Graco Endura-Flo 4D150 Parts list manual

Instructions-Parts
Endura-Flo™ 4D150 and 4D350
Diaphragm Pump333015E
EN
Used to pump waterborne and solvent-based paints and catalysts. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these
instructions.
See page 3 for model information,
including maximum pressures and
approvals.
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Related Manuals ................................................ 2
Models............................................................... 3
Warnings ........................................................... 4
Installation.......................................................... 6
General Information ..................................... 6
Instructions Before First Use......................... 6
Mount the Pump .......................................... 6
Air Line........................................................ 7
Fluid Suction Line ........................................ 8
Fluid Outlet Line........................................... 8
Grounding ................................................... 12
Operation........................................................... 13
Start and Adjust the Pump............................ 13
Pressure Relief Procedure............................ 13
Pump Shutdown .......................................... 13
Maintenance ...................................................... 14
Lubrication................................................... 14
Flushing and Storage ................................... 14
Tighten Threaded Connections ..................... 14
Preventive Maintenance Schedule ................ 14
Troubleshooting.................................................. 15
Repair/Service.................................................... 17
Repair or Replace the Air Valve .................... 17
DataTrak ..................................................... 20
Disassemble the Fluid Section...................... 21
Disassemble the Center Section ................... 23
Reassemble the Center Section.................... 24
Reassemble the Fluid Section....................... 26
Torque Instructions ............................................. 29
Parts.................................................................. 30
Repair Kits ......................................................... 35
Upgrade Kit........................................................ 35
Accessories........................................................ 35
Performance Charts............................................ 36
Mounting Dimensions ......................................... 38
Technical Specifications...................................... 40
Graco Standard Warranty.................................... 42
Related Manuals
Manual
Number
Title
313840 DataTrak Kit Instructions
2333015E

Models
Models
All models have the following maximum pressures. See Performance Charts, page 36, for actual working
pressures and flow rates.
• 100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure
• 400 psi (2.8 MPa, 28 bar) Maximum Fluid Working Pressure
• 430 psi (3.0 MPa, 30 bar) Maximum Static Fluid Pressure
Model Size Porting Air Valve
24W345 150 cc Tri-clamp
24W346 150 cc npt
24W347 150 cc bspp
Standard
24W348 150 cc Tri-clamp
24W349 150 cc npt
4D150
24W350 150 cc bspp
Advanced (with DataTrak monitoring and runaway
protection)*
24W351 350 cc Tri-clamp
24W352 350 cc npt
24W353 350 cc bspp
Standard
24W354 350 cc Tri-clamp
24W355 350 cc npt
4D350
24W356 350 cc bspp
Advanced (with DataTrak monitoring and runaway
protection)*
Standard pump models are certified:
II 2GcIIBT6Gb
Advanced pump models are certified
II 2GcE
XiaIIAT3GbX
*DataTrak is certified:
II 1G
9902471 0359 Ex ia IIAT3Ga
Class 1, Div. 1, ITS13ATEX27862X
Group DT3A
333015E 3

Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation 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.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint
or solvent 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 arc).
• 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 antistatic 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.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin
and cause serious injury.
•Foll
ow the Pressure Relief Procedure when you stop spraying/dispensing and before
cleaning, checking, or servicing equipment.
•Tig
hten all fluid connections before operating the equipment.
•Che
ck hoses, tubes, and couplings daily. Replace worn or damaged parts immediately
4333015E

Warnings
WARNING
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.
• 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
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which youareusingit.
• 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.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyesoronskin,
inhaled, or swallowed.
• Read Safety Data Sheet (SDS) to know the specific hazards of the fluids you areusing.
• Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into
the air.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment
includes but is not limited to:
•Pro
tective eyewear, and hearing protection.
•Res
pirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
333015E 5

Installation
Installation
General Information
• The Typical Installation shown on p. 8 is only
a guide for installing system components and
accessories. It is not an actual system design.
Contact your Graco distributor for assistance in
designing a system to suit your particular needs.
• Always use Genuine Graco Parts and Accessories,
available from your Graco distributor. If you supply
your own accessories, be sure they are adequately
sized and pressure-rated for your system.
• Reference numbers and letters in parentheses
refer to the reference numbers in the figures and
in the Parts Lists.
Instructions Before First Use
Before using the pump:
1. Check that all fluid cover and fluid
manifold fasteners are tight. Follow the
Torque Instructions, page 29.
2. Install muffler (AB).
Mount the Pump
1. For ease of operation and service, mount the
pump so the air inlet (T), fluid inlet (N), and fluid
outlet (M) ports are easily accessible.
NOTE: The arrow labels on the pump show fluid
inlet and outlet directions.
2. Mountthepumpinawell-ventilatedareawith
sufficient clearance on all sides for operator
access and servicing.
3. The air inlet (T) must be on the opposite side of
the pump from the muffler (AB).
4. The pump can be mounted in any orientation.
The fluid manifolds can be rotated to face either
direction.
NOTE: Stand Kit 17H315 is available as a
mounting option.
5. Be sure the mounting can support the weight of
the pump, hoses, and accessories as well as the
stress caused during operation. The pump has
four mounting holes (V) for M10 (3/8 in.) bolts.
See Mounting Dimensions, page 38.
Triton Users Note: The mounting hole pattern is
the same.
KEY
N Fluid Inlet
4D150: 1 in. tri-clamp flange, 1/2 in. npt,
or 1/2 in. bspp
4D350: 1 in. tri-clamp flange, 3/4 in. npt, or
3/4 in. bspp
MFluid Outlet
4D150: 1 in. tri-clamp flange, 1/2 in. npt, or
1/2 in. bspp
4D350: 1 in. tri-clamp flange, 3/4 in. npt, or
3/4 in. bspp
TCompressed Air Connection; 1/2 npt
4D150: 1/4 in. npt
4D350: 1/2 in. npt
VMounting holes for M10 (3/8 in.) bolts
(4 required)
AB Muffler
6333015E

Installation
Air Line
1. Install the air line accessories as shown in
Typical Installation, page 8. Use adaptors as
needed. Be sure the air line supplying the
accessories is grounded.
a. Thefluidpressurecanbecontrolledwith
either an air regulator (F) to control the air
into the pump, or with a fluid regulator (H) to
control the fluid out of the pump.
b. Install a bleed-type master air valve (B) close
to the pump. This valve is required in your
system to relieve air trapped between it and
the pump when the valve is closed. Be sure
the bleed valve is easily accessible from the
pump, and is located downstream from the
air regulator.
Trapped air can cause the pump to cycle
unexpectedly, which could result in serious
injury from splashing.
c. Install a second air valve (E) upstream from
all air line accessories to isolate them during
cleaning and repair.
d. Install an air line filter (D) to remove
contaminants such as dirt, moisture, and oil
from the compressed air supply.
2. The air valve on the pump does not require
lubrication.
3. Install a grounded, flexible air hose between
the accessories and the pump air inlet (T). See
Technical Specifications, page 40, to determine
the air inlet size of your pump. Use a minimum
1/2 in. (13 mm) ID air hose.
4. If desired, install an accessory Pressure Limit
Kit in the air line, close to the air inlet. See
Repair Kits, page 35, for the correct kit for your
pump size.
333015E 7

Installation
Fluid Suction Line
•SeeTechnical Specifications, page 40,to
determine the fluid inlet size of your pump.
• For maximum suction lift (wet and dry) information,
see Technical Specifications, page 40.
1. Use flexible, conductive hoses.
2. Use a compatible liquid thread sealant on
connections to prevent air from entering the fluid
line.
3. Attach the suction line into the pump inlet (N)
snugly.
Fluid Outlet Line
1. Use electrically conductive fluid hoses (P). Attach
thefluidfi
tting onto the pump outlet (M) snugly
while supporting the outlet with a wrench. See
Technical Specifications, page 40, to determine
thefluido
utlet size of your pump.
2. Install a fluid regulator (H) at the pump fluid
outlet to control fluid pressure, if desired. See
Air Line,page 7, Step 1a, for an alternative
method to control pressure.
3. Install a fluid drain valve (J) near the fluid outlet.
To use the valve as a circulation valve, connect a
tube (K) between the valve and pail.
A fluid drain (J) valve is required in your system
to relieve pressure in the hose if it is plugged.
The drain valve reduces the risk of serious injury,
including splashing in the eyes or on the skin,
or contamination from hazardous fluids when
relieving pressure.
Some systems may require installation of a
pressure relief valve (not supplied) at the pump
outlet to prevent overpressurization and rupture of
the pump or hose.
Thermal expansion of fluid in the outlet line can
cause overpressurization. Thermal expansion
can occur when using long fluid lines exposed
to sunlight or ambient heat, or when pumping
from a cool to a warm area (for example, from an
underground tank).
Overpressurization also can occur if the pump is
used to feed fluid to a piston pump, and the intake
valve of the piston pump does not close, causing
fluid to back up in the outlet line.
8333015E

Installation
Notes
333015E 9

Installation
Typical Installation
The pump is sold separately from all accessories. Filters, regulators, fittings, hoses, etc., are shown here to
depict one possible system setup.
10 333015E

Installation
KEY
APump NPump fluid inlet
BBleed-type master air valve (required) P Fluid hose
CAir supply line R Gun air hose
DAir line filter S Spray gun
EAir line shutoff valve TPumpairinl
et
F Pump air regulator U Agitator
G Gun air regulator WGround wire
H Fluid pressure regulator X Fluid filter
J Drain/circulation valve Y Fluid circulation line
KDraintube ZBack pressure regulator (BPR)
L Fluid suction line AA BPR air regulator
MPump fluid outlet
333015E 11

Installation
Grounding
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.
• Pump: use a ground wire and clamp. Loosen the
grounding screw (X). Insert one end of a 12 ga
(1.5 mm2) minimum ground wire (W) under the
clamp and tighten the screw securely. Connect the
other end of the wire to a true earth ground. For a
ground wire and clamp, order Part No. 222011.
•
Air and fluid hoses: Use only electrically conductive
hoses.
•
Air compressor: Follow manufacturer’s
recommendations.
•
Fluid supply drum:
Follow your local code.
•
All fluid pails used when flushing:
Follow your
local code. Use only conductive metal pails
placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper
or cardboard, which interrupts the grounding
continuity.
Figure 1 Ground the Pump.
12333015E

Operation
Operation
Start and Adjust the Pump
1. Be sure the pump is properly grounded. Refer
to Grounding, page 12.
2. Check all fittings to be sure they are tight. Be
sure to use a compatible liquid thread sealant on
all male threads.
3. Place the suction line (L) in the fluid to be
pumped.
4. Place the end of the fluid outlet hose (P) into
an appropriate container (if flushing) or connect
to a gun or other dispensing device. See
Typical Installation, page 8.
5. Close the fluid drain valve (J).
6. With the pump air regulator (F) closed, open the
bleed-type master air valve (B).
7. If the fluid hose has a dispensing device, hold it
open while continuing with the following step.
8. Slowly open the air regulator (F) until the pump
starts to cycle. Allow the pump to cycle slowly
until all air is pushed out of the lines and the
pump is primed.
If you are flushing, run the pump long enough to
thoroughly clean the pump and hoses. Close the
air regulator. Remove the suction line (L) from
compatible flushing fluid and place it in the fluid to
be pumped.
NOTICE
Operating the pump dry for extended periods
or operating at pressures higher than the
recommended maximum input air pressure may
reduce diaphragm life.
Pressure Relief Procedure
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 splashing
in the eyes or on skin, follow the Pressure Relief
Procedure when you stop pumping and before you
clean, check, or service the equipment.
1. Shut off the air supply to the pump.
2. Hold a metal part of the gun (if used) to a
grounded metal pail. Trigger the gun to relieve
the pressure.
3. Open all fluid drain valves in the system, having a
waste container ready to catch drainage. Leave
drain valve(s) open until you are ready to return
to operation.
Pump Shutdown
Short Term Shutdown
For a short term shutdown, relieve the pressure (see
procedure on this page).
Long-Term Shutdown
For a long term shutdown, such as several hours or
overnight:
1. Flush the pump thoroughly.
2. Leave compatible flushing fluid in the pump.
3. Relieve the pressure (see procedure on this
page).
333015E 13

Maintenance
Maintenance
Lubrication
The pump is lubricated at the factory. It is designed to
requirenofu
rther lubrication for the life of the pump.
NOTICE
Do not over-lubricate the pump. Oil is exhausted
through the muffler and could contaminate your
fluid supply or other equipment. Excessive
lubrication can also cause the pump to malfunction.
Flushing and Storage
To avoid fire and explosion, always ground
equipment and waste container. To avoid injury
from splashing and static buildup, always flush at
the lowest possible pressure.
• Flush the pump often enough to prevent the fluid
you are pumping from curing, drying, or freezing in
the pump and damaging it.
• Flushwithafluidthatiscompatiblewiththefluid
you are pumping and with the equipment wetted
parts.
• Flush the pump and follow the
Pressure Relief Procedure, page 13, before storing
the pump.
Flush procedures vary widely
by system requirements. See
Start and Adjust the Pump, page 13, for one common
method of flushing. If your system is different, or if
you are unsure how to completely flush your system,
contact your Graco distributor.
Tighten Threaded Connections
1. Before each use, check all hoses for wear or
damage, and replace as necessary.
2. Check to be sure all threaded connections are
tight and leak-free.
Preventive Maintenance Schedule
Establish a preventive maintenance schedule based
on the service history of the pump. Scheduled
maintenance is especially important to prevent spills
or leakage due to diaphragm failure.
14333015E

Troubleshooting
Troubleshooting
• Follow the Pressure Relief Procedure, page 13,
before checking or servicing the equipment.
• Check all possible problems and causes before
disassembly.
Problem Cause Solution
The check valve cartridges (9) are
worn.
Replace.
Theoutletfluidvalveisworn. Replace.
Pump cycles at stall or fails to hold
pressure at stall.
The diaphragm (18) is worn. Replace.
The air valve is stuck or dirty. Disassemble and clean air valve.
Use filtered air.
The check valve cartridges (9) are
worn.
Replace.
The fluid dispensing valve is
clogged.
Relieve pressure and clear valve.
The fluid hose line is pinched. Check lines.
The diaphragm plate (21) is installed
backwards.
Follow installation directions in
Install the Diaphragms, page 26.
The checks are not installed
properly.
Follow installation directions in
Install the Fluid Manifolds, page 28.
Pump will not cycle, or cycles once
and stops.
Pilot valves (12) are not working. Replace.
Suction line is clogged. Inspect; clear.
Check valves are sticky or leaking. Clean or replace check valve
cartridges (9).
Diaphragm (18) is ruptured. Replace.
Exhaust is restricted. Remove restriction.
Pump operates erratically.
Checks are not installed properly. Follow installation directions in
Install the Fluid Manifolds, page 28.
Suction line is loose. Tighten.
Fluid contains air bubbles.
Diaphragm (18) is ruptured. Replace.
Diaphragm (18) is ruptured or pump
has worn parts.
Replace worn parts. Check
compressed air supply.
Pump is running irregularly. Stroke
frequency is dropping, coming to a
standstill. Pump is icing. Possible causes
include: compressed air too moist,
stroke frequency too high, local
temperature too low.
Remove ice by changing operating
conditions.
333015E 15

Troubleshooting
Problem Cause Solution
Air valve cup (112) is damaged. Replace damaged parts.
Foreign matter is inside the pump. Check air filter.
Air escapes continually from the
muffler.
Shaft seals (26) are worn. Replace.
Check valve cartridges (9) are worn. Replace.
Inlet strainer is blocked. Maximum
suction is exceeded. Hose or seal is
defective.
Clean strainer. Replace defective
parts.
Fluid is contaminated. Pump was
installed or operated incorrectly.
Check fluid supply. Follow
installation and operation
instructions in this manual.
Pump does not start, or pressure
fluctuates.
Checks are not installed properly. Follow installation directions in
Install the Fluid Manifolds, page 28.
16 333015E

Repair/Service
Repair/Service
Repair or Replace the Air Valve
Replace Complete Air Valve
1. Stop the pump. Follow the
Pressure Relief Procedure, page 13.
2. Disconnect the air line.
3. For models with DataTrak:
Remove the screw to disconnect the reed switch
assembly from the air valve. Then, remove
two screws and the solenoid bracket. Pull the
solenoid out of the air valve.
4. Remove screws (17). Remove the air valve (1)
and the gasket (13).
5. To repair the air valve, go to
Replace Seals or Rebuild Air Valve, page 18,in
next section.
6. Align the new air valve gasket (13) on the
manifold, then attach the new or repaired air
valve. See Torque Instructions, page 29.
7. For models with DataTrak:
Remember to reattach the solenoid bracket and
the solenoid. Then, use the screw to attach
the reed switch assembly to the new air valve.
Reconnect cable.
8. Reconnect the air line.
1Torque to 100–120 in-lb (11–14 N•m).
333015E 17

Repair/Service
Replace Seals or Rebuild Air Valve
See Repair Kits, page 35, to find the correct repair
kits for your pump. Parts in Air Valve Seal Kits are
marked †. Parts in Air Valve Repair Kits are marked
. Parts in End Cap Kits are marked .
Disassemble the Air Valve
1. Perform steps 1–4 under
Replace Complete Air Valve, page 17.
2. Use a T8 Torx screwdriver to remove two screws
(109). Remove the valve plate (105), the cup
(112, 4D150 models) or the cup assembly
(112–114, 4D350 Models), the spring (111), and
the detent assembly (103).
3. 4D350 Models: Pull the cup (112) off of the base
(114). Remove the o-ring (113) from the cup.
4. Remove the retaining ring (110) from each end
of the air valve. Use the piston (102) to push the
end caps (107, 117) out of the ends. Remove
the end cap o-rings (106). If the pump model
is equipped with DataTrak, also remove the
solenoid release button (118) and o-ring (119).
5. Remove the u-cup seals (108) from each end
of the piston (102), then remove the piston.
Remove the detent cam (104) from the air valve
housing (101).
Reassemble the Air Valve
NOTE: Apply lithium-based grease whenever
instructed to grease.
1. Use all parts in the repair kits. Clean other parts
and inspect for damage. Replace as needed.
2. Grease the detent cam (104) and install it into
the housing (101).
3. Grease the u-cups (108) and install on the piston
with the lips facing toward the center of the
piston.
18 333015E

Repair/Service
Air Valve Disassembly or Reassembly
1Apply lithium-based grease.
2U-cup lips must face piston.
333015E 19

Repair/Service
4. Grease both ends of the piston (102) and install
it in the housing (101), with the flat side toward
the cup. Be careful not to tear u-cups (108) when
sliding piston into housing.
5. Standard Models: Grease new o-rings (106) and
install on the end caps (107). Install the end caps
into the housing.
DataTrak Models: Orient the air valve so the air
inlet faces forward. Grease and install new o-ring
(106) on right-side end cap (107). Grease and
install new o-ring (106) and the solenoid release
button (118) and o-ring (119) on the left-side end
cap (117). Install the end caps into the housing.
6. Install a retaining ring (110) on each end to hold
caps in place.
7. Grease and install the detent assembly (103) into
the piston.
8. 4D150 Models: Install the spring (111). Grease
the side of the air valve cup (112) that will contact
the valve plate (105) Install the air valve cup
(112). Align the small round magnet (B) with the
air inlet.
4D350 Models: Install the o-ring (113) on the
cup (112). Apply a light film of grease to the
outside surface of the o-ring and the inside
mating surface of the base (114). Orient the end
of the base that has a magnet toward the end of
the cup that has the larger cutout. Engage the
opposite end of the parts. Leave the end with
the magnet free. Tilt the base toward the cup
and fully engage the parts, using care so that the
o-ring remains in place. Install the spring (111)
onto the protrusion on the cup. align the magnet
in the base with the air inlet and install the cup
assembly.
9. Grease the cup side, and install the valve plate
(105). Align the small hole (A) in the plate with
the air inlet. Tighten the screws (109) to hold it
in place.
DataTrak
NOTE: See DataTrak manual, 313840, for all
DataTrak service, repair and operation information.
Replace DataTrak Battery or Fuse
To reduce the risk of fire and explosion, the battery
and fuse must be replaced in a non-hazardous
location. Follow all instructions in the DataTrak
manual 313840.
Use only an approved replacement battery, and
an approved fuse (see DataTrak manual). Use of
an unapproved battery or fuse will void Graco’s
warranty and Ex approvals.
20 333015E