equipment.
• Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts
immediately. Permanently coupled hoses cannot be repaired; replace the entire hose.
• Use only Graco approved hoses. Do not remove the spring guard that is used to help protect the
hose 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 12 to prevent
the equipment from starting unexpectedly.

308151 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 7.
• If there is any static sparking or you feel an electric shock while using this equipment, stop
spraying 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.
• Keep a fire extinguisher in the work 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 308151
Notes
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308151 7
Installation
Grounding
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 the wire
to a true earth ground. Order Part No. 222011
Ground Wire and Clamp.
XL10000TM Pumps: See figure 3. Verify that the
ground screw (GS) is attached and tightened
securely to the air motor. connect the clamp (U) of
the static ground cable (H) to a true earth ground.
For a ground wire and clamp, order part No.
244524.
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 mm2(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.
2. Air, fluid, and hydraulic hoses: Use only electrically
conductive hoses with a maximum of 500 feet
(150 m) combined hose length to ensure grounding
continuity. Check the electrical resistance of your
hoses at least once a week. If the total resistance to
ground exceeds 29 megohms, replace the hose
immediately.
NOTE: Use a meter that is capable of measuring
resistance at this level.
3. Air compressor or hydraulic power supply: follow
manufacturer’s recommendations.
4. Spray gun/dispensing valve: grounding is obtained
through connection to a properly grounded fluid
hose and pump.
5. Fluid supply container: according to your local code.
6. Object being sprayed: according to your local code.
7. 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.
8. To maintain grounding continuity when flushing or
relieving pressure, 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.
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read the
section FIRE AND EXPLOSION
HAZARD on page 5.
W
X
Z
Y
WLD
*6
8
Fig. 2
Fig. 1
TI1052
0864
Fig. 3

8 308151
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.
NOTE: Accessories are available from your Graco
distributor. If you supply your own accessories, be sure
they are adequately sized and pressure-rated to meet
the system’s requirements.
Fig. 4 is only a guide for selecting and installing system
components and accessories. Contact your Graco
distributor for assistance in designing a system to suit
your particular needs.
Fig.4
TYPICAL INSTALLATION
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/Valve Swivel
SAirless Spray Gun
or Dispensing Valve
TDrum Suction Kit
YGround Wire (required; see page 7 for
installation instructions)
MAIN AIR LINE
200 LITER (55 GAL.) DRUM
0626C

308151 9
Installation
(AIR-POWERED PUMPS)
SYSTEM ACCESSORIES
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/valve (S) to allow freer gun/valve movement.
Mounting Accessories
Mount the pump (A) to suit the type of installation
planned. Fig. 4 illustrates a wall-mounted system. Pump
dimensions and the mounting hole layout are shown on
pages 40 and 41.
If you are using an elevator or a cart, refer to the
separate manuals supplied with those components for
installation and operation instructions.
Air Line Accessories
Install the following accessories in the order shown in
Fig. 4, 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 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.
•A pump 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 swivel air inlet. It mounts
to a wall 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.
•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 positions 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. 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 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 200 liter (55 gallon) drum.
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.
The fluid drain valve assists in relieving fluid pressure
in the displacement pump, hose, and gun. Triggering
the gun to relieve pressure may not be sufficient.
WARNING
For Model 222942 XL10000TM Pump, do not lift
the pump by the lift ring when the total weight
exceeds 550 lb (250 kg).

10 308151
Installation
(HYDRAULIC-POWERED PUMPS)
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
NOTE: Accessories are available from your Graco
distributor. If you supply your own accessories, be sure
they are adequately sized and pressure-rated to meet
the system’s requirements.
Fig. 5 is only a guide for selecting and installing system
components and accessories. Contact your Graco
distributor for assistance in designing a system to suit
your particular needs.
CAUTION
It is very important to keep the hydraulic supply
system clean at all times. Be sure that all hydraulic
fluid lines are absolutely clean. Blow out the lines with
air and flush thoroughly with solvent before connecting
to the hydraulic motor, to avoid introducing harmful
contaminants into the motor. Plus the hydraulic lines
immediately when they are disconnected.
Do not exceed 37.8 liter/min (10 gpm) hydraulic oil
volume to the motor, to avoid pump stalling.
For optimum pump performance, keep the
temperature of the hydraulic oil below 54° C (130° F)
TYPICAL INSTALLATION
SAirless Spray Gun or Dispensing Valve
TDrum Suction Kit
UHydraulic Supply Line Shutoff Valve
VHydraulic Return Line Shutoff Valve
YGround Wire (required, see page 7 for
installation instructions)
AA Hydraulic Return Line Filter
HYDRAULIC
POWER SUPPLY
DRAINAGE
CONTAINER
200 LITER
(55 GAL.) DRUM
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/Valve Swivel
Fig. 5 0627B

308151 11
Installation
(HYDRAULIC-POWERED PUMPS)
SYSTEM ACCESSORIES
Mounting Accessories
Mount the pump (A) to suit the type of installation
planned. Fig. 5 illustrates a wall-mounted system. Pump
dimensions and the mounting hole layout are shown on
pages 40 and 41.
Filters
Be sure your hydraulic power supply is equipped with a
suction filter to the hydraulic pump and a system return
line filter (AA) of 10 micron size.
Carefully follow the manufacturer’s recommendations
on reservoir and filter cleaning, and periodic changes of
hydraulic fluid. Use only Graco-approved hydraulic oil.
Order Part No. 169236, 5 gal. (19 liter) or 207428, 1 gal.
(3.8 liter). Do not substitute a lower grade oil or one with
a lower flash point.
Hydraulic Lines
The motor has a 3/4 npt(f) hydraulic oil supply fitting,
and a 1 in. npt(f) hydraulic oil return fitting. Use a
minimum 13 mm (1/2 in.) ID hydraulic supply line, and a
minimum 22 mm (7/8 in.) ID return line.
On the hydraulic supply line (C), install the following
accessories in the order shown in Fig. 5, using adapters
as necessary:
•A shutoff valve (U) isolates the pump for service.
•A fluid pressure gauge (F) to monitor hydraulic oil
pressure to the motor and to avoid overpressurizing
the motor or displacement pump, and a pressure-
and temperature-compensated flow control
valve (G) to prevent the motor from running too fast
and possibly damaging itself.
•A pressure reducing valve (H), with a drain line
(E) run directly to the hydraulic return line (D).
•An accumulator (J) to reduce the hammering
effect caused by the motor reversing direction.
On the hydraulic return line (D), install the following
accessories in the order shown in Fig. 5, using adapters
as necessary:
•A shutoff valve (V) isolates the pump for service.
•A filter (AA) of 10 micron size.
Hydraulic Motor Drip Pan
The hydraulic motor has a drip pan to collect any
leakage. Connect a 6 mm (1/4 in.) ID drain line (K) to the
barbed fitting on the drip pan, and place the free end in
a container to receive the drainage.
Fluid Supply Hoses
Be sure all fluid supply 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/valve (S) to allow freer gun/valve movement.
Fluid Line Accessories
Install the following accessories in the positions shown
in Fig. 5, 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. 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 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 200 liter (55 gallon) drum.
WARNING
A fluid drain valve (M) is required in your system to
help reduce the risk of serious injury, including fluid
injection and splashing of fluid in the eyes or on the
skin if you are adjusting or repairing the pump. The
fluid drain valve assists in relieving fluid pressure in the
displacement pump, hose, and gun. Triggering the gun
to relieve pressure may not be sufficient.

12 308151
Pressure Relief Procedure
1. Lock the gun/valve trigger safety.
2. Shut off 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 systems, close the hydraulic
supply line valve first, then the return line valve.
4. Unlock the gun/valve trigger safety.
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 pressure.
6. Lock the gun/valve trigger safety.
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/dispense 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, very slowly
loosen the tip guard retaining nut, nozzle, or hose end
coupling and relieve pressure gradually, then loosen
completely. Now clear the tip/nozzle or hose.
Packing Nut/Wet-Cup
Fill the packing nut/wet-cup (3) 1/3 full with Graco Throat
Seal Liquid (TSL) or compatible solvent. See Fig. 6.
Using the supplied wrench (104), adjust the packing nut
weekly so it is just snug; do not overtighten. Follow the
Pressure Relief Procedure Warning above before
adjusting the packing nut.
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
solvent before using the pump.
Fig. 6
WARNING
INJECTION HAZARD
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/dispensing,
• check or service any of the system equipment,
• or install or clean the spray tip/nozzle.
WARNING
For your safety, read the warning section, FIRE AND
EXPLOSION HAZARD on page 5 before flushing, and
follow all recommendations given there.
3
104
Model 222832
Shown
32
33
Bleed hole
must face
down.
Operation/Maintenance
(ALL PUMPS)

308151 13
Operation/Maintenance
(AIR-POWERED PUMPS)
Starting and Adjusting the Pump
1. Refer to Fig. 4 on page 8. Connect the suction kit (T)
to the pump’s fluid inlet, and place the tube into the
fluid supply.
2. Be sure the air regulator (F) is closed. Then open
the pump’s bleed-type master air valve (E). Hold a
metal part of the spray gun/dispensing valve (S)
firmly to the side of a grounded metal pail and hold
the trigger open. Now slowly open the air regulator
until the pump starts.
3. Cycle the pump slowly until all air is pushed out and
the pump and hoses are fully primed. Release the
gun/valve trigger and lock the trigger safety. The
pump should stall against pressure when the trigger
is released.
4. If the pump fails to prime properly, open the bleeder
valve plug (33) slightly. Use the bleed hole on the
underside of the valve body (32) as a priming valve
until the fluid appears at the hole. See Fig. 6. Close
the plug (33).
NOTE: When changing fluid containers with the hose
and gun already primed, open the bleeder valve plug
(33), to assist in priming the pump and venting air before
it enters the hose. Close the bleeder valve when all air
has been eliminated.
5. With the pump and lines primed, and with adequate
air pressure and volume supplied, the pump will start
and stop as the gun/valve is opened and closed. In a
circulating system, the pump will speed up or slow
down on demand, until the air supply is shut off.
6. Use the air regulator to control the pump speed and
the fluid pressure. Always use the lowest air
pressure necessary to get the desired results.
Higher pressures cause premature tip/nozzle and
pump wear.
7. Never allow the pump to run dry of the fluid being
pumped. A dry pump will quickly accelerate to a high
speed, possibly damaging itself. A pump runaway
valve (C), which shuts off the air supply to the pump
if the pump accelerates beyond the pre-set speed, is
available. See Fig. 4 on page 8. If your pump
accelerates quickly, or is running too fast, stop it
immediately and check the fluid supply. If the supply
container is empty and air has been pumped into the
lines, refill the container and prime the pump and the
lines with fluid, or flush and leave it filled with a
compatible solvent. Be sure to eliminate all air from
the fluid system.
Shutdown and Care of the Pump
For overnight shutdown, relieve the pressure. Stop the
pump at the bottom of its stroke to prevent fluid from
drying on the exposed displacement rod and damaging
the throat packings.
Always flush the pump before the fluid dries on the
displacement rod. Never leave water or water-based
fluid in the pump overnight. First, flush with water or a
compatible solvent, then with mineral spirits. Relieve the
pressure, but leave the mineral spirits in the pump to
protect the parts from corrosion.
WARNING
INJECTION HAZARD
To reduce the risk of fluid injection, do not use your
hand or fingers to cover the bleed hole on the
underside of the bleeder valve body (32) when
priming the pump. Use a crescent wrench to open and
close the bleeder plug (33). Keep your hands away
from the bleed hole.
WARNING
To reduce the risk of overpressurizing your system,
which could result in component rupture and cause
serious injury, never exceed the specified Maximum
Incoming Air Pressure to the pump (see the
Technical Data on pages 32–38).
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.

14 308151
Operation/Maintenance
(HYDRAULIC-POWERED PUMPS)
Starting and Adjusting the Pump
1. Refer to Fig. 5 on page 11. Connect the suction kit
(T) to the pump’s fluid inlet, and place the tube into
the fluid supply.
2. Check the hydraulic fluid level before each use, and
add fluid as necessary.
3. Make certain that the supply line shutoff valve (U)
and the return line shutoff valve (V) are closed.
4. Start the hydraulic power supply.
5. Hold a metal part of the gun/valve (S) firmly to the
side of a grounded metal pail and hold the trigger
open.
6. Open the return line shutoff valve (V) first, then
slowly open the supply line shutoff valve (U).
7. Cycle the pump slowly until all air is pushed out and
the pump and hoses are fully primed. Release the
gun/valve trigger and engage the safety latch. The
pump should stall against pressure when the trigger
is released.
8. If the pump fails to prime properly, open the bleeder
valve plug (33) slightly. Use the bleed hole, on the
underside of the body (32), as a priming valve until
the fluid appears at the hole. See Fig. 6. Close the
plug (33).
NOTE: When changing fluid containers with the hose
and gun already primed, open the bleeder valve plug
(33), to assist in priming the pump and venting air before
it enters the hose. Close the bleeder valve when all air
has been eliminated.
9. With the pump and lines primed, and with adequate
hydraulic volume supplied, the pump will start and
stop as the gun/valve is opened and closed. In a
circulating system, the pump will speed up or slow
down on demand, until the hydraulic power supply is
shut off.
10. Use the fluid pressure gauge (F) and flow control
valve (G) to control the pump speed and the fluid
outlet pressure. Always use the lowest hydraulic
flow and pressure necessary to get the desired
results. Higher pressures cause premature
tip/nozzle and pump wear.
11. Never allow the pump to run dry of the fluid being
pumped. A dry pump will quickly accelerate to a high
speed, possibly damaging itself. If your pump
accelerates quickly, or is running too fast, stop it
immediately and check the fluid supply. If the supply
container is empty and air has been pumped into the
lines, refill the container and prime the pump and the
lines with fluid, or flush and leave it filled with a
compatible solvent. Be sure to eliminate all air from
the fluid system.
WARNING
INJECTION HAZARD
To reduce the risk of fluid injection, do not use your
hand or fingers to cover the bleed hole on the
underside of the bleeder valve body (32) when priming
the pump. Use a crescent wrench to open and close
the bleeder plug (33). Keep your hands away from the
bleed hole.
WARNING
To reduce the risk of overpressurizing your system,
which could result in component rupture and cause
serious injury, never exceed 10 MPa, 103 bar (1500
psi) Maximum Hydraulic Input Pressure to the pump, or
14.0 MPa, 140 bar (2000 psi) Maximum Fluid Working
Pressure (see the Technical Data on page 38).
To prevent overpressurizing the hydraulic motor or its
seals, always shut off the supply line valve (U) first,
then shut off the return line valve (V).
CAUTION
Do not allow the hydraulic oil temperature to exceed
54° C (130° F). The pump seals will wear faster and
leakage may occur if the pump is operated at higher
oil temperatures.

308151 15
Shutdown and Care of the Pump
For overnight shutdown, relieve the pressure. Stop the
pump at the bottom of the stroke to prevent fluid from
drying on the exposed displacement rod and damaging
the throat packings.
Always flush the pump before the fluid dries on the
displacement rod. Never leave water or water-based
fluid in the pump overnight. First, flush with water or a
compatible solvent, then with mineral spirits. Relieve the
pressure, but leave the mineral spirits in the pump to
protect the parts from corrosion.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
Operation/Maintenance
(HYDRAULIC-POWERED PUMPS)

16 308151
Troubleshooting Chart
1. Relieve the pressure.
2. Check all possible causes and problems before
disassembling 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 12.
*To determine if the fluid hose or gun is obstructed, relieve the pressure. Disconnect the fluid hose and place a
container at the pump fluid outlet to catch any fluid. Turn on the air/hydraulic power just enough to start the pump. If
the pump starts when the air/hydraulic power is turned on, the obstruction is in the fluid hose or gun.
NOTE: If you experience air motor icing, contact your Graco distributor.
PROBLEM CAUSE SOLUTION
Pump fails to operate Restricted line or inadequate
air/hydraulic supply; closed or clogged
valves
Clear; increase air/hydraulic supply.
Check that valves are open.
Obstructed fluid hose or gun/valve; fluid
hose ID is too small
Open, clear*; use a hose with a larger ID.
Fluid has dried on the displacement rod Clean; always stop pump at bottom of stroke;
keep wet-cup 1/3 filled with compatible solvent.
Dirty, worn, or damaged motor parts. Clean or repair; see separate motor manual.
Pump operates, but
output low on both
strokes
Restricted line or inadequate
air/hydraulic supply; closed or clogged
valves
Clear; increase air/hydraulic supply.
Check that the valves are open.
Obstructed fluid hose or gun/valve; fluid
hose ID is too small
Open, clear*; use a hose with a larger ID.
Bleeder valve open Close.
Fluid too heavy for pump priming Use bleeder valve (see pages 13 and 14); use
ram.
Worn packings in the displacement
pump
Replace packings.
Pump operates, but
out-put low on
downstroke
Held open or worn intake valve. Clear valve; service.
Fluid too heavy for pump priming Use bleeder valve (see pages 13 and 14); use
ram.
Pump operates, but
out- put low on upstroke
Held open or worn piston valve or
packings
Clear valve; replace packings.
Erratic or accelerated
pump speed
Exhausted fluid supply Refill and prime.
Fluid too heavy for pump priming Use bleeder valve (see pages 13 and 14); use
ram.
Held open or worn piston valve or
packings
Clear valve; replace packings.
Held open or worn intake valve Clear valve; service.

308151 17
Service
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® 2760TM or equivalent
NOTE: Service Tool 109507 is available as an
accessory. The tool fits over the top of the displacement
rod, making it easier to apply a 24 inch adjustable
wrench or 3/4 in. drive socket when connecting or
disconnecting the rod from the piston assembly.
DISCONNECTING DISPLACEMENT PUMP
1. Flush the pump, if possible. Stop the pump at the
bottom of its stroke. Relieve the pressure.
2. Disconnect the air or hydraulic hose. Plug all
hydraulic hoses immediately, to prevent
contamination of the hydraulic system. Hold the fluid
outlet fitting (4) with a wrench to keep it from being
loosened while you disconnect the fluid hose.
3. Disconnect the displacement pump (105) from the
motor (101) as follows. Be sure to note the relative
position of the pump’s fluid outlet to the air or
hydraulic inlet of the motor. If the motor does not
require servicing, leave it attached to its mounting.
4. Using adjustable wrenches, unscrew the coupling
nut (103) from the connecting rod adapter (102).
Remove the coupling collars (108). Take care not to
lose or drop them. See Fig. 7.
5. Hold the tie rod flats with a wrench to keep the rods
from turning. Unscrew the nuts (106) from the tie
rods (107). Carefully remove the displacement pump
(105) from the motor (101).
6. Refer to page 20 for displacement pump service. To
service the air or hydraulic motor, refer to the
separate motor manual, supplied.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
CAUTION
Be sure to use at least two people when lifting,
moving, or disconnecting the pump. The 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, to prevent it from falling and causing
injury or property damage. Do this by securely bracing
the pump, or by having at least two people hold it
while another disconnects it.

18 308151
Service
RECONNECTING DISPLACEMENT PUMP
NOTE: On XL10000TM models, ensure that the rod
adapter (102) has not loosened during maintenance.
Proper torque is necessary to prevent the rod adapter
from loosening during the pump operation.
If the rod adapter (102) has loosened during
maintenance, remove the adapter and apply Loctite®
2760TM (or equivalent) to the rod adapter and air motor
piston threads, and then torque as specified in Fig. 7.
1. Use at least two people to hold the displacement
pump while another reconnects it to the motor (see
the CAUTION at left). Orient the pump’s fluid outlet
to the air or hydraulic inlet as was noted in step 3
under Disconnecting the Displacement Pump.
Position the displacement pump (105) on the tie
rods (107). See Fig. 7.
2. Screw the nuts (106) onto the tie rods (107) and
torque as noted in Fig. 7.
3. Place the coupling nut (103) on the displacement
rod (1), then place the coupling collars (108) into the
nut. Screw the coupling nut onto the connecting rod
adapter (102) loosely. Hold the connecting rod
adapter flats with a wrench to keep it from turning.
Use an adjustable wrench to tighten the coupling
nut. Torque as noted in Fig. 7.
4. Torque the packing nut (3) to 135–169 N.m
(100–125 ft–lb).
5. Reconnect all hoses. Reconnect the ground wire if it
was disconnected. Fill the wet-cup (3) 1/3 full of
Graco Throat Seal Liquid or compatible solvent.
6. Turn on the air or hydraulic power supply. On
hydraulic pumps, open the hydraulic return line
valve first, then the supply line valve. Run the pump
slowly to ensure that it is operating properly.
WARNING
To reduce the risk of pinching or injuring hands or
fingers caught between the hydraulic motor drip pan
and the coupling nut, always use connecting rod
adapter 184595 and tie rods 184596 on Model 222834
Viscount Pump. Never use connecting rod adapter
184451 and tie rods 184452 on Model 222834; those
parts do not allow sufficient clearance between the drip
pan and coupling nut.

308151 19
Service
King, Bulldog, and Viscount Pumps
(Model 222832 Shown) XL10000TM Pumps
(Model 24Y192 Shown)
Torque to 196–210 N.m (145–155 ft–lb)
Torque to 135–169 N.m (100–125 ft–lb)
Torque to 81–889 N.m (60–66 ft–lb)
Square hole is for use with torque wrench.
101
107
106
104
4
105
3
1
103
108
102
5
6
7
6
2
5
4
Torque to 129–142 N.m (95–105 ft–lb)
Torque to 312–340 N.m (230–250 ft–lb)
Apply Loctite®2760TM (or equivalent) to threads.
Fig. 7

20 308151
Service
DISPLACEMENT PUMP SERVICE
Disassembly
When disassembling the pump, lay out all the removed
parts in sequence, to ease reassembly. Clean all parts
with a compatible solvent and inspect them for wear or
damage. Refer to Fig. 8.
NOTE: 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 (8*). These kits can also be used to convert the
pump to different packing materials. Refer to pages 29
and .
1. Stand the displacement pump upright in a large
vise. Loosen, but do not remove, the packing nut
(3). Remove the six long cap screws (20) and
washers (33, if present), using a socket wrench.
2. Lift the outlet housing (19) straight up off the pump.
Be careful not to scratch the displacement rod (1)
while removing the housing.
3. Lift the cylinder (7), displacement rod (1), and piston
assembly off the intake housing (17).
4. Remove the seal (6), ball guide (14), intake ball (16),
intake seat housing (15), and o-ring (31) from the
intake housing (17). Inspect the ball (16) and the ball
seat (A) on the housing (15) for wear or damage.
5. Remove the seal (6) from the bottom of the outlet
housing (19). Unscrew the packing nut (3). Re-
move the glands and v-packings (T) from the
housing. Do not remove the outlet fitting (4) and
o-ring (5) unless they need replacement.
6. Unscrew the bleeder valve plug (33) completely
from the valve body (32). Clean the valve threads
and the bleed hole. It is not necessary to remove the
valve body from the pump outlet housing (19).
7. 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
cylinder 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.
NOTE: Service Tool 109508 is available as an
accessory. The tool fits over the top of the displacement
rod (1), making it easier to apply a 24 inch adjustable
wrench or 3/4 in. drive socket when disconnecting the
rod from the piston assembly.
8. 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 to
catch the piston ball (10) as you separate the
housing (12) and ball guide (9), so that it doesn’t fall
and suffer damage.
9. Remove the glands and v-packings (P) from the
piston seat housing (12). Inspect the ball (10) and
ball seat (B) on the housing (12) for wear or
damage.
10. Inspect the outer surface of the displacement rod (1)
and the inner surface of the cylinder (7) for scoring
or wear; replace either part if necessary. If the rod is
being replaced, remove the ball guide (9) as
explained in step 11.
NOTE: Do not remove the ball guide (9) from the
displacement rod (1) unless either part is damaged.
11. 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.
CAUTION
To reduce the possibility of costly damage to the rod
(1) and cylinder (7), always use a rubber mallet or an
arbor press to drive the rod out of the cylinder. Be sure
to place the cylinder on a soft block of wood. Never
use a hammer to drive the rod.