Graco Dura-Flo 1800 Technisches Referenzhandbuch

Instructions - Parts

Dura-Flo™Lowers

Carbon Steel or Stainless Steel Lowers, with Severe-Duty Rod and Cylinder. For use on

Graco pumps, sprayers and fluid handling systems. For professional use only.

Dura-Flo 1800 (430 cc) Lowers

Dura-Flo 2400 (580 cc) Lowers

See page 3 for model information, including maximum working pressure.

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

TI8341a

311825L

2311825L

Contents

Models ...................................3

Warnings .................................4

Repair ....................................6

Pressure Relief Procedure .................6

Required Tools ..........................6

Disassembly ............................7

Reassembly ............................8

Parts ....................................11

Dura-Flo 1800 (430 cc) Lowers .............12

Dura-Flo 2400 (580 cc) Lowers .............14

Repair Kits ...............................16

UHMWPE and PTFE Packings .............16

PTFE and Leather Packings ...............17

PTFE Packings .........................18

UHMWPE and Leather Packings ...........19

Dimensions ..............................21

Technical Data ............................21

Graco Standard Warranty ...................22

GracoInformation .........................22

Models

311825L 3

Models

Lower Part

No. and

Series Description Packings

Maximum Fluid

Working Pressure

222796, A Dura-Flo 1800 (430 cc) carbon steel 3 PTFE/2 leather 32 MPa (324 bar, 4700 psi)

24W644 Dura-Flo 1800 (430 cc) carbon steel 3 UHMWPE/2 PTFE 32 MPa (324 bar, 4700 psi)

222988, A Dura-Flo 1800 (430 cc) carbon steel 5 PTFE 32 MPa (324 bar, 4700 psi)

222805, A Dura-Flo 1800 (430 cc) stainless steel 3 UHMWPE/2 PTFE 32 MPa (324 bar, 4700 psi)

241956, A Dura-Flo 1800 (430 cc) stainless steel 3 UHMWPE/2 PTFE 32 MPa (324 bar, 4700 psi)

246925, A Dura-Flo 1800 (430 cc) stainless steel 3 UHMWPE/2 leather 32 MPa (324 bar, 4700 psi)

246987, A Dura-Flo 1800 (430 cc) stainless steel 4 leather, 3 UHMWPE throat/

3 UHMWPE, 2 leather piston

32 MPa (324 bar, 4700 psi)

246988, A Dura-Flo 1800 (430 cc) stainless steel 4 leather, 3 UHMWPE throat/

3 UHMWPE, 2 leather piston

32 MPa (324 bar, 4700 psi)

249992, A Dura-Flo 1800 (430 cc) stainless steel 4 leather, 3 UHMWPE throat/

3 UHMWPE, 2 UHMWPE piston

32 MPa (324 bar, 4700 psi)

687055, A Dura-Flo 1800 (430 cc) stainless steel 3 UHMWPE/2 carbon-filled PTFE 32 MPa (324 bar, 4700 psi)

C59703, A Dura-Flo 1800 (430 cc) stainless steel 3 UHMWPE/2 PTFE 32 MPa (324 bar, 4700 psi)

L430CM Dura-Flo 1800 (430 cc) carbon steel 4 leather, 3 UHMWPE throat/

3UHMWPE, 2 leather piston

32 MPa (324 bar, 4700 psi)

L430CS, A Dura-Flo 1800 (430 cc) carbon steel 3 UHMWPE/2 PTFE 32 MPa (324 bar, 4700 psi)

L430SS, A Dura-Flo 1800 (430 cc) stainless steel 3 UHMWPE/2 PTFE 32 MPa (324 bar, 4700 psi)

L430SM, A Dura-Flo 1800 (430 cc) stainless steel 4 leather, 3 UHMWPE throat/

3 UHMWPE, 2 leather piston

32 MPa (324 bar, 4700 psi)

222801, A Dura-Flo 2400 (580 cc) carbon steel 3 PTFE/2 leather 24 MPa (235 bar, 3400 psi)

222991, A Dura-Flo 2400 (580 cc) carbon steel 4 leather/1 PTFE backup 24 MPa (235 bar, 3400 psi)

222992, A Dura-Flo 2400 (580 cc) carbon steel 5 PTFE 24 MPa (235 bar, 3400 psi)

C59798, B Dura-Flo 2400 (580 cc) carbon steel 3 PTFE/2 leather 24 MPa (235 bar, 3400 psi)

222803, A Dura-Flo 2400 (580 cc) stainless steel 3 UHMWPE/2 PTFE 24 MPa (235 bar, 3400 psi)

222993, A Dura-Flo 2400 (580 cc) stainless steel 3 PTFE/2 leather 24 MPa (235 bar, 3400 psi)

222994, A Dura-Flo 2400 (580 cc) stainless steel 5 PTFE 24 MPa (235 bar, 3400 psi)

236226, A Dura-Flo 2400 (580 cc) stainless steel 3 UHMWPE/2 PTFE 24 MPa (235 bar, 3400 psi)

236230, A Dura-Flo 2400 (580 cc) stainless steel 4 leather/1 PTFE backup 24 MPa (235 bar, 3400 psi)

241648, A Dura-Flo 2400 (580 cc) stainless steel 3 UHMWPE/2 carbon-filled PTFE 24 MPa (235 bar, 3400 psi)

249991, A Dura-Flo 2400 (580 cc) stainless steel 4 leather, 3 UHMWPE throat/

3 UHMWPE, 2 UHMWPE piston

24 MPa (235 bar, 3400 psi)

15F298, A Dura-Flo 2400 (580 cc) stainless steel 4 leather, 3 UHMWPE throat/

3 UHMWPE, 2 leather piston

24 MPa (235 bar, 3400 psi)

L580CS, A Dura-Flo 2400 (580 cc) carbon steel 3 UHMWPE/2 PTFE 24 MPa (235 bar, 3400 psi)

L580SS, A Dura-Flo 2400 (580 cc) stainless steel 3 UHMWPE/2 PTFE 24 MPa (235 bar, 3400 psi)

L580SM, A Dura-Flo 2400 (580 cc) stainless steel 4 leather, 3 UHMWPE throat/

3 UHMWPE, 2 leather piston

24 MPa (235 bar, 3400 psi)

Warnings

4311825L

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back

to these warnings. Additional, product-specific warnings may be found 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. 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).

• 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.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just

a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

checking, or servicing equipment.

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 MSDS forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-

facturer’s replacement parts only.

• Do not alter or modify equipment.

• 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.

Warnings

311825L 5

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,

follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or

swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear impervious gloves when spraying or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating

area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic

fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

WARNING

Repair

6311825L

Repair

Pressure Relief Procedure

1. Engage trigger lock.

2. Shutoff the pump:

a. For air-powered pumps, close the bleed-type

master air valve.

b. For hydraulic-powered pumps, close the supply

line shutoff valve (U) first, then close the return

line shutoff valve (V).

3. Disengage the trigger lock.

4. Hold a metal part of the gun firmly to a grounded

metal pail. Trigger the gun to relieve pressure.

5. Engage the trigger lock.

6. 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 spray

again.

7. If you suspect the spray tip or hose is clogged or

that pressure has not been fully relieved after follow-

ing the steps above, VERY SLOWLY loosen tip

guard retaining nut or hose end coupling to relieve

pressure gradually, then loosen completely. Clear

hose or tip obstruction.

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®2760™or equivalent

Trapped air can cause the pump to cycle unexpect-

edly, which could result in serious injury from splashing

or moving parts.

Accessory Service Tools are available which fit

over the top of the displacement rod, making it eas-

ier to use a 24 in. adjustable wrench or 3/4 in. drive

socket when disassembling/assembling the rod

and piston.

• For Dura-Flo 1800 (430 cc) Lowers, order Part

No. 109507 Tool.

• For Dura-Flo 2400 (580 cc) Lowers, order Part

No. 109508 Tool.

Repair

311825L 7

Disassembly

Lay out all the removed parts in sequence, to ease reas-

sembly. Clean all parts with a compatible solvent and

inspect them for wear or damage. Refer to FIG.1.

1. Flush the pump, if possible. Stop the pump at the

bottom of its stroke. Relieve the pressure, page 6.

2. Disconnect the lower from the motor. See your sep-

arate pump assembly manual.

3. Stand the lower upright in a large vise. Loosen, but

do not remove, the packing nut (3). Remove the six

long cap screws (20).

4. Lift the outlet housing (19) straight up off the lower.

Be careful not to scratch the displacement rod (1)

while removing the housing.

5. Lift the cylinder (7), displacement rod (1), and piston

assembly off the intake housing (17).

6. Remove the seal (6), ball guide (14), intake ball

(16), intake seat housing (15), and o-ring (27) from

the intake housing (17). Inspect the ball (16) and the

ball seat (A) on the housing (15) for wear or dam-

age.

7. Remove the seal (6) from the bottom of the outlet

housing (19). Unscrew the packing nut (3). Remove

the glands and v-packings (T) from the housing. Do

not remove the outlet fitting (4) and o-ring (5) unless

they need replacement.

8. Unscrew the bleeder valve plug (35) completely

from the valve body (34). Clean the valve threads

and the bleed hole. It is not necessary to remove the

valve body.

9. 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 cylin-

der 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.

10. 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

that the piston ball (10) doesn't fall as you separate

the housing (12) and ball guide (9).

11. Remove the glands and v-packings (P) from the pis-

ton seat housing (12). Inspect the ball (10) and ball

seat (B) on the housing (12) for wear or damage.

12. Inspect the outer surface of the displacement rod (1)

and the inner surface of the cylinder (7) for scoring

or wear; replace if damaged. If replacing the rod,

remove the ball guide (9) (see step 13).

13. 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.

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 (11*). These kits also can be

used to convert the lower to different packing mate-

rials. Refer to pages 16-20.

CAUTION

To reduce the possibility of costly damage to the rod

(1) and cylinder (7), first place the cylinder on a soft

block of wood. Always use a rubber mallet or an arbor

press to drive the rod (1) out of the cylinder (7). Never

use a hammer to drive the rod.

Accessory Service Tools are available which fit

over the top of the displacement rod, making it eas-

ier to use a 24 in. adjustable wrench or 3/4 in. drive

socket when disassembling/assembling the rod

and piston.

• For Dura-Flo 1800 (430 cc) Lowers, order Part

No. 109507 Tool.

• For Dura-Flo 2400 (580 cc) Lowers, order Part

No. 109508 Tool.

Do not remove the ball guide (9) from the displace-

ment rod (1) unless either part needs replacement.

Repair

8311825L

Reassembly

1. If the ball guide (9) was removed, place the flats of

the displacement rod (1) in a vise. Apply anti-seize

lubricant 222955 to the threads and mating faces of

the rod and the ball guide. Screw the ball guide onto

the rod, hand tight. Remove from the vise. See FIG.

2. Install the piston packings (P) on the piston (12) in

the correct order for your lower, see Repair Kits,

pages 16-20. Install the v-packings one at a time

with the lips facing up.

3. Apply anti-seize lubricant 222955 to the threads and

mating faces of the ball guide (9) and piston seat

housing (12). Place the flats of the piston seat hous-

ing in a vise. Place the ball (10) on the piston seat.

Screw the assembled rod (1) and ball guide (9) onto

the piston assembly hand tight, then torque to

459-481 N•m (338-354 ft-lb).

4. Use an arbor press to reinstall the rod (1) into the

cylinder (7), as follows. (The cylinder is symmetrical,

so either end may face up.) Lubricate the piston

packings (P). With the piston end facing down,

lower the rod into the cylinder. Start the piston into

the cylinder as much as possible, then drive the rod

and piston the rest of the way into the cylinder with

the arbor press.

5. Lubricate the o-ring (27*) and seal (6*). Install the

o-ring on the intake seat housing (15). Install the

intake seat housing (15), intake ball (16), ball guide

(14), and seal (6*) in the intake housing (17). Set the

intake housing all the way into the vise.

6. Place the cylinder (7) on the intake housing (17).

Tap on the top of the displacement rod (1) with a

rubber mallet, to seat the cylinder.

7. Lubricate the throat packings (T). Install the throat

packings (T) in the outlet housing (19) in the correct

order for your lower, see Repair Kits, pages 16-20.

Install the v-packings one at a time with the lips fac-

ing down.

8. Lubricate the threads of the packing nut (3), and

loosely install it in the outlet housing (19).

9. Lubricate the seal (6*) and install it in the bottom of

the outlet housing (19). Set the outlet housing on

top of the cylinder (7). Apply thread lubricant to the

six long cap screws (20). Install the cap screws

through the outlet housing (19) and thread them

loosely by hand into the intake housing (17). Tighten

the cap screws oppositely and evenly, then torque

to 244-264 N•m (180-195 ft-lb).

10. Install the bleeder valve plug (35). The plug has two

sets of threads. Be sure to screw the plug fully into

the valve body (34). Torque the plug to 30-38 N•m

(22-28 ft-lb).

11. Reconnect the lower to the motor as explained in

your separate pump assembly manual.

To convert the lower to a different packing material,

see pages 16-20.

Accessory Service Tools are available which fit

over the top of the displacement rod, making it eas-

ier to use a 24 in. adjustable wrench or 3/4 in. drive

socket when disassembling/assembling the rod

and piston.

• For Dura-Flo 1800 (430 cc) Lowers, order Part

No. 109507 Tool.

• For Dura-Flo 2400 (580 cc) Lowers, order Part

No. 109508 Tool.

CAUTION

To reduce the possibility of costly damage to the rod

(1) and cylinder (7), first place the cylinder on a soft

block of wood. Always use a rubber mallet or an arbor

press to drive the rod (1) into the cylinder (7). Never

use a hammer to drive the rod.

To convert the lower to a different packing material,

see pages 16-20.

It is not ordinarily necessary to remove the outlet fit-

ting (4) and o-ring (5*). However, if they were

replaced because of damage, lubricate the o-ring

and place it on the fitting. Screw the fitting into the

outlet housing (19). Torque to 156-171 N•m

(115-126 ft-lb).

Repair

311825L 9

FIG. 1. Cutaway View

910

27*A

Torque to 156-171 N•m (115-126 ft-lb).

Torque to 135-169 N•m (100-125 ft-lb).

For 241648, 249991, and 15F298, limit torque to 27-40 N•m

(20-30 ft-lb).

Torque to 459-481 N•m (338-354 ft-lb).

Torque oppositely and evenly to 244-264 N•m (180-195 ft-lb).

Apply anti-seize lubricant to threads and mating faces.

Lubricate.

Apply thread lubricant.

Use arbor press to drive into cylinder (7).

Unscrew plug from valve housing

and clean.

Torque to 30-38 N•m (22-28 ft-lb).

Used on lowers with stainless steel

capscrews only.

33 11

TI8392a

Repair

10 311825L

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