Graco 230-998 Operation manual

307–636
Rev. J
Supersedes Rev. G
and PCN H
First choice when
quality counts. 
MODEL 230–978
(GUN AND HOSES
NOT SHOWN)
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
AIR-ASSISTED AIRLESS
10:1 Ratio Monark  Sprayers
950 psi (6.6 MPa, 66 bar) Maximum Fluid Working Pressure
95 psi (0.66 MPa, 6.6 bar) Maximum Air Working Pressure
Model 230–998, Series B
Includes pump and 5 gallon (19 liter) pail
Model 231–015
Includes pump 230–998, hose, gun, and tip
Model 230–978 Series B
Includes pump 230–998, fluid regulation kit 222–564,
hose, gun, and tip
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Graco Inc. is registered to I.S. EN ISO 9001

307–636
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 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
corresponding instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury .
D
This equipment is for professional use only .
D
Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D Check equipment daily . Repair or replace worn or damaged parts immediately .
D Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
T echnical Data on page 14 for the maximum working pressure of this equipment.
D 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.
D 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.
D Do not use hoses to pull equipment.
D 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).
DW
ear hearing protection when operating this equipment.
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

3
307–636
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 dif fuser 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 10 whenever you: are instructed to relieve pres -
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
T ighten 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.

4307–636
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 6.
 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.
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 .

5
307–636
Notes

6307–636
Installation
Grounding
T o reduce the risk of static sparking, ground the pump,
object being sprayed, and all other spray/dispensing
equipment used or located in the spray/dispensing
area. Check you local electrical code for detailed
grounding instructions for your area and type of equip -
ment. Be sure to ground all of this spray/dispensing
equipment:
1.
Pump : loosen the grounding lug locknut (W) and
washer (X). Insert one end of a 1.5 mm
2(12 ga)
minimum ground wire (Y) into the slot in lug (Z)
and tighten the locknut securely . See Fig. 1.
Connect the other end of the wire to a true earth
ground. Order Part No. 237–569, Ground Wire and
Clamp.
2. Air compressor: follow manufacturer ’ s recommen -
dations.
3.
Air and fluid hoses: use only grounded hoses with
a maximum of 500 ft (150 m) combined hose
length to ensure grounding continuity .
4. Spray gun: grounding is obtained through connec -
tion to a properly grounded fluid hose and pump.
5. Object being sprayed: according to your local
code.
6. Fluid supply container: according to your local
code.
7.
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 nonconductive surface, such as
paper or cardboard, which interrupts the grounding
continuity.
8. T o 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
WX
Y
Z

7
307–636
Installation
NOTES:

The reference numbers and letters in parentheses
in the text refer to the callouts in the drawings.
 The accessories mentioned are available from your
Graco distributor .

The following manuals are supplied with your unit:
ManualComponent
307–595
10:1 Ratio Monark Pump
308–640 Air–Assisted Airless
Spray Gun
308–167 Air Regulator
307–273 Fluid Filter
307–886 Fluid Regulator (Model 230–978
Sprayer only)
WARNING
For your safety in installing, operating, and servic -
ing this system, thoroughly read and follow all
warnings and instructions given in this manual or in
any other manuals supplied with this system or any
accessories you add to the system. If a manual is
missing or you need additional copies, copies are
available from Graco at no charge.
All Models (See Fig 2)
DO NOT install the spray tip in the gun yet.
Install an air line filter (H) in the main air line, to re -
move harmful dirt and moisture from the compressed
air supply . Install a bleed–type master air valve (J)
close to the pump air inlet, and downstream from the
pump air regulator (K). Install a second bleed valve (L)
upstream from all other accessories, to isolate the
accessories for servicing.Connect an air supply hose
between the main air supply line and the sprayer ’ s air
inlet swivel (1).
CAUTION
T o avoid contaminating the air supply to the gun, do
not use an automatic air line lubricator; lubricate the
motor manually , instead. See OPERATION on page
11.
WARNING
The bleed-type master air valve (J), air relief valve
(9), and fluid drain valve (E) are required 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 are adjusting or repairing the pump.
The bleed-type master air valve relieves air trapped
between this valve and the pump. T rapped air can
cause the pump to cycle unexpectedly .
The air relief valve (supplied) opens automatically
to relieve air pressure to the pump if the pressure
exceeds a preset level. This valve prevents over-
pressurization of the spray gun.
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.

8307–636
Installation
Assembling Sprayer Model 231–015
(See Fig 2)
Connect the gun air supply hose (71) between the air
inlet (A) of the gun (70) and the nipple (14) at the outlet
of the gun air regulator (B).
Connect the gun fluid supply hose (72) between the
gun fluid inlet (C) and the ball valve (D) mounted in the
side outlet of the fluid filter (25).
WARNING
T o reduce the risk of serious injury, never connect a
fluid hose to the drain valve (E) mounted in the
bottom outlet of the fluid filter (25). This valve is for
use only as a drain valve, to relieve fluid pressure
in the system during shutdown.
Assembling Sprayer Model 230–978
(See Fig 2)
Remove the plug button (64) from the hole (F) in the
pail cover (40).
Assemble the fluid regulation kit (75) as shown in
Detail A and Detail B of Fig 2. Install the regulator
mounting bracket (75k) on the regulator (75f), using
the two screws (75p) and lockwashers (75q). Mount
the assembled regulator kit on the pail cover with the
capscrew (75l), washer (75m) and nut (75n). Connect
the regulator hose (75h) between the nipple (75b) at
the regulator inlet (G) and the ball valve (D) mounted
in the side outlet of the fluid filter (25).
Connect the gun air supply hose (71) between the air
inlet (A) of the gun and the nipple (14) at the outlet of
the gun air regulator (B).
Connect the gun fluid supply hose (72) between the
gun fluid inlet (C) and the nipple (75b) mounted in the
pipe cross (75c).
WARNING
T o reduce the risk of serious injury, never connect a
fluid hose to the drain valve (E) mounted in the
bottom outlet of the fluid filter (25) or the drain
valve (75a) mounted in the pipe cross (75c) of the
fluid regulation kit. These valves are for use only as
drain valves, to relieve fluid pressure in the system
during shutdown.

Fig. 2
DET AIL B
DET AIL A
DET AIL C
71
A
14
B
72
C
D
25
E
64, F
40
75k
75f
75p
75q
75l
75m
75n
75h
75b
75b
75c
75a
75e
75d
75j
K
1
Y
MAIN AIR SUPPL Y
25
75h
D
75l
75m
75n
Ref No. 75 includes
items 75a–75q.
G
75h
75b
75c
75a
70
9
HL
INST ALL BLEED–TYPE MASTER
AIR V AL VE (J) A T PUMP AIR IN -
LET
, DOWNSTREAM FROM ALL
OTHER AIR ACCESSORIES
AIR SUPPL Y
HOSE
AIR SUPPL Y
HOSE
9
307–636
Installation
WARNING
Never connect a spray hose to these valves. They
are for use only as drain valves, to relieve system
fluid pressure.

10 307–636
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be in -
jected 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 tip.
1. Lock the spray gun trigger safety .
2.
Shut of f the air to the pump.
3. Close the bleed-type master air valve (required in
your system).
4. Unlock the spray gun trigger safety .
5. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and trigger the spray gun to
relieve pressure.
6. Lock the spray gun trigger safety .
7.
Open the drain valve connected to the fluid filter
outlet, and all other drain valves used in the sys -
tem (such as in systems using fluid regulation), to
help relieve fliud pressure in the displacement
pump, hose, and gun. T riggering the gun to relieve
pressure may not be suf ficient. Have a container
ready to catch the drainvage.
8. Leave the drain valve(s) 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
air cap or hose end coupling and relieve pressure
gradually , then loosen completely . Now clear the tip or
hose.