This manual contains IMPORTANT

WARNINGS AND INSTRUCTIONS

READ AND RETAIN FOR REFERENCE

Rev R

Supersedes P

FLUID INJECTION HAZARD

General Safety

This equipment generates very high fluid pressure. Spray from the gun/ valve, leaks or ruptured components can inject fluid through your skin and into your body and cause extremely serious bodily injury, including the need for amputation. Also, fluid injected or splashed into the eyes or on the skin can cause serious damage.

NEVER point the gun/valve at anyone or at any part of the body. NEVER put hand or fingers over the spray tip/nozzle, or over the bleeder valve hole.

ALWAYS follow the Pressure Relief Procedure, right, before cleaning or removing the spray tip/nozzle or servicing any system equipment.

NEVER try to stop or deflect leaks with your hand or body.

Be sure equipment safety devices are operating properly before each use.

Tip Guard (only on spray guns)

ALWAYS have the tip guard in place on the spray gun while spraying. The tip guard alerts you to the fluid injection hazard and helps reduce, but does not prevent, the risk of accidentally placing your fingers or any part of your body close to the spray tip.

Spray Tip/Nozzle Safety

Use extreme caution when cleaning or changing spray tips/nozzles. If the spray tip/nozzle clogs while spraying/dispensing, engage the gun/valve safety latch immediately. ALWAYS follow the Pressure Relief Proce- dure and then remove the spray tip/nozzle to clean it.

NEVER wipe off build???up around the spray tip/nozzle until pressure is fully relieved and the gun/valve safety latch is engaged.

Medical Alert??????Airless Spray Wounds

If any fluid appears to penetrate your skin, get EMERGENCY MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE CUT. Tell the doctor exactly what fluid was injected.

Note to Physician: Injection in the skin is a traumatic injury. It is im- portant to treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern with some ex- otic coatings injected directly into the blood stream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.

Spray Gun/Dispensing Valve Safety Devices

Be sure all gun/valve safety devices are operating properly before each use. Do not remove or modify any part of the gun/valve; this can cause a

malfunction and result in serious bodily injury.

Safety Latch

Whenever you stop spraying/dispensing, even for a moment, always set the gun/valve safety latch in the closed or ???safe??? position, making the gun/ valve inoperative. Failure to set the safety latch can result in accidental triggering of the gun/valve.

Trigger Guard (only on spray guns)

Never operate the spray gun with the trigger guard removed. This guard

helps prevent the spray gun from triggering accidentally if it is dropped or bumped.

Diffuser (only on spray guns)

The spray gun diffuser breaks up spray and reduces the risk of fluid injec- tion when the tip is not installed. Check the diffuser operation regularly.

Follow the Pressure Relief Procedure, to the right, then remove the spray tip. Aim the spray gun into a grounded metal pail, holding the spray gun firmly to the pail. Using the lowest possible pressure, trigger the spray gun. If the fluid emitted is not diffused into an irregular stream, re- place the diffuser immediately.

Pressure Relief Procedure

To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin, or injury from moving parts, always follow this procedure whenever you shut of f the pump, when checking or servicing any part of the spray/dispensing sys- tem, when installing, cleaning or changing spray tips/nozzles, and whenever you stop spraying/dispensing.

1.Engage the gun/valve safety latch.

2.Shut off the air to the pump.

3.Close the bleed???type master air valve (required in your sys- tem).

4.Disengage the safety latch.

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 pres- sure.

6.Engage the gun/valve safety latch.

7.Open the drain valve and/or the pump bleeder valve (required in your system), having a container ready to catch the drain- age.

8.Leave the drain valve open until you are ready to spray/dis- pense again.

If you suspect that the spray tip/nozzle 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, nozzle, or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip/nozzle or hose.

EQUIPMENT MISUSE HAZARD

General Safety

Any misuse of the spray/dispensing equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and flu- ids, or using worn or damaged parts, can cause them to rupture and result in fluid injection, splashing in the eyes or on the skin, or other serious bod- ily injury, or fire, explosion or property damage.

NEVER alter or modify any part of this equipment; doing so could cause it to malfunction.

CHECK all spray/dispensing equipment regularly and repair or replace worn or damaged parts immediately.

Always wear protective eyewear, gloves, clothing and respirator as rec- ommended by the fluid and solvent manufacturer.

HOSE SAFETY

High pressure fluid in the hoses can be very dangerous. If the hose devel- ops a leak, split or rupture due to any kind of wear, damage or misuse, the high pressure spray emitted from it can cause a fluid injection injury or other serious bodily injury or property damage.

ALL FLUID HOSES USED WITH A FLEXING MOTION MUST HAVE SPRING GUARDS ON BOTH ENDS! The spring guards help protect the hose from kinks or bends at or close to the coupling which can result in hose rupture.

TIGHTEN all fluid connections securely before each use. High pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coupling.

NEVER use a damaged hose. Before each use, check the entire hose for cuts, leaks, abrasion, bulging cover, or damage or movement of the hose couplings. If any of these conditions exist, replace the hose immediately. DO NOT try to recouple high pressure hose or mend it with tape or any other device. A repaired hose cannot safely contain the high pressure fluid.

FIRE OR EXPLOSION HAZARD

Static electricity is created by the flow of fluid through the pump and hose. If every part of the spray/dispensing equipment is not properly grounded, sparking may occur, and the system may become hazardous. Sparking may also occur when plugging in or unplugging a power supply cord. Sparks can ignite fumes from solvents and the fluid being sprayed, dust particles and other flammable substances, whether you are spraying/dis- pensing indoors or outdoors, and can cause a fire or explosion and seri- ous bodily injury and property damage. Do not plug in or unplug any power supply cords in the spray/dispensing area when there is any chance of igniting fumes still in the air.

If you experience any static sparking or even a slight shock while using this equipment, STOP SPRAYING IMMEDIATELY. Check the entire sys- tem for proper grounding. Do not use the system again until the problem has been identified and corrected.

To ground the pump:

To ground the pump, loosen the grounding lug locknut (W) and washer (X). Insert one end of a 1.5 mm@ (12 ga) minimum ground wire (Y) into the slot in lug (Z) and tighten the locknut securely. See

Fig 1. Connect the other end of the wire to a true earth ground. See ACCESSORIES on page 16 to order a ground wire and clamp.

Y

W

System Pressure

The 10:1 Bulldog Pump develops 1000 psi (70 bar) MAXIMUM WORK- ING PRESSURE at 100 psi (7 bar) air pressure. The 20:1 King Pump de- velops 1800 psi (124 bar) MAXIMUM WORKING PRESSURE at 90 psi (6 bar) air pressure. Never exceed these pressures.

Be 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.

Fluid Compatibility

BE SURE that all fluids and solvents used are chemically compatible with the wetted parts shown in the TECHNICAL DATA on the back cover. Al- ways read the manufacturer???s literature before using fluid or solvent in this pump.

HANDLE AND ROUTE HOSES CAREFULLY. Do not pull on hoses to move equipment. Do not use fluids which are not compatible with the in- ner tube and cover of the hose. DO NOT expose Graco hoses to tem- peratures above 82_??? C (180_??? F) or below ???40_??? C (???40_??? F).

Hose Grounding Continuity

Proper hose grounding continuity is essential to maintaining a grounded spray system. Check the electrical resistance of your air and fluid hoses at least once a week. If your hose does not have a tag on it which speci- fies the maximum electrical resistance, contact the hose supplier or manufacturer for the maximum resistance limits. Use a resistance meter in the appropriate range for your hose to check the resistance. If the resis- tance exceeds the recommended limits, replace it immediately. An un- grounded or poorly grounded hose can make your system hazardous.

Also, read FIRE OR EXPLOSION HAZARD, below.

Grounding

To reduce the risk of static sparking, ground the pump, object being sprayed, and all other spray/dispensing equipment used or located in the spray/dispensing area. CHECK your local electrical code for detailed grounding instructions for your area and type of equipment. BE SURE to ground all of this spray/dispensing equipment:

Fig 1

Z

X

Flushing Safety

Before flushing, be sure the entire system and flushing pails are properly grounded. Refer to Grounding, above. Follow the Pressure Relief Procedure on page 2, and remove the spray tip/nozzle from the gun/valve. Always use the lowest possible fluid pressure, and maintain firm metal???to???metal contact between the gun/valve and the pail during flushing to reduce the risk of fluid injection injury , static sparking and splashing.

The reference numbers and letters in the text refer to the callouts in Figures 1???3 and the Parts Drawings.

See pages 16???18 for accessories available from Graco. Be sure all accessories are properly sized to withstand the pressures in the system.

The Typical Installation shown above is only a guide to selecting and installing required and optional accesso- ries. For assistance in designing a system to suit your particular needs, contact your Graco representative.

The Dimensional Drawing on page 19 provides neces- sary measurements for mounting the pump. If you use an accessory ram (J), as shown in the T ypical Installation, 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 a pump runaway valve (F) to shut off the air to the pump if the pump accelerates beyond the pread- justed setting. A pump which runs too fast can be seri- ously damaged.

Next, install an air line lubricator (E) for automatic air mo- tor lubrication, a bleed???type master air valve (D) to re- lieve air trapped between the valve and the pump, an air regulator (C) to control pump speed, and an air line filter

(B) to remove harmful dirt and moisture from the com- pressed air supply. Install a second bleed valve (G) on the pump air line 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. An air???powered ram (J) requires a separate grounded air supply line (N).

4306???646

WARNING

Two accessories are required in your system: a bleed???type master air valve (D) and a fluid drain valve (H). These accessories help reduce the risk of serious bodily injury including fluid injection, splash- ing 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 unex- pectedly. Locate the valve close to the pump.

The fluid drain valve assists in relieving fluid pres- sure in the displacement pump, hose and spray gun; triggering the spray gun to relieve pressure may not be sufficient.

Install a fluid drain valve (H) close to the pump fluid outlet. Then connect a grounded fluid supply hose (L). Be- tween the fluid supply hose (L) and the gun/dispensing valve (K), install a whip hose (M) for greater flexibility.

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.

GROUNDING

WARNING

Before operating the pump, ground the system as explained under FIRE OR EXPLOSION HAZARD and Grounding on page 3.

WARNING

Pressure Relief Procedure

To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin, or injury from moving parts, always follow this pro- cedure whenever you shut of f the pump, when checking or servicing any part of the spray/dis- pensing system, when installing, cleaning or changing spray tips/nozzles, and whenever you stop spraying/dispensing.

1.Engage the gun/valve safety latch.

2.Shut off the air to the pump.

3.Close the bleed???type master air valve (re- quired in your system).

4.Disengage the gun/valve safety latch.

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.Engage the gun/valve safety latch.

7.Open the drain valve and/or the pump bleeder valve (required in your system), having a con- tainer 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/nozzle 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, nozzle or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip/nozzle or hose.

WARNING

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 piston (located behind the air motor shield) move. Therefore, NEVER operate the pump with the air motor 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, follow the Pres- sure Relief Procedure Warning above to prevent the pump from starting accidentally.

Flush the Pump Before Using

This pump was tested with lightweight motor oil which was left in to protect the pump parts. To prevent contami- nation of the fluid being pumped, flush the pump with a compatible solvent before using it. If the pump is being used to supply a circulating system, allow the solvent to circulate until the pump and lines are thoroughly flushed.

Keep the packing nut/wet???cup (21) 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.

Starting and Adjusting the Pump

1.Make sure the air regulator (C), drain valve (H), and pump bleeder valve (4) 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 and smoothly (about 20 psi [1.4 bar]). Cycle 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 (4) slightly. Do not open it all the way; the han- dle can come off. Cover the bleeder valve hole with something other than your hand or fingers and use it as a priming valve until the fluid appears at the bleeder hole. Close the bleeder valve.

WARNING

To reduce the risk of fluid injection, DO NOT use your hand or fingers to cover the bleeder hole when priming the pump.

6.Release the trigger and engage the safety latch. 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 circulat- ing 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 re- sults.

WARNING

To reduce the risk of serious bodily injury, including fluid injection and splashing in the eyes or on the skin, and property damage, never exceed the maxi- mum air and fluid working pressure of the lowest rated component in your system. See EQUIPMENT MISUSE HAZARD, System Pressure, on page 3.

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.

Shutdown and Care of the Pump

Always follow the Pressure Relief Procedure Warning on page 7 whenever you shut of f 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 (21) is tight. Follow the Pressure Relief Proce- dure Warning on page 7 first. Tighten 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.

Flushing

To reduce the risk of fluid injection injury, static sparking, or splashing in the eyes or on the skin, follow the Pres- sure Relief Procedure Warning on page 7, and remove the spray tip (spray guns 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 automatic air motor lubrication. For daily , manual lubrication, dis- connect the air regulator (C), place about 15 drops of light machine oil in the pump air inlet, reconnect the regulator and turn on the air supply to blow oil into the motor.

Corrosion Protection

WARNING

Water, or even moist air, can cause your pump to corrode. To help prevent corrosion, never leave the pump filled with water or air. After normal flushing, flush the pump again with mineral spirits or oil??? based solvent, relieve pressure, and leave the min- eral spirits in the pump. Be sure to follow all steps

of the Pressure Relief Procedure W arning on

page 7.

WARNING

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 piston (located behind the air motor shield) move. Therefore, NEVER operate the pump with the air motor 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, follow the Pres-

sure Relief Procedure Warning on page 7 to pre-

vent the pump from starting accidentally.

Before You Start (All Models)

1.Repair Kit 220???861 is available. See pages 13 and 15. For the best results, use all the new parts in the

kit, even if the old ones look good. Repair kit parts are indicated in the text and the parts list with an asterisk, for example (27*).

2.To reduce down time, keep spare parts on hand. Recommended spare parts are indicated in the parts list with a double asterisk, for example (41**).

3.The gland/packing stacks (64*, 65*) are preas- sembled. Do not disassemble the stacks when in- stalling them in the pump.

4.For air motor service and parts information, refer to manual 307???049 for motor Model 208???356, manual 306???968 for motor Model 206???647, manual 307???304 for motor Model 215???255, or manual 307???741 for motor Model 220???106.

5.If possible, flush the pump before service with a com- patible solvent. Follow the Pressure Relief Proce- dure Warning on page 7. Stop the pump at the bot- tom of its stroke.

6.Disconnect all the hoses. Remove the pump from its mounting and clamp it in a vise.

Model 204???641 Displacement Pump (Used on Models 204???287, 215???873 and 222???248)

Disassembly

NOTE: Refer to Fig 2 and the parts drawing.

1.Remove the cotter pin (41). Unscrew the coupling nut (50) and the three tie rod locknuts (44). Pull the displacement pump (2) off the air motor (1).

2.Remove the cotter pin (42). Loosen the locknut (45). Unscrew the connecting rod (53) from the upper cap

3.Insert a 1/4 in. (6 mm) diameter rod in the holes of the packing nut/wet???cup (21), and loosen it. Push the displacement rod (18) down until the priming piston

(37)clears the intake valve housing (28). Remove

the nut (6), priming piston (37), valve plate (36) and plate guide (31).

4.Unscrew the four tie bolts (8) and pull the intake valve housing (28) off the pump. Pull the priming rod (32) and displacement rod (18) out of the bottom of the cylinder (39). Remove the pin (7) and unscrew the priming rod (32) from the connecting rod (20).

8306???646

5.Pull the cylinder (39) down out of the outlet housing (26). Inspect the inner surface of the cylinder and the outer surface of the displacement rod (18) for scratches or scoring, which can cause premature packing wear and leaking. To check, run a finger over the surface or hold the part up to the light at an angle.

6.Disassemble the intake valve (3). Clean and inspect all parts, replacing as necessary . Check the intake valve seat (30) for nicks or damage.

7.Unscrew the upper cap (33) from the connecting rod (20). Pull the displacement rod (18) off the lower cap (19), and remove the piston assembly from the con- necting rod. Disassemble the piston.

8.Unscrew the packing nut/wet???cup (21). Remove the wiper seal (66). Remove the throat packings from the outlet housing (26).

9.Clean and inspect all parts, replacing as necessary.

Reassembly

NOTE: Refer to Fig 2 and the parts drawing during the following procedure.

1.See Detail A of Fig 2. The gland/packing stack (64*) for the throat is preassembled. Do not disassemble the stack. Lubricate the gland/packing stack and in- stall it into the outlet housing (26). Be sure the lips of the v???packings are facing down. Install the wiper seal (66) in the groove of the wet???cup (21) with the lips facing down. Loosely install the packing nut/wet??? cup (21).

2.See Detail B of Fig 2. Install the two bearings (35*) and the u???cup packing (56*) on the piston (38). Be sure the lips of the packing are facing up. Install the small o???ring (15) in the lower cap (19) and the larger o???ring (17) on the outside of the lower cap.

3.Install the piston (38), valve plate (34), and lower cap

(19)on the connecting rod (20).

4.Insert the connecting rod (20) into the displacement rod (18) so the lower cap (19) fits into the bottom of the displacement rod. Screw the top cap (33) onto the connecting rod (20) until it is tight against the top of the displacement rod (18).

5.Install one copper gasket (27*) in the outlet housing

(26).Screw the priming rod (32) into the connecting rod (20) and secure with the pin (7). Push the dis- placement rod (18) and priming rod (32) up into the outlet housing (26) so the top of the displacement rod just protrudes from the packing nut/wet???cup (21).

Lubricate the priming rod (32).

6.Install the cylinder (39) in the outlet housing (26), be- ing careful not to scratch the polished inner surface of the cylinder.

7.See Detail C of Fig 2. Slide the intake valve gland/ packing stack (65*) into the intake valve seal housing

(3).Do not disassemble the stack. Be sure the lips of the v???packings are facing up. Tighten the packing nut (11). Install the valve seat (30) in the intake valve housing (28). Place the intake valve seal housing (3) on the seat (30).

8.Install two copper gaskets (27*) on the intake valve stop (29). Install the stop in the intake valve housing

9.Carefully guide the intake valve housing (28) up over the priming rod (32) and install it on the cylinder (39).

Insert the four tie bolts (8) through the outlet housing (26) and engage the holes in the intake valve hous- ing. Torque the tie bolts oppositely and evenly to 60 ft???lb (82 N.m).

10.Install the plate guide (31), plate (36), priming piston (37) and nut (6) on the priming rod (32). If necessary,

push down on the displacement rod (18) to provide sufficient clearance from the intake valve housing (28).

11.Tighten the packing nut/wet???cup (21) just enough to prevent leakage ??? no tighter.

12.Check the alignment of the displacement rod (18) by inserting a size E (0.254 in. diameter) drill shank be- tween the packing nut/wet???cup (21) and the rod. If the drill shank cannot be passed freely around the

rod, tighten the tie bolt (8) on the side which is bind- ing.

13.Screw the connecting rod (53) into the upper cap (33). Insert the cotter pin (42) and tighten the locknut (45).

14.Align the pump outlet on the outlet housing (26) with the optional outlet at the base of the air motor (1). Loosely screw the tie rod locknuts (44) onto the tie rods (52). Lubricate the o???ring (47) and the top thread of the connecting rod (53). TIghten the cou- pling nut (50) to attach the displacement pump to the motor. Insert the cotter pin (41).

15.Start the pump and run it slowly to check for binding. Adjust the tie rods as necessary , then torque the locknuts (44) to 40???50 ft???lb (54???68 N.m).

16. Reconnect the fluid and air lines. Reconnect the ground wire if it was disconnected during service.

DISPLACEMENT PUMP 204???641

REF. NO. 2

DISPLACEMENT 41

PUMP INCLUDES

ITEMS 3???39, 56???66

52

42

4

20

44

TORQUE TO 40???50 ft???lb (54???68 N.m)

*15 34

38 7

29

*27

11 32

31 28

SEE DETAIL B

DETAIL C

306???646 9

Model 222???638 Displacement Pump

(Used on Models 222???526, 222???539, 223???984 and 223???991)

NOTE: Before beginning, read ???Before Y ou Start??? on page 8.

Disassembly

NOTE: Refer to Fig 3 and the parts drawing during the following procedure.

1.Remove the cotter pin (41). Unscrew the coupling nut (50) and the three tie rod locknuts (44). Pull the displacement pump (2) off the air motor (1).

2.Remove the cotter pin (42). Loosen the locknut (45). Unscrew the connecting rod (53) from the displace- ment rod (60).

3.Insert a 1/4 in. (6 mm) diameter rod in the holes of the packing nut/wet???cup (21), and loosen it. Push the displacement rod (60) down until the priming piston

(37)clears the intake valve housing (28). Remove the nut (6), priming piston (37), valve plate (36) and plate guide (31).

4.Unscrew the four tie bolts (8) and pull the intake valve housing (28) off the pump. Pull the priming rod (62) and displacement rod (60) out of the bottom of the cylinder (59). Remove the pin (7) and unscrew the priming rod (62) from the adapter (61).

5.Pull the cylinder (59) down out of the outlet housing

(26).Inspect the inner surface of the cylinder and the outer surface of the displacement rod (18) for scratches or scoring, which can cause premature packing wear and leaking. To check, run a finger over the surface or hold the part up to the light at an angle.

6.Disassemble the intake valve (3). Clean and inspect all parts, replacing as necessary . Check the intake valve seat (30) for nicks or damage.

7.Unscrew the adapter (61) from the displacement rod

(60).Remove and inspect the piston (38). Disas- semble the piston.

8.Unscrew the packing nut/wet???cup (21). Remove the wiper seal (66). Remove the throat packings from the outlet housing (26).

9.Clean and inspect all parts, replacing as necessary.

Reassembly

NOTE: Refer to Fig 3 and the parts drawing during the following procedure.

1.See Detail A of Fig 3. The gland/packing stack (64*) for the throat is preassembled. Do not disassemble the stack. Lubricate the gland/packing stack and in- stall it into the outlet housing (26). Be sure the lips of the v???packings are facing down. Install the wiper seal (66) in the groove of the wet???cup (21) with the lips facing down. Loosely install the packing nut/wet??? cup (21).

2.See Detail B of Fig 3. Install the two bearings (35*) and the u???cup packing (56*) on the piston (38). Be sure the lips of the packing are facing up.

10 306???646

3.Install the piston (38), valve plate (34), and adapter

(61)on the displacement rod (60).

4.Thread the connecting rod (62) into the adapter (61) and secure with the pin (7).

5.Install one copper gasket (27*) in the outlet housing

(26).Push the displacement rod (60) and priming rod

(62)up into the outlet housing (26) so the top of the displacement rod just protrudes from the packing

nut/wet???cup (21). Lubricate the priming rod (62).

6.Install the cylinder (59) in the outlet housing (26), be- ing careful not to scratch the polished inner surface of the cylinder.

7.See Detail C of Fig 3. Slide the intake valve gland/ packing stack (65*) into the intake valve seal housing

(3). Do not disassemble the stack. Be sure the lips of the v???packings are facing up. Tighten the packing nut (11). Install the valve seat (30) in the intake valve housing (28). Place the intake valve seal housing (3) on the seat (30).

8.Install two copper gaskets (27*) on the intake valve stop (29). Install the stop in the intake valve housing (28).

9.Carefully guide the intake valve housing (28) up over the priming rod (62) and install it on the cylinder (59).

Insert the four tie bolts (8) through the outlet housing (26) and engage the holes in the intake valve hous- ing. Torque the tie bolts oppositely and evenly to 60 ft???lb (82 N.m).

10. Install the plate guide (31), plate (36), priming piston (37) and nut (6) on the priming rod (62). If necessary, push down on the displacement rod (60) to provide sufficient clearance from the intake valve housing (28).

11.Tighten the packing nut/wet???cup (21) just enough to prevent leakage ??? no tighter.

12.Check the alignment of the displacement rod (60) by inserting a size E (0.254 in. diameter) drill shank be- tween the packing nut/wet???cup (21) and the rod. If the drill shank cannot be passed freely around the rod, tighten the tie bolt (8) on the side which is bind- ing.

13.Screw the connecting rod (53) into the top of the dis- placement rod (60). Insert the cotter pin (42) and tighten the locknut (45).

14.Align the pump outlet on the outlet housing (26) with the optional outlet at the base of the air motor (1). Loosely screw the tie rod locknuts (44) onto the tie rods (52). Lubricate the o???ring (47) and the top thread of the connecting rod (53). TIghten the cou- pling nut (50) to attach the displacement pump to the motor. Insert the cotter pin (41).

15.Start the pump and run it slowly to check for binding. Adjust the tie rods as necessary , then torque the locknuts (44) to 40???50 ft???lb (54???68 N.m).

16. Reconnect the fluid and air lines. Reconnect the ground wire if it was disconnected during service.

Model 222???248, Series A

20:1 Ratio King Pump with Standard Air Motor

Includes items 1???66

Model 204???287, Series K

10:1 Ratio Bulldog Pump with Standard Air Motor

Model 215???873, Series B

10:1 Ratio Bulldog Pump with Quiet Air Motor

Includes items 1???66

Includes items 1???66

LIPS OF

V???PACKINGS MUST

FACE DOWN

UHMWPE

PTFE

UHMWPE

PTFE 64*

UHMWPE

MALE

GLAND

26

20

27*

29

27*

27*

39

33

7

**32

11

MALE

GLAND

UHMWPE

PTFE

UHMWPE

PTFE

*35

38

*65

LIPS OF

V???PACKINGS

MUST FACE UP

3

**30

UHMWPE

FEMALE

GLAND

SHIM

(AS REQ???D)

28

31

36

37

6

Model 222???248, Series A

20:1 Ratio King Pump with Standard Air Motor

Includes items 1???66

Model 204???287, Series K

10:1 Ratio Bulldog Pump with Standard Air Motor

Includes items 1???66

1207???647 KING, STANDARD AIR MOTOR,

2204???641 DISPLACEMENT PUMP ASSEMBLY

3205???161 .HOUSING, intake valve seal

7101???354 .PIN, roll; 0.188??? (4.8 mm) dia;

Model 215???873, Series B

10:1 Ratio Bulldog Pump with Quiet Air Motor

Includes items 1???66

*Included in repair kit 220???861.

**Recommended ???tool box??? spare parts. Keep on hand to reduce down time.

***Extra warning labels and tags are available free.

306 and 307 numbers in descriptions refer to separate in- struction manuals, supplied.

Displacement Pump Repair Kit 220???861

Must be purchased separately

Includes:

641

651

NOTE: O???ring 104???445 included in the kit is not used with these models.

HOW TO ORDER PARTS

1To be sure you receive the correct replacement parts, kits or accessories, always give all of the information requested in the chart below.

2.Check the parts list to identify the correct part number; do not use the ref. no. when ordering.

3.Order all parts from your nearest Graco distributor.

Model 222???539, Series A

20:1 Ratio King Pump with Standard Air Motor and Severe???Duty Displacement Pump

Includes items 1???66

Model 223???991, Series A

20:1 Ratio King Pump with Quiet Air Motor

and Severe???Duty Displacement Pump

Includes items 1???66

Model 222???526, Series A

10:1 Ratio Bulldog Pump with Standard Air Motor

and Severe???Duty Displacement Pump

Includes items 1???66

Model 223???984, Series A

10:1 Ratio Bulldog Pump with Quiet Air Motor

and Severe???Duty Displacement Pump

Includes items 1???66

1

TORQUE TO 60 ft???lb (82 N.m)

21**

LIPS OF

V???PACKINGS MUST

FACE DOWN

UHMWPE

PTFE

UHMWPE

PTFE 64*

UHMWPE

MALE

GLAND

7

26

11

27*

59

*65

LIPS OF

V???PACKINGS

MUST FACE UP

3

**30

38

56*

LIPS OF

PACKING

MUST FACE

UP

35* 27*

29

27*

62**

MALE

GLAND

UHMWPE

PTFE

UHMWPE

PTFE

UHMWPE

FEMALE

GLAND

SHIM

(AS REQ???D)

28

31

36

37

6

Model 222???539, Series A

20:1 Ratio King Pump with Standard Air Motor and Severe???Duty Displacement Pump

Includes items 1???66

Model 223???991, Series A

20:1 Ratio King Pump with Quiet Air Motor

and Severe???Duty Displacement Pump

Includes items 1???66

1207???647 KING, STANDARD AIR MOTOR,

2222???638 DISPLACEMENT PUMP ASSEMBLY

3205???161 .HOUSING, intake valve seal

7101???354 .PIN, roll; 0.188??? (4.8 mm) dia;

Model 222???526, Series A

10:1 Ratio Bulldog Pump with Standard Air Motor

and Severe???Duty Displacement Pump

Includes items 1???66

Model 223???984, Series A

10:1 Ratio Bulldog Pump with Quiet Air Motor

and Severe???Duty Displacement Pump

Includes items 1???66

*Included in repair kit 220???861.

**Recommended ???tool box??? spare parts. Keep on hand to reduce down time.

***Extra warning labels and tags are available free.

306 and 307 numbers in descriptions refer to separate in- struction manuals, supplied.

Displacement Pump Repair Kit 220???861

Must be purchased separately

Includes:

641

651

NOTE: O???rings 108???832, 108???833, and 104???445 in- cluded in the kit are not used with these models.

HOW TO ORDER PARTS

1To be sure you receive the correct replacement parts, kits or accessories, always give all of the information requested in the chart below.

2.Check the parts list to identify the correct part number; do not use the ref. no. when ordering.

3.Order all parts from your nearest Graco distributor.

AIR PRESSURE REGULATOR 207???755

10???125 psi (1???9 bar) MAXIMUM WORKING PRESSURE

3/4 npt inlet and outlet

AIR PRESSURE GAUGE 101???180

0???200 psi (0???14 bar) RANGE

3/4 NPT INLET

AND OUTLET

PUMP RUNAWAY VALVE 215???362

180 psi (12 bar) MAXIMUM WORKING PRESSURE

Shuts off air supply to the pump if the pump accelerates beyond the pre???adjusted setting due to an empty supply container, interrupted fluid supply to the pump, or exces- sive cavitation. 3/4 npt(f) inlet and outlet.

Must be purchased separately.

GRACO THROAT SEAL LIQUID

Non???evaporating liquid for wet cup

206???995 1 quart (0.95 liter) 206???996 1 gallon (3.8 liter)

FLUID DRAIN VALVE 210???658

350 bar (5000 psi) MAXIMUM WORKING PRESSURE

3/8 npt(f) mbe; Viton seals

FLOOR STAND KIT 222???699

Provides secure floor mounting for pump when used with bulk fluid containers. 3??? npt fluid inlet. Includes instruc- tions. (Part nos. 185???443 Ring and 185???445 Plate, in- cluded in the kit, are not used with these pumps.)

Must be purchased separately.

HYDRA???MASTIC AUTOMATIC AIRLESS SPRAY GUN 206???660

3000 psi (210 bar) MAXIMUM WORKING PRESSURE

Has a 0.180 in. (4.57 mm) fluid valve orifice and internal 3???pin safety diffuser for spraying highly viscous, semi??? solid fluids. Requires installing a 3 way air solenoid con- trol valve with a timer to operate the gun.

PISTOL GRIP FLO???GUN 207???945

6000 psi (420 bar) MAXIMUM WORKING PRESSURE

EXTRUSION FLO???GUN 204???355

3000 psi (210 bar) MAXIMUM WORKING PRESSURE

JOINT SEALER POLE GUN 203???810

(Less Nozzle)

3000 psi (210 bar) MAXIMUM WORKING PRESSURE

For sealing joints in concrete. 3/4 npt

GROUNDED BUNA???N AIR SUPPLY HOSE

175 psi (12 bar) MAXIMUM WORKING PRESSURE

GROUNDED BUNA???N FLUID HOSE

3500 psi (240 bar) MAXIMUM WORKING PRESSURE

GROUNDED NYLON FLUID HOSE

3000 psi (210 bar) MAXIMUM WORKING PRESSURE

GROUNDED BUNA???N FLUID HOSE

5000 psi (345 bar) MAXIMUM WORKING PRESSURE

GROUNDED NEOPRENE FLUID HOSE

5000 psi (345 bar) MAXIMUM WORKING PRESSURE

DIMENSIONS

MOUNTING HOLE LAYOUT

21.25??? (540 mm)

3/4 NPSM(F)

AIR INLET

OPTIONAL

FLUID

OUTLET

9.75??? (248 mm) DIA.

(1391 mm)

SERVICE INFORMATION

SERIES CHANGE NOTE: Model 222???638 Displace- ment Pump is advanced to Series B.

ADDED MODELS NOTE: Model 223???984 Quiet Bulldog and 223???991 Quiet King are added to the manual.

Air Operating Range

Bulldog Models 204???287, 215???873,

222???526, and 223???984 . . . . . . . . . . 40???100 psi (3???7 bar) King Models 222???248, 222???539,

and 223???991 . . . . . . . . . . . . . . . . . . . . 40???90 psi (3???6 bar) Air consumption

Bulldog Models 204???287, 215???873,

222???526, and 223???984 . . . . . 13 cfm per gallon pumped (0.10 m#/min/liter) at 100 psi (7 bar) air pressure; up to 120 cfm (3.4 m#/min/liter) with pump operated within recommended range

King Models 222???248, 222???539,

and 223???991 . . . . . . . . . . . . . . . 11 cfm per gallon pumped (0.31 m#/min/liter) at 70 psi (5 bar) air pressure; up to 80 cfm (2.26 m#/min/liter) with pump operated within recommended range

Pump Cycles Per Gallon (liter) . . . . . . . . . . . . . . . . . . . 7 (26.5)

Maximum Recommended

Pump Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 cycles/min;

8.5 gpm (32 liter/min) delivery

Maximum Pump Discharge Pressure

Bulldog Models 204???287, 215???873,

222???526, and 223???984 . . . . . . . . . . . . . 1000 psi (70 bar)

King Models 222???248, 222???539,

and 223???991 . . . . . . . . . . . . . . . . . . . . . 1800 psi (124 bar) Wetted Parts . . Carbon Steel, Zinc Plating, Nitralloy, Bronze, Ultra???High Molecular Weight Polyethylene, PTFEr, Delrinr, Vitonr, Thiokolr

Weight . . . . . . . . . . . . . . . . . . . . . . . 101 lb (46 kg) approximate

Delrinr,PTFEr, and Vitonr??? ???are registered trademarks of the

DuPont Co.

Thiokolr??? is a registered trademark of the Thiokol Chemical Corp.