Graco BULLDOG HYDRA-CAT E Series Operation manual

307132
Rev. M
First choice when
quality counts.
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
BULLDOGHYDRA-CAT
PROPORTIONING PUMPS
2500 psi (17 MPa, 170 bar)
Maximum Working Pressure
MODELS WITH TWO DISPLACEMENT PUMPS
Model 209028, Series E
1:1 Mix Ratio
MODELS WITH THREE DISPLACEMENT PUMPS
Model 208958, Series E
1–1/4:1 Mix Ratio
Model 208999, Series E
1–1/2:1 Mix Ratio
Model 209000, Series E
2:1 Mix Ratio
Model 209001, Series E
3:1 Mix Ratio
Model 209002, Series E
4:1 Mix Ratio
Model 209003, Series E
2–1/2:1 Mix Ratio
RELIEF VALVE INSTALLATION KITS
Required for safe operation of the pump. Attaches to
wall mounting bracket or pump stand and connects
relief valves (which relieve fluid pressure if it exceeds
preset limit), to displacement pumps.
209005 Relief Valve Installation Kit
For two displacement pump models.
209006 Relief Valve Installation Kit
For three displacement pump models.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1974, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
TI0645
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2 307132
Table of Contents
Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 26. . . . . . . . . . . . . . . . . . . . . . . . . .
The Graco Warranty and Disclaimers 26. . . . . . . . . . . .
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
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 9.
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.
Electrically disconnect all equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not operate a gasoline engine in the spray area.
MOVING PARTS HAZARD
Moving parts, such as the air motor piston and the secondary pump lever and connecting rod area,
can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the Pressure Relief Procedure on page 10 to prevent the
equipment from starting unexpectedly.

307132 3
WARNING
INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause
extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause serious injury.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
Do not point the gun at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip.
Do not stop or deflect leaks with your hand, body, glove or rag.
Do not “blow back”fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the spray gun when spraying.
Check the spray gun diffuser operation weekly. Refer to the gun manual.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 10 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
Use only Graco approved hoses. Do not remove any spring guard that is used to help protect the
hose from rupture caused by kinks or bends near the couplings.
PLURAL COMPONENT FLUID HAZARD
Before using this equipment, read the fluid manufacturer’s warnings and determine all facts relating to
the fluids used, including any of the potential hazards relating to toxic fumes, fires, explosions, reac-
tion times, and exposure of human beings to the individual components or their resultant mixtures.
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.
Graco does not manufacture or supply any of the reactive chemical components that may be used
in this equipment and is not responsible for their effects. Graco assumes no responsibility for loss,
damage, expense or claims for personal injury or property damage, direct or consequential, arising
from the use of such chemical components.

4 307132
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check equipment daily. Repair or replace worn or damaged parts immediately.
All system components must meet or exceed the pressure ratings printed on the pressure relief
valve. The lever amplification of the secondary pump enables very high fluid pressures to be
achieved. A 475 to 575 psi working pressure range relief valve is provided on the secondary side to
limit the fluid pressure. Do not tamper with this pressure relief valve or serious injury could result.
Do not lift pressurized equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
Do not use hoses to pull equipment.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
Fluid hoses must have spring guards on both ends to protect them from rupture caused by kinks or
bends near the couplings.
Wear hearing protection when operating this equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.

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Installation
These pumps are designed to be part of a Hydra-Catspray system that will proportion, mix, and spray/dispense
two-component fluids. The following two typical installations are only guidelines to setting up a complete Hydra-
Cat system. For assistance in designing a system to suit your particular needs, contact your Graco distributor.
05225
For pressure feed to proportioning pump, mount
fluid pressure gauges at proportioning pump inlets
to properly adjust feed pump pressures.
1
1
DA
CN
E
A
B
A
D
A
M
F
P
F
J
G
G
CB
H
PART A PART B
LIGHT VISCOSITY SYSTEM
5:1 RATIO MAXIMUM RATIO FEED PUMPS
KEY
A Bleed-type master
air valve
B Pump runaway valve
C Air line lubricator
D Air regulator
E Air line filter
F Fluid filter
G Fluid drain valve
H Feed pump
J Proportioning pump
K Solvent pump
L Flushing valve
M Static mixer
N Spray valve
P Ground wire
AAA
C B
G
L
PART A
PART B
K
D C
H
G
G
D A
B