Graco Bulldog 221-104 Operation manual

307–871
Rev. F
Supersedes D
and PCN E
5:1 Ratio Bulldog

Pump
500 psi (35 bar, 3.5 MPa) Maximum Working Pressure
100 psi (7 bar, 700 KPa) Maximum Air Input Pressure
Model 221–104, Series A
With a Severe-Duty Displacement Pump*
* Severe–Duty Displacement Pumps have an abrasion
and corrosion-resistant displacement rod and sleeve.
Refer to the T echnical Data in the separate displacement
pump manual 308–043 for wetted parts information.

INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1988, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

 
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Drawings 11. . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 11. . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco W arranty 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco T oll-Free Phone Number 12. . . . . . . . . . . . . . . . .
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

This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.


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 not sure, call your Graco distributor .
D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D Check equipment daily . Repair or replace worn or damaged parts immediately .
D
Do not exceed the maximum working pressure stated on the equipment or in the T echnical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
D 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.
D Handle hoses carefully . Do not use hoses to pull 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 Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

 

FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury
.

Ground the equipment and the object being sprayed. Refer to Grounding on page 4.
 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 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 .
  
Moving parts can pinch or amputate your fingers.
 Keep clear of all moving parts when starting or operating the pump.
 Before checking or servicing the equipment, follow the Pressure Relief Procedure on page 6 to
prevent the equipment from starting unexpectedly .

 
Installation
Grounding
Proper grounding is an essential part of maintaining a
safe system.
T o reduce the risk of static sparking, ground the pump.
Check your local electrical code for detailed grounding
instructions for your area and type of equipment. Be
sure to ground all of this equipment:
1. Pump: use a ground wire and clamp as shown
below.
2. Air and fluid hoses: use only electrically conductive
hoses with a maximum 500 ft (150 m) combined
hose length to ensure grounding continuity .
3. Air compressor: follow manufacturer ’ s recommen -
dations.
4.
Spray gun: grounding is obtained through connec -
tion to a properly grounded fluid hose and pump.
5. Object being sprayed: follow your local code.
6. Fluid supply container: follow your local code.
7. All solvent pails used when flushing or relieving
pressure, always hold a metal part of the gun
firmly to the side of a grounded metal pail, then
trigger the gun.
 T o maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
spray gun firmly to the side of a grounded metal
pail, then trigger the spray gun.
To ground the pump:
To ground the pump , loosen the grounding lug locknut
(W) and washer (X). Insert one end of a 12 ga (1.5
mm2 ) 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
X
WY
Z04111

 
Installation
KEY
A
B
C
D
E
F
G
H
J
K
L
M
Ground
Wire
Pump Runaway V alve
Air Motor Lubricator
Bleed-T ype Master Air V alve
Air Regulator and Gauge
Air Line Filter
Electrically Conductive Air Supply Line
Pump
Fluid Outlet Hose
Fluid Drain V alve
55 Gallon Drum Cover
Wet-Cup
Typical Installation
06753
A
BC
D
E
FG H
J
K
L
M
NOTE:
Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawings.
1. Mount the pump to suit the type of installation
planned. The pump dimensions and mounting hole
layout are shown on page 1 1.
2. The T ypical Installation shown above is only a
guide. Contact your Graco distributor for assis -
tance in designing a system to suit your needs.
3. Install the accessories as explained in the following
steps. If you supply your own accessories, be sure
they are adequately sized for you system.
WARNING
T wo accessories, the bleed-type master air
valve (D), and the fluid drain valve (K) are required
in your system to reduce the risk of serious injury
from moving parts or splashing fluid in the eyes or
on the skin when shutting of f the pump.
The Bleed-T ype Master Air V alve relieves air
trapped between the valve and the pump, after the
pump is shut of f. T rapped air can cause the pump
to cycle unexpectedly and result in serious bodily
injury if you are adjusting or repairing the pump.
The Fluid Drain V alve helps relieve fluid pressure in
the displacement pump, hose, and gun/dispensing
valve when shutting of f the pump. T riggering the
gun/dispensing valve may not be suf ficient, espe -
cially if there is a clog in the hose, gun/dispensing
valve, or tip/nozzle.
4. Install the air line accessories in the approximate
order shown. T o reduce stress on the air inlet
fitting, do not mount any accessories directly at the
air inlet fitting. Mount accessories on a bracket or
other fixture and use a hose between the accesso -
ries and air inlet. Use the shortest practical length
of hose.
The pump runaway valve (B) stops the supply of
air to the pump if the pump begins to run too fast,
which usually indicates a depleted fluid supply .
The air motor lubricator (C) automatically lubri -
cates the motor . Adjust the lubricator to dispense
about one drop of lubricant per minute.
The air regulator and gauge (E) controls pump
speed and fluid pressure.
The air filter (F) removes dirt and moisture from
the compressed air supply . Damp or dirty air can
damage the air motor .
Use electrically conductive air hoses. Connect an
electrically conductive air supply hose (G) to the
main air supply line. Read the Fire and Explosion
Hazard on page 3.
5. Install a fluid drain valve (K) close to the pump fluid
outlet. Read the Warning to the left. Use a fluid
filter (not shown), if needed.
6. Connect an electrically conductive fluid outlet hose
(J) to the pump. Read the warning section Fire
and Explosion Hazard on page 3.

 
Operation
NOTE: Flush the pump before using it for the first time
to remove the lightweight oil which is left in the pump
after factory testing it. The oil protects the pump from
corrosion. Be sure the solvent used is compatible with
the fluid to be sprayed, and with the wetted parts of the
pump. Refer to the T echnical Data on page 1 1 and in
the separate displacement pump manual for the
wetted parts.
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT 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.
1. Shut of f the air to the pump.
2. Close the bleed-type master air valve (required in
your system).
3. Hold a metal part of the gun to the side of a
grounded metal pail and trigger the gun to relieve
pressure.
4.
Open the fluid drain valve (required in your sys -
tem), having a container ready to catch the drain -
age.
If you suspect that the spray tip or hose is clogged or
that fluid pressure is not fully relieved after following
the steps above, very slowly loosen the tip guard
retaining nut or hose end coupling and relieve pressure
gradually . Clear the tip or hose obstruction.
Check V alve Adjustment
The fluid piston and intake valve are factory set for
high-volume pumping of heavy , spray-viscosity fluids.
T o adjust the check valves, refer to the Operation
section in the separate displacement pump manual.
Starting and Adjusting the Pump
NOTE: If the pump is not immersed in fluid, fill the
wet-cup (M) 1/2 full with Graco Throat Seal Liquid
(TSL) or a compatible solvent.
1. Open the bleed-type master air valve.
2. Open the spray gun or dispensing valve.
3. Slowly open the air regulator until the pump is
running at about 40 psi (3 bar , 300 KPa) air pres -
sure. Run the pump slowly until all the air is
pushed out of the lines and fluid is flowing smooth
-
ly
. Close the spray gun or dispensing valve; the
pump will stall.
NOTE: In a direct supply system, the pump starts and
stops automatically when the spray gun or dispensing
valve is opened or closed, if the pump is supplied with
suf ficient air pressure and air volume.
In a circulating system, the pump runs continuously ,
speeding up or slowing down as the spray gun or
dispensing valve is opened and closed, until the air
supply is shut of f.
Lubrication
1. For automatic air motor lubrication, install an air
line lubricator . Refer to step 4 of installation. Lu -
brication helps keep the motor running smoothly
and prolongs its life.
2. Keep the displacement pump wet-cup 1/2 full with
TSL or a compatible solvent. This prolongs the life
of the displacement pump packings.

 
Operation
Flushing
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
Y our fluid supplier should be able to tell you the rate at
which your fluid dries, or its contents settle during
non-use. Flush the pump frequently enough to prevent
the fluid from drying or settling in the pump and hoses
to prevent costly damage. Use a compatible solvent.
Refer to the T echnical Data on page 1 1 and in the
separate displacement pump manual for a list of the
wetted parts.
If you are pumping water-based fluid, first flush with
water and then with a compatible solvent.
Water , or even moist air , can cause your pump to
corrode. Read and follow the Caution below .
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
mineral spirits. Relieve the pressure, but leave the
rust inhibitor in the pump to protect the parts from
corrosion.
Keep the Fluid Supply Container Filled
If your pump is running too fast, or accelerates quickly ,
it is probably out of fluid. Shut of f the air supply imme -
diately to prevent damage to the pump. Check the fluid
supply frequently and replenish it as needed. If the
fluid supply is empty , and air has been sucked into the
fluid lines, be sure to pime the pump again before
regular operation.
Shutdown
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
Always stop the pump with the displacement rod in the
down position. This prevents fluid from drying on the
displacement rod and damaging the packings when
the pump is restarted.
Relieve the pressure whenever you shut of f the
pump.

 
Troubleshooting
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
Relieve the Pressure before you check or service any
system equipment.
NOTE: Check all other possible problems and solu -
tions before disassembling the pump.
Problem Cause Solution
Pump fails to operate Restricted air line or inadequate air supply Clear the line. See the T echnical Data on page
11 for air volume requirements.
Insuf ficient air pressure Increase air pressure – the pump will not oper -
ate
below 30 psi (2.1 bar , 210 KPa) air pressure.
Closed or clogged valves or regulators on the air
and/or fluid side of the system.
Check the valves and regulators and adjust or
clean as needed.
Fluid has dried on the displacement rod Clean. See displacement pump manual
308–043.
Also, keep TSL in the pump wet-cup,
and stop the pump at the bottom of its stroke
during
non-use.
Air motor is dirty , worn, or damaged Service the motor. See manual 307–049. Be
sure
the air supply is clean and dry , and that the
motor is properly lubricated.
Pump operates, but the fluid output is low on
both strokes
Empty fluid supply container Refill the fluid supply container
p p, p
both strokes
Restricted air line or inadequate air supply Clear the lines. See the T echnical Data on page
11 for air volume requirements.
Insuf ficient air pressure Increase air pressure – the pump will not oper -
ate
below 30 psi (2.1 bar , 210 KPa) air pressure.
Fluid hose or gun is clogged Clean the hose or gun, flush frequently .
Fluid is too heavy for the pump to prime Use an inductor plate or ram.
Loose packing nut or worn throat packings Tighten packing nut or replace packings as
needed.
See manual 308–043.
Ball travel restricted too much for the viscosity of
fluid being pumped.
See Check Valve Adjustment in manual
308–043.
Pump operates, but the output is low on the
down stroke
Fluid is too heavy for the pump to prime Use an inductor plate or ram.
p p, p
down stroke
Damaged cylinder o-rings Replace o-rings. See manual 308–043.
The intake valve is stuck open or worn Check; replace parts as needed. See manual
308–043.
Ball travel restricted too much for the viscosity of
fluid being pumped.
See Check Valve Adjustment in manual
308–043
Pump operates, but the output is low on the
upstroke
The piston valve is stuck open or the packings are
worn Check,
replace parts as needed. See manual
308–043
p
Damaged cylinder o-rings Replace o-rings. See manual 308–043
Pumps is operating erratically , or speeds up
suddenly
Empty fluid supply container Refill. Also see Operation on page 6.
p pg y ,p p
suddenly Fluid
hose or gun is clogged Clean the hose or gun. Flush frequently .
The piston valve is stuck open or the packings are
worn Check,
replace parts as needed. See manual
308–043.
The intake valve is stuck open or worn Check; replace parts as needed. See manual
308–043.
Loose packing nut or worn throat packings Tighten packing nut or replace packings as
needed.
See manual 308–043.

 
Service
General Information
DFollow the torque and assembly notes on page 10.
DT o service the air motor , refer to manual 307–049,
supplied.
DT
o service the displacement pump, refer to manual
308–043, supplied.
Disassembly (See page 10)
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
1. Flush the pump with a compatible solvent, relieve
the pressure, and stop the pump at the bottom of
its stroke.
2. Disconnect the hoses from the pump. Remove the
pump from its mounting and clamp it in a vise.
3. Remove the upper cotter pin (1). Unscrew the
coupling nut (8). Unscrew the three tie rod lock-
nuts (3). Unscrew the nut (56) be sure not to lose
the two rings (57, 58). Carefully pull the displace -
ment pump (12) away from the air motor (1 1).
4.
Remove the lower cotter pin (1). Loosen the
locknut (4). Unscrew the connecting rod (9) from
the displacement rod (N). The pipe (53) slides out
of the air motor as the pump is detached
Reassembly (See page 10)
1. If removed, screw the three tie rods (6) into the
motor (11).
2.
If removed, screw the bushing (59) into the outlet
of the displacement pump (12). Screw the riser
tube (53) into the bushing (59).
3. Screw the connecting rod (9) into the displacement
rod (N). Install the cotter pin (1) and tighten the
locknut (4).
4. Make sure the riser tube rings (57, 58) are in
place. Guide the displacement pump (12) onto the
tie rods (6), so the outlet of the displacement pump
is aligned with the auxiliary outlet of the motor (1 1).
The riser tube (53) will slide into the motor . Screw
the nut (56) onto the elbow (60) loosely .
5.
Install the locknuts (3) on the tie rods. T orque the
nuts to 40–50 ft-lb (54–68 N Sm).
6. T
ighten the coupling nut (8). Insert the upper cotter
pin (1) through the coupling (7). T ighten the riser
tube nut (56).
7. Connect the hoses to the pump. Run the pump
slowly to be sure it runs smoothly and does not
bind. If necessary
, adjust the displacement pump
tie rods and locknuts (see manual 308–043), or the
tie rods (6) and locknuts (3) which attach the
motor , to eliminate binding.
8. Reconnect the ground wire to the motor .

 
Parts
06752
1
3
4
5
6
7
8
9
11
12
51
60
53
54
55
56
57
58
59
1
3
4
2
1
T orque to 40–50 ft-lbs (54–68 N m)
Apply lubricant
2
2
Apply sealant to threads
3
3
Apply lubricant to top thread of rod
4
N
1
Ref
No. Part No. Description Qty. Ref No. Part No. Description Qty.
1 100–103
PIN, cotter; 1.5” long 2
3 101–712 LOCKNUT
; 5/8–1 1;
with nylon insert 3
4 101–936 NUT
, hex, jam; 3/4–10 1
5 158–674
O-RING; nitrile ribber 1
6 161–541
ROD, tie; 13.5” (343 mm) long 3
7 161–543 COUPLING, connecting rod 1
8 161–544 NUT
, coupling 1
9 164–444
ROD, connecting; 7.325” (186 mm) 1
11 208–356 AIR MOTOR
See manual 307–049 for parts 1
12 210–208 DISPLACEMENT PUMP
See manual 308–043 for parts 1
51 161–612
TUBE, intake extension 1
53 190–397 TUBE, riser 1
54 166–153 NUT
, collet 1
55 190–401 ADAPTER 1
56 190–398 NUT
, tube 1
57 190–399 RING 1
58 190–400 RING 1
59 112–972 BUSHING 1
60 190–402 ELBOW 1