Graco 970022 Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1998, Graco Inc. is registered to I.S. EN ISO 9001
55 Gallon, 55:1 Bulldog
Module Supply Units
4950 psi (347 bar) Maximum Working Pressure
Model 970022, Tandem with Pneumatic Crossover
Model 970023, Tandem with Electric Crossover
Model 970024, Pneumatic Low Level Shutoff
310310 Rev.B
Read warnings and instructions.
See page 2 for table of contents.
Model 970022 Tandem Shown 8642A
Parts

2310310
Table of Contents
List of Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Information 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 7. . . . . . . . . . . .
System Setup 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 24. . . . . . . . . . . . . . . . . . . . . .
Graco Information 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Models
Part No. Pump Model
Displacement
Pump Model Ratio
Maximum Fluid
Working Pressure
Maximum Pump
Air Input Pressure
Parts
Page
970022 BulldogtCheck-Matet450 55:1 341 bar, 34 MPa
(4950 psi)
6.2 bar, 0.6 MPa
(90 psi)
16
970023 BulldogtCheck-Matet450 55:1 341 bar, 34 MPa
(4950 psi)
6.2 bar, 0.6 MPa
(90 psi)
17
970024 BulldogtCheck-Matet450 55:1 341 bar, 34 MPa
(4950 psi)
6.2 bar, 0.6 MPa
(90 psi)
18
Related Manuals
Ram–Mounted Pumps (Model C59521) 308017
Pneumatic Crossover (Model 918468) 310293
Low–Level Shutoff (Model 918478) 310294
Electrical Crossover (Model C59519) 310295
Manual No.

310310 3
Warnings
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
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in
serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, warnings, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck the equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed 75 psi (5.1 bar) maximum inbound air pressure to the air–powered ram.
DNever exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the Technical Data on page 21.
DBe 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.
DRoute the hoses away from the 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).
DDo not use the hoses to pull the equipment.
DUse fluids and solvents that are chemically compatible with the equipment wetted parts. Refer to
the Technical Data sections of all the equipment manuals. Always read the material manufactur-
er’s literature before using fluid or solvent in this pump.
DAlways wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid and
solvent manufacturers.
DWear hearing protection when operating this equipment.
DComply with all applicable local, state and national fire, electrical and other safety regulations.

4310310
WARNING
INJECTION HAZARD
Spray from the spray gun, hose leaks, or ruptured components can inject fluid into your body and
cause extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the
skin can also cause serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
DDo not point the gun/valve at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip/nozzle.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DAlways have the trigger guard on the gun when dispensing.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DBe sure the gun/valve trigger safety operates before dispensing.
DLock the gun/valve trigger safety when you stop dispensing.
DFollow the Pressure Relief Procedure on page 12 if the nozzle clogs, and before cleaning, check-
ing or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Do not repair high pressure couplings; you must replace the entire hose.
DFluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
FIRE, EXPLOSION AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in fire, explosion, or electricshock and other serious injury.
DGround the equipment, the object being dispensed, and all other electrically conductive objects in
the dispense area. Proper grounding dissipates static electricity generated in the equipment. Refer
to System Grounding on page 8.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvent or material.
DExtinguish all open flames or pilot lights in the dispense area.
DDo not turn on or off any light switch in the dispense area.
DDo not use this equipment with flammable liquids.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DKeep the dispense area free of debris, including solvent, rags, and gasoline.
DDo not smoke in the dispense area.
DIf there is any static sparking or you feel an electric shock while using the equipment, stop dis-
pensing immediately. Do not use the equipment until you have identified and and corrected the
problem.

310310 5
WARNING
MOVING PARTS HAZARD
Moving parts, such as the ram plate/pump inlet can pinch fingers.
DDo not operate the equipment with the guard removed.
DKeep clear of all moving parts when starting or operating the equipment.
DKeep hands and fingers away from the priming piston during operation and whenever the pump
is charged with air.
DKeep clear of the ram plate, pump fluid inlet, and lip of the fluid container when raising or lower-
ing the ram.
DBefore checking or servicing the ram or pump, follow the Pressure Relief Procedure on
page 12.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
DAvoid exposure to heated material fumes.
DProvide adequate ventilation.

6310310
System Information
System Description
The 970022 system consists of a 55 gallon supply unit
with pneumatic crossover for continuous material
supply. The 970023 system consists of a 55 gallon
supply unit with an electric crossover for continuous
material supply. System 970024 is a single 55 gallon
supply unit with a low–level shutoff. See Fig. 1.
Each system air–powered ram pushes a plate (C) into
a drum of material, while the pump (A) removes mate-
rial from the drum and pushes it through a supply hose
to a customer–supplied header. Material flows through
the header to individual dispense drops.
WARNING
A main air bleed valve (E) and pump air bleed
valve (H), are required. These accessories help
reduce the risk of serious injury, including fluid
injection and splashing of fluid in the eyes or on the
skin, and injury from moving parts if you are adjust-
ing or repairing the pump.
The main air bleed valve (E) shuts off and relieves
the air to the pump and ram. The ram will hold
pressure if the ram director valve (U) is in the
horizontal (neutral) position. To relieve air pressure
in the ram, close the main air bleed valve (E) and
move the director valve (U) to DOWN. The ram will
slowly drop.
The pump air bleed valve (H) relieves air trapped
between it and the pump after the air is shut off.
Trapped air can cause the pump to cycle unexpect-
edly. Locate the valve close to the pump.
The fluid drain valve assists in relieving fluid pres-
sure in the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may not be
sufficient.
System Accessories and Modules
Before you install the system, you should be familiar
with the parts discussed in the following paragraphs.
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
DMain air bleed valve (E) is required in your system
to shut off the air supply to the pump and ram (refer
to the preceding WARNING ). When closed, the
valve bleeds off all air in the ram and pump, and the
ram slowly lowers. Be sure the valve is easily
accessible from the pump, and is located upstream
from the air manifold (F).
DPump air bleed valve (H) is required in your
system to relieve air trapped between it and the air
motor when the valve is closed (refer to the preced-
ing WARNING). Be sure the valve is easily accessi-
ble from the pump, and is located downstream
from the air regulator (G).
DAir regulator (G) controls pump speed and outlet
pressure by adjusting the air pressure to the pump.
Locate the regulator close to the pump, but up-
stream from the pump air bleed valve.
DAir manifold (F) has a swivel air inlet. It mounts to
the ram, and provides ports for connecting lines to
air-powered accessories.
DAir line filter (J) removes harmful dirt and moisture
from the compressed air supply.
DSecond bleed-type air valve (K) isolates the air
line accessories for servicing. Locate upstream
from all other air line accessories.
DPneumatic (Model 970022) or electrical (Model
970023) crossover (L) provides switching between
dual rams to provide a constant supply of material
to the system. The crossover controls the air supply
to each of the ram air motors. A low–level shutoff
(L) (Model 970024) provides automatic shutdown
of a single ram system when only a small amount of
material remains. The shutoff controls the air supply
to the ram air motor.
DRam air regulator (T) controls the air pressure to
the ram.
DRam director valve (U) controls the raising and
lowering of the ram.
DAir release valve (V) opens and closes the flow of
air to assist raising the ram plate (C) out of an
empty drum.
DBleed handle (CC) bleeds air from under the ram
plate (C) to assist in priming the pump and lowering
the ram plate into the drum.

310310 7
Component Identification and Function
Fig. 1
KEY
APump
BRam (two used on 970022 and 970023,
one used on 970024)
CRam Plate
DElectrically Conductive Air Supply Hose
E Main Air Bleed Valve (required, for pump
and ram)
FAir Manifold
GPump Air Regulator
HPump Air Bleed Valve
(required, for pump)
JAir Line Filter
KBleed-Type Air Valve
(for accessories)
LPneumatic Crossover (for 970022), Elec-
trical Crossover (for 970023), Low–level
Shutoff (for 970024)
NElectrically Conductive Fluid Hose
SBall Valve
TRam Air Regulator
URam Director Valve
VAir Release Valve
WAir Line Drain Valve
YGround Wire (required; Refer to
page 8 for setup)
AA Safety Valve
CC Bleed Handle
8642A
U
T
NV
E
JK
D
C
CC
B A AA
S
W
Y
H
G
F
Supply Unit A Supply Unit B
Model 970022 Tandem Shown
L
AB

8310310
System Setup
System Setup
The following typical system installation is only a guide
for selecting and installing system components and
accessories. Contact your Graco distributor for help in
designing a system to suit your particular needs.
Air-powered ram extruder systems force high viscosity
fluids into the intake valve of the fluid pump. Make
certain all accessories are adequately sized and pres-
sure-rated to meet your system’s requirements.
Air and Fluid Hoses
Be sure all air hoses (D) and fluid hoses (N) are prop-
erly sized and pressure-rated for your system. Use
only electrically conductive hoses. See Fig. 1.
Selecting System Ram Locations
System rams are to be positioned so that air regulator
controls for pumps and rams are easily accessible.
Make sure there is overhead clearance for rams when
fully raised. Refer to Dimensional Drawing on page 20
and separate ram manual 306934 (supplied) for addi-
tional setup data.
Use holes in ram base as a guide, drill holes for 13 mm
(1/2 in.) anchors.
Check that ram base is level in all directions. If neces-
sary, level base using metal shims. Secure base to
floor using 13 mm (1/2 in.) anchors to prevent ram
from tipping.
System Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE, EXPLOSION AND
ELECTRIC SHOCK HAZARD on
page 4.
1. Ram Pumps: check ground wire and clamp. See
Fig. 2. To install, loosen grounding lug locknut (W)
and washer (X). Insert one end of 1.5 mm@(12 ga)
minimum ground wire (Y) into slot in lug (Z) and
tighten locknut securely. Connect other end of wire
to true earth ground.
Fig. 2
W
X
Y
Z
0864
Pump Ground
2. Air and fluid hoses: use only electrically conduc-
tive hoses.
3. Air compressor: follow manufacturer’s recom-
mendations.
4. Dispense gun: ground through connection to
properly grounded fluid hose and pump.
5. Material supply container: follow your local code.
6. Object material is applied to: follow your local
code.
7. Solvent pails used when flushing: follow your
local code. Use only metal pails, which are conduc-
tive, placed on grounded surface. Do not place pail
on nonconductive surface, such as paper or card-
board, which interrupts grounding continuity.
8. To maintain grounding continuity when flush-
ing or relieving pressure, hold metal part of
dispense gun firmly to side of grounded metal pail,
then trigger gun.

310310 9
System Setup
Pneumatic Crossover Setup (Model
970022)
Install the pneumatic crossover as shown in Fig. 3.
Also See Schematic, Fig. 7, page 22.
NOTE: During system operation, as the ram ap-
proaches the drum bottom, the top of the ram contacts
the limit valve switch. The switch shuts off air to the
ram air motor via a 4–way piloted air valve (3). As the
valve stops air to one ram, it starts air to the other ram.
This allows constant material flow and changing out of
material drums.
NOTE: The position of the limit valve (4) on the ram
determines when the ram air motor is turned on and
off. During operation, this position can be adjusted as
desired. See Fig. 3.
Fig. 3
1
KEY
1Ball Valves (2)
2Regulator
34–Way Piloted Air Valve
4Limit Valves (2)
5Main Air Inlet
2 3
4
5
4
8582A
Pneumatic Crossover Setup (Model 970022)

10 310310
System Setup
Electrical Crossover Setup (Model 970023)
The electrical crossover is setup as shown in Fig. 4.
The position of the empty level indicator kit (2) on the
ram determines when the ram air motor is turned on
and off. During operation, this position can be adjusted
as desired. See Fig. 4.
8584A
Fig. 4
A A
KEY
1Unloader Crossover
2Empty Level Indicator Kit (2)
33/4 in. npt Muffler
4Solenoid Valve
53/4 in. Hex Nipple
1
2 2
Detail A
34
5
Electrical Crossover Setup (Model 970023)

310310 11
System Setup
Low–Level Shutoff Setup (Model 970024)
Setup the low–level shutoff as shown in Fig. 5.
NOTE: The position of the air limit valve (2) on the
ram determines when the ram air motor is turned on
and off. During operation, this position can be adjusted
as desired. See Fig. 5.
Fig. 5
1
2
3
5
Low–Level Shutoff Setup (Model 970024)
Detail A
A
1 REF
4
KEY
13–Way Pilot Valve
2Air Limit Valve
3Limit Valve Bracket
4Breather Vent
5Pipe Cross Fitting
8586A

12 310310
Operation
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. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
Dare instructed to relieve the pressure,
Dstop dispensing,
Dcheck or service any of the system equipment,
Dor install or clean the dispense ball valve.
1. Relieve system pressure to which Graco module
supply units are attached.
2. Close dispenser ball valves (S). Unhook ball valves
from system. See Fig. 1.
3. Close pump air bleed valve (H, required in your
system). See Fig. 1 or Fig. 6.
4. Shut off main air bleed valve (E, required in your
system). Set ram director valve (U) to DOWN.
Ram will slowly drop.
5. Hold metal part of dispenser ball valve firmly to
side of grounded metal pail, and open ball valve to
relieve pressure.
6. Close dispenser ball valve.
7. Repeat procedure for each ram (for models
970022 and 970023 only).
Flushing the System
Flush the system before initial use to prevent material
contamination.
CAUTION
Flush the system before performing the initial
material loading procedure. The system was fac-
tory-tested using a light soluble oil, a soybean oil, or
other oil as tagged. Flush the system to avoid con-
taminating the material that has been designated for
initial material loading.
To flush the system, perform the following procedure:
1. Select material to be used.
WARNING
Use fluids and solvents that are chemically compat-
ible with the equipment wetted parts. Refer to the
Technical Data sections of all the equipment
manuals. Always read the material manufacturer’s
literature before using fluid or solvent in this pump.
2. Verify that factory-test oil and material are compat-
ible:
a. If substances are compatible, omit following
step b and proceed to step 4.
b. If substances are incompatible, perform re-
maining steps to flush system.
3. Select drum of solvent that dissolves, cleans, and
eliminates factory-test oil from system. If neces-
sary, check with Graco Distributor or material sup-
plier for recommended solvent.
4. Before flushing, be sure entire system and flushing
drums are properly grounded. Refer to System
Grounding, on page 8.
5. Using compatible solvent, perform Starting and
Adjusting System Rams procedure and Starting
and Adjusting the Pump procedure on page 14.
6. Flush solvent through system for 1 to 2 minutes.
7. Remove drum containing solvent.

310310 13
Operation
8320B
E
C
Fig. 6
T
U
V
CC
G
Model 970022 Tandem Ram Shown
H
05698B
DD

14 310310
Operation
Starting and Adjusting System Rams
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce risk of injury or equipment
damage:
DMake sure all material hose connec-
tions are secure.
DCheck that all routing of air lines will
not interfere with any moving compo-
nents within the fixture.
DDo not pressurize the system until
you have verified the system is ready
and it is safe to do so.
1. Use following instructions to start and adjust
system rams.
2. Close all air regulators and air valves. See Fig. 6.
3. Open main air bleed valve (E) and set ram air
regulator (T) to 2.8 bar, 0.26 MPa (40 psi). Move
director valve (U) handle so arrow points to UP,
and let ram rise to full height.
4. Set full drum of fluid on ram base, slide drum back
against tube stop, and center under ram plate (C).
Use drum clamps (DD) to center, hold, and proper-
ly align drum with ram.
5. Remove drum cover. Smooth material surface with
straightedge.
WARNING
MOVING PARTS HAZARD
Moving parts can pinch or amputate your
fingers. When the pump is operating and
when raising or lowering the ram, keep
your fingers and hands away from the pump intake,
ram plate, and lip of the drum.
CAUTION
To help avoid damage to equipment, do not use
drums that have side bungs or large dents with this
ram. Rough bung openings or large dents will dam-
age the wipers or stop the ram plate, resulting in a
runaway pump.
6. Move director valve handle to DOWN position to
lower ram. Lower ram until ram plate is just above
drum, then set valve to neutral position. Reposition
drum as necessary so wipers do not hit drum lip.
Open vent valve (CC) on ram plate.
7. Set director valve to DOWN position and lower ram
until fluid appears at vent valve (CC). Set director
valve to neutral and close vent valve.
Starting and Adjusting the Pump
1. Be sure pump air regulator (G) is closed. Set ram
air regulator (T) to 3.5 bar, 0.35 MPa (50 psi). Set
director valve (U) to DOWN. See Fig. 6.
2. Start pump as explained in separate pump instruc-
tion manual.
3. Keep director valve (U) set to DOWN while pump
is operating.
NOTE: Increase air pressure to the ram if the pump
does not prime properly with heavier fluids. If fluid is
forced out around the top wiper, ram pressure is too
high and the air pressure should be decreased.

310310 15
Operation
Changing Drums
WARNING
MOVING PARTS HAZARD
Moving parts can pinch or amputate your
fingers. When the pump is operating and
when raising or lowering the ram, keep
your fingers and hands away from the pump intake,
ram plate, and lip of the drum.
1. Stop pump. Close pump air bleed valve (H). See
Fig. 6.
2. Before raising wiper plate, locate push button on
air release valve (V).
3. Set director valve (U) to UP to raise wiper plate. At
the same time, carefully equalize pressure in drum
by operating air release valve.
4. Raise wiper plate until it is completely out of drum.
5. Remove empty drum.
6. Inspect wiper plate and, if necessary, remove any
remaining material or material build–up.
7. Place full drum on ram base.
8. Lower ram and adjust position of drum relative to
ram plate, as explained under Starting and Ad-
justing Ram on page 14.
Shutdown and Care of the Pump
1. Set director valve (U) to neutral. 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 12.
2. Relieve pressure.
3. Follow pump shutdown instructions in your sepa-
rate pump manual.

16 310310
Parts
Model 970022
Tandem with Pneumatic Crossover, 55:1 Ratio Bulldog Pump
Includes items 1–7
Ref No. 3 Fluid Supply Hose
Includes Items 4–7
1
3
8322A
2
7 6 5 4
2 REF
Ref Part
No. No. Description Qty
Ref Part
No. No. Description Qty
1 C59523 PUMP, ram–mounted 200 liter (55 gal.)
See 308027 for parts 2
2 918468 KIT, pneumatic crossover
See 310293 for parts 1
3 C56995 HOSE ASSEMBLY, fluid supply;
Includes items 4–7 2
4 521973 . HOSE 1
5 521975 . UNION, pipe 1
6 C20490 . NIPPLE, hex 1
7 118854 . VALVE, ball 1

310310 17
Parts
Model 970023
Tandem with Electrical Crossover, 55:1 Ratio Bulldog Pump
Includes items 1–7
1
3
8322A
2
Ref No. 2 Electrical Crossover Kit
Ref No. 3 Fluid Supply Hose
Includes Items 4–7
7 6 5 4
Ref Part
No. No. Description Qty
Ref Part
No. No. Description Qty
1 C59523 PUMP, ram–mounted 200 liter (55 gal.)
See 308027 for parts 2
2 C59519 KIT, electrical crossover
See 310295 for parts 1
3 C56995 HOSE, fluid supply;
Includes items 4–7 2
4 521973 . HOSE ASSEMBLY 1
5 521975 . UNION, pipe 1
6 C20490 . NIPPLE, hex 1
7 118854 . VALVE, ball 1

18 310310
Parts
Model 970024
Supply Unit with Pneumatic Low Level Shut–Off, 55:1 Ratio Bulldog Pump
Includes items 1–7
1
3
2
Ref No. 3 Fluid Supply Hose
Includes Items 4–7
7 6 5 4
Ref Part
No. No. Description Qty
Ref Part
No. No. Description Qty
1 C59523 PUMP, ram–mounted 200 liter (55 gal.)
See 308027 for parts 1
2 918478 KIT, shut–off, low level, pneumatic
See 310294 for parts 1
3 C56995 HOSE, fluid supply;
Includes items 4–7 1
4 521973 . HOSE ASSEMBLY 1
5 521975 . UNION, pipe 1
6 C20490 . NIPPLE, hex 1
7 118854 . VALVE, ball 1

310310 19
Notes

20 310310
Ram Mounted Pump Clearance Dimensions
8320B
A
B
C
D
E
F
G
14.2 mm (0.56 in.)
Diameter Holes
Model 970022 Ram Shown
Model
A
(Raised)
B
(Lowered)
C D E F G
All 2578 mm
(101.5 in.)
1575 mm
(62 in.)
533 mm
(21 in.)
635 mm
(25 in.)
965 mm
(38 in.)
1067 mm
(42 in.)
1111 mm
(43.74 in.)