Graco Series D Operation manual

Instructions–Parts List
307044R
Divorced Design, 55 Gallon Drum Size, 2” npt Bung Mounting
5:1 Ratio Monark Pump
For transfer and supply of solventborne and waterborne finishing materials.
900 psi (6.2 MPa, 62 bar) Maximum Fluid Working Pressure
180 psi (1.2 MPa, 12 bar) Maximum Air Input Pressure
Part No. 218956, Series D
With PTFE Packings
II 1/2 G T2
ITS03ATEX11228
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.

2 307044
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 18. . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
corresponding instructions.
WARNING
INSTRUCTIONS
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 uncertain about usage, call your Graco
distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 18 for the maximum working pressure of this equipment.
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.
DDo not exceed the maximum working pressure of the lowest rated system component. This equip-
ment has a 900 psi (6.2 MPa, 62 bar) maximum working pressure.
DDo not use hoses to pull equipment.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).
DWear hearing protection when operating this equipment.
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.

3307044
WARNING
SKIN INJECTION HAZARD
Spray from the gun, 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.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
surgical treatment.
DDo not point the gun at anyone or at any part of the body.
DDo not put your hand or fingers over the spray 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 gun when spraying.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DBe sure the gun trigger safety operates before spraying.
DLock the gun trigger safety when you stop spraying.
DFollow the Pressure Relief Procedure on page 8 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
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.
DUse only Graco approved hoses. Do not remove any 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.
DKeep clear of all moving parts when starting or operating the pump.
DBefore servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the
equipment from starting unexpectedly.

4 307044
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.
DGround the equipment and the object being sprayed. Refer to Grounding on page 5.
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.
DElectrically disconnect all equipment in the spray area.
DExtinguish 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 operating or 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.

5307044
Installation
Grounding
To reduce the risk of static sparking, ground the pump,
object being sprayed, and all other spray/dispensing
equipment used or located in the spray/dispensing
area. Check you local electrical code for detailed
grounding instructions for your area and type of equip-
ment. Be sure to ground all of this spray/dispensing
equipment:
1. Pump: loosen the grounding lug locknut (W) and
washer (X). Insert one end of a 12 ga. (1.5 mm2)
minimum ground wire (Y) into the slot in lug (Z)
and tighten the locknut securely. See Fig. 1. Con-
nect the other end of the wire to a true earth
ground.
2. Air hoses: use only electrically conductive air
hoses.
3. Fluid hoses: use only electrically conductive fluid
hoses.
4. Air compressor: follow manufacturer’s recommen-
dations.
5. Spray gun/dispensing valve: grounding is obtained
through connection to a properly grounded fluid
hose and pump.
6. Fluid supply container: according to your local
code.
7. Object being sprayed: according to your local
code.
8. 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.
9. 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
WY
XZ

6 307044
Installation
KEY
ABleed–Type Master Air Valve (required, for pump)
BFluid Drain Valve (required)
CAir Line Lubricator
DPump Air Regulator
EAir Line Filter
FBleed–Type Master Air Valve (for accessories)
GElectrically Conductive Air Line
HElectrically Conductive Fluid Line
JPump Runaway Valve
YGround Wire (required)
A
B
CDEF
G
H
Y
J
MAIN AIR SUPPLY LINE
Typical Installation

7307044
Installation
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and parts
drawing.
The Typical Installation shown on page 6 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.
System Accessories
See the Typical Installation on page 6.
WARNING
Two accessories are required in your system: a
bleed-type master air valve (A) and a fluid drain
valve (B). These accessories help reduce the risk
of serious injury including fluid injection, splashing
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
regulator 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 pres-
sure in the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may not be
sufficient.
Mounting Accessories
Mount the pump to suit the type of installation planned.
The pump dimensions and mounting hole layout are
shown on page 18.
The bung adapter has 2” npt threads. Install the pump
in the drum cover until it is 1/2” (13 mm) from the
bottom of the drum, then tighten the bung adapter.
Air and Fluid Hoses
Be sure all air and fluid hoses are properly sized and
pressure-rated for your system. Use only electrically
conductive air and fluid hoses. Fluid hoses must have
spring guards on both ends.
Connect an electrically conductive fluid hose (H) to the
pump’s 3/4 npt(f) fluid outlet.
Connect an electrically conductive 3/8 in. ID (mini-
mum) air hose (G) to the pump’s 3/8 npt(f) air inlet.
Air Line
Install the following accessories in the order shown in
the Typical Installation, using adapters as necessary:
DA pump runaway valve (J) 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. Install closest to the pump
air inlet.
DAn air line lubricator (C) provides automatic air
motor lubrication.
DA bleed-type master air valve (A) is required in
your system to relieve air trapped between it and
the motor when the valve is closed (see the WARN-
ING at left). Be sure the bleed valve is easily ac-
cessible from the pump, and is located downstream
from the air regulator.
DAn air regulator (D) 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.
DAn air line filter (E) removes dirt and moisture
from the compressed air supply.
DA second bleed-type air valve (F) isolates the air
line accessories for servicing. Locate upstream
from all other air line accessories.
Fluid Line
DA fluid drain valve (B) is required in your system
to relieve fluid pressure in the hose and gun (see
the WARNING at left). Install the drain valve point-
ing down, but so the handle points up when
opened.

8 307044
Operation
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
Fluid under high pressure can be in-
jected 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:
Dare instructed to relieve the pressure,
Dstop spraying/dispensing,
Dcheck or service any of the system equipment,
Dor install or clean the spray tip/nozzle.
1. Lock the spray gun/dispensing valve trigger safety.
2. Close the pump air regulator.
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 (required in your system),
having a container ready to catch the drainage.
8. Leave the drain valve open until you area 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 or hose end coupling
and relieve pressure gradually, then loosen completely.
Now clear the tip/nozzle or hose.

9307044
Operation
Flush the Pump Before Using
The pump is tested in lightweight oil, which is left in to
protect the pump parts. To prevent contamination of
fluid, flush the pump with a compatible solvent before
using it.
Fill the wet-cup 1/2 full with Graco Throat Seal Liquid
(TSL) or a compatible solvent. Keep the cup half-filled
at all times to help prevent the fluid you are pumping
from drying on the exposed displacement rod and
damaging the throat packings.
Starting and Adjusting 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.
1. See the Typical Installation on page 6. Be sure
the air regulator (D) and bleed-type master air
valve (A) are closed. Do not install the spray tip
yet!
2. Hold a metal part of the spray gun/dispensing
valve firmly to the side of a grounded metal pail
and hold the trigger open. Then open the pump’s
bleed-type master air valve (A). Now slowly open
the air regulator (D) until the pump starts, about 40
psi (280 kPa, 2.8 bar).
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. Relieve the pressure.
5. With the pump and lines primed, and with ade-
quate 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 run
continuously and will speed up or slow down as
the system demands until the air supply is shut off.
Always use the lowest air pressure necessary to
get the desired results. Higher pressures waste
fluid and cause premature wear of the pump
packings and spray tip/nozzle.
WARNING
Never exceed the Maximum Working Pressure of
the lowest rated component in the system, to
reduce the risk of component rupture which can
cause serious injury, including fluid injection or
splashing in the eyes or on the skin.
6. 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 (J), which shuts off the air supply to
the pump if the pump accelerates beyond the
pre-set speed is available. If your pump acceler-
ates quickly or is running too fast, stop it immedi-
ately 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.

10 307044
Maintenance
Check Valve Adjustment
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
The piston and intake check valves are set for medium
viscosity fluids. To adjust the valves, first relieve the
pressure, then disassemble the pump as described in
the Service section on page 12.
Remove the ball stop pin (17) from the intake valve
seat (30). Move the pin to a higher set of holes to
increase the ball travel for heavier fluids, or to a lower
set of holes to decrease the ball travel for lighter fluids.
To adjust the piston ball travel, loosen the locknut (3)
and turn the piston (11) counterclockwise to increase
the ball travel and clockwise to decrease the ball
travel. For medium viscosity fluid, the ball travel should
be 0.19” (4.8 mm). See Fig. 2.
Fig. 2
37
11
4
17
1530
5
26
3
PIN (17) IN
MIDDLE HOLES
FOR MEDIUM
VISCOSITY)
19” (4.8 mm)
FOR MEDIUM
VISCOSITY)
19” (4.8 mm)
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, always relieve the pressure.
Always stop the pump at the bottom of its stroke to
prevent the fluid from drying on the exposed displace-
ment rod and damaging the throat packings.
Keep the packing nut/wet-cup 1/2 filled with Graco
Throat Seal Liquid (TSL) or compatible solvent to help
prolong packing life. Adjust the packing nut (35) weekly
so it is just tight enough to prevent leakage; do not
overtighten. Relieve the pressure before adjusting the
packing nut. Then use a spanner wrench or a 0.25”
(6.3 mm) diameter rod to tighten the nut. See Fig. 3.
Fig. 3
35
0.25”
(6.3 mm)
DIA. ROD
If you are pumping fluid which dries, hardens, or
sets-up, flush the system with a compatible solvent as
often as necessary to prevent a buildup of the fluid in
the pump or hoses.
CAUTION
Never leave the pump or hoses filled with water or
air. To help prevent corrosion, flush the water and all
air out of the system and leave it filled with mineral
spirits or an oil-based solvent. Be sure to relieve the
pressure after flushing.
Flushing
To reduce the risk of fluid injection injury, static spark-
ing, or splashing, relieve the pressure and remove
the spray tip (airless 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 when flushing.
Lubrication
The accessory air line lubricator (C) provides automat-
ic air motor lubrication. For daily, manual lubrication,
disconnect the regulator, place about 15 drops of light
machine oil in the pump air inlet, reconnect the regula-
tor and turn on the air supply to blow oil into the motor.