Graco BULLDOG E Series Operation manual

307–050
Rev. J
Supersedes Rev. G
and PCN H
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
BULLDOG
Adjust-A-Stroke Air Motor
Model 210–302, Series E
Stroke Adjustor (only) 207–583
Stroke adjuster infinitely varies the stroke length from
1–9/16 to 4–1/4 inches (39.5 – 106 mm).
Three digit indicator allows repeat settings with +/– 1%
accuracy.
These air motors and special order air motor 952–356
can be used with any of the displacement pumps
shown in the chart on pages 20 and 21. The chart also
gives the required connecting parts and pump dimen -
sions.
01812
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1993, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

 
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Parts Drawing 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Parts List 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke Adjuster Parts Drawing and List 18. . . . . . . . . . .
Dimensions 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Mounting Diagram 19. . . . . . . . . . . . . . . . . . . . . . .
Technical Data 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump V ariation Chart 20. . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust-A-Stroke Pump Specification 21. . . . . . . . . . . . .
Warranty 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 24. . . . . . . . . . . . . . . . . . . . . . . . . .
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 .
D
This equipment is for professional use only .
D
Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are unsure about usage, call your Graco
distributor.
D
Do not alter or modify this equipment.
D Check equipment daily . Repair or replace worn or damaged parts immediately .
D Do not exceed the maximum working pressure stated for your equipment. Do not exceed the
maximum working pressure of the lowest rated component in your system.
D Do not lift pressurized equipment.
D Handle hoses carefully . Do not pull on hoses to move equipment.
D Route 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).
DW
ear hearing protection when operating this equipment.
D 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 is a serious injury . The injury may look like just a cut, but it is a serious
injury . Get immediate medical 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.
 Always have the tip guard and the trigger guard on the gun when spraying.
 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 7 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, damaged, or loose parts immediately .

4 307-050
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
being sprayed.
 Keep the spray area free of debris, including solvent, rags, and gasoline.
 Before operating this equipment, electrically disconnect all equipment in the spray area.
 Before operating this equipment, 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 spraying or while operating 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 .


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 .
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.
1. Pump: use a ground wire and clamp as shown in
Fig. 1. Loosen the grounding lug locknut (W) and
washer (X). Insert one end of a 12 ga (1.5 mm )
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
number 222–01 1 Grounding Clamp and Wire.
2. Air and fluid hoses: use only electrically conductive
hoses.
3. Air compressor: follow manufacturer ’ s recommen -
dations.
4.
Spray gun or dispensing valve: ground through
connection to a properly grounded fluid hose and
pump.
5.
Object being sprayed: follow your local code.
6. 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.
7.
T 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.

Y
W
ZX
Fig 1

6 307-050
Installation
KEY
ABleed–type
Master Air V alve
B
Fluid Check V alve
C
Fluid Drain V alve
D
Air Regulator
E Pneumatic or Electric
Solenoid V alve
G
Air Filter
H Pneumatic or Electric
Control Center
J Control Switch
K Automatic Dispensing V alve
L
Optional Fluid Regulator
Y Ground Wire
3 Stroke Adjuster
01813
A
B
C
D
E
G
H
J
K
L
Y3
A
G
ED
The Typical Metering System shown above is only a
guide
to selecting and installing required and optional ac -
cessories.
Contact your Graco distributor or Graco T ech-
nical Assistance (see back page) for assistance in de-
signing
a system to suit your particular needs.
CAUTION
In order to prevent damage to the adjuster and
motor , do not move the stroke adjuster (3) until the
motor is completely installed and the system is fully
primed. Always have the air motor operating when
adjusting the stroke. See page 9 for adjusting
instructions. Never force the adjusting knob; if it does
not turn easily, service the adjusting mechanism (see
page 1 1).
Grounding
Before operating the air motor or system, be sure the
pump and all system components are thoroughly
grounded.
See page 5.
Accessories
Many accessories mentioned or shown in the Typical
Installation are available from Graco. See ACCESSO-
RIES
on page 17 or contact your distributor .
WARNING
A bleed-type master air valve (A) and a fluid drain
valve (C) are required in your system to help
reduce the risk of serious injury , including fluid
injection, splashing in the eyes, or injury from
moving parts, if you are adjusting or repairing the
pump or motor.
The bleed-type master air valve stops the air
supply to the motor and relieves the air from the
motor so that the pump cannot cycle unexpectedly .
The fluid drain valve relieves fluid pressure in the
displacement pump, hose, and dispensing valve;
triggering or actuating the dispensing valve may
not be suf ficient to relieve pressure.


Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
including fluid injection, splashing in the
eyes or on the skin, or injury from mov -
ing parts or electric shock, always follow this proce -
dure whenever you:
 are instructed to relieve the pressure,
 stop spraying,
 check or service any of the system equipment,
 install or clean the spray tips,
 or shut off the pump.
1. Engage the spray gun safety latch.
2. T urn of f the air to the pump.
3. Close the bleed-type master air valve (required in
your system).
4. Disengage the gun safety latch. Hold a metal part
of the gun or valve firmly to a grounded metal
waste container and trigger it to relieve the fluid
pressure. Engage the safety latch.
5. Open the pump drain valve (required in your
system), having a container ready to catch the
drainage.
6. 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.

8 307-050
Operation
1. The piston must be at the bottom of its stroke. Apply
low pressure air to move the piston down.
2. Fasten the restraining bracket (32) to two of the three
tie rods (M), using the clamps (31), with the screws
(30)
and washers (29) loosely installed.
3. Turn the piston tube stud (73) to align it with the slot
in the bracket (32). Raise the bracket to 1/2 to 3/4 in.
(12–19 mm) from the top of the stud. Hold the brack -
et and tighten the tie rod clamps securely . See Fig 2.
CAUTION
Run the motor for a couple of cycles at low air pres -
sure to see that the piston tube or pump coupling
nut (N) do not hit the bracket (32)
4. Screw the electric control pressure switch or pneu-
matic count line tube from the control center (H) to
the
1/4 npt(f) fitting on the side of the motor shield.
01814
1/2 to 3/4”
(12–19 mm)
31
73 32
M
PISTON
IN DOWN
POSITION
N
30
29
Fig 2
5. To change the stroke length , first be sure the motor
air regulator (D) is closed. Then open the master air
valve (A). Slowly open the air regulator until the mo -
tor starts. Then loosen the locking knob (19) of the
stroke
adjustor (3), and turn the adjusting knob (20)
counterclockwise to shorten the stroke. Now tighten
the locking knob (19). See Fig 3.
NOTE: The air motor is factory set for the full stroke
length
of 4.25 in. (106 mm) or 480 on the adjuster
indicator (12). The shortest possible stroke
length
is 1.5625 in. (39.5 mm).
6. Record the number shown on the indicator (12). If
you change this setting, and at a later date want to
repeat
this setting, return the indicator to that setting.
If the pressure and fluid temperature are the same as
before, the amount of fluid dispensed will be the
same
within one percent.
01815
Fig 3
Turn adjusting knob (20)
counterclockwise
to shorten stroke
12
20 19
3
1
1

9307-050
Operation
How To Find The Stroke Setting
NOTE: Read this procedure, then study the example be -
fore
determining the stroke setting.
1.
Set the adjuster to 480 on the indicator (12). Operate
the pump to measure the Maximum Full Stroke
Output
of the displacement pump, measure the out -
put
in ounces.
2. Multiply the Maximum Full Stroke Output by 0.375
(37 1/2% – a constant number) which gives the Mini-
mum Output Possible.
3. The Output Range is all of the numbers between the
Minimum Output Possible and Maximum Full Stroke
Output.
4. Determine the Lowest Number in the Output Range
which can be evenly divided into the Container Size,
and then divide that number into the total ounces of
the container to get the Ounces Per Cycle.
5. Subtract the Minimum Output Possible from the
needed Ounces Per Cycle to determine the Vari-
able
Number .
6. Subtract the Minimum Output Possible from the
Maximum Full Stroke Output to determine the
Output
Range Number .
7. Divide the Variable Number by the Output Range
Number
to determine the Percent of Range.
8. Multiply the Percent of Range by 4.83 (a constant
number)
to determine the T rial Setting.
EXAMPLE:
1. In this example, the Maximum Full Stroke Output
is
8 oz. The Container Size is 20 oz.
2. 0.375 (37 1/2% – Constant Number)
x8 (Maximum Full Stroke Output)
=3 (Minimum Output Possible)
3. 3 oz. to 8 oz. is the Output Range
4. 20 (Container Size)
4 (Lowest number in Output Range
which divides evenly into
Container Size)
=5 (Ounces Per Cycle)
5. 5 (Ounces Per Cycle)
–3 (Minimum Output Possible)
=2(V ariable Number)
6. 8 (Maximum Full Stroke Output)
–3 (Minimum Output Possible)
=5 (Output Range Number – not related
to ounces per cycle)
7. 2(Variable Number)
5 (Output Range Number)
=.40 (or 40% of the Range)
8. 4.83 (Constant Number)
x40 (Percent of Range)
=193 (YOUR TRIAL SETTING)
NOTE: Remember, the pump exhausts twice each
cycle,
so in this case, set the counter to 8 (2 x 4)
rather than 4 which is the lowest number in the
output range which divides evenly into the con-
tainer size.

10 307-050
Troubleshooting
Motor Icing
As the motor exhausts air, the compressed air rapidly
expands and lowers the temperature inside the motor
to below freezing. If there is moisture in your air sup -
ply
, it can cause icing on the outside of the motor .
T
o help prevent icing, be sure the compressed air
supply is clean and dry . An air and water seperator
with a 20 micron filter element can remove much of the
moisture, oil and other contaminants. A dessicant air
dryer , downstream from the seperator , will dry the air
to –45 F (–42.8 C) dewpoint to provide very dry air to
the motor .
Air Leaking
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
Relieve the pressure , then disconnect the air supply
hose from the motor .
Screw the inlet union (35) out of the air manifold.
remove the adjuster (see page 1 1). Remove the air
motor shield (37). Screw the union into the manifold.
Connect the air hose. Open the bleed-type master air
valve (A), and slowly open the air regulator (D). use
the Check Chart to determine the source of the leak.
WARNING
T o reduce the risk of pinching or amputating your
fingers, keep them clear of all moving parts in the
motor and keep them out of the exhaust openings.
Check Chart
NOTE: The reference numbers in the Check Chart
refer only to Fig. 4.
Stroke
Position Ref.
Points
Checking Method Cause of
Leakage
UP only
1 By feel Blown air manifold
gaskets
UP , only
(air
valve 2
By feel Blown air cylinder
gasket
valve
housing
down) 3
Squirt oil
around wiper
W orn throat
packing
)
4 By feel Blown air manifold
gaskets
DOWN,
only (air
5 By feel Damaged
connecting tube
gasket
only (air
valve
housin
g
6 Squirt oil around
bearing W
orn trip rod
packing
housing
up) 7
Squirt oil around
air bearing
Damaged trip rod
bearing gasket
BOTH
8 Squirt oil around
air valves W
orn air valves or
their packings
BOTH 9
Hold paper strip
over exhaust
holes
W orn air piston
packing
Fig 4
01816
8
1, 4
AIR INLET
UNION
01817
WIPER
7
6
1
2
3
5
9
Hold paper strip over ex -
haust holes.
1
2
1
Push trip rod down
to start stalled motor .2

11307-050
Service
Stroke Adjuster Repair (Fig 5)
CAUTION
If you do not remove the trip rod (33), record the
indicator reading BEFORE removing the adjuster
assembly (3) so that you can set it at the same
number when reinstalling it. This will keep the adjust -
er setting in agreement with the stroke setting and
prevent possible damage to the air motor .
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
1. Relieve the Pressure
2. Loosen the housing collar setscrew (9). Holding the
adjuster assembly (3), screw the collar (24) out of the
detent housing (82). Now lift the adjuster assembly
up.
3.
Remove the cover (15). Remove the setscrew (6) on
the side which holds the gear adjusting shaft (21).
4. Pull out the shaft (21) and adjusting knob (20), and
then remove the gear (14).
5. Remove the end plate (18). Remove the setscrew (6)
from the gear (14). Pull out the shaft (22) and indica -
tor
(12), and then remove the gear (14).
CAUTION
Be careful not to drop or damage the indicator (12),
which can be easily damaged.
6. If you need to replace the indicator (12), loosen the
two
setscrews (1 1) in the shaft (22) and pull the indi -
cator
of f of the shaft. When installing a new indicator ,
tighten
the setscrews (1 1) firmly into the shaft.
7. Remove the remaining gear (26) from the retainer
(23).
8.
Clean the gears and shafts thoroughly. Inspect all
parts
and replace any that are worn or damaged.
9. When reassembling the adjuster, align the holes in
the shafts with the setscrews, and tighten the
setscrews
snugly .
10. If
necessary , add more grease to the stroke adjuster
housing (16) until it just covers the center gear (26).
Do not lubricate the indicator (12).
01818
Fig 5
10131920
21
24
78
18 25 12 2211
5
4
15
6
14
26
23
27
17
REF NO. 3
STROKE ADJUSTER ASSEMBL Y
INCLUDES ITEMS 4–27
9
16

12 307-050
Service
NOTE: Packing Repair Kit 206–734 is available. Use all
the new parts in the kit, even if the old ones look good.
Be
sure you have all the repair parts available to reduce
down time. Reference numbers with an asterisk, for ex-
ample (52*), indicate parts included in the kit.
Air V alve Repair (See Fig 6)
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
1. Relieve the pressure .
2. Remove the stroke adjuster as explained in Step 2
of
Stroke Adjuster Repair .
3. Remove the air inlet fitting (35) and disconnect the
ground
wire. See the Parts Drawing.
4. Remove the screws (43), washers (38) and air motor
shield (37). See the Parts Drawing.
5. Unscrew each spring retainer (66) and remove the
spring (68), guide (67) and plunger (83) from each
side
of the detent housing (82).
CAUTION
Handle all springs carefully . Nicks and scratches
cause extra stress on the weakened points of the
springs and may cause them to break during use.
6. Remove the screws (46) and washers (40) from the
detent housing (82). Carefully lift the housing so the
rollers (85) and axles (86) are not dropped or dam-
aged.
Remove the washer (60) and pad (61).
7. While holding in the director valves (74), push the
motor
piston up from the bottom of the base (2). T urn
the
air valve housing (64) so it rests on the manifolds
(78). Remove the spring (59), o–ring (52) and air di -
rector
valve (74) from each side of the housing.
8. Pull the trip rod (33) up as far as possible and grasp
it with the special locking pliers (order part no.
207-579).
Hold the flats of the air valve housing with
a wrench, screw of f the trip rod nut (65) and remove
the lockwasher (42). Remove the air valve housing
(64).
Screw of f the hub (69). Release the pliers.
CAUTION
Be sure the trip rod (33) does not turn, which would
change the stroke setting. Also, be careful not to
damage the rod surface.
9. Remove the two screws (41) and lockwashers (42)
from each air manifold (78). Remove the manifold
gaskets (75) from the cylinder (81).
WARNING
The valve plate (84) openings are razor sharp! Be
careful not to cut yourself when handling them.
10. Check the valve plates (84) and seals (76) and re-
place
them if they are worn or damaged.
11. Clean the mating surfaces of the valve plates and
manifolds,
then reassemble using the screws (47).
NOTE: If no further service is needed, skip to Reas-
sembly
Step 1 1.
NOTE: T
o service the piston, continue as follows.
01819
Fig 6
66
68*
67
83
85 86
61
60
65
42
64 69
33
41
42
46
40
82
78
*75
*84 47
*74
*52*59
91
76
61
60
49

13307-050
Service
Piston Repair (See Fig. 9)
12. Remove the screws (44) and lockwashers (39) and
pull the cylinder (81) straight up off the piston. Re-
move
the dampener pad (61) and washer (60).
13. Remove the trip rod bearing (1), using a 1 in.socket
wrench. Remove the gasket (51), washer (54) and
packing (55) from the bearing.
14. Pull
the piston (89), piston rod (90) and trip rod (33)
up out of the base (2). Remove the o–ring (62).
15. Place a wrench on the turned down part of the piston
rod (90) and screw out the stud (73).
16. Place a wrench on the top of the trip rod (33) and turn
the rod clockwise until the top socket (72) is free.
Then
count the number of turns it takes to screw out
the bottom socket (71). W rite the number down: it is
important when reassembling the motor .
NOTE: If the trip rod is broken, use a 9/16 in. hex key
wrench to remove the bottom socket (71). A
damaged
trip rod cannot be repaired; use a new
one.
17. Remove the trip rod (33) from the piston rod (90).
See Fig 7.
01820
62
90
33
89
Fig 7
Reassembly (See Fig. 9)
1. Clean all parts thoroughly and inspect for wear or
damage.
Replace parts as necessary .
2. Screw the bottom socket (71) into the piston rod (90)
the number of turns you counted in Step 16, above.
The end of the socket should extend 1/8 in.(3 mm)
from
the piston (89). Slide the trip rod into the piston.
Install the top socket (72), turning it clockwise until
the
socket is flush with the top of the piston; the bot -
tom socket should be 1 in. (25 mm) into the piston
rod.
See Fig 8.
Fig 8
50
73
62
33
89
1
3

72
1
23
Flush
with piston (89)
when assembled corectly
Apply thread locking
compound
1”
to threaded
part when
assembled
correctly
3. Place a copper gasket (50) on the piston stud (73).
Apply
thread sealant to the stud threads, and screw
the stud firmly into the piston assembly .
4. Check the adjusting mechanism by turning the trip
rod (33) clockwise until it stops. The top socket
should extend about 1/16 in. (2 mm) above the pis-
ton. Now turn the rod counterclockwise until the
socket
is again flush with the piston.
5. Grease the cavity in the base (2) and install a washer
(57*) and a v–packing (56*) so the lips of the v–pack -
ing
face up in the base.

14 307-050
Service
6. Grease the piston (89), o–ring (62*), and inside of the
cylinder (81). Place the cylinder upside down on a flat
surface. Place the o–ring around the piston; the o–
ring
is larger than the piston groove. Install the piston
in the cylinder so the excess of the o–ring fits into the
one of the notches on the flange of the cylinder. Use
your fingers to push the o–ring out of the notch and
seat
it in the piston groove. Push the piston into the
the cylinder to hold the o–ring in place.
7. Regrease the inside of the cylinder (81), the trip rod
(33) and the piston stud (73). Be sure the gasket (53)
is properly located on the base (2).
8. Guide the piston assembly and cylinder into the
base,
aligning the cylinder and base correctly . Install
the lockwashers (39) and screws (44) snugly .
9. Install a washer (54*) and v–packing (55*) in the
bearing
(1) so the lips of the v–packing face down in
the cylinder . Install the o–ring (51) on the bearing.
10. Install the bearing (1) in the cylinder throat.
11. Push the piston up and thread the trip rod nut (65)
loosely onto the trip rod. Use a 1 in. socket wrench
to
tighten the bearing (1) into the cylinder .
12. Install
the dampener pad (61) and washer (60) in cyl -
inder
throat.
01822
Fig 9
60
65
61
54*
55*
62*
56*
57*
2
90
33*
*1
*51
72
89
81
39,44
53
71
73

15307-050
Service
13. Place the air valve spacer tool (168–513) on the cyl -
inder.
Position the gaskets (75*) and manifolds (78)
on the cylinder . Install the screws (41) and washers
(42). Remove the tool. See Fig 10.
14. Push the piston all the way up. Remove the trip rod
nut
(65). Slide the hub (69) onto the rod, then grasp
the rod below the hub with the special locking pliers.
Screw the hub down as far as possible.
15. Install the air valve housing (64), washer (42) and trip
rod nut (65). Hold the flats of the valve housing with
a wrench and with another wrench, tighten the trip
rod
nut so the top of the threads are flush with the top
of the nut, or one screw thread is visible above the
nut, and the nut is torqued to 21–25 ft–lb (28–35
N.m).
See Fig 10. T urn the valve housing so it rests
on the manifolds, then release the pliers.
16. Install the o–rings (52*) on the director valves (74).
Grease the director valves and springs (59) and
place
in each side of the air valve housing. Hold the
parts in at the top and carefully rotate the valve hous -
ing until it slides down between the manifolds. Be
very
careful not to pinch your fingers!
17. Recheck the clearance by holding the air valve
spacer
tool up close to the manifold.
18. Grease the plunger (83), and guide (67) and install
them
with the spring (68) into each side of the detent
housing (82). Loosely screw a retainer (66) into each
side of the housing.
19. Install the dampener pad (61) and washer (60) in the
bottom of the detent housing. Grease and assemble
the axles (85) and rollers (86) and install in housing.
20. Position the detent housing on the manifolds and in -
stall the washers (40) and screws (46). Now finish
tightening the retainers (66). Finally, tighten the
screws (46) firmly.
21. Install
the air motor shield, washers, screws, and the
air inlet fitting. Install the Stroke Adjuster as de-
scribed
on page 8. Reconnect the ground wire.
SPACING T OOL
168–513 41
42
75*
0.031” (0.79 mm) Max
Fig 10
64
78
01823
01816
78
1
3
2
1
Torque
to 21–25 ft-lb (28–35 N m)
3Top
of threads flush with top
of nut (65), or one thread
visible above nut.
2
65

 
Parts Drawing
49
91
87
88
82
**84
47
**7476
*52 *59 64
72
62*
89
90
33**
71
50
73
56*
57*
2
29
31 30
70
58
63
45
41
42
66
68*
67
83
85 86
61
60
65
42
69
1**
51**
*54
*55 61
60
81
44
39
**53
78
*75
35
37
46
40
43
38
80
01826
28
3
1See
seperate parts list on page 18
1

17307-050
Parts List
Model 210–302, Series E
Includes items 1–91
REF
NO. PART NO. DESCRIPTION QTY REF NO. PART NO. DESCRIPTION QTY
1
204–649** BEARING, trip rod 1
2 235–995
BASE, air motor 1
3 207–583 STROKE ADJUSTER ASSY
See separate parts list on page 16 1
28 207–590 RESTRAINING BRACKET
Includes items 29–32 1
29 100–086 .W
ASHER, plain; 3/16” 4
30 100–643 .CAPSCREW
, soc hd; 1/4–20 x 1” 4
31 168–044 .CLAMP 2
32 207–589 .BRACKET
, restraining 1
33 207–593** TRIP ROD 1
35 207–648 UNION, 90_
adapter;
3/4 npsm(f) x 3/4 npsm(m) swivel 1
37 171–791 SHIELD, motor 1
38 100–016 LOCKW
ASHER, spring; 1/4” 8
39 100–018 LOCKW
ASHER, spring; 1/2” 8
40 100–052 LOCKW ASHER, spring; 7/16” 4
41 100–101 CAPSCREW
, hex hd; 3/8–16 x 1” 4
42 100–133 LOCKW ASHER, spring; 3/8” 5
43 100–333 CAPSCREW
, hex hd; 1/4–20 x 1/2” 8
44 100–424 CAPSCREW
, hex hd;
1/2–13 x 1–1/4” 8
45 101–845 SCREW
, self tap, type “F”;
6–32 x 1/4” 8
46 101–713 CAPSCREW
, hex hd;
7/16–14 x 3–1/2” 8
47 101–716 SCREW
, mach, flat hd; 10–24 x 1/2” 8
49 100–403 PLUG, pipe; 1/8 npt 1
50 150–429** GASKET
; copper 2
51
150–647** GASKET ; copper 1
52 156–698* P ACKING, o–ring; nitrile rubber 2
53
161–556** GASKET , cylinder 1
54 161–559* W ASHER, flat; leather 1
55 161–560* V–P
ACKING; leather 1
56 161–562* V–PACKING; buna–N 1
57 161–563* W
ASHER, flat; leather 1
58 161–569
SEAL, plain encased 1
59
161–575** SPRING, compression 2
60 161–576 W
ASHER, flat; steel 2
61 161–577 P
AD, dampener; rubber 2
62 161–578* P
ACKING, o–ring; nitrile rubber 1
63 176–305 PLA
TE, name 1
64 161–585 HOUSING, air valve 1
65 161–586 NUT
, trip rod 1
66 161–587 RETAINER, spring 2
67 161–588 GUIDE, spring 2
68
161–589** SPRING, compression 2
69 161–590 HUB, valve housing 1
70 168–054
STUD, pump conn. 1
71 168–057 SOCKET
, trip rod, right hand thd 1
72 168–058 SOCKET , trip rod, left hand thd 1
73 168–059
STUD, piston tube 1
74 168–182** VAL
VE, air director 2
75 168–183* GASKET , air manifold 2
76 168–184
SEAL, valve plate 2
77 168–185 GROMMET ; nitrile rubber 1
78 168–187 MANIFOLD, air 1
171–715 MANIFOLD, air 1
80 168–491 DECAL, “Graco” 1
81 169–372 CYLINDER 1
82 177–664 HOUSING, detent 1
83 169–583 PLUNGER, detent 2
84
169–584** PLATE, valve 2
85 169–585 ROLLER 2
86 169–586
AXLE 2
87 104–029 GROUNDING LUG 1
88 104–582 WASHER 1
89 168–055 PISTON 1
90 168–056 ROD, piston 1
91 171–714 UNION, adapter; 1/8 npt(mxf) 1
*Included in Repair Kit 206–734.
**Recommended spare parts to keep on hand.

 
Parts
10131920
21
16
24
9
27
17
14
26
23
5
4
15
6
11 22
12
2518
78
01818
REF
NO. PART NO. DESCRIPTION QTY
4 100–079 .LOCKW
ASHER, spring; No. 8 4
5 100–649 .SCREW
, mach, fil hd; 8–32 x 1/2” 4
6 101–702 .SETSCREW , soc hd, cup pt;
5–40 x 1/4” 2
7 101–791 .SCREW
, mach, rd hd; 5–40 x 3/8” 3
8 101–792 .LOCKWASHER, ext shkprf; No. 5 3
9 101–949 .SETSCREW
, soc hd, cup pt;
10–32 x 5/8” 1
10 102–296 .CAPSCREW , soc hd; 5–40 x 1/2” 1
11 102–679 .SETSCREW , soc hd, cup pt;
3–48 x 3/16” 2
12 102–682 .INDICAT OR, odometer 1
13 151–395 .W
ASHER, flat; steel, No. 5 1
14 168–028 .GEAR, bevel 2
REF
NO. PART NO. DESCRIPTION QTY
15 168–031 .COVER, housing 1
16 168–032 .HOUSING, stroke adjuster 1
17 168–033 .SCREW
, shoulder , hex hd; 3/8–24 x
1–1 1/32” 2
18 168–034 .PLA
TE, instruction 1
19 168–035 .KNOB, locking 1
20 168–036
.KNOB, adjusting 1
21 168–037 .SHAFT
, adjusting 1
22 168–038 .SHAFT , straight, gear 1
23 168–039 .RET
AINER, housing 1
24 168–042
.COLLAR, housing 1
25 168–324 .BEARING, indicator; aluminum 1
26 207–582 .GEAR, bevel 1
27 207–587
.CLEVIS, lifting 1
207–583 STROKE ADJUSTER ASSY
Includes items 4–27


Dimensions
01812
24 1/4”
(616 mm)
3/4 npt
AIR INLET
1 1 1/3”
(285.7 mm)
DIA.
Mounting Hole
Layout
7/16” (1 1 mm) DIA.
4 holes on 10 1/2”
(266 mm) Bolt Circle
9 3/4”
(246.65 mm)
DIA.
4”
(101.6 mm)
USE GASKET
161–806
90_
45_
1 3/8”
(35 mm)
R
Manual Change Summary
The following changes have been added to this manual:
 The entire manual was updated electronically .

The air motor base for assembly 210–302 (Ref. 2) was changed from Part No. 206–782 to 235–995.
Technical Data
Effective piston area 38 sq. in. (2470 mm
2).
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston diameter 7 in. (177.8 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke 1–9/16 to 4–1/4 in. (39.5–106 mm), continuously variable . . . . . . . . . . . . . . . .
Air valves Nitralloy; dual, slide type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve housing Balanced, opposing seals and detent rollers . . . . . . . . . . . . . . . . . . . . .
Packings Nitrile rubber , leather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 
ADJUST-A-STROKE Pump V ariation Chart
C linder Material Piston T pe Packing Material Reference to Air Motor Displacement Connecting
Tie Rods Tube
Elbow Std. Pump No. Dimension Pump Rod

Displacement Pump
15:1 Senator
SD T & U PP 222–518 32.75” (831.8 mm) 217–540 222–639 168–212 620–013 None None
CST T & U PP 222–489 32.75” (831.8 mm) 217–540 222–639 168–212 620–013 None None
25:1 Senator
SD T & U PP 222–525 32.5” (826 mm) 217–540 222–640 168–054* 620–056 None None
CST T & U PP 222–519 32.5” (826 mm) 217–540 222–640 168–054* 620–056 None None
5:1 Bulldog
CST L DB 221–104 32.50” (825.5 mm) 210–302 210–208 168–054* 620–054 161–612 None
SST R DP 206–418 19.25” (489 mm) 210–302 206–452 166–041 620–055 None None
SST T DP 206–796 19.25” (489 mm) 210–302 206–453 166–041 620–055 None None
SST R DP 207–321 32.25” (819.1 mm) 210–302 206–452 166–041 620–055 166–047 None
10:1 Bulldog
CST T & U PP 204–287 32.25 (819.1 mm) 210–302 204–641 168–054* 620–056 None None
SD T PP 207–172 31.375” (796.9 mm) 210–302 207–242 166–041 620–057 None None
SST R DB 206–596 21.875” (555.6 mm) 210–302 206–613 166–041 620–058 None None
SST T DB 206–797 21.875” (555.6 mm) 210–302 206–792 166–041 620–058 None None
CST T DB 207–268 23.50” (596.9 mm) 210–302 208–577 168–212 620–059 None None
SST T DB 32.25 (819.1 mm) 210–302 206–792 166–041 620–058 166–625 None
CST L DB 206–281 32.375” (822.3 mm) 210–302 207–655 168–212 620–013 165–950 None
SD T & U PP 222–526 31.375” (796.9 mm) 208–356 222–638 166–041 620–057 None None
20:1 Bulldog
CST L & U DB 218–985 20.906” (503 mm) 210–302 217–527 168–212 620–060 None None
25:1 Bulldog
CST T & U PP 217–565 32.75” (831.8 mm) 210–302 217–201 168–212 620–013 None None
SD T & U PP 222–527 32.75” (831.8 mm) 210–302 217–201 168–212 620–013 None None
CST T & U PP 217–564 25.875” (657.2 mm) 210–302 217–201 166–548 620–060 None None
SD T & U PP 222–528 25.75” (654 mm) 208–356 222–639 166–548 620–060 None None
30:1 Bulldog
CST L & U DB 217–579 21.094” (535.7 mm) 210–302 217–530 168–212 620–060 None 166–634
CST L & U DB 221–064 32.656” (829.4 mm) 210–302 217–530 168–212 620–061 None None
SST T DB 900–300 21.094” (535.7 mm) 210–302 950–162 600–233 620–062 None 600–152
40:1 Bulldog
CST T & U PP 220–447 25.625” (650.8 mm) 210–302 220–449 166–548 620–060 None None
CST T & U PP 220–448 32.50” (825.5 mm) 210–302 220–449 168–054* 620–056 None None
SD T & U PP 222–535 32.50” (825.5 mm) 210–302 220–449 168–054* 620–056 None None
SD T & U PP 222–536 25.75” (654 mm) 208–356 222–640 166–548 620–060 None None
KEY:
Packing Material Piston T ype Cylinder Material
L Leather T PTFE DB Double Ball C ST N itrated Carbon Steel
N Neoprene U UHMWPE DP Double Poppet SST Stainless Steel
R Rubber PP Priming Piston SD Severe Duty
* Included with Air Motor 210–302.