Graco Series A User manual

Instructions–Parts List
306916U
ENG
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Bulldogrand KingrPumps
Use for transfer of medium to high viscosity materials. For
professional use only.
Not for use in explosive atmospheres.
See List of Models and Table of Contents on page 2.
01557A

2 306916
List of Models
Part No.
(Series) Pump
Type Pump Size Ratio
Maximum Fluid
Working Pressure
Maximum Pump Air
Input Pressure
949444 (A) Bulldog 55 gal. (200 liter)
Drum 10:1 1000 psi (7 MPa, 70 bar) 100 psi (0.7 MPa, 7 bar)
954180 (A) Bulldog 55 gal. (200 liter)
Drum 10:1 1000 psi (7 MPa, 70 bar) 100 psi (0.7 MPa, 7 bar)
220648 (B) King 55 gal. (200 liter)
Drum 20:1 1800 psi (12 MPa, 124 bar) 90 psi (0.6 MPa, 6.2 bar)
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 18. . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

3306916
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment. Use genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
DUse 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.
DHandle hoses carefully. Do not pull on hoses to move equipment.
DRoute 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).
DWear hearing protection when operating this equipment.
DDo not move or lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.

4 306916
WARNING
SKIN INJECTION HAZARD
Spray from the valve, leaks or ruptured components can inject fluid into your body and cause ex-
tremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can
also cause serious injury.
DFluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious
injury. Get immediate surgical treatment.
DDo not point the valve at anyone or at any part of the body.
DDo not put your hand or fingers over the valve tip.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DDo not “blow back” fluid; this is not an air spray system.
DAlways have the tip guard and the trigger guard on the valve when spraying.
DBe sure the valve trigger safety operates before dispensing.
DLock the valve trigger safety when you stop dispensing.
DFollow the Pressure Relief Procedure on page 8 if the spray tip clogs and before cleaning,
checking 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.
Permanently coupled hoses cannot be repaired; replace the entire hose.
MOVING PARTS HAZARD
Moving parts, such as the pump’s priming piston, can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DKeep hands and fingers away from the priming piston during operation and whenever the pump is
charged with air.
DBefore checking or servicing the equipment, follow the Pressure Relief Procedure on page 8 to
prevent the equipment from starting unexpectedly.

5306916
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.
DGround the equipment and the object being sprayed. Refer to Grounding on page 6.
DIf 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.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
DKeep the spray area free of debris, including solvent, rags, and gasoline.
DBefore operating this equipment, electrically disconnect all equipment in the spray area.
DBefore operating this equipment, extinguish all open flames or pilot lights in the spray area.
DDo not smoke in the spray area.
DDo not turn on or off any light switch in the spray area while spraying or while operating if fumes
are present.
DDo 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.
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.

6 306916
Installation
General Information
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the Installation and
Parts drawings.
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 AND EXPLOSION
HAZARD on page 5.
1. King Pumps: Use a ground wire and clamp as
shown in Fig. 1. Remove the ground screw (Z) and
insert through eye of ring terminal at the end of
ground wire (Y). Fasten ground screw back onto
pump and tighten securely. Connect the other end
of the wire to a true earth ground. Order Part No.
222011 Ground Wire and Clamp.
Bulldog Pumps: Use a ground wire and clamp as
shown in Fig. 2. 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. 237569 Ground Wire and Clamp.
2. Air and fluid hoses: Use only electrically conduc-
tive hoses with a maximum of 500 ft (150 m)
combined hose length to ensure grounding conti-
nuity,
3. Air compressor: Follow the manufacturer’s recom-
mendations.
4. Spray gun/dispensing valve: Grounding is obtained
through connection to a properly grounded fluid
hose and pump.
5. Fluid supply container: According to your local
code
6. Object being sprayed: According to your local
code.
7. 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.
8. 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.
Fig. 1 TI1052
Y
Z
Fig. 2
Y
W
X
Z

7306916
Installation
01559
Grounded Air Hose to Pump
Air Line Filter
Air Regulator and Gauge
Bleed-Type Master Air Valve
(required, for pump)
Air Line Lubricator
Pump Runaway Valve
Air Powered Ram
Fluid Drain Valve (required)
Bleed-Type Master Air Valve
(for accessories)
Air Exhaust Hose
(Models 949444 and 954180 only)
Muffler (Models 949444 and 954180 only)
Fluid Hose
Whip Hose
Gun/Dispensing Valve
Air Supply Hose to Ram
Pump Ground Wire
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
Y
KEY
Typical Installation
LKYGEB J
A
R
D
C
F
P
N
MH
The Typical Installation above is only a guide to select-
ing and installing accessories. For assistance in de-
signing a system to meet your needs, contact your
Graco distributor.
The Dimensional Drawings on page 18 provide neces-
sary measurements for mounting the pump. If you use
an accessory ram (G), as shown in the Typical Installa-
tion, 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 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,
and an air regulator (C) to control pump speed. 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.
Install an air line filter (B) to remove harmful dirt and
moisture from the compressed air supply, and a sec-
ond bleed valve (J) 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.
WARNING
A bleed-type master air valve (D) and a fluid drain
valve (H) are required in your system. These
accessories help reduce the risk of serious 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 . Position 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.
On the pump fluid line (M), install a fluid drain valve (H)
close to the pump fluid outlet.
NOTE: To use the optional fluid outlet at the base of
the air motor, connect a riser tube between the stan-
dard outlet and the optional outlet.
On models 949444 and 954180 only, connect the air
exhaust hose (K) and muffler (L) to the air motor.

8 306916
Operation
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
Fluid under high pressure can be in-
jected through the skin and cause seri-
ous injury. To reduce the risk of an injury
from injection, splashing fluid, or moving parts, fol-
low the Pressure Relief Procedure whenever you:
Dare instructed to relieve the pressure,
Dstop spraying/dispensing,
Dcheck or service any of the system equipment,
Dor install or clean the spray tips/nozzles.
1. Lock the gun/valve trigger safety.
2. Shut off the air to the pump.
3. Close the bleed-type master air valve (required in
your system).
4. Unlock the gun/valve trigger safety.
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. Lock the gun/valve trigger safety.
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 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, then clear
the tip or hose.
WARNING
MOVING PARTS HAZARD
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 pis-
ton (located behind the air motor shield) move.
Therefore, never operate the pump with the air mo-
tor 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, relieve the
pressure to prevent the pump from starting acci-
dentally.
Flush the Pump Before Using
This pump was tested with water, and some of it may
still be in the pump. If the water will contaminate the
fluid you are pumping, flush it out with a compatible
solvent before using.
Keep the packing nut/wet-cup (45) 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. See Fig. 3. Do not
use TSL with food or sanitary applications.
Starting and Adjusting the Pump
1. Make sure the air regulator (C), drain valve (H),
and pump bleeder valve plug (52) 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 (about 20 psi [1.4 bar,
0.14 MPa]). Run 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 plug (52) slightly. Use the bleed hole
on the underside of the valve body (50) as a
priming valve until the fluid appears at the hole.
Close the plug (52).
WARNING
To reduce the risk of fluid injection, do not use your
hand or fingers to cover the bleeder hole when
priming the pump.

9306916
Operation
6. Release the trigger and lock the trigger safety. 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 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.
01560A
Fig. 3
45
52
50
Shutdown and Care of the Pump
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
Relieve the pressure. Whenever you shut off 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 is tight. Relieve the pressure and tighten
the nut 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.
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 acceler-
ates 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.
Flushing
To reduce the risk of fluid injection injury, static spark-
ing, or splashing in the eyes or on the skin, relieve the
pressure, and remove the spray tip (spray guns or
spray valves 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 automat-
ic air motor lubrication. For daily, manual lubrication,
disconnect the air supply, place about 15 drops of light
machine oil in the pump air inlet, and reconnect the air
supply to blow oil into the motor.

10 306916
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
Before servicing this equipment, always make sure to
relieve the pressure.
NOTE: Check all possible problems and solutions
before disassembling the pump.
Problem Cause Solution
Pump fails to operate Exhausted fluid supply Refill and reprime or flush
pp
Restricted line or inadequate air sup-
ply
Clear line; see Technical Data on
page 19
Insufficient air pressure; closed or
clogged air valve, etc.
Open; clear
Obstructed fluid hose or gun Clear*
Dried fluid built up on the displace-
ment rod.
Clean; see Service on page 11
Dirty or worn motor parts Clean; service, see manual 307049
and 309347
Pump operates, but output is low Exhausted fluid supply Refill and reprime or flush
pp , p
on both strokes Restricted line or inadequate air sup-
ply
Clear line; See Technical Data on
page 19
Insufficient air pressure; closed or
clogged air valve, etc.
Open, clear
Obstructed fluid hose or gun Clear*
Open or worn bleeder valve Close; replace
Air leaking into fluid pressure cham-
ber
Check inductor on ram plate, seal,
etc.
Fluid too heavy for pump to prime Use bleeder valve (see Operation on
page 8). Use inductor or ram unit
Worn throat packings in displacement
pump
Clear; service
Pump operates, but output low on
down stroke
Fluid too heavy for pump to prime Use bleeder valve (see Operation on
page 8). Use inductor or ram unit
Held open or worn intake valve Clear, service
Pump operates but output low on
up stroke
Held open or worn piston valve or
packings
Clear; service
Erratic or accelerated pump Exhausted fluid supply Refill and reprime or flush
pp
speed Fluid too heavy for pump to prime Use bleeder valve (See Operation on
page 8). Use inductor or ram unit
Held open or worn piston valve or
packings
Clear; service
Held open or worn intake valve Clear; service
Worn throat packings in displacement
pump
Clear; service
* Relieve the pressure and disconnect the fluid hose. If the pump starts when the air is turned on, the hose, spray
gun, or dispensing valve is clogged