Graco Inc. 235459 Paint Sprayer User Manual
Contents
1. 6 Caution Symbol How to Flush the Gun 8 Service usario ins La eli i le ei ansi 9 A CAUTION Parts Drawing 11 Technical Data eee 14 This symbol alerts you to the possibility of damage to Graco Phone Numbers 14 or destruction of equipment if you do not follow the Watranty sita atria boris 4 16 instructions A WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury ka INSTRUCTIONS This equipment is for professional use only Read all instruction manuals tags and labels before operating the equipment Use the equipment only for its intended purpose If you are not sure call your Graco distributor Do not alter or modify this equipment Check equipment daily Repair or replace worn or damaged parts immediately Do 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 Use fluids and solvents which are compatible with the equipment wetted parts Refer to the Tech nical Data section of all equipment manuals Read the fluid and solvent manufacturer s warnings Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use could result in a chemical reaction with the p2. 210 731 Three 60 mesh 250 micron screens 210 732 Three 100 mesh 149 micron screens 210 733 Three 200 mesh 74 micron screens SWIVELS and WHIP HOSES Swivels and whip hoses provide more flexible gun movement for easier handling and less fatigue Working pressures are listed in the descriptions 207 946 Swivel 1 2 npsm x 3 8 npt f 5000 psi 350 bar Max Working Pressure 204 940 Swivel 1 4 npt x 1 4 npsm 3000 psi 210 bar Max Working Pressure 214 701 Whip hose nylon coupled 1 4 npsm f x 3 8 npt m spring guards both ends 3000 psi 210 bar Max Working Pressure TOOLS NYLON BRUSHES Use to thoroughly clean the gun s fluid passages 101 891 0 375 9 mm dia 101 892 0 625 16 mm dia WRENCH 171 147 Fits all hexes on the gun NEEDLE TOOL 188 369 Required to install new needle without damaging it TIP GUARDS These tip guards fit all Graco airless spray guns Choose the one that s right for your application One of these tip guards is included with every Graco airless gun 220 422 RAC IV DripLess Tip Guard Includes SwitchTip of choice See your distributor for available sizes 220 222 Standard DripLess Tip Guard Order flat tip separately See your distributor for available sizes 222 674 Heavy Duty RAC DripLess Tip Guard Order SwitchTip separately See your distributor for available sizes 308 235 13 Technical Data Maximum Working Pressure
3. Procedure page 5 Service 4 Insert a punch into the rear of the gun and tap it to A CAUTION push the needle 2c out the front of the gun See Fig 7 Do not attempt to install an old style needle in this 2 gun The front of the new needle is marked with a below the Graco symbol Notes Use Needle Kit 235 474 Use all the new parts for the best results Parts included in the kit are shown with one asterisk 2a Keep parts very clean Dried paint or other contami nants cause friction which causes parts to wear faster Needle Replacement 44 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 Follow the Pressure Relief Procedure page 5 2 Remove the hose tip guard spray tip and gasket l 5 Clean the internal passages of the gun 3 Remove the diffuser seat 2a and gasket 2b Remove the screw 12 pivot pin 11 and trigger Sega 6 Grease the rings A of the new needle 2c See Fig 8 Lubricate then torque 11 to 20 25 ft lb 27 34 N m eo Fig 8 Fig 6 UY 02349 308 235 9 Service 7 Slide the rear of the needle 2c into the front of 8 Grease the end of the needle the gun Slide the tool B provided with the repair kit into the gun around the needle Lightly tap the 9 Grease the diffuser seat threads Place the new tool with a hammer or lightly press the tool against
4. operating the equipment Check the hoses tubes and couplings daily Replace worn or damaged parts immediately Do not repair high pressure couplings you must replace the entire hose Fluid hoses must have spring guards on both ends to help protect them from rupture caused by kinks or bends near the couplings MOVING PARTS HAZARD Moving parts can pinch or amputate your fingers e Keep clear of all moving parts when starting or operating the pump e Before servicing the equipment follow the Pressure Relief Procedure on page 5 to prevent the equipment from starting unexpectedly RECOIL HAZARD Due to the high pressure fluid emitted a strong recoil action may occur when you trigger this gun If you are unprepared your hand could be forced back toward your body or you could lose your balance and fall resulting in serious injury 308 235 3 4 44 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 e Ifthere is any static sparking or you feel an electric shock while using this equipment stop spray ing immediately Do not use the equipment until you identify and correct the problem Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed Keep the spray area free of debris including solvent rags and gasoline Electrically disconn
5. 2 203 953 SCREW hex washer hd 10 24 1 13 235 470 GUN HANDLE 1 14 218 139 HOSE HOLDER 1 15 107 257 CAPSCREW 1 4 20 x 1 2 1 164 187 987 WARNING TAG not shown Model 235 458 only 1 A 187 346 WARNING SHEET not shown Model 235 459 only 1 17A 222 385 WARNING CARD not shown 1 18 220 422 RAC IV DripLess TIP GUARD Model 235 459 only 1 19 221 517 SwitchTip Size 517 Model 235 459 only 1 These parts are also included in Repair Kit 235 474 which may be purchased separately Kit also includes installation tool Part not sold separately A Replacement Danger and Warning labels tags and cards are available at no cost 308 235 11 Notes 12 308 235 Accessories FILTERS 3000 psi 210 bar Maximum Working Pressure Adequate filtering is important for a good surface finish and to minimize tip clogging These filters provide secondary filtering Various screen meshes are avail able Mounts in hose 213 068 Includes filter body spring and one 100 mesh screen 213 069 Includes filter spring and one 60 mesh screen Use with above filter body 210 742 Includes filter spring and one 100 mesh screen Use with above filter body 210 729 Includes assembly 213 068 plus a 3 ft 0 9 m whip hose for more flexible gun movement Mounts between hose and gun 210 500 Includes swivel adapter and one 60 mesh screen Replacement screens for above filters
6. 5000 psi 350 bar Fluid Orifice Size 0 090 in 2 3 mm Wetted Parts Stainless steel Polyethylene Polyurethane Nylon PTFE WEIGNE oere rer EERIE dati 18 oz 510 g ISE E E EE E 1 4 npsm m Maximum material temperature 120 F 50 C Sound Data Sound Pressure Level 78 dB A Sound Power Level 87 dB A Measured while spraying waterbase paint gravity 1 36 through a 517 tip at 3 000 psi 207 bar Per ISO 3744 PTFE is a registered trademark of the DuPont Company 14 308 235 Graco Phone Number TO PLACE AN ORDER contact your Graco distrib utor or call this number to identify the distributor closest to you 1 800 328 0211 Toll Free Manual Change Summary Changed Model 237 691 Series C To Model 237 691 Series B 308 235 15 The Graco Warranty and Disclaimers WARRANTY Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use As purchaser s sole remedy for breach of this warranty Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment proven defec tive This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written rec ommendations This warranty does not cover and Graco shall
7. INSTRUCTIONS PARTS LIST 5 308 235 i This manual contains important GRACO Rev F KA warnings and information Supersedes Rev E READ AND KEEP FOR REFERENCE INSTRUCTIONS Flex Airless Spray Gun 5000 psi 345 bar MAXIMUM WORKING PRESSURE Model 235 457 Series C Bare gun Model 237 691 Series B Includes RAC IV DripLess Tip Guard 517 size SwitchTip and 2 finger trigger Model 235 459 Series D Includes RAC IV DripLess Tip Guard 517 size SwitchTip and 2 finger trigger Model 235 458 Series C Includes the Standard non reversing DripLess Tip Guard Spray tip not included order separately Patents Pending C Model 235 458 GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1992 GRACO INC Graco Inc is registered to l S EN ISO 9001 Table of Contents Symbols Wamings spie oi ca op ssl 2 Installation Operation oooooocococooooo 4 Warning Symbol Pressure Relief Procedure 5 System Requirements 5 A WARNING How to Use the Gun Trigger Safety 5 How to Use the Gun 2 2 2 2 eee eee 6 This symbol alerts you to the possibility of serious How to Adjust the Spray Pattern ooo 6 injury or death if you do not follow the instructions How to Clean the Spray Tip and Clear a Spray Tip Obstruction 7 How to Check the Gun Diffuser 8 How to Clean the Filter
8. ION Never soak the entire gun in solvent Prolonged exposure to solvent can ruin the packings Gun 235 459 and 237 691 with RAC IV tip guard 1 KEY Engage the trigger safety latch Rotate the RAC IV tip handle 180 See Fig 4 Disengage the trigger safety latch Trigger the gun into a pail or onto the ground to remove clog Engage the trigger safety latch Rotate the tip handle to the spraying position If the tip is still clogged lock the gun trigger safety shut off the sprayer and disconnect the power source and open the pressure drain valve to relieve pressure Clean the spray tip as shown in manual 308 644 supplied with the RAC IV Handle shown in spraying position Turn handle 180 and trigger gun to clear clog Fig 4 308 235 7 Installation Operation How to Check the Gun Diffuser Operation Check the diffuser operation weekly The gun diffuser seat 2a breaks up spray and reduces the risk of fluid injection when the tip is not installed Perform the test below If it fails replace the entire Needle Kit Part No 235 474 as instructed on page 7 Diffuser seats are not sold separately since the gun will leak if an old needle is used with a new diffuser seat A 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 Follow the Pressure Relief Procedure page 5 2 Remove the tip guar
9. d and spray tip 3 Start the sprayer and adjust it to the lowest pressure 4 Aim the gun into a grounded metal pail while holding it firmly to the pail Trigger the gun If the fluid emitted is not diffused into an irregular stream replace the entire needle kit immediately See Fig 5 Fig 5 8 308 235 How to Flush the Gun Always flush the pump and the gun before the fluid being sprayed can dry in it NOTE If it is available the flushing procedure provided in your pump or sprayer manual should be used instead of this procedure A WARNING FIRE AND EXPLOSION HAZARD Static sparking and splashing may cause fire explosion and serious injury To reduce static sparking and splashing always remove the spray tip from the gun and hold a metal part of the gun firmly to the side of a grounded metal pail when flushing A 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 Follow the Pressure Relief Procedure page 5 2 Remove the tip guard and spray tip Soak and clean the parts 3 Put the pump intake in a grounded pail of water or solvent 4 Start the pump at its lowest pressure 5 Trigger the gun into the original pail When solvent appears release the trigger 6 Now trigger the gun into the solvent pail Circulate the fluid until the system is thoroughly flushed 7 Follow the Pressure Relief
10. ect all equipment in the spray area Extinguish all open flames or pilot lights in the spray area Do not smoke in the spray area Do not turn on or off any light switch in the spray area while operating or if fumes are present Do not operate a gasoline engine in the spray area Ground the equipment and the object being sprayed Refer to your pump instruction manual 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 Know the specific hazards of the fluid you are using Store hazardous fluid in an approved container Dispose of hazardous fluid according to all local state and national guidelines Always wear protective eyewear gloves clothing and respirator as recommended by the fluid and solvent manufacturer 308 235 Installation Operation Pressure Relief Procedure 44 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 e are instructed to relieve the pressure e stop spraying e check or service any of the system equipment e orinstall or clean the spray tips 1 Lock the gun trigger safety 2 Shut off the power su
11. gasket 2b on the diffuser seat 2a and screw a flat surface to seat the needle See Fig 9 the assembly into the fluid housing 7 Torque to Remove the tool 20 25 ft lb 27 34 N m See Fig 6 10 Install the trigger 8 pivot pin 11 and screw 12 A CAUTION See Fig 6 Tapping or pressing the tool too hard may jam the tool and damage the needle NOTE No needle or trigger adjustment is needed 02351 Fig 9 Ny 10 308 235 Model 235 459 Series D Model 237 691 Series B ncludes RAC IV DripLess Tip Guard Includes items 2 to 19 as indicated by model number Model 235 457 Series C Includes the Standard non reversing DripLess Tip Guard Includes items 2 not 2d to 17 as indicated by model number Model 235 458 Series C Includes the Standard non reversing DripLess Tip Guard Includes items 1 to 17 as indicated by model number Ref No PartNo Description Qty 1 220 222 STANDARD TIP GUARD Model 235 458 only 1 2 235 474 NEEDLE KIT Includes items 2a to 2d 1 2a DIFFUSER SEAT 1 2b GASKET copper 1 2c NEEDLE 1 2d 166 969 TIP GASKET Use in gun model 235 458 only Lubricate then torque to 20 25 ft lb 27 34 N m Lubricate Torque to 30 40 in Ib 3 4 4 5 N m PEE Purchase separately 01468 Ref No PartNo Description Qty 6 169 797 ADAPTER 1 7 187 972 FLUID HOUSING 1 8 187 985 TRIGGER 1 9 102 207 SETSCREW 1 4 20 1 11 187 965 PIVOT PIN 1 1
12. he 1 To adjust the spray pattern direction follow the Pressure Relief Procedure on page 5 Pressure Relief Procedure on page 5 Loosen the tip guard retaining nut B Turn the tip guard 3 Relieve the pressure Be sure the gun trigger tip groove horizontally C for a horizontal pattern safety is locked See Fig 1 and vertically A for a vertical pattern Tighten the retaining nut 4 Model 235 459 Unscrew the tip guard 1 and install the tip A and the gasket 2d in the nut of the tip guard Screw the assembly firmly onto the gun Tighten the assembly with a wrench See Fig 2 2 The spray tip orifice and spray angle determines the coverage and size of the pattern When more coverage is needed use a larger spray tip rather than increasing the fluid pressure NOTE If the gasket 2d is not installed the gun will leak A CAUTION 5 Models 235 459 and 237 691 install the SwitchTip 19 and the tip guard 18 See manual The openings in the tip guard reduce paint buildup on 308 644 supplied the tip guard while spraying Any damage to the sharp edges of the openings causes paint to collect at that area Never hang the gun by the tip guard Tip guard shown in position for vertical spray pattern B Retaining nut C Tip guard shown in position for horizontal spray pattern NN NL o 01463 Fig 2 6 Start the pump Adjust the fluid pressure until the spray is completely atomized Use the lowest pressure
13. ity Every form of liability for direct special or consequen tial damages or loss is expressly excluded and denied In no case shall Graco s liability exceed the amount of the purchase price Any action for breach of warranty must be brought within two 2 years of the date of sale EQUIPMENT NOT COVERED BY GRACO WARRANTY Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose with respect to accessories equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motor switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Sales Offices Atlanta Chicago Detroit Los Angeles Foreign Offices Belgium Canada England Korea Switzerland France Germany Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 PRINTED IN U S A 308 235 December 1992 Revised February 1998 16 308 235
14. necessary to get the desired results Higher pressure may not improve the spray pattern and will cause premature tip wear and pump wear 6 308 235 Installation Operation How to Clean the Spray Tip and Clear a Spray Tip Obstruction 44 WARNING To reduce the risk of fluid injection or splashing in the eyes or on the skin do not hold a hand body or rag in front of the spray tip when cleaning or checking a clogged tip Point the gun toward the ground or into a waste container when checking to see if the spray tip is cleared Do not try to blow back paint this is not an air spray gun Do not wipe fluid buildup off the gun or spray tip until pressure is relieved Cleaning during the day 1 Follow the Pressure Relief Procedure page 5 2 Clean the front of the tip frequently during the day to help reduce buildup Also clean the tip and tip guard at the end of each work day Use a solvent soaked brush to clean the spray tip Clearing an obstruction If the spray tip clogs while spraying immediately stop spraying then Gun 235 458 with standard tip guard 1 Engage the trigger safety latch open the pressure drain valve 2 Remove the spray tip and blow out the obstruction by applying air to the front of the spray tip Or let the spray tip and gun nozzle soak to dissolve the obstruction If it won t dissolve jar it out by tapping the back of the spray tip against a flat surface 44 CAUT
15. not be liable for any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility with Graco equipment of structures accessories equipment or materials not supplied by Graco or the improper design manufacture instal lation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claim If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation DISCLAIMERS AND LIMITATIONS The terms of this warranty constitute purchaser s sole and exclusive remedy and are in lieu of any other warranties express or implied including warranty of merchantability or warranty of fitness for a particular purpose and of any non contractual liabilities including product liabilities based on negligence or strict liabil
16. ossibility of explosion Do not use hoses to pull equipment Route 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 Wear hearing protection when operating this equipment Do not lift pressurized equipment Comply with all applicable local state and national fire electrical and safety regulations 2 308 235 44 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 Fluid injected into the skin might look like just a cut but it is a serious injury Get immediate medi cal attention Do not point the gun at anyone or at any part of the body Do not put your hand or fingers over the spray tip Do not stop or deflect leaks with your hand body glove or rag Do not blow back fluid this is not an air spray system Always have the tip guard and the trigger guard on the gun when spraying Check the gun diffuser operation weekly See page 8 Be sure the gun trigger safety operates before spraying Lock the gun trigger safety when you stop spraying Follow the Pressure Relief Procedure on page 5 if the spray tip clogs and before cleaning checking or servicing the equipment Tighten all fluid connections before
17. pply to the pump Close any bleed type master air valves 3 Unlock the gun trigger safety 4 Hold a metal part of the gun firmly to the side of a grounded metal pail and trigger the gun to relieve pressure 5 Lock the gun trigger safety 6 Open the drain valve required in your system having a container ready to catch the drainage 7 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 System Requirements 44 WARNING Keep the wallet sized warning card provided with this gun with the operator at all times The card contains important treatment information should an injection injury occur Additional cards are available at no charge from Graco Inc A WARNING Be sure your system has a bleed type master air valve pneumatic pumps only and a pressure drain valve These accessories help reduce the risk of serious bodily injury including fluid injection splashing in the eyes or on the skin or injury from moving parts if you are adjusting or repairing the pump or gun 1 The bleed type master air valve air powered pumps only relieves air trapped between this valve and the pump after the air regulator i
18. s shut off Trapped air can cause the pump to cycle unexpectedly 2 The pressure drain valve assists in relieving fluid pressure in the displacement pump hose and gun triggering the gun to relieve pressure may not be sufficient 3 Strain the fluid you are spraying if it contains particles which could clog the spray tip How to Use the Gun Trigger Safety 1 To lock the gun trigger safety turn the latch A to a right angle with the gun body See Fig 1 2 To unlock the gun trigger safety push the latch A out and turn it parallel with the gun body UNLOCKED 01464 Fig 1 308 235 5 Installation Operation How to Use the Gun 7 If adjusting the pressure does not give a good spray pattern follow the Pressure Relief Proce 1 Guide a grounded fluid hose with spring guard dure on page 5 and then try another tip size through the hose guard 14 and connect the hose to the gun inlet See Fig 2 8 Use a full open full close triggering action Hold 2 With no tip installed start the pump Flush the the gun about 14 in 350 mm from and at right pump according to the instructions supplied with it angles to the work surface Don t swing the gun in Prime the system with the fluid an arc Practice to find the best length and speed of stroke 44 WARNING How to Adjust the Spray Pattern To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow t
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