Graco 238256 Operation manual

308630
Rev. C
05890B
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
33:1 AND 41:1 RATIO BULLDOGrCARBON STEEL
Cart-Mounted Air-Assisted Package
33:1 RATIO BULLDOGrPUMPS
3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
Part No. 238256, Series B
With High Pressure Fluid Filter,
hoses and AA gun
41:1 RATIO BULLDOGrPUMPS
4100 psi (28.3 MPa, 283 bar) Maximum Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
Part No. 238260, Series B
With High Pressure Fluid Filter,
hoses and AA gun
Refer to page 2 for Table of Contents.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
eCOPYRIGHT 1996, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Parts

2 308630
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 16. . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 16. . . . . . . . . . . . . . . . . . . . . . . . .
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
INSTRUCTIONS
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.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 14 for the maximum working pressure of this equipment.
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.
DDo not use hoses to pull equipment.
DRoute 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).
DWear hearing protection when operating this equipment.
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.

308630 3
WARNING
INJECTION HAZARD
Spray from the gun, 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.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
DDo not point the gun at anyone or at any part of the body.
DDo not put your hand or fingers over the spray 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 gun when spraying.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DBe sure the gun trigger safety operates before spraying.
DLock the gun trigger safety when you stop spraying.
DFollow the Pressure Relief Procedure on page 5 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 or damaged parts immediately.
Do not repair high pressure couplings; you must replace the entire hose.
MOVING PARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore servicing the equipment, follow the Pressure Relief Procedure on page 5 to prevent the
equipment from starting unexpectedly.

4 308630
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.
DGround the equipment and the object being sprayed. Refer to Grounding on page 9.
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.
DElectrically disconnect all equipment in the spray area.
DExtinguish 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 operating or 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.

308630 5
Operation
Pressure Relief Procedure
WARNING
INJECTION 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. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray tips.
1. Lock the gun trigger safety.
2. Close the red-handled bleed-type master air valve
(35, required in your system).
3. Open the fluid shutoff valve (9).
4. Unlock the gun trigger safety.
5. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and trigger the gun to relieve
pressure.
6. Lock the gun trigger safety.
7. Open the drain valve (required in your system),
having a container ready to catch the drainage.
8. Leave the drain valve open until you are ready to
spray 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. Now clear
the tip or hose.
Packing Nut/Wet-Cup
Before starting, fill the packing nut (F) 1/3 full with
Graco Throat Seal Liquid (TSL) or compatible solvent.
See Fig. 1.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
The packing nut is torqued at the factory and is ready
for operation. If it becomes loose and there is leaking
from the throat packings, relieve pressure, then
torque the nut to 61–75 N.m (45–55 ft-lb) using the
supplied wrench. Do this whenever necessary. Do not
overtighten the packing nut.
Flush the Pump Before First Use
The pump is tested with lightweight oil, which is left in
to protect the pump parts. If the fluid you are using
may be contaminated by the oil, flush it out with a
compatible solvent. See Flushing on page 7.
Using the Air-Assisted Spray Gun
Before operating the equipment, read the instruction
manual supplied with the gun.
Use the gun air regulator (207) to control the air pres-
sure to the gun.
Adjust the air pressure to the pump to control the fluid
pressure at the gun. For more precise fluid pressure
control, install a fluid regulator.
Spray some test patterns before doing any finished
work. Refer to the gun manual for detailed information
on correct spraying technique.

6 308630
Operation
CAUTION
To avoid tip-over, the cart must be on a flat and level
surface. Failure to follow this caution could result in
injury or equipment damage.
Prime the Pump
1. See Fig. 1. Remove the tip guard and spray tip
from the gun (102). See the gun instruction manu-
al.
2. Close the air filter/regulator (41), gun air regulator
(207), and bleed-type air valves (B, 35).
3. Close the fluid drain valve (D).
4. Engage the air line coupler (38) with the mating
coupler (37) attached to the air filter/regulator (41)
inlet and twist with a wrench to lock.
5. Check that all fittings throughout the system are
tightened securely.
6. Place the suction tube (11) into the fluid supply
container.
7. Open the fluid shutoff valve (9).
8. Open the bleed-type air valves (B, 35) and the gun
air regulator (207).
9. Hold a metal part of of the gun (102) firmly to the
side of a grounded metal pail and hold the trigger
open.
10. Slowly open the air filter/regulator (41) until the
pump starts.
11. Cycle the pump slowly until all air is pushed out
and the pump and hoses are fully primed.
12. Release the gun trigger and lock the trigger safety.
The pump should stall against pressure.
13. If the pump fails to prime properly, open the drain
valve (D). Use the drain valve as a priming valve
until the fluid flows from the valve. Close the valve.
NOTE: When changing fluid containers with the hose
and gun already primed, open the drain valve (D) to
help prime the pump and vent air before it enters the
hose. Close the drain valve when all air is eliminated.
Set the Air and Fluid Pressure
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 5.
1. Relieve the pressure. Install the spray tip in the
gun, as explained in the gun manual.
2. Open the air filter/regulator (41) slowly. Use the
regulator to control pump speed and fluid pres-
sure. Always use the lowest air pressure neces-
sary to get the desired results. Higher pressures
cause premature tip and pump wear.
NOTE: To open the air filter/regulator, turn the
T-handle in (clockwise). To close the regulator, turn the
handle counterclockwise. To lock the regulator setting,
tighten the jam nut.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of overpressurizing
your system, which could cause compo-
nent rupture and serious injury, never
exceed the specified Maximum Incoming Air Pres-
sure to the pump (see the Technical Data, on
page 14).
3. With the pump and lines primed, and with ade-
quate air pressure and volume supplied, the pump
will start and stop as you open and close the gun.
CAUTION
Do not allow the pump to run dry. It will quickly
accelerate to a high speed, causing damage. If your
pump is running too fast, stop it immediately and
check the fluid supply. If the container is empty and
air has been pumped into the lines, refill the con-
tainer and prime the pump and the lines, or flush and
leave it filled with a compatible solvent. Eliminate all
air from the fluid system.

308630 7
Operation
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 5.
For overnight shutdown, stop the pump at the bottom
of its stroke to prevent fluid from drying on the ex-
posed displacement rod and damaging the throat
packings. Relieve the pressure.
Always flush the pump before the fluid dries on the
displacement rod. See Flushing below.
Flushing
WARNING
FIRE AND EXPLOSION HAZARD
Before flushing, read the section FIRE
OR EXPLOSION HAZARD on page 4.
Be sure the entire system and flushing
pails are properly grounded. Refer to
Grounding on page 9.
Flush the pump:
DBefore the first use
DWhen changing colors or fluids
DBefore fluid can dry or settle out in a dormant pump
(check the pot life of catalyzed fluids)
DBefore storing the pump.
Flush with a fluid that is compatible with the fluid you
are pumping and with the wetted parts in your system.
Check with your fluid manufacturer or supplier for
recommended flushing fluids and flushing frequency.
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.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 5.
1. Relieve the pressure.
2. Remove the tip guard and spray tip from the gun.
See the gun instruction manual.
3. Remove the filter element from the fluid filter (7).
Reinstall the filter bowl.
4. Place the suction tube (11) in a container of sol-
vent.
5. Hold a metal part of the gun firmly to the side of a
grounded metal pail.
6. Start the pump. Always use the lowest possible
fluid pressure when flushing.
7. Trigger the gun.
8. Flush the system until clear solvent flows from the
gun.
9. Relieve the pressure.
10. Clean the spray tip and fluid filter element sepa-
rately, then reinstall them.
11. Clean the inside and outside of the suction tube
(11).

8 308630
Operation
KEY
8 Suction Hose
11 Suction Tube
35 Red-Handled Bleed-Type Master Air Valve
(required, for pump)
37 Air Line Male Coupler
38 Air Line Female Coupler
41 Pump Air Regulator
102 Spray Gun
207 Gun Air Regulator
D Fluid Drain Valve (required)
F Packing Nut/Wet-Cup
Fig. 1
1Torque to 61–75 N.m (45–55 ft-lb)
F
1
35
D
102
8
11
37
38
41
207
05892B

308630 9
Setup
General Information
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
NOTE: Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor. Refer to
the Product Data Sheet for your pump, Form No.
305754. If you supply your own accessories, be sure
they are adequately sized and pressure rated for your
system.
Fig. 3 is only a guide for selecting and installing sys-
tem components and accessories. Contact your Graco
distributor for assistance in designing a system to suit
your particular needs.
Prepare the Operator
All persons who operate the equipment must be
trained in the safe, efficient operation of all system
components as well as the proper handling of all fluids.
All operators must thoroughly read all instruction
manuals, tags, and labels before operating the equip-
ment.
Prepare the Site
The pump requires 2.8 m#/min (100 scfm) of com-
pressed air while operating at 100 psi (0.7 MPa, 7 bar)
air pressure and 60 cycles per minute. Ensure that you
have an adequate compressed air supply.
Refer to Fig. 3. Bring a compressed air supply line (A)
from the air compressor to the pump location. Be sure
all air hoses (A) are properly sized and pressure-rated
for your system. Use only electrically conductive
hoses. The air hose should have a 3/4 npt(m) thread.
Install a bleed-type shutoff valve (B) in the air line to
isolate the air line components for servicing. Install an
air line moisture trap and drain valve (C) to help re-
move moisture from the compressed air supply.
Keep the site clear of any obstacles or debris that
could interfere with the operator’s movement.
Have a grounded, metal pail available for use when
flushing the system or draining the fluid filter.
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE OR EXPLOSION HAZ-
ARD on page 4.
1. Pump: use the ground wire and clamp (supplied).
See Fig. 2. Loosen the grounding lug locknut (W)
and washer (X). Insert one end of the ground wire
(34) into the slot in lug (Z) and tighten the locknut
securely. Connect the other end of the wire to a
true earth ground.
Fig. 2
W
X
34
Z
0864
2. Air and fluid hoses: use only electrically conductive
hoses.
3. Air compressor: follow manufacturer’s recommen-
dations.
4. Spray gun: ground through connection to a prop-
erly grounded fluid hose and pump.
5. Fluid supply container: follow your local code.
6. Object being sprayed: follow your local code.
7. Solvent pails used when flushing: follow 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 continu-
ity.
8. To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray
gun firmly to the side of a grounded metal pail,
then trigger the gun.

10 308630
Setup
Supplied Components
Refer to Fig. 3.
WARNING
A red-handled bleed-type master air valve (35) and
a fluid drain valve (D) are supplied. These accesso-
ries help reduce the risk of serious injury, including
fluid injection and splashing of fluid 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 valve is
closed. Trapped air can cause the pump to cycle
unexpectedly. Locate 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.
DThe red-handled bleed-type master air valve
(35) is required in your system to relieve air trapped
between it and the air motor when the valve is
closed (see the WARNING above). Be sure the
bleed valve is easily accessible from the pump, and
is located downstream from the air filter/regulator
(41).
DWith a wrench, loosen and remove the female air
line coupler (38). Screw it onto the main air hose
(A). Leave the mating coupler (37) attached to the
air filter/regulator (41).
DThe air filter/regulator (41) controls pump speed
and outlet pressure by adjusting the air pressure to
the pump. It also removes harmful dirt and mois-
ture from the compressed air supply. Locate close
to the pump, but upstream from the bleed-type
master air valve (35).
DThe gun air regulator (207) adjusts the air pres-
sure to the air-assisted spray gun (102).
DThe air manifold (47) provides ports for connect-
ing lines to air-powered accessories.
DThe air relief valve (48) opens automatically to
prevent overpressurization of the pump and gun.
DThe air line lubricator (43) provides automatic air
motor lubrication.
DThe fluid filter (7) includes a 60 mesh (250 mi-
cron) stainless steel element to filter particles from
the fluid as it leaves the pump. It includes the fluid
drain valve (D), which is required in your system to
relieve fluid pressure in the hose and gun (see the
WARNING at left).
DThe suction hose (8) and tube (11) allow the
pump to draw fluid from a 19 liter (5 gallon) pail (E).
DTwo fluid shutoff valves (9) are supplied at the
fluid filter outlets. Attach the fluid hose (103) to one
of the valves. Keep the other valve capped and
closed at all times unless you are using a second
hose and gun.
Connect the Suction Hose
Apply thread sealant to the suction hose (8) and screw
it into the bushing (5) at the pump’s fluid intake. Screw
the suction tube (11) onto the other end of the hose.
Connect the Hoses and Gun
NOTE: The sprayer includes a Hose and Gun Kit
(101), which supplies air and fluid hoses, a spray gun,
and connecting parts (ref. nos. 102–106). If you supply
your own hoses and gun, be sure they are properly
sized and pressure-rated for your system. Use only
electrically conductive hoses.
1. Screw the coupling (105) onto the fluid shutoff
valve (9) at the fluid filter (7).
2. The gun air and main fluid hoses (103) are joined
together. The shorter hose is the fluid hose. Con-
nect the fluid hose to the coupling (105).
3. Screw the nipple (106) into the other end of the
fluid hose (103).
4. Screw the short fluid whip hose (104) onto the
nipple (106).
5. Screw the whip hose (104) onto the fluid inlet of
the spray gun (102).
6. Screw the air hose onto the nipple (204) at the gun
air regulator (207). Screw the other end onto the
air inlet of the spray gun (102).