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
2 finger trigger . T ip Guard and
Spray tip not included; order separately .
Model 235–460, Series C
Includes the Standard (non-reversing) DripLess 
T
ip Guard and 2 finger trigger .
Spray tip not included; order separately .
Model 235–461, Series B
Includes the Standard (non-reversing) DripLess 
T
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 5. . . . . . . . . . . . . . . . . . .
System Requirements 5. . . . . . . . . . . . . . . . . . . . . . .
How to Use the Gun Trigger Safety 5. . . . . . . . . . .
How to Use the Gun 6. . . . . . . . . . . . . . . . . . . . . . . .
How to Adjust the Spray Pattern 6. . . . . . . . . . . . . .
How to Clean the Spray Tip and
Clear a Spray T ip Obstruction 7. . . . . . . . . . . . . . . .
How to Check the Gun Dif fuser 8. . . . . . . . . . . . . . .
How to Flush the Gun 8. . . . . . . . . . . . . . . . . . . . . . .
Service 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco W 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
T 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 P 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.
1. Lock the gun trigger safety .
2. Shut of f the power supply 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
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.
1. 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.
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 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
in the locked position.
The trigger safety is shown
in the unlocked position.


01474A

 
Installation/Operation
How to Use the Gun
1. Connect a grounded fluid hose to the gun inlet.
See Fig. 2.
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
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 5.
3. Relieve the pressure. Be sure the gun trigger
safety is locked. See Fig. 1.
4. 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.
5. 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
17
16
6.
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 .
7. 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.
8. 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
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. 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.
2. 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
AB
C
KEY
ATip
guard shown in position for
vertical spray pattern
B Retaining nut
CT ip guard shown in position for
horizontal spray pattern

 
Installation/Operation
How to Clean the Spray Tip
and Clear a Spray Tip Obstruction
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 of f the gun or spray tip
until pressure is relieved.
Cleaning During the Day
WARNING
T o 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. 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
1. Lock the gun trigger safety , 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.
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
1. Lock the gun trigger safety . Rotate the RAC guard
handle 180  . See Fig. 4.
2. Unlock the gun trigger safety . T rigger the gun into
a pail or onto the ground to remove the clog.
3. Lock the gun trigger safety . Rotate the tip handle
to the spraying position.
4. 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.
A

 
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
T o 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.
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. 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
2a
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
T o 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. 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. T rigger 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. 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
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 hose, tip guard, spray tip and gasket.
3. Remove the dif fuser/seat (2a*) and gasket (2b*).
Remove the screw (12), pivot pin (10), and trigger
(8). See Fig. 6.
4. 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.
5. Clean the internal passages of the gun.
6. Grease the rings (A) of the new needle (2c*). See
Fig. 8.
Fig. 6
8
2a*2b*
12
10
02352
Fig. 7 02353
2c
Fig. 8
A

10 308-236
Service
7. 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
T apping or pressing the tool too hard may jam the
tool and damage the needle.
8. Grease the end of the needle.
9. 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
2c
02354
B
Fig. 10
8
2a*
2b*
12
10
Lubricate, then torque
to 20–25 ft–lb (27–34 N.m)


02352
6