Graco Series A Bedienungsanleitung

308–359

Rev. B

Supersedes A





Model

237–513

Model 237–512

INSTRUCTIONS-PARTS

LIST

INSTRUCTIONS

This

manual contains important

warnings and information.

READ AND KEEP FOR REFERENCE.

CARBON STEEL

Dura-Flo

1200 Pumps

With

Severe-Duty Rod and Cylinder

Part No. 237–512 Pump, Series A,

21:1 Ratio, with Bulldog Air Motor

145 bar (2100 psi) Maximum Fluid Working Pressure

7 bar (100 psi) Maximum Air Input Pressure

Part No. 237–513 Pump, Series A,

13:1 Ratio, with Senator Air Motor

90 bar (1300 psi) Maximum Fluid Working Pressure

7 bar (100 psi) Maximum Air Input Pressure

Refer

to page 2 for T

able of Contents.

GRACO INC. P.O. BOX 1441

MINNEAPOLIS, MN

55440–1441

COPYRIGHT

1994, GRACO INC.

 

Table

of Contents

Warnings 2.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation/Maintenance 8

. . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

Chart

11.

. . . . . . . . . . . . . . . . . . . . . . . .

Service 12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required Tools 12.

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Disconnecting

the Displacement Pump

12.

. . . . . .

Reconnecting

the Displacement Pump

12.

. . . . . .

Displacement

Pump Service

14.

. . . . . . . . . . . . . . .

Parts

Drawings and Parts Lists

18.

. . . . . . . . . . . . . . . . .

Pump

Assemblies

18.

. . . . . . . . . . . . . . . . . . . . . . . .

Displacement

Pump

19.

. . . . . . . . . . . . . . . . . . . . . .

Technical

Data

21.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 23

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting

Hole Layout

23.

. . . . . . . . . . . . . . . . . . . . . . . . .

Warranty 24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco

Phone Numbers

24.

. . . . . . . . . . . . . . . . . . . . . . . .

Symbols

Warning Symbol

WARNING

his

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

INSTRUCTIONS

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 not sure, call Graco T

echnical Assis

tance at 1–800–543–0339.



Do not alter or modify this equipment.



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

echnical Data

on pages 21–22 for the maximum working pressure of this equipment.



Use 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.



Do not 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 82



C (180



F) or below –40



C (–40

F).

W

ear hearing protection when operating this equipment.



Do not lift pressurized equipment.



Comply with all applicable local, state, and national fire, electrical, and safety regulations.

 

WARNING

INJECTION HAZARD

Spray

from the gun, 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 medi

cal attention.



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



Do not put your hand or fingers over the spray tip.



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 when spraying.



Check the gun dif

fuser operation weekly

. Refer to the gun manual.



Be sure the gun trigger safety operates before spraying.



Lock the gun trigger safety when you stop spraying.



Follow the

Pressure Relief Procedure

on page 8 if the spray tip clogs and before cleaning,

checking or servicing the equipment.

T

ighten all fluid connections before operating the equipment.



Check the hoses, tubes, and couplings daily

. Replace worn or damaged parts immediately.

Do not repair high pressure couplings; you must replace the entire hose.



Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by

kinks or bends near the couplings.

MOVING

ARTS 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 8 to prevent the

equipment from starting unexpectedly

4 308-359

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



Ground the equipment and the object being sprayed. Refer to

Grounding

on page 5.



If 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.



Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid be

ing 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 of

f any light switch in the spray area while operating or if fumes are present.



Do 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.



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

Manual

Change Summary

The

manual has been generally updated.

 

Installation

General Information

NOTE:

Reference numbers and letters in parentheses

in the text refer to the callouts in the figures and the

parts drawing.

NOTE:

Always use Genuine Graco Parts and Acces

sories, available from your Graco distributor

. Refer to

Product Data Sheet, Form No. 305–713 (Senator

Pumps) and Form No. 305–714 (Bulldog Pumps). If

you supply your own accessories, be sure they are

adequately sized and pressure rated for your system.

Grounding

WARNING

FIRE AND EXPLOSION HAZARD

Before operating the pump, ground the

system as explained below

. Also read

the section

FIRE OR EXPLOSION HAZ

ARD

on page 4.

Pump:

use a ground wire and clamp. See Fig. 1.

Loosen the grounding lug locknut (W) and washer

(X). Insert one end of a 1.5 mm



(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.

237–569 Ground Wire and Clamp.

Fig. 1



Air and fluid hoses:

use only electrically conductive

hoses.

Air compressor:

follow manufacturer

’

s recommen

dations.

Spray gun:

ground through connection to a prop

erly grounded fluid hose and pump.

Fluid supply container:

follow your local code.

Object being sprayed:

follow your local code.

Solvent pails used when flushing:

follow 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 continu

ity.

o maintain grounding continuity when flushing or

relieving pressure

, hold a metal part of the spray

gun firmly to the side of a grounded

metal

pail,

then trigger the gun.

System Accessories

Fig.

2 is only a guide for selecting and installing

system components and accessories. Contact your

Graco representative or Graco T

echnical Assistance

(1–800–543–0339) for assistance in designing a

system to suit your particular needs.

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 (S) to allow freer gun movement.

Mounting Accessories

Mount the pump (A) to suit the type of installation

planned. Fig. 2 illustrates a wall mount system. Pump

dimensions and the mounting hole layout are shown

on page 23.

If you are using a floor stand, refer to its separate

manual for installation and operation instructions.

6 308-359

Installation

System Accessories (continued)

WARNING

bleed-type master air valve (E) and a fluid drain

valve (M) are required in your system. These ac

cessories help reduce the risk of serious injury

, in

cluding 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 of

f. T

rapped air can cause the pump to cycle

unexpectedly

. Locate the valve close to the pump.

Order Part No. 107–141.

The fluid drain valve assists in relieving fluid pres

sure in the displacement pump, hose, and gun.

riggering the gun to relieve pressure may not be

suf

ficient. Order Part No. 210–658.

Air Line Accessories

Install the following accessories in the locations shown

in Fig. 2, 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 eas

ily accessible from the pump, and is located

downstream

from the air regulator

An

air regulator (F)

controls pump speed and out

let 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

f the air to the motor

. A pump which runs too fast

can be seriously damaged.



An air manifold (G)

has a 3/4 npsm(f) swivel air

inlet. It mounts to the pump support 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

. Also,

install a

drain valve (W)

at the bottom of each air

line drop, to drain of

f moisture.

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 locations shown

in Fig. 2, 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.

A fluid drain valve (M),

which is required in your

system, helps relieve fluid pressure in the hose

and gun (see the

WARNING

at left).

A gun (S)

dispenses the fluid. The gun shown in

Fig. 2 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 supply container

308-359 7

Installation



Fig. 2

KEY

APump

BWall

Bracket

Pump Runaway V

alve

Air Line Lubricator

EBleed-T

ype Master Air V

alve

(required, for pump)

Pump Air Regulator

Air Manifold

Electrically Conductive Air Supply Hose

Air Line Filter

KBleed-T

ype Master Air V

alve

(for accessories)

Fluid Filter

Fluid Drain V

alve (required)

Electrically Conductive

Fluid Supply Hose

Fluid Whip Hose

Gun Swivel

Airless Spray Gun

Suction Kit

Ground Wire and Clamp

(required; see page 5

for installation instructions)

Air Line Drain V

alve

TYPICAL INSTALLATION

MAIN

AIR LINE

 

Operation/Maintenance

Pressure Relief Procedure

WARNING

INJECTION

HAZARD

The system pressure must be manually

relieved to prevent the system from

starting or spraying accidentally

. Fluid

under high pressure can be injected through the

skin and cause serious injury

. T

o 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,



check or service any of the system equipment,



or install or clean the spray tips.

Lock the gun trigger safety

Shut of

f the air supply to the pump.

Close the bleed-type master air valve (required in

your system).

Unlock the gun trigger safety

Hold a metal part of the gun firmly to the side of a

grounded metal pail, and trigger the gun to relieve

pressure.

Lock the gun trigger safety

Open the drain valve (required in your system),

having a container ready to catch the drainage.

Leave the drain valve open until you are ready to

spray 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

. Now clear

the tip or hose.

Packing Nut/Wet-Cup

Before

starting, fill the packing nut (2) 1/3 full with

Graco Throat Seal Liquid (TSL) or compatible solvent.

See Fig. 3.

WARNING

o reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure

at left.

The packing nut is torqued at the factory and is ready

for operation. If it becomes loose and there is leaking

from the throat packings,

relieve the pressure,

then

torque the nut to 136–149 N.m (100–1

10 ft-lb) using

the supplied wrench (1

10). Do this whenever neces

sary

. Do not overtighten the packing nut.



Fig. 3

110

Torque

to 136–149 N.m

(100–1

10 ft-lb)



Model

237–512

Shown

 

Operation/Maintenance

Flush the Pump Before First Use

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. See

Flushing

on page 10.

Starting and Adjusting the Pump

1. See

Fig. 2. Connect the suction kit (T) to the

pump’

s fluid inlet. Place the tube into the fluid sup

ply.

Close the air regulator (F).

Open the pump’

s bleed-type master air valve (E).

Hold a metal part of the gun (S) firmly to the side

of a grounded metal pail and hold the trigger open.

Slowly open the regulator until the pump starts.

Cycle the pump slowly until all air is pushed out

and the pump and hoses are fully primed.

Release the gun trigger and engage the safety

latch. The pump should stall against pressure.

If the pump fails to prime properly

, open the drain

valve (M). Use the drain valve as a priming valve

until the fluid flows from the valve. Close the valve.

NOTE:

When changing fluid containers with the hose

and gun already primed, open the drain valve (M) to

help prime the pump and vent air before it enters the

hose. Close the drain valve when all air is eliminated.

CAUTION

Do not allow the pump to run dry

. It will quickly accel

erate to a high speed, causing damage. If your pump

is running too fast, stop it immediately and check the

fluid supply

. If the container is empty and air has

been pumped into the lines, refill the container and

prime the pump and the lines, or flush and leave it

filled with a compatible solvent. Eliminate all air from

the fluid system.

With the pump and lines primed, and with ade

quate air pressure and volume supplied, the pump

will start and stop as you open and close the gun.

In a circulating system, the pump will speed up or

slow down on demand, until the air supply is shut

off.

WARNING

COMPONENT RUPTURE HAZARD

o reduce the risk of overpressurizing

your system, which could cause compo

nent rupture and serious injury

never

exceed the specified Maximum Incoming Air Pres

sure to the pump

(see the

echnical Data,

pages 21 and 22).

10.

Use the air regulator (F) to control pump speed

and fluid pressure. Always use the lowest air pres

sure necessary to get the desired results. Higher

pressures cause premature tip and pump wear

10 308-359

Operation/Maintenance

Shutdown and Care of the Pump

WARNING

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, stop the pump at the bottom

of its stroke to prevent fluid from drying on the ex

posed displacement rod and damaging the throat

packings.

Relieve the pressure.

Always flush the pump before the fluid dries on the

displacement rod. See

Flushing

below

Flushing

WARNING

FIRE AND EXPLOSION HAZARD

Before flushing, read the section

FIRE

OR EXPLOSION HAZARD

on page 4.

Be sure the entire system and flushing

pails are properly grounded. Refer to

Grounding

on page 5.

Flush with a fluid that is compatible with the fluid you

are pumping and with the wetted parts in your system.

Check with your fluid manufacturer or supplier for rec

ommended flushing fluids and flushing frequency

. Al

ways flush the pump before fluid dries on the displace

ment rod.

CAUTION

Never leave water or water-base fluid in the pump

overnight. If you are pumping water-base fluid, flush

with water first, then with a rust inhibitor such as min

eral spirits. Relieve the pressure, but leave the rust

inhibitor in the pump to protect the parts from corro

sion.

WARNING

o reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure

on page 8.

Relieve the pressure.

Remove the spray tip from the gun.

Hold a metal part of the gun firmly to the side of a

grounded

metal

pail.

Start the pump. Always use the lowest possible

fluid pressure when flushing.

5. T

rigger the gun.

Flush the system until clear solvent flows from the

gun.

Relieve the pressure.

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