Graco Power-Flo Senator User manual

Instructions -- Parts List
Kingr, Bulldogr, and SenatorrPumps, with Priming Piston and Severe--Duty
Displacement Pump
Power--FlorPumps
15:1 Ratio Senator Pump
10.5 MPa, 105 bar (1500 psi) Maximum Working Pressure
Model 222518, Series A
200 liter (55 gallon) drum size, Standard Air Motor
25:1 Ratio Bulldog Pumps
17.5 MPa, 175 bar (2500 psi) Maximum Working Pressure
Model 222527, Series A
200 liter (55 gallon) drum size, Standard Air Motor
Model 222528, Series A
19 liter (5 gallon) ram size, Standard Air Motor
Model 223985, Series A
200 liter (55 gallon) drum size, Quiet Air Motor
Model 223986, Series A
19 liter (5 gallon) ram size, Quiet Air Motor
55:1 Ratio King Pumps
34.5 MPa, 345 bar (5000 psi) Maximum Working Pressure
Model 222545, Series B
200 liter (55 gallon) drum size, Standard Air Motor
Model 223992, Series B
200 liter (55 gallon) drum size, Quiet Air Motor
307982J
EN
Read warnings and instructions.
See page 2 for table of contents.
TI1597A

2 307982
Table of Contents
Warnings 2......................................
Installation 7.....................................
Operation 8.....................................
Troubleshooting 12...............................
Displacement Pump Service 14....................
Parts Lists and Drawings 18.......................
Technical Data and Performance Charts 22..........
15:1 Ratio Senator Pump 22.....................
25:1 Ratio Bulldog Pump 23.....................
55:1 Ratio King Pumps 24.......................
Dimensions 25...................................
Air Motor Mounting Layout 25......................
Graco Warranty 26...............................
Graco Information 26.............................
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment. Use genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
DUse 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.
DHandle hoses carefully. Do not pull on hoses to move equipment.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 66_C (150_F) or below --40_C(--40_F).
DWear hearing protection when operating this equipment.
DDo not move or lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.

3307982
WARNING
INJECTION HAZARD
Spray from the valve, leaks or ruptured components can inject fluid into your body and cause ex-
tremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can
also cause serious injury.
DFluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious
injury. Get immediate medical attention.
DDo not point the valve at anyone or at any part of the body.
DDo not put your hand or fingers over the valve tip.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DDo not “blow back” fluid; this is not an air spray system.
DAlways have the tip guard and the trigger guard on the valve when spraying.
DBe sure the valve trigger safety operates before dispensing.
DLock the valve trigger safety when you stop dispensing.
DFollow the Pressure Relief Procedure on page 8 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
MOVING PARTS HAZARD
Moving parts, such as the pump’s priming piston, can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DKeep hands and fingers away from the priming piston during operation and whenever the pump is
charged with air.
DBefore checking or servicing the equipment, follow the Pressure Relief Procedure on page 8 to
prevent the equipment from starting unexpectedly.

4 307982
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.
DGround the equipment and the object being sprayed. Refer to Grounding on page 6.
DIf 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.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
DKeep the spray area free of debris, including solvent, rags, and gasoline.
DBefore operating this equipment, electrically disconnect all equipment in the spray area.
DBefore operating this equipment, extinguish all open flames or pilot lights in the spray area.
DDo not smoke in the spray area.
DDo not turn on or off any light switch in the spray area while spraying or while operating if fumes
are present.
DDo 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.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

5307982
Notes

6 307982
Installation
General Information
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the Installation and
Parts drawings.
NOTE: Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor.
Grounding
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 4.
1. King Pumps: Use a ground wire and clamp as
shown in 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.
Bulldog Pumps: Use a ground wire and clamp as
shown in Fig. 2. Loosen the grounding lug locknut
(W) and washer (X). Insert one end of a 12 ga (1.5
mm
2
) 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 and fluid hoses: Use only electrically conduc-
tive hoses with a maximum of 500 ft (150 m)
combined hose length to ensure grounding conti-
nuity,
3. Air compressor: Follow the manufacturer’s recom-
mendations.
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
gun/valve firmly to the side of a grounded metal
pail, then trigger the gun/valve.
Fig. 1
TI1052
Y
Z
Fig. 2
Y
W
X
Z

7307982
Installation
Air Line Filter
Air Line Lubricator
Bleed--Type Master Air Valve
Air Regulator and Gauge
Fluid Drain Valve
Grounded Fluid Supply Hose
Whip Hose
Air Supply Hose to Pump
3/4 npsm(f) Air Inlet
Pump Runaway Valve
Air Supply Hose to Elevator
Pump Ground Wire
E
F
G
H
J
K
L
M
N
R
S
Y
KEY
Typical Installation
L
K
J
G
H
E
G
S
M
NR F
The Typical Installation above is only a guide to
selecting and installing accessories. For assistance in
designing a system to meet your needs, contact your
Graco distributor.
The Dimensional Drawings on page 25 provide
necessary measurements for installing the pump on a
custom designed mounting.
System Accessories
Refer to the Typical Installation drawing, above for
assistance in setting up your system. If you supply
your own accessories, be sure they are adequately
sized to meet the system’s requirements. If your pump
is mounted in a ram or elevator, refer to the manual
supplied with it for installation and operation instruc-
tions.
Install the accessories in the order shown in the Typi-
cal Installation drawing. The pump runaway valve (R)
senses when the pump is running too fast and shuts
off the air supply to the motor. The air line lubricator
(F) provides automatic air motor lubrication. The
bleed--type master air valve (G) relieves air trapped
between it and the pump when it is closed. Be sure the
valve is easily accessible from the pump. The air
regulator (H) controls pump speed and outlet pressure.
The air line filter (E) removes harmful dirt and moisture
from the compressed air supply.
WARNING
A bleed-type master air valve (G) and a fluid drain
valve (J) are required in your system. These acces-
sories help reduce the risk of serious injury includ-
ing fluid injection, splashing in the eyes or on the
skin, and injury from moving parts if you are adjust-
ing 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 . Position the valve close to the
pump.
The fluid drain valve assists in relieving fluid pres-
sure in the displacement pump, hose, and spray
gun; triggering the spray gun to relieve pressure
may not be sufficient.
Using a suitable adapter, connect a fluid drain valve (J)
near the 1 in. npt(f) fluid outlet of the pump. Then
connect a grounded fluid supply hose (K). For more
flexible spray gun movement, use a shorter 13 mm
(1/2 in.) ID hose (L) between the spray gun and the
main hose.

8 307982
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be in-
jected through the skin and cause seri-
ous injury. To reduce the risk of an injury
from injection, splashing fluid, or moving parts, fol-
low the Pressure Relief Procedure whenever you:
Dare instructed to relieve the pressure,
Dstop spraying/dispensing,
Dcheck or service any of the system equipment,
Dor install or clean the spray tips/nozzles.
1. Lock the gun/valve trigger safety.
2. Shut off the air 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/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 and/or the pump bleeder
valve (required in your system), having a container
ready to catch the drainage.
8. Leave the drain valve open until you are ready to
dispense 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, then clear
the tip or hose.
WARNING
MOVING PARTS HAZARD
Moving parts can pinch or amputate your
fingers or other body parts. When the
pump is operating, the priming piston (Q)
(located at the pump intake) and the air motor pis-
ton (located behind the air motor shield) move.
Therefore, never operate the pump with the air mo-
tor shield removed, and keep your fingers and
hands away from the priming piston.
Before attempting to clear an obstruction from the
priming piston (Q) or service the pump, follow the
Pressure Relief Procedure at left to prevent the
pump from starting accidentally.
Flush the Pump Before Using
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.
Keep the wet-cup (136) one-half full with Graco Throat
Seal Liquid (TSL), to help prevent the fluid being
pumped from drying on the displacement rod and
damaging the packings. Do not use TSL with food or
sanitary applications.
WARNING
For your safety, read the warning section Fire or
Explosion Hazard on page 4 before flushing, and
follow all recommendations given there.

9307982
Operation
Starting and Adjusting the Pump
1. Make sure the air regulator (H) is closed.
2. Open the bleed--type master air valve (G).
3. Hold a metal part of the spray gun firmly to the
side of a grounded metal pail and hold the trigger
open. Now slowly open the air regulator until the
pump starts. See the Typical Installation on page
7.
4. Cycle the pump slowly until all the air is pushed
out and the pump and hoses are fully primed.
5. Release the spray gun trigger and engage the
safety latch. The pump will stall against pressure
when the trigger is released.
6. If the pump fails to prime properly, open the bleed-
er valve plug (139) slightly. Use the bleeder hole
(P) on the underside of the valve body (138) as a
priming valve until the fluid appears at the hole.
See Fig. 3.
7. Close the bleeder valve plug (139).
WARNING
To reduce the risk of fluid injection, do not use your
hand or fingers to cover the bleeder hole when
priming the pump.
With the pump and lines primed, and with adequate air
pressure and volume supplied, the pump will start and
stop as the spray gun is opened and closed.
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.
WARNING
To reduce the risk of overpressurizing your system,
which could result in component rupture and cause
serious bodily injury, never exceed 0.7 MPa, 7 bar
(100 psi) incoming air pressure to the pump.
Fig. 3
136
P
139
Q
138
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, which shuts off the air supply to the pump if the
pump accelerates beyond the pre--set speed, is avail-
able.
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
fluid system.

10 307982
Operation
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, follow the Pressure Relief
Procedure on page 8. Always stop the pump at the
bottom of the stroke to prevent the fluid from drying on
the exposed displacement rod and damaging the
throat packings.
Every 40 hours of operation, check that the packing
nut/wet cup is tight. Follow the Pressure Relief Pro-
cedure and tighten the nut just snug -- do not overtigh-
ten, or the packings may be damaged.
Flushing
To reduce the risk of fluid injection injury, static spark-
ing, or splashing in the eyes or on the skin, relieve the
pressure, and remove the spray tip (spray guns or
spray valves only) before flushing. Hold a metal part of
the gun/valve firmly to the side of a grounded metal
pail and use the lowest possible fluid pressure during
flushing.
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.
Lubrication
The accessory air line lubricator (F) provides automatic
air motor lubrication. For daily manual lubrication,
disconnect the air supply, place about 15 drops of light
machine oil in the pump air inlet, and reconnect the air
supply to blow oil into the motor.