Graco Bulldog Hydra-Cat 231836 Instructions And Parts List Download Page 24

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308225

Troubleshooting

WARNING

INJECTION HAZARD

To reduce the risk of an injury from
injection, splashing fluid, or moving
parts, follow the

Pressure Relief Proce-

dure

on page 19 if the spray tip/nozzle clogs and

whenever you:

are instructed to relieve the pressure,

stop spraying,

check or service any of the system equipment,

or install or clean the spray tip.

WARNING

MOVING PARTS HAZARD

To reduce the risk of serious injury,
including amputation, from moving parts
inside the air motor housing, never

operate the pump with the air motor plate removed.

The chart below is specific to the air motor and pump.
Refer to the other instruction manuals included with
the system to troubleshoot individual components.

FALLING

RISING

RESIN

PUMP

HARDENER

PUMP

TROUBLE AREA:

RESIN PUMP LEAKAGE

1. THROAT PACKING
2. PISTON PACKING
3. PISTON BALL CHECK

FALLING

RESIN

PUMP

HARDENER

PUMP

TROUBLE AREA:

HARDENER PUMP LEAKAGE

1. THROAT PACKING
2. PISTON PACKING
3. PISTON BALL CHECK

RISING

FALLING

RISING

RESIN

PUMP

HARDENER

PUMP

TROUBLE AREA:

RESIN PUMP LEAKAGE

1. THROAT PACKING
2. FOOT VALVE BALL CHECK

FALLING

RISING

RESIN

PUMP

HARDENER

PUMP

TROUBLE AREA:

HARDENER PUMP LEAKAGE

1. THROAT PACKING
2. FOOT VALVE BALL CHECK

This chart uses the proportioner
gauges to determine pump mal-
functions.

Faulty manifold check valves can
mask pump cylinder problems.
Always keep these valves operat-
ing properly.

Observe the gauge readings dur-
ing the stroke direction indicated
by the bold arrow, and
immediately after closing the
manifold.

Summary of Contents for Bulldog Hydra-Cat 231836

Page 1: ...omatic Pressure Relief Valves Check Valves Pressure Gauges and Regulators Table of Contents Warnings 2 Model Charts 6 Typical Installations 7 8 Installation 9 Installation Optional Fluid Heaters 13 Installation Optional Solvent Pump 15 Flushing 16 Operation 19 Shutdown and Care of the System 23 Troubleshooting 24 Service Displacement Pump 26 Parts 28 Accessories 40 Dimensions 43 Technical Data 45 ...

Page 2: ... rag D Do not blow back fluid this is not an air spray system D Check the gun diffuser operation weekly Refer to the gun manual D Always have the trigger guard on the spray gun when spraying D Check the gun diffuser operation weekly Refer to the gun manual D Be sure the gun trigger safety operates before spraying D Lock the gun trigger safety when you stop spraying D Follow the Pressure Relief Pro...

Page 3: ...spray area free of debris including solvent rags and gasoline D Electrically disconnect all the equipment within the spray area D Do not turn on or off any light switch within the spray area while operating or if fumes are present D Do not operate a gasoline engine within the spray area TOXIC FLUID HAZARD Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or o...

Page 4: ...ur pump Do not exceed the maximum working pressure of the lowest rated system component D Never operate the pump without the automatic pressure relief valves and drainage kits installed These valves relieve fluid pressure through a drain port at the bottom of the valve if the displace ment pump pressure exceeds the working pressure D Do not lift pressurized equipment D Use only Graco approved hose...

Page 5: ...308225 5 Notes head notes ...

Page 6: ... Models with Two Displacement Pumps A B Mix Model No Maximum Pump Fluid Output Pressure At Maximum Air Pressure Of Minimum Component Working Pressure Normal Pressure Ratio Fl id t Ai Nominal Flow Volume 40 cpm Mix Ratio Bare Wall Stand psi MPa bar psi MPa bar psi MPA bar Fluid to Air gpm lpm 1 1 231897 231836 231865 3000 21 207 86 0 6 6 3000 21 207 34 7 1 8 6 8 Models with Three Displacement Pumps...

Page 7: ...propor tioning pump inlets to monitor proper adjustment of the feed pump pressures Never exceed 25 of the Hydra Cat pump outbound fluid pressure on the feed supply Light Viscosity System Two Displacement Pumps 5 1 Ratio Feed Pumps 1 See note above Connect to drain bottle See Fig 5 page 11 2 KEY A Bleed type master air valve B Air filter C Air lubricator D Pump runaway valve E Pump air regulator F ...

Page 8: ...tioning pump inlets to monitor proper adjustment of the feed pump pressures Never exceed 25 of the Hydra Cat pump outbound fluid pressure on the feed supply Heavy Viscosity Heated System Three Displacement Pumps 10 1 Ratio Feed Pumps 1 2 See note above Connect to drain bottle See Fig 5 page 11 KEY A Bleed type master air valve B Air filter C Air lubricator D Pump runaway valve E Pump air regulator...

Page 9: ...structions in the Installation section for further details NOTES 1 Models with three displacement pumps always use the two outer displacement pumps to supply the resin and the middle displacement pump to supply the hardener 2 Label all pumps hoses fluid regulators etc to indicate whether they are for the resin side or hardener side of the system Mounting the Pump Mount the pump to suit your instal...

Page 10: ...ire to a true earth ground Order part number 237569 grounding clamp wire Fig 3 G BB AA CC 2 Air hoses use only grounded hoses with a maxi mum of 500 feet 150 m combined hose length to ensure grounding continuity 3 Fluid hoses use only grounded fluid hoses 4 Air compressor follow manufacturer s recom mendations 5 Spray gun or dispensing valve grounding is obtained through connection to a properly g...

Page 11: ...runaway valve D for each feed pump to automatically shut off the air to the pump if the pump accelerates beyond the pre adjusted setting A pump which runs too fast can be seri ously damaged 4 Install an air line lubricator C for automatic air motor lubrication 5 Install an air filter B to remove harmful dirt and moisture from the compressed air supply Automatic Pressure Relief Valves WARNING COMPO...

Page 12: ...emblies CC to face forward rather than backwards as shown in Fig 76 For Two Displacement Pump Models 1 Connect the resin supply hose EE to the 3 4 npt swivel inlet 37B for the resin displacement pump See Fig 6 2 Connect the hardener supply hose DD to the 3 4 npt swivel inlet 37A for the hardener displace ment pump See Fig 6 For Three Displacement Pump Models 1 Connect the resin supply hose EE to t...

Page 13: ... heater See Fig 8 2 Connect a swivel union 202 to the outlet of each heater See Fig 8 3 Connect a swivel union 203 to the inlet of each heater See Fig 8 For Two Displacement Pump Models 1 Disconnect the existing hardener hose 10B from the inlet of the mixer manifold 23 See Fig 8 Connect the free end of the hose to the swivel 203 at the hardener heater inlet See Fig 9 2 Install a new fluid hose 204...

Page 14: ...23 must be disconnected from the bracket and mounted remotely 1 Loosen the swivel of the unions 17A 17B to remove the elbow 16A 16B on each side of the mixer manifold 23 Turn the unions 17A 17B so the outlet faces up See Fig 10 and 11 2 Connect a new hardener fluid hose 204B between the union 17B and the swivel 203B at the heater inlet See Fig 10 3 Install another hardener fluid hose FB between th...

Page 15: ...to the solvent pump Remove the plug from the back of the swivel union 3 and install the adapter 301 Rotate the regulator gauge elbow 4 so the gauge is facing the opera tor 4 Couple the hose 303 and couplings 302 Connect the hose 303 to the adapter 301 5 Install the other adapter 301 needle valve 304 and adapter 305 to the pump inlet 6 Connect the adapter 307 elbow 308 and fluid hose 309 to the pum...

Page 16: ...moisture may get into the lines which could contaminate the hardener so flush again before restarting the system How to Operate the Mixer Manifold To open or close the mixer manifold fluid valves LL push the handle KK down to open and up to close See Fig 13 Fig 13 1 2 UP closed DOWN open 1 2 KK LL LL N2 N1 N P2 P1 02895 RES HARD 02914 Fig 14 A3 E3 A2 E2 H J1 J2 KEY A Bleed type master air valve A1...

Page 17: ...See Fig 14 5 Open the main master air valve A5 See Fig 14 6 Open the hardener pump master air valve A1 See Fig 14 7 Slowly increase the air regulator E1 setting until the pump is running slowly 8 Open the hardener side drain valve P1 Open the mixer manifold handle KK See Fig 13 9 When the hardener lines are flushed close the mixer manifold handle and close the drain valve P1 Close the air valve A1...

Page 18: ...n stop the pumps If you are not going to use the system 14 Close all air regulators master air valves and fluid shutoff valves Follow the Pressure Relief Proce dure on page 19 WARNING INJECTION HAZARD To reduce the risk of serious injury from fluid injec tion or fluid splashing always close the air valve A4 to the solvent pump before opening the fluid drain valves P2 to relieve system pressure Thi...

Page 19: ...y relieved after following the steps above very slowly loosen the nozzle or hose end coupling and relieve pressure gradually then loosen completely Now clear the nozzle or hose Handling Plural Component Fluid WARNING PLURAL COMPONENT FLUID HAZARD Be extremely cautious when handling plural component materials and solvents used with them Some are extremely toxic See the Toxic Fluid Hazard warnings o...

Page 20: ...system See Fig 16 Fig 16 38 02948A Monitor the Material Supply CAUTION Establish a rigid system for monitoring the material supply to prevent the pumps from running dry A sudden lack of material in one pump may cause many system problems including air entrapment spitting of the fluids fluid crossovers pump damage downtime and added system stresses Never allow the feed pump or solvent pump containe...

Page 21: ...e the gauges J1 to monitor this pressure Higher pressures may prevent the proportioning pump inlet ball checks from setting properly 8 Set the air pressure to the proportioning pump H to obtain the required fluid pressure Refer to the proportioning pump chart on page 6 for the fluid to air pressure 9 While triggering the dispensing valve check the fluid outlet pressure gauges J2 and make note of t...

Page 22: ...rounded metal pail under the drain valves 9 Open the mixer manifold 10 While observing the pump outlet gauges J2 adjust the resin and hardener drain valves P1 P2 until the gauges show your normal operating pressure NOTE The pressure must be within 20 of the orig inal spraying pressure to get a usable test 11 Close the mixer manifold Put a separate sampling container under each drain valve 12 Open ...

Page 23: ...en follow the Pressure Relief Procedure page 19 Cleaning the Pump Inlet Strainer If the fluid pressure from the feed pump to the propor tioning pump cannot be maintained on the propor tioning pump intake gauge J1 check and clean the strainer V See Fig 17 page 21 Care of the Pump Throat Packing Nuts Keep the throat packing nuts JJ filled with appropri ate lubricant and check the tightness of the pa...

Page 24: ...ncluded with the system to troubleshoot individual components FALLING RISING RESIN PUMP HARDENER PUMP TROUBLE AREA RESIN PUMP LEAKAGE 1 THROAT PACKING 2 PISTON PACKING 3 PISTON BALL CHECK FALLING RESIN PUMP HARDENER PUMP TROUBLE AREA HARDENER PUMP LEAKAGE 1 THROAT PACKING 2 PISTON PACKING 3 PISTON BALL CHECK RISING FALLING RISING RESIN PUMP HARDENER PUMP TROUBLE AREA RESIN PUMP LEAKAGE 1 THROAT PA...

Page 25: ... separate manual 307944 or 684004 Pump operates but resin output pressure drops during both strokes Dirty worn or damaged resin pump pis ton valve Fluid supply low Clean service pump See instructions in separate manual 307944 or 684004 Refill or change container Pump operates but hard ener output pressure drops during upstroke Dirty worn or damaged resin pump in take valve Worn or damaged hardener...

Page 26: ...ove the fluid outlet hoses from the displacement pumps 1 For Two Displacement Pump Models Only Unscrew the swivel unions 33 from the bottom of the displacement pumps See Fig 20 2 For Three Displacement Pump Models Only Unscrew the swivel union 33 from the bottom of the center displacement pump Unscrew the swivel unions 126 from the outer displacement pumps Remove the supply manifold 125 from the o...

Page 27: ...lacement pump rod through the tie plate 121 center locknut 123 and wash er 115 Thread the displacement rod into the yoke 114 by turning the complete cylinder Use a wrench on the flats of the displacement rod for final tightening Torque to 53 67 ft lb 72 91 NSm Push the cylinder up into place in the tie plate and install the center locknut 123 2 All pumps Slide the outer two displacement pump rods ...

Page 28: ...ps Model 231897 1 4 2 Torque to 53 67 ft lb 72 91 NSm Apply anaerobic sealant and torque to 100 200 ft lb 135 270 NSm Label 1 4 4 119 120 101 103 104 106 111 113 114 115 116 118 117 121 122 RES HARD 02915 109 105 107 108 112 1 2 1 ...

Page 29: ... 2b 4 109 172726 COUPLER 1 111 168455 TIE ROD 8 937 227 mm long shoulder to shoulder 4 112 150429 GASKET 1 Ref No Part No Description Qty 113 101926 LOCKNUT 1 2 20 unf with nylon insert 2 114 164414 YOKE connector tube 1 115 164416 WASHER flat 1 2 2 116 101712 LOCKNUT 5 8 11 unc 2b with nylon insert 4 117 188975 LABEL resin 1 118 188974 LABEL hardener 1 119 222012 RESIN DISPLACEMENT PUMP see manua...

Page 30: ...to 53 67 ft lb 72 91 NSm Apply anaerobic sealant and torque to 100 200 ft lb 135 270 NSm Label Apply stainless steel pipe sealant to all threaded connections 5 5 125 124 124 RES HARD RES 02916 1 4 4 119 120 103 104 106 111 113 114 115 116 118 121 122 109 105 107 108 112 1 2 117 117 4 123 122 1 ...

Page 31: ... flat 1 2 3 116 101712 LOCKNUT 5 8 11 unc 2b with nylon insert 4 117 188975 LABEL resin 2 118 188974 LABEL hardener 1 119 see table RESIN DISPLACEMENT PUMP 2 120 see table HARDENER DISPLACE MENT PUMP 1 121 see table TIE PLATE 1 122 see table OUTER LOCKNUT 2 123 see table CENTER LOCKNUT 1 124 100345 PLUG pipe 11 1 2 npt f 2 125 208334 SUPPLY MANIFOLD 1 126 156589 SWIVEL UNION 90_ 3 4 npt m x f 2 Re...

Page 32: ...Pumps Model 231836 02917A 1 Apply stainless steel pipe sealant to all threaded connections except at swivels 1 1 1 1 1 1 1 1 1 1 1 1 11 12 13 14 10 1 15 16 17 18 38 23 13 26 27 19 20 21 22 33 32 34 35 36 37 29 30 31 11 28 24 25 2 37 ...

Page 33: ...1591 WASHER flat 1 4 4 21 100016 LOCKWASHER 1 4 4 22 100270 SCREW cap hex head 1 4 20 x 5 8 4 23 215626 MIXER MANIFOLD see manual 307400 1 24 156823 SWIVEL UNION 1 4 npt m x 1 4 npt f 2 25 108233 NEEDLE DRAIN VALVE 2 26 164259 ELBOW street 3 8 18 npt m 1 4 18 npt f 2 27 235905 HOSE cpld 3 8 18 npt x 30 mbe 0 318 ID PTFE 1 Ref No Part No Description Qty 28 188974 LABEL hardener 1 29 101748 PLUG pip...

Page 34: ...nd 231854 02918A 1 Apply stainless steel pipe sealant to all threaded connections except at swivels Included with bare pump 1 1 1 1 1 1 1 1 1 1 1 1 11 12 13 14 2 10 1 15 16 17 18 38 23 13 26 27 42 20 21 22 33 41 34 35 36 37 29 30 31 11 28 24 25 1 41 40 26 39 2 2 2 19 37 ...

Page 35: ...DLE DRAIN VALVE 2 26 164259 ELBOW street 3 8 18 npt m 1 4 18 npt f 4 27 235905 HOSE cpld 3 8 18 npt x 30 mbe 0 318 ID PTFE 1 28 188974 LABEL hardener 1 29 101748 PLUG pipe 3 8 18 npt f sst 2 30 206962 CHECK VALVE 3 8 npt mbe 3 31 100483 TEE pipe 3 8 18 npt f 3 33 16X233 ELBOW street 90_ 1 4 18 npt f x 3 4 14 npt m x f 1 34 101078 FLUID STRAINER 3 4 npt Includes item 34a 2 34a 187758 S GASKET PTFE ...

Page 36: ...308225 36 Parts Stand Mount Two Pumps Model 231865 1 Apply anaerobic sealant and torque to 10 15 ft lb 14 20 NSm 1 50 51 52 53 51 50 55 54 53 02919A 1 1 ...

Page 37: ...iption Qty 1 231836 WALL MOUNT PUMP see parts on page 33 1 50 100321 NUT hex 1 2 13 unc 6 51 100018 LOCKWASHER 1 2 6 Ref No Part No Description Qty 52 217297 LEG frame 2 53 100679 SCREW hex cap head 1 2 13 unc 2a x 3 1 2 6 54 178473 BRACE frame 1 55 168422 CAP square tube 6 ...

Page 38: ...38 Parts Stand Mount Three Pumps Models 231876 231878 231880 and 231883 02920A Apply anaerobic sealant and torque to 10 15 ft lb 14 20 NSm 1 1 50 51 52 53 51 50 55 54 53 1 1 38j 38a 38b 38c 38d 38e 38f 38g 38h ...

Page 39: ...68422 CAP square tube 6 Ref No 38 Drain Valve Kit Supplied with the Wall Mount units and Stand Mount units Ref No Part No Description Qty 38a 190738 S TUBE nylon 36 x 1 2 OD 1 38b 112279 S BOTTLE 1 38c 236272 S HOLDER bottle 1 38d 100022 S SCREW hex cap head 1 4 20 unc 2a 1 38e 112278 S TIE WRAP 1 38f 100016 S LOCKWASHER 1 4 1 38g 111591 S WASHER flat 1 4 1 38h 100015 S NUT HEX 1 4 20 unc 2b 1 38j...

Page 40: ... x 30 mbe 0 318 ID PTFE 1 205 217378 HOSE nylon with spring guards resin cpld 3 8 18 npt x 30 mbe 3 8 ID 1 201 202 203 204 205 201a 201b 02891 Viscon HP Fluid Heaters Style A Model 245848 120 Volt Stainless Steel 4000 psi 28 MPa 276 bar Maximum Working Pressure 85_ 220_ F 29_ 104_ C Temperature Range Model 245863 240 Volt Stainless Steel 4000 psi 28 MPa 276 bar Maximum Working Pressure 85_ 220_ F ...

Page 41: ...TION TUBE ASSEMBLY 3 4 npt 1 313 100101 SCREW hex cap head 3 8 16 unc 2a x 1 4 314 100133 LOCK WASHER 3 8 4 315 100307 NUT hex 3 8 16 unc 2b 4 316 100132 WASHER flat 7 16 4 309 310 312 308 307 305 304 314 313 301 Ref 5 311 306 316 315 301 302 303 A 02902 A B B Miscellaneous Accessories Nitrogen Regulator Kit 207638 Maintains a nitrogen head on the supply drum to protect materials from moisture Kit...

Page 42: ...rrupted fluid supply to the pump or excessive cavitation Air Regulator 206197 300 psi 2 1 MPa 21 bar Maximum Working Pressure Controls air pressure to feed sol vent or proportioning pumps 1 2 npt inlets and outlets with 2 1 4 npt pressure gauge outlets Fluid Control Accessories Fluid Filter 5000 psi 34 MPa 345 bar Maximum Working Pressure 60 mesh 250 micron screen Model 218029 Carbon steel bowl an...

Page 43: ... 718 mm 17 3 4 451 mm 1 3 4 2 1 3 4 2 5 7 6 7 6 5 30 1 4 768 mm 11 279 mm 12 1 2 318 mm 01154 1 2 3 4 3 712 94 mm 3 46 88 mm 4 102 mm 2 51 mm 5 8 11 UNC 3 for pump mounting 0 44 11 1 mm diameter 4 5 6 2 1 3 4 6 1 5 02910A Mounting Hole Layout for Air Motor ...

Page 44: ...308225 44 Notes head notes ...

Page 45: ...olyethylene Manifold assemblies Manifold outlets 3 8 npt Hoses 3 8 in ID PTFE cpld 3 8 npt m 4000 psi 28 MPa 276 bar maximum working pressure Hoses 3 8 in ID nylon cpld 3 8 npt m 3000 psi 21 MPa 207 bar maximum working pressure Automatic pressure relief valves wetted parts 303 stainless steel tungsten carbide fluoroelastomer Air consumption example When the air pressure to the pump is 60 psi 410 k...

Page 46: ...profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories equipment materials or components sold but not man...

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Graco Bulldog Hydra-Cat 231836, Instructions And Parts List

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