INSTRUCTIONS–PARTS LIST |
306–646 |
This manual contains IMPORTANT WARNINGS AND INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
Rev R
Supersedes P
BULLDOG and KING PUMPS
DRUM LENGTH, WITH PRIMING PISTON
10:1 RATIO BULLDOG PUMPS
100 psi (7 bar) MAXIMUM AIR WORKING PRESSURE
1000 psi (70 bar) MAXIMUM FLUID WORKING PRESSURE
Model 204–287, Series K
With Standard Air Motor
Model 215–873, Series B
With Quiet Air Motor
Model 222–526, Series A
With Standard Air Motor and Severe–Duty Displacement Pump
Model 223–984, Series A
With Quiet Air Motor and Severe–Duty Displacement Pump
20:1 RATIO KING PUMPS
90 psi (6 bar) MAXIMUM AIR WORKING PRESSURE
1800 psi (124 bar) MAXIMUM FLUID WORKING PRESSURE
Model 222–248, Series A
With Standard Air Motor
Model 222–539, Series A
With Standard Air Motor and Severe–Duty Displacement Pump
Model 223–991, Series A
With Quiet Air Motor and Severe–Duty Displacement Pump
TABLE OF CONTENTS |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
||
Warnings |
2, 3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . 4 |
|
|
|
|
|
|
|
|
|
|
|
|
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . 4 |
|
|
|
|
|
|
|
|
|
|
|
|
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . 5 |
|
|
|
|
|
|
|
|
|
|
|
|
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . 6 |
|
|
|
|
|
|
|
|
|
|
|
|
. . . . . . . . . . . . . . . . . . .Troubleshooting Guide |
. . . . . . . . 7 |
|
|
|
|
|
|
|
|
|
|
|
|
Displacement Pump Service . . . . . . . . . . . . . . |
. . . . . 8–11 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
Parts Drawing – Standard Pumps |
12 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
Parts List – Standard Pumps . . . . . . . . . . . . . . |
. . . . . . . 13 |
|
|
|
|
|
|
|
|
|
|
|
|
Parts Drawing – Severe–Duty Pumps . . . . . . |
. . . . . . . 14 |
|
|
|
|
|
|
|
|
|
|
|
|
Parts List – Severe–Duty Pumps . . . . . . . . . . |
. . . . . . . 15 |
|
|
|
|
|
|
|
|
|
|
|
|
How To Order Replacement Parts . . . . . . . . . |
. . . . 13, 15 |
|
|
|
|
|
|
|
|
|
|
|
|
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . 16–18 |
|
|
|
|
|
|
|
|
|
|
|
|
Dimensional Drawing . . . . . . . . . . . . . . . . . . . . |
. . . . . . . 19 |
|
|
|
|
|
|
|
|
|
|
|
|
Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . |
. . . . . . . 19 |
|
|
|
|
|
|
|
|
|
|
|
|
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . |
Back Cover |
Model 204–287 Shown |
|||||||||||
Warranty |
Back Cover |
||||||||||||
|
|
|
|
|
|
|
|
|
|
|
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
SAFETY WARNINGS
HIGH PRESSURE FLUID CAN CAUSE SERIOUS INJURY. FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS. Read And Understand All Instruction Manuals Before Operating Equipment.
MOVING PARTS HAZARD
KEEP HANDS AND FINGERS AWAY FROM THE PRIMING PISTON DURING OPERATION AND WHENEVER THE PUMP IS CHARGED WITH AIR to reduce the risk of injury! On the pump downstroke the priming piston extends beyond the intake cylinder to pull the material into the pump. The priming piston works under extreme force. During operation and whenever the pump is charged with air, the priming piston can severely injure or amputate a hand or finger, or break a tool, caught between it and the intake cylinder. Always follow the Pressure Relief Procedure, below, before checking, clearing, cleaning, flushing or servicing any part of the pump.
The air motor piston (located behind the air motor shield) also moves when air is supplied to the motor. NEVER operate the pump with the air motor shield removed. Before servicing the pump, follow the Pressure Relief Procedure below to prevent the pump from starting accidentally.
FLUID INJECTION HAZARD
General Safety
This equipment generates very high fluid pressure. Spray from the gun/ valve, leaks or ruptured components can inject fluid through your skin and into your body and cause extremely serious bodily injury, including the need for amputation. Also, fluid injected or splashed into the eyes or on the skin can cause serious damage.
NEVER point the gun/valve at anyone or at any part of the body. NEVER put hand or fingers over the spray tip/nozzle, or over the bleeder valve hole.
ALWAYS follow the Pressure Relief Procedure, right, before cleaning or removing the spray tip/nozzle or servicing any system equipment.
NEVER try to stop or deflect leaks with your hand or body.
Be sure equipment safety devices are operating properly before each use.
Tip Guard (only on spray guns)
ALWAYS have the tip guard in place on the spray gun while spraying. The tip guard alerts you to the fluid injection hazard and helps reduce, but does not prevent, the risk of accidentally placing your fingers or any part of your body close to the spray tip.
Spray Tip/Nozzle Safety
Use extreme caution when cleaning or changing spray tips/nozzles. If the spray tip/nozzle clogs while spraying/dispensing, engage the gun/valve safety latch immediately. ALWAYS follow the Pressure Relief Procedure and then remove the spray tip/nozzle to clean it.
NEVER wipe off build–up around the spray tip/nozzle until pressure is fully relieved and the gun/valve safety latch is engaged.
Medical Alert––Airless Spray Wounds
If any fluid appears to penetrate your skin, get EMERGENCY MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE CUT. Tell the doctor exactly what fluid was injected.
Note to Physician: Injection in the skin is a traumatic injury. It is important to treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the blood stream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.
Spray Gun/Dispensing Valve Safety Devices
Be sure all gun/valve safety devices are operating properly before each use. Do not remove or modify any part of the gun/valve; this can cause a malfunction and result in serious bodily injury.
Safety Latch
Whenever you stop spraying/dispensing, even for a moment, always set the gun/valve safety latch in the closed or “safe” position, making the gun/ valve inoperative. Failure to set the safety latch can result in accidental triggering of the gun/valve.
Trigger Guard (only on spray guns)
Never operate the spray gun with the trigger guard removed. This guard helps prevent the spray gun from triggering accidentally if it is dropped or bumped.
Diffuser (only on spray guns)
The spray gun diffuser breaks up spray and reduces the risk of fluid injection when the tip is not installed. Check the diffuser operation regularly.
Follow the Pressure Relief Procedure, to the right, then remove the spray tip. Aim the spray gun into a grounded metal pail, holding the spray gun firmly to the pail. Using the lowest possible pressure, trigger the spray gun. If the fluid emitted is not diffused into an irregular stream, replace the diffuser immediately.
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin, or injury from moving parts, always follow this procedure whenever you shut of f the pump, when checking or servicing any part of the spray/dispensing system, when installing, cleaning or changing spray tips/nozzles, and whenever you stop spraying/dispensing.
1.Engage the gun/valve safety latch.
2.Shut off the air to the pump.
3.Close the bleed–type master air valve (required in your system).
4.Disengage the safety latch.
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.Engage the gun/valve safety latch.
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 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, nozzle, or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip/nozzle or hose.
306–646
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the spray/dispensing equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in fluid injection, splashing in the eyes or on the skin, or other serious bodily injury, or fire, explosion or property damage.
NEVER alter or modify any part of this equipment; doing so could cause it to malfunction.
CHECK all spray/dispensing equipment regularly and repair or replace worn or damaged parts immediately.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.
HOSE SAFETY
High pressure fluid in the hoses can be very dangerous. If the hose develops a leak, split or rupture due to any kind of wear, damage or misuse, the high pressure spray emitted from it can cause a fluid injection injury or other serious bodily injury or property damage.
ALL FLUID HOSES USED WITH A FLEXING MOTION MUST HAVE SPRING GUARDS ON BOTH ENDS! The spring guards help protect the hose from kinks or bends at or close to the coupling which can result in hose rupture.
TIGHTEN all fluid connections securely before each use. High pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coupling.
NEVER use a damaged hose. Before each use, check the entire hose for cuts, leaks, abrasion, bulging cover, or damage or movement of the hose couplings. If any of these conditions exist, replace the hose immediately. DO NOT try to recouple high pressure hose or mend it with tape or any other device. A repaired hose cannot safely contain the high pressure fluid.
FIRE OR EXPLOSION HAZARD
Static electricity is created by the flow of fluid through the pump and hose. If every part of the spray/dispensing equipment is not properly grounded, sparking may occur, and the system may become hazardous. Sparking may also occur when plugging in or unplugging a power supply cord. Sparks can ignite fumes from solvents and the fluid being sprayed, dust particles and other flammable substances, whether you are spraying/dispensing indoors or outdoors, and can cause a fire or explosion and serious bodily injury and property damage. Do not plug in or unplug any power supply cords in the spray/dispensing area when there is any chance of igniting fumes still in the air.
If you experience any static sparking or even a slight shock while using this equipment, STOP SPRAYING IMMEDIATELY. Check the entire system for proper grounding. Do not use the system again until the problem has been identified and corrected.
To ground the pump:
To ground the pump, 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. See
Fig 1. Connect the other end of the wire to a true earth ground. See ACCESSORIES on page 16 to order a ground wire and clamp.
Y
W
Z
X
Fig 1
System Pressure
The 10:1 Bulldog Pump develops 1000 psi (70 bar) MAXIMUM WORKING PRESSURE at 100 psi (7 bar) air pressure. The 20:1 King Pump develops 1800 psi (124 bar) MAXIMUM WORKING PRESSURE at 90 psi (6 bar) air pressure. Never exceed these pressures.
Be sure that all spray/dispensing equipment and accessories are rated to withstand the maximum working pressure of the pump. DO NOT exceed the maximum working pressure of any component or accessory used in the system.
Fluid Compatibility
BE SURE that all fluids and solvents used are chemically compatible with the wetted parts shown in the TECHNICAL DATA on the back cover. Always read the manufacturer’s literature before using fluid or solvent in this pump.
HANDLE AND ROUTE HOSES CAREFULLY. Do not pull on hoses to move equipment. Do not use fluids which are not compatible with the inner tube and cover of the hose. DO NOT expose Graco hoses to temperatures above 82_ C (180_ F) or below –40_ C (–40_ F).
Hose Grounding Continuity
Proper hose grounding continuity is essential to maintaining a grounded spray system. Check the electrical resistance of your air and fluid hoses at least once a week. If your hose does not have a tag on it which specifies the maximum electrical resistance, contact the hose supplier or manufacturer for the maximum resistance limits. Use a resistance meter in the appropriate range for your hose to check the resistance. If the resistance exceeds the recommended limits, replace it immediately. An ungrounded or poorly grounded hose can make your system hazardous.
Also, read FIRE OR EXPLOSION HAZARD, below.
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 your local electrical code for detailed grounding instructions for your area and type of equipment. BE SURE to ground all of this spray/dispensing equipment:
1.Pump: use a ground wire and clamp. See Fig 1.
2.Air hoses: use only grounded air hoses.
3.Fluid hoses: use only grounded fluid hoses.
4.Air compressor: follow manufacturer’s recommendations.
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.
Flushing Safety
Before flushing, be sure the entire system and flushing pails are properly grounded. Refer to Grounding, above. Follow the Pressure Relief Procedure on page 2, and remove the spray tip/nozzle from the gun/valve. Always use the lowest possible fluid pressure, and maintain firm metal–to–metal contact between the gun/valve and the pail during flushing to reduce the risk of fluid injection injury , static sparking and splashing.
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards – particularly the General Standards, Part 1910, and the Construction Standards, Part 1926 – should be consulted.
306–646 3
|
INSTALLATION |
|
|
TYPICAL INSTALLATION |
|
Y |
F |
|
|
E |
|
K |
|
J |
|
|
|
D |
|
A |
C |
G |
N |
|
M
|
B |
KEY |
|
|
|
A |
Air Supply Hose to Pump |
|
|
B |
Air Line Filter |
|
|
C |
Air Regulator and Gauge |
|
|
D |
Bleed–Type Master Air Valve |
L |
|
E |
Air Line Lubricator |
|
F |
Pump Runaway Valve |
|
|
|
G |
Bleed–Type Master Air Valve |
|
4 |
H |
Fluid Drain Valve |
H |
J |
Air–Powered Ram |
|
|
K |
Gun/Dispensing Valve |
|
|
|
L |
Grounded Fluid Supply Hose |
|
|
M |
Whip Hose |
|
|
N |
Air Supply Hose to Ram |
|
|
Y |
Pump Ground Wire |
|
|
4 |
Pump Bleeder Valve |
The reference numbers and letters in the text refer to the callouts in Figures 1–3 and the Parts Drawings.
See pages 16–18 for accessories available from Graco. Be sure all accessories are properly sized to withstand the pressures in the system.
The Typical Installation shown above is only a guide to selecting and installing required and optional accessories. For assistance in designing a system to suit your particular needs, contact your Graco representative.
The Dimensional Drawing on page 19 provides necessary measurements for mounting the pump. If you use an accessory ram (J), as shown in the T ypical Installation, refer to the separate ram manual for mounting dimension requirements.
System Accessories
Install the air line accessories in the order shown in the Typical Installation. Working upstream from the pump air inlet, install a pump runaway valve (F) to shut off the air to the pump if the pump accelerates beyond the preadjusted setting. A pump which runs too fast can be seriously damaged.
Next, install an air line lubricator (E) for automatic air motor lubrication, a bleed–type master air valve (D) to relieve air trapped between the valve and the pump, an air regulator (C) to control pump speed, and an air line filter
(B) to remove harmful dirt and moisture from the compressed air supply. Install a second bleed valve (G) on the pump air line to isolate the accessories for servicing.
Be sure the pump air line (A) is properly grounded, and is large enough to supply an adequate volume of air to the motor. An air–powered ram (J) requires a separate grounded air supply line (N).
4306–646
WARNING
Two accessories are required in your system: a bleed–type master air valve (D) and a fluid drain valve (H). These accessories help reduce the risk of serious bodily 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 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 pressure in the displacement pump, hose and spray gun; triggering the spray gun to relieve pressure may not be sufficient.
Install a fluid drain valve (H) close to the pump fluid outlet. Then connect a grounded fluid supply hose (L). Between the fluid supply hose (L) and the gun/dispensing valve (K), install a whip hose (M) for greater flexibility.
NOTE: To use the optional fluid outlet at the base of the air motor, connect a riser tube between the standard outlet and the optional outlet.
GROUNDING
WARNING
Before operating the pump, ground the system as explained under FIRE OR EXPLOSION HAZARD and Grounding on page 3.
OPERATION
WARNING
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin, or injury from moving parts, always follow this procedure whenever you shut of f the pump, when checking or servicing any part of the spray/dispensing system, when installing, cleaning or changing spray tips/nozzles, and whenever you stop spraying/dispensing.
1.Engage the gun/valve safety latch.
2.Shut off the air to the pump.
3.Close the bleed–type master air valve (required in your system).
4.Disengage the gun/valve safety latch.
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.Engage the gun/valve safety latch.
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/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, nozzle or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip/nozzle or hose.
WARNING
Moving parts can pinch or amputate your fingers or other body parts. When the pump is operating, the priming piston (located at the pump intake) and the air motor piston (located behind the air motor shield) move. Therefore, NEVER operate the pump with the air motor shield removed, and keep your fingers and hands away from the priming piston.
Before attempting to clear an obstruction from the priming piston or service the pump, follow the Pressure Relief Procedure Warning above to prevent the pump from starting accidentally.
Flush the Pump Before Using
This pump was tested with lightweight motor oil which was left in to protect the pump parts. To prevent contamination of the fluid being pumped, flush the pump with a compatible solvent before using it. If the pump is being used to supply a circulating system, allow the solvent to circulate until the pump and lines are thoroughly flushed.
Keep the packing nut/wet–cup (21) 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.
Starting and Adjusting the Pump
1.Make sure the air regulator (C), drain valve (H), and pump bleeder valve (4) are closed.
2.Open the bleed–type master air valve (D).
3.Hold a metal part of the gun/valve firmly to the side of a grounded metal pail, and trigger the gun/valve.
4.Slowly open the air regulator (C) until the pump starts running slowly and smoothly (about 20 psi [1.4 bar]). Cycle the pump slowly until all the air is purged from the pump and lines.
5.If the pump is not priming properly, open the bleeder valve (4) slightly. Do not open it all the way; the handle can come off. Cover the bleeder valve hole with something other than your hand or fingersand use it as a priming valve until the fluid appears at the bleeder hole. Close the bleeder valve.
WARNING
To reduce the risk of fluid injection, DO NOT use your hand or fingers to cover the bleeder hole when priming the pump.
6.Release the trigger and engage the safety latch. The pump will stall against pressure.
7.In a direct supply system, the pump will start and stop as the gun/valve is opened and closed. In a circulating system, it will run continuously and speed up or slow down as the system demands. Always use the lowest pressure necessary to obtain the desired results.
WARNING
To reduce the risk of serious bodily injury, including fluid injection and splashing in the eyes or on the skin, and property damage, never exceed the maximum air and fluid working pressure of the lowest rated component in your system. See EQUIPMENT MISUSE HAZARD, System Pressure, on page 3.
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. 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, prime the pump and the lines with fluid, or flush the pump and leave it filled with a compatible solvent. Be sure to eliminate all air from the fluid system.
NOTE: A pump runaway valve (F) can be installed on the air line to automatically shut off the pump if it starts to run too fast.
306–646 5
MAINTENANCE
Shutdown and Care of the Pump
Always follow the Pressure Relief Procedure Warning on page 7 whenever you shut of f the pump. Stop the pump at the bottom of its stroke to keep 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 (21) is tight. Follow the Pressure Relief Procedure Warning on page 7 first. Tighten just snug – do not overtighten or the packings may be damaged.
Always flush the pump before the fluid dries in the pump and hoses. If the pump is to be stored for any period of time, and you are pumping water–based fluid, first flush the pump with water, then with mineral spirits to protect the pump parts.
Flushing
To reduce the risk of fluid injection injury, static sparking, or splashing in the eyes or on the skin, follow the Pressure Relief Procedure Warning on page 7, and remove the spray tip (spray guns 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.
Lubrication
The accessory air line lubricator (E) provides automatic air motor lubrication. For daily , manual lubrication, disconnect the air regulator (C), place about 15 drops of light machine oil in the pump air inlet, reconnect the regulator and turn on the air supply to blow oil into the motor.
Corrosion Protection WARNING
Water, or even moist air, can cause your pump to corrode. To help prevent corrosion, never leave the pump filled with water or air. After normal flushing, flush the pump again with mineral spirits or oil– based solvent, relieve pressure, and leave the mineral spirits in the pump. Be sure to follow all steps of the Pressure Relief Procedure W arningon page 7.
6306–646