Graco 235-463 Operation manual

308–236

Rev. J

Supersedes Rev. H

First

choice when

quality counts.



01472A

Model

235–463

Model 235–460

01471

INSTRUCTIONS-PARTS

LIST

INSTRUCTIONS

This

manual contains important

warnings and information.

READ AND KEEP FOR REFERENCE.

Silver

Airless Spray Gun

5000 psi (345 bar) Maximum Working Pressure

Model 237–695, Series B

finger trigger

. T

ip Guard and

Spray tip not included; order separately

Model 235–460, Series C

Includes

the Standard (non-reversing) DripLess



ip Guard and 2 finger trigger

Spray tip not included; order separately

Model 235–461, Series B

Includes

the Standard (non-reversing) DripLess



ip Guard and 4 finger trigger

Spray tip not included; order separately

Model 235–462, Series C

For

Fine-Finish. Includes the standard

(non-reversing) DripLess

T

ip Guard

and 2 finger trigger

Spray tip not included; order separately

Model 235–463, Series D

Includes

RAC



DripLess



Guard, 517 size

SwitchTip

, and 2 finger trigger

Model 235–464, Series C

Includes

Heavy Duty RAC

T

ip Assembly

617 size SwitchT

ip

, and 2 finger trigger

Model 238–591, Series A

Includes

Heavy Duty RAC

T

ip Assembly

525 size SwitchT

ip

, and 4 finger trigger

Model 236–531, Series C

Includes

Heavy Duty RAC

T

ip Assembly

415 size SwitchT

ip

, and 2 finger trigger

Model 238–966, Series A

Includes

Heavy Duty RAC

T

ip Assembly

Customer specified tip, four finger fluid housing

and 2 finger trigger

Patents Pending

GRACO INC. P.O. BOX 1441

MINNEAPOLIS, MN

55440–1441

http://www.graco.com

COPYRIGHT

1992, GRACO INC.

Graco

Inc. is registered to I.S. EN ISO 9001

 

Table

of Contents

Warnings 2.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation/Operation 5

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure

Relief Procedure

. . . . . . . . . . . . . . . . . .

System

Requirements

. . . . . . . . . . . . . . . . . . . . . .

How

to Use the Gun Trigger Safety

. . . . . . . . . .

How

to Use the Gun

. . . . . . . . . . . . . . . . . . . . . . .

How

to Adjust the Spray Pattern

. . . . . . . . . . . . .

How

to Clean the Spray Tip and

Clear a Spray T

ip Obstruction

. . . . . . . . . . . . . . .

How

to Check the Gun Dif

fuser 8.

. . . . . . . . . . . . . .

How

to Flush the Gun

. . . . . . . . . . . . . . . . . . . . . .

Service 9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories 13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical

Data

14.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco

arranty 16.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco

Phone Number

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



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. Use only genuine Graco parts.



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

echnical 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 possibility 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).

W

ear hearing protection when operating this equipment.



Do not lift pressurized equipment.



Comply with all applicable local, state, and national fire, electrical, and safety regulations.

 

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 dif

fuser 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.

T

ighten all fluid connections before 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

ARTS HAZARD

Moving

parts can pinch or amputate your fingers.



Keep clear of all moving parts when starting or operating the pump.



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

4 308-236

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



If 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.



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 disconnect 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 of

f 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

308-236 5

Installation/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

. T

o reduce the risk of

an injury from injection, splashing fluid, or moving

parts, follow the

Pressure Relief Procedure

whenever you:



are instructed to relieve the pressure,



stop spraying,



check or service any of the system equipment,



or install or clean the spray tips.

Lock the gun trigger safety

Shut of

f the power supply to the pump. Close any

bleed-type master air valves.

Unlock the gun trigger safety

Hold a metal part of the gun firmly to the side of a

grounded metal pail, and trigger the gun to relieve

pressure.

Lock the gun trigger safety

Open the drain valve (required in your system),

having a container ready to catch the drainage.

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

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.

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.

The bleed-type master air valve

(air-powered

pumps only) relieves air trapped between this

valve and the pump after the air regulator is shut

off. T

rapped air can cause the pump to cycle

unexpectedly.

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.

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 to a

right angle with the gun body

. See Fig. 1.

2. T

o unlock the gun trigger safety

, push the latch out

and turn it parallel with the gun body

Fig. 1





The

trigger safety is shown

the locked position.

The

trigger safety is shown

the unlocked position.





01474A

 

Installation/Operation

How to Use the Gun

1. Connect

a grounded fluid hose to the gun inlet.

See Fig. 2.

With no tip installed, start the pump. Flush the

pump according to the instructions supplied with it.

Prime the system with the fluid.

WARNING

o reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure

on page 5.

Relieve the pressure.

Be sure the gun trigger

safety is locked. See Fig. 1.

Models 235–460, 235–461, and 235–462:

screw

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. T

ighten the assem

bly with a wrench. See Fig. 2.

NOTE:

If the gasket (2d) is not installed, the gun

will leak.

Models 235–463, 235–464, 238–591, 236–531 and

238–966:

install the SwitchT

ip (16) and the tip

guard (17). See manual 308–644 or 307–991,

supplied.

Fig. 2 01473

1A2d

Start the pump. Adjust the fluid pressure until the

spray is completely atomized. Use the lowest

pressure necessary to get the desired results.

Higher pressure may not improve the spray pattern

and will cause premature tip wear and pump wear

If adjusting the pressure does not give a good

spray pattern, follow the

Pressure Relief Proce

dure

on page 5 and then try another tip size.

Use a full-open, full-close triggering action. Hold

the gun about 14 in. (350 mm) from and at right

angles to the work surface. Don’t swing the gun in

an arc. Practice to find the best length and speed

of stroke.

How to Adjust the Spray Pattern

WARNING

reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure

on page 5.

Relieve the pressure. Loosen the retaining nut

(B). T

urn the tip guard so the groove in the tip is

horizontal (C) for a horizontal pattern and vertical

(A) for a vertical pattern. T

ighten the retaining nut.

See Fig. 3.

The orifice of the spray tip and the angle of the

spray pattern determines the coverage and the

size of the pattern. When more coverage is

needed, use a larger spray tip rather than

increasing the fluid pressure.

CAUTION

The openings in the tip guard reduce paint buildup on

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.

7658A

01472A

Fig. 3

KEY

ATip

guard shown in position for

vertical spray pattern

Retaining nut

ip guard shown in position for

horizontal spray pattern

 

Installation/Operation

How to Clean the Spray Tip

and Clear a Spray Tip Obstruction

WARNING

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 of

f the gun or spray tip

until pressure is relieved.

Cleaning During the Day

WARNING

o reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure

on page 5.

Relieve the pressure.

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 235–460, 235–461, 235–462

– with standard tip guard

Lock the gun trigger safety

, open the pressure

drain valve.

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.

CAUTION

Never soak the entire gun in solvent. Prolonged

exposure to solvent can ruin the packings.

Gun 235–463, 235–464, 238–591, 236–531 and

238–966 – with RAC guard or Heavy Duty RAC guard

Lock the gun trigger safety

. Rotate the RAC guard

handle 180



. See Fig. 4.

Unlock the gun trigger safety

. T

rigger the gun into

a pail or onto the ground to remove the clog.

Lock the gun trigger safety

. Rotate the tip handle

to the spraying position.

If the tip is still clogged, lock the gun trigger safety

shut of

f 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; or in

manual 307–991, supplied with HD RAC.

01472A

Fig. 4

KEY

A Handle

shown in spraying

position. T

urn handle

180

and

trigger gun to clear clog.

 

Installation/Operation

How to Check the Gun Diffuser Operation

WARNING

The

Fine–Finish Gun, Model 235–462, uses a

pre–orifice in the seat to develop the type of spray

pattern required for fine finishes. The pre-orifice

does not

dif

fuse the spray from the nozzle into an

irregular pattern, as with the other guns covered in

this manual. Therefore, to reduce the risk of an

injection injury when the tip guard is not installed,

such as during cleaning, take extra precautions to

keep your hands and body away from the nozzle of

the gun.

For all other guns, check the dif

fuser operation weekly

The gun dif

fuser/seat (2a) breaks up spray and re

duces 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 9. Dif

fuser/seats are not sold separately since

the gun will leak if an old needle is used with a new

diffuser/seat.

WARNING

o reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure

on page 5.

Relieve the pressure.

Remove the tip guard and spray tip.

Start the sprayer and adjust it to the lowest

pressure.

Aim the gun into a grounded metal pail while

holding it firmly to the pail. T

rigger the gun. If the

fluid emitted

is not

dif

fused into an irregular

stream, replace the entire needle kit immediately

See Fig. 5.

Fig. 5

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.

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.

WARNING

o reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure

on page 5.

Relieve the pressure.

Remove the tip guard and spray tip. Soak and

clean the parts.

Put the pump intake in a grounded pail of water or

solvent.

Start the pump at its lowest pressure.

5. T

rigger the gun into the original pail. When solvent

appears, release the trigger

Now trigger the gun into the solvent pail. Circulate

the fluid until the system is thoroughly flushed.

Relieve the pressure.

 

Service

CAUTION

Do not attempt to install an old style needle in this

gun. The front of the new needle is marked with a +

below the Graco symbol.

Notes:



Use Needle Kit 235–475 for Model 235–462 and

Repair Kit 235–474 for the other models.



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

WARNING

reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure

on page 5.

Relieve the pressure.

Remove the hose, tip guard, spray tip and gasket.

Remove the dif

fuser/seat (2a*) and gasket (2b*).

Remove the screw (12), pivot pin (10), and trigger

(8). See Fig. 6.

Insert a punch into the rear of the gun and tap it to

push the needle (2c*) out the front of the gun. See

Fig. 7.

Clean the internal passages of the gun.

Grease the rings (A) of the new needle (2c*). See

Fig. 8.

Fig. 6

2a*2b*

02352

Fig. 7 02353

Fig. 8

10 308-236

Service

Slide the rear of the needle (2c*) into the front of

the gun. Slide the tool (B), provided with the repair

kit, into the gun, around the needle. Lightly tap the

tool with a hammer or lightly press the tool against

a flat surface to seat the needle. See Fig. 9.

Remove the tool.

CAUTION

apping or pressing the tool too hard may jam the

tool and damage the needle.

Grease the end of the needle.

Grease the dif

fuser/seat threads. Place the new

gasket (2b*) on the dif

fuser/seat (2a*) and screw

the assembly into the fluid housing (6). T

orque to

20–25 ft-lb (27–34 N.m). See Fig. 10.

10.

Install the trigger (8), pivot pin (10) and screw (12).

See Fig. 10.

NOTE:

No needle or trigger adjustment is needed.

Fig. 9

02354

Fig. 10

2a*

2b*

Lubricate,

then torque

to 20–25 ft–lb (27–34 N.m)



02352

This manual suits for next models

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