Graco 231161 Operation manual

Instructions – Parts List

GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441

PORTABLE, AIR-ASSISTED AIRLESS

10:1 Ratio Monark

Hydra-Spray Pumps

95 psi (0.66 MPa, 6.6 bar) MAXIMUM AIR INLET PRESSURE

950 psi (6.6 MPa, 66 bar) MAXIMUM FLUID WORKING PRESSURE

Model 231158

For cold spray applications. Includes pump, cart, hose, gun and tip

Model 231162, Series B

For cold spray applications. Includes pump, cart,

fluid regulation kit 222564, hose, gun and tip

Model 224629, Series A

For heated spray applications. Includes pump, cart,

Viscon heater, heater mounting kit 222262,

and circulating kit 222436

Model 231161

For heated spray applications. Includes pump, cart,

Viscon heater, heater mounting kit 222262,

circulating kit 222436, hose, gun and tip

307929J

Read warnings and instructions.

See page 2 for table of contents.

Model 231158 Shown

Parts

2 307929

Table of Contents

Warnings 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 14–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Drawings and Lists 16–21. . . . . . . . . . . . . . . . . . .

Conversion Kits 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Information 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

corresponding 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 uncertain about usage, call your Graco

distributor.

Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

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 23 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 exceed the maximum working pressure of the lowest rated system component. This equip-

ment has a 950 psi (6.6 MPa, 66 bar) maximum working pressure.

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 82C (180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.

3307929

WARNING

INJECTION HAZARD

Spray from the gun, hose 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. Refer to the gun manual.

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 14 whenever you: are instructed to relieve pres-

sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.

Tighten all fluid connections before operating the equipment.

Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.

Permanently coupled hoses cannot be repaired; replace the entire hose.

Use only Graco approved hoses. Do not remove any spring guard that is used to help protect the

hose from rupture caused by kinks or bends near the couplings.

MOVING PARTS HAZARD

Moving parts, such as the air motor piston, 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 14 to prevent the

equipment from starting unexpectedly.

4 307929

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.

Ground the equipment and the object being sprayed. Refer to Grounding on page 5.

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 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.

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.

5307929

Installation

General

Be sure that all operators read and understand this

entire manual and the separate manuals supplied with

components and accessories before using this equip-

ment.

Reference numbers and letters in parentheses refer to

the illustrations and the parts lists on pages 16–23.

Accessories mentioned in the text are available from

your Graco distributor. If you supply your own acces-

sories, be sure they are adequately sized to meet your

system’s requirements.

The Typical Installation shown in Fig. 2 is only an

example. For assistance in designing a system to meet

your particular needs, contact your Graco distributor.

System Accessories

Refer to Fig. 2. Install an air line filter (A) in the main

air line (B), to remove harmful dirt and moisture from

the compressed air supply. To provide automatic

lubrication of the air motor, install an air line lubricator

Install a second bleed valve (G) in the main air line, to

isolate the accessories for servicing.

Grounding

To reduce the risk of static sparking, ground the pump,

object being sprayed, and all other spray equipment

used or located in the spray 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 equipment.

1. Pump: loosen the grounding lug locknut (W) and

washer (X). Insert one end of a 1.5 mm2 (12 ga)

minimum ground wire (Y) into the slot in lug (Z)

and tighten the locknut securely. See Fig. 1. Con-

nect the other end of the wire to a true earth

ground. Order Part No. 237569 Ground Wire and

Clamp.

2. Air hoses: use only electrically conductive air

hoses.

3. Fluid hoses: use only electrically conductive fluid

hoses.

4. Heater, if used: refer to the Viscon2Heater manu-

al, 307805.

5. Air compressor: follow manufacturer’s recommen-

dations.

6. Spray gun: grounding is obtained through connec-

tion to a properly grounded fluid hose and pump.

7. Fluid supply container: according to your local

code.

8. Object being sprayed: according to your local

code.

9. All solvent pails used when flushing, according to

local code. Use only metal pails, which are con-

ductive, placed on a grounded surface. Do not

place the pail on a non-conductive surface, such

as paper or cardboard, which interrupts the

grounding continuity.

10. To maintain grounding continuity when flushing or

relieving pressure, always hold a metal part of the

spray gun firmly to the side of a grounded metal

pail, then trigger the spray gun.

Fig. 1

0864

6 307929

Installation

0972A

KEY

AAir Line Filter

BMain Air Line

CAir Line Lubricator

DFluid Hose

ESpray Gun

FGun Air Supply Hose

GBleed-Type Master Air Valve

(for accessories)

YGround Wire (required)

5Pump

22 Suction Hose

23 Suction Tube

25 Fluid Filter

31 Air Regulators

52 Air Relief Valve

62 Bleed-Type Master Air Valve

(for pump)

65 Fluid Drain Valve

31 31

Fig. 2

WARNING

Three required components are supplied in your

system, to help reduce the risk of serious injury

including fluid injection, splashing in the eyes or on

the skin, overpressurization, or injury from moving

parts if you area adjusting or repairing the pump.

The bleed-type master air valve (62) relieves air

tapped between this valve and the pump. Trapped

air can cause the pump to cycle unexpectedly. To

bleed air from the pump, the pump air regulator

must be open when you close this valve.

The air relief valve (52) opens automatically to

relieve air pressure to the pump if the the pressure

exceeds a preset level. This vale prevents over-

pressurization of the spray gun.

The fluid drain valve (65) assists in relieving fluid

pressure in the displacement pump, hose, and gun;

triggering the gun to relieve pressure may not be

sufficient.

Hose and Gun Connections

Refer to the Typical Installation drawing (Fig. 2). Con-

nect one end of the fluid hose (D) to the filter (25)

outlet and the other to the fluid inlet of the gun (E). Do

not install the spray tip in the gun yet. To use a second

gun with the sprayer, refer to pages 11–13.

Close the bleed-type master air valve (62) and both

the air regulators (31). Connect the main air line (B) to

the bleed valve. Connect an air supply hose (F) to the

outlet nipple of the gun (left) air regulator. Connect the

other end of the hose to the gun’s air inlet.

7307929

Installation

Installing Fluid Regulation Kit 222564

(Pump Model 231162)

WARNING

Before installing the fluid regulation kit, follow the

Pressure Relief Procedure on page 14. Discon-

nect all hoses from the pump.

Assemble the fluid regulation kit (66) as shown in

Detail A of Fig. 3. (Refer to the parts list on page 19.)

Install the mounting bracket (66k) on the regulator

(66f) using the two screws (66p) and lockwashers

(66q). Connect the fluid regulator and bracket to the

side of the cart (7) using the screw (66l), lockwasher

(66m) and nut (66n). Connect the 22” (560 mm) hose

(66h) to the outlet of the fluid filter (25).

Connect the gun air supply hose (F) between the air

inlet of the gun (E) and the outlet nipple of the gun

(left) air regulator. See Fig. 2.

Connect the fluid hose (D) between the gun fluid inlet

and the outlet nipple (66b) of the fluid regulation kit.

Fig. 3

DETAIL A

66d

66a

66b

66h (REF)

(SEE DETAIL A)

66b

66c

66e66f

66h 66j

66k

66l

66m 66n

66p66q

Fluid Regulation Kit 222564

includes items 66a–66q.

0973B

1Connect fluid hose here.

8 307929

Installation

Converting the Pump to a Heated

Circulating System

To convert pump Model 231162 to a heated circulating

unit, order the following:

VisconFluid Heater, Model 220522

Heater Mounting Kit 222262

Circulating Kit 222436

Hose Kit 222264

WARNING

The Viscon2Heater must be installed by a qualified

electrician in compliance with all state and local

codes and regulations, to reduce the risk of electric

shock or other serious injury during installation or

operation.

The heater requires a 120 VAC, single-phase, 16.7

Amp power supply. Refer to the Viscon2 Heater

Manual 307805 for further information.

Do not plug or unplug the power cord in any area

containing flammable materials or fumes to avoid

fire or explosion, which can result in serious injury.

Installing Heater Mounting Kit 222262

WARNING

Before installing the heater, heater mounting kit

and circulating kit, follow the Pressure Relief

Procedure on page 14. Disconnect all hoses from

the pump.

NOTE: Reference numbers marked with an asterisk

(for example, 68*) are included in kit 222262.

Apply 110110 pipe sealant (included in the kit) to all

male threads, except at swiveling connections.

1. Remove the cover from the electrical box (H) at

the back of the heater (67). Screw the bushing

(74*) into the inlet of the electrical box. Install the

cord grip elbow (75*) in the bushing. See Fig. 4.

2. Thread the cord (76*) through the elbow (75*) and

into the electrical box. Attach the black lead to the

leftmost terminal, the white lead to the center

terminal, and the green ground wire to the right-

most terminal. Tighten all terminal nuts to 30 in–lb

(3.4 N.m). Tighten the nut on the cord grip elbow

(75*) to secure the cord. See Fig. 4.

WARNING

The electrical cord (76*) is rated for 105 C (221

F). Do not substitute a lower temperature rated,

generally available cord.

NOTE: Mount the heater (67) on the back of the cart

as follows. Two people are required to perform this

operation.

3. Align the heater (67) mounting posts with the four

holes at the back of the cart’s pump support brack-

et (J). See Fig. 5. Secure the heater to the bracket

with the M8 x 1.25 screws and lockwashers sup-

plied with the heater.

4. Unscrew the swivel adapter (26) and remove the

fluid filter (25) from the pump (5). Remove the

adapter from the filter, and remove the 3/8 npt

nipple (24) from the pump fluid outlet. See Fig. 3.

Fig. 4

GREEN

(GROUND)

WHITEBLACK

Tighten terminal nuts

to 30 in–lb (3.4 N.m).

*74

0867

*75

*76 1

63*

*72

74*75*

76*

73*

PART OF

ITEM 67

77

*70

40 82

83

81

38

41

80

REF)

41

40

79

78

*71

*73

(REF)

19*

82

80

40

Fig. 5

1Arrow on body must point away from pump.

0974

9307929

Installation

5. Screw the check valve (70*) into the pump’s fluid

outlet, making certain that the arrow on the check

valve points away from the pump. Screw the rigid

end of the adapter (71*) onto the check valve. See

Fig. 5.

6. Install the 3/8 npt nipple (63*) in the heater outlet.

Screw the male end of the 90swivel (19*) into the

inlet of the fluid filter (25). Screw the female end of

the swivel (19*) onto the nipple (63*) at the heater

outlet, and tighten securely.

7. Screw the elbow (72*) into the heater’s inlet.

Attach the 1/2” x 3’ (0.9 m) hose (73*) to the

elbow. Attach the other end of the hose to the

swivel of the adapter (71*) at the pump outlet.

10 307929

Installation

Installing Circulating Kit 222436

WARNING

Before installing the heater, heater mounting kit

and circulating kit, follow the Pressure Relief

Procedure on page 14. Disconnect all hoses from

the pump.

NOTE: Reference numbers marked with a symbol (for

example, 77), are included in kit 222436.

Apply 110110 pipe sealant (included in the kit) to all

male threads, except at swiveling connections.

1. Unscrew the suction hose (22) from the pump

intake elbow (21) and set the hose aside. Remove

the elbow (21) from the pump intake and discard.

See Fig. 3.

2. Screw the rigid end of the manifold (77) onto the

pump intake, and attach the suction hose (22) to

the swivel end of the manifold. See Fig. 5.

3. Place a washer (81) and insulator (82) on each

of the screws (38). Insert the screws through the

mounting holes on the left side of the pump sup-

port bracket (J), working from the inside. Place

another insulator (82) on each of the screws on

the outside of the bracket. Use the screws to

attach the back pressure regulator (83) to the

pump support bracket.

4. Screw one of the nipples (41) into the outlet in

the base of the back pressure regulator (83), then

screw one of the elbows (40) onto the nipple so

the male end of the elbow faces forward. Install

another elbow (40) in the inlet of the back pres-

sure regulator, then install the other nipple (41) in

the elbow. Install plugs in the other regulator

ports.

5. Screw an elbow (40) into the open port of the

pump fluid intake manifold (77), so the female

end of the elbow faces left. Install the CIRC end of

the three-way ball valve (78) in the elbow, so the

valve handle is at the front.

6. Screw a second elbow (40) onto the IN branch of

the three-way valve (78), so the elbow points

upward. Connect one end of the hose (80) to this

elbow, and the other end to the nipple (41) at the

outlet of the back pressure regulator.

7. Connect the drain hose (79) to the DRAIN end of

the three-way valve (78).

8. Connect the fluid return line to the nipple (41) at

the inlet of the back pressure regulator.

9. Connect the air and fluid hoses and gun as ex-

plained on page 6.

0975B

Fig. 6

SRP

Connect air hose for first gun here

Air Regulator Connections for a Two-Gun System (All Models)

Connect air hose for second gun here

This manual suits for next models

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