Graco 237-418 Operation manual

INSTRUCTIONS–P ARTS LIST 308–457
Rev. B
Supersedes A
23:1 MONARK CARBON STEEL, CART MOUNTED
AA200hs Air-Assisted Airless
Spray Package
See the Data Sheet, 305–663, for application information.
2760 psi (190 bar) Maximum System Working Pressure
120 psi (8.3 bar) Maximum Air Inlet Pressure
Model 237–418, Series A
This complete package includes a pump,
an AA200hs air-assisted airless–spray gun
with a 41 1 spray tip ,a portable cart , 25 ft. (7.6 m) air
and fluid hoses,
air and fluid controls, and a fluid feed.
IMPORTANT
This manual provides the basic safety , installation and
operation information for the package. For your safety ,
also read the component manuals supplied with this
package before operating it.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1994, GRACO INC.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
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Table of Contents
Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground the system 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
System Component Information 7. . . . . . . . . . . . . . . . . .
Operation 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure relief procedure 8. . . . . . . . . . . . . . . . . . . . . .
Flushing 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 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 SymbolCAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
corresponding instructions.

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WARNINGWARNING
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. Splashing fluid in the eyes or on the skin
can also cause can also cause serious injury .
D
Fluid injected into the skin is a serious injury . The injury might look like just a cut, but it is a seri -
ous injury . Get immediate medical attention.
D Do not point the spray gun at anyone or any part of the body .
D
Do not put hand or fingers over the spray tip.
D Do not stop or deflect fluid leaks with your hand, body , glove or rag.
D Do not “blow back” fluid; this is not an air spray system.
D Always have the tip guard and the trigger guard on the spray gun when spraying.
D Check the gun dif fuser operation weekly . Refer to the gun manual.
D Be sure the gun trigger safety operates before spraying the gun.
D Lock the gun trigger safety when you stop spraying.
D Follow the Pressure relief procedure on page 8 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
DT ighten all fluid connections before each use.
D Check the hoses, tubes and couplings daily . Replace worn or damaged parts immediately . Per -
manently coupled hoses cannot be repaired.
D Handle and route hoses and tubes carefully. Keep hoses and tubes away from moving parts and
hot surfaces. Do not use the hoses to pull equipment. Do not expose Graco hoses to tempera -
tures above 180 _F (82_ C) or below –40 _F (–40_C).
TOXIC FLUID HAZARD
Improper handling of hazardous fluids or inhaling toxic fumes can cause extremely serious injury ,
even death, due to splashing in the eyes, ingestion, or bodily contamination.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container . Dispose hazardous fluid according to all local,
state and national guidelines.
DW ear appropriate clothing, gloves, eyewear and respirator .

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FIRE AND EXPLOSION HAZARD
Improper grounding, poor air ventilation, open flames or sparks can cause a hazardous condition
and result in a fire or explosion and serious injury
.
D
Ground the equipment and the object being sprayed. See Ground the system on 6.
D If there is any static sparking while using the equipment, stop spraying immediately . Identify
and correct the problem.
D Provide fresh air ventilation to avoid the buildup of flammable vapors from solvent or the fluid be -
ing sprayed.
D Do not smoke in the spray area.
D Extinguish all open flames or pilot lights in the spray area.
D Do not turn on or of f any light switch in the spray area.
D Electrically disconnect all equipment in the spray area.
D Keep the spray area free of debris, including solvent, rags and gasoline.
D Do not operate a gasoline engine in the spray area.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction or start unexpectedly 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 in doubt about this, call Graco T echni-
cal Assistance at 1–800–543–0339.
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 2760 psi (190 bar) maximum working pressure at 120 psi (8.3 bar) maxi -
mum incoming air pressure of the pump, or the maximum working pressure of any accessory
used with it.
D Do not move or lift pressurized equipment.
DUse fluids or solvents which are compatible with equipment wetted parts. Refer to the T echnical Data
section of all equipment manuals. Read the fluid and solvent manufacturer ’ s warnings.
D Fluid hoses must have spring guards on both ends to protect it from rupture caused by kinks or
bends at or close to the couplings.
D Comply with all applicable local, state and national fire, electrical and other safety regulations.
D Do not touch the heater during operation; it is very hot.
MOVING P ARTS HAZARD
Moving parts, such as the air motor piston located behind the air motor plates, which can pinch or
amputate fingers.
D Never operate the equipment with the air motor plates removed.
D Keep clear of any moving parts when starting or operating the equipment.
WARNINGWARNING

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Setup
I. Prepare the operator.
All persons who operate the system should be trained
in the safe, efficient operation of all system compo -
nents as well as the proper handling of the chemical
coating. At a minimum, all operators should
thoroughly read the safety , installation and operation
sections of this manual and the component manuals.
II. Prepare the site.
1. Use a minimum recommended 5 HP (3.7 kW) air
compressor for ef ficient operation.
2. Clear obstacles and debris that could hinder the
operator’ s movement.
3. Bring an air line from your compressed air supply
to the pump location. Be sure the air is dry and
filtered. Install a bleed–type master air valve (A)
upstream from the pump. Another master air valve
(14) is supplied with the package. When the
bleed–type master air valve is closed and the
pump air regulator (8a) is opened, the valve
relieves all air pressure to the system.
4. Have a grounded, metal waste–pail available to
use when draining the fluid filter .
5. V entilate the spray booth.
WARNING
T o prevent hazardous concentrations of toxic and/
or flammable vapors, spray only in a properly venti -
lated spray booth. Never operate the spray gun
unless ventilation fans are operating.
Check and follow all of the national, state and local
codes
regarding air exhaust velocity requirements.
Fig. 1
AB
C30
1
8b 8a
04072
KEY
Components you must supply:
A Bleed-type master air valve
Required for pump; order
part no. 107–142, 1/4” npt(f)
B Air filter . Order part no.
106–149, 1/2 npt(f)
C Air supply line
D Grounded 5 gallon metal pail
E Air line moisture trap
Components supplied with package:
1 23:1 Monark pump
3 Air-assisted airless spray gun
4 Spray tip
6 Gun fluid hose
7 Gun air hose
8a Pump air regulator
8b Gun air regulator
14 Bleed–type air valve
30 Pump ground wire
E
6
7
3,4
14
C
D

6308-457
Setup
III. Unpack the system.
1. In addition to the assembled components, the air
and fluid hoses, gun and instruction manuals are
packaged separately in the main shipping con -
tainer
. These are the manuals you should receive:
307–619 23:1 ratio Monark pump
308–176 Air-assisted airless spray gun
307–273 Fluid filter
308–167 Air regulator
308–861 Ball valve
IV. Connect the hoses and gun to the
system. See Fig. 1.
1. Connect the blue fluid hose (6) between the fluid
filter and the fluid inlet of the spray gun (3). These
are 1/4–18 npsm(f) swivel fittings.
2. Connect the red air hose (7) between the gun air
regulator (8b) and the air inlet of the spray gun (3).
These are 1/4–18 npsm(f) swivel fittings.
3. V erify that all fittings throughout the system are
tightened securely .
V. Ground the system.
WARNING
To reduce the risk of static sparking, ground the
pump and all other equipment used or located in
the spray area. Check your local electrical code for
detailed grounding instructions for your area and
type of equipment. Ground all of this equipment.
Also read FIRE OR EXPLOSION HAZARD on
page 4 .
1.
Pump : one end of the ground wire (30) is already
connected to the air motor grounding lug. Connect
the clamp end of the ground wire to a true earth
ground.
2.
Air and fluid hoses : use only electrically conductive
hoses with a maximum of 500 feet (150 m) com -
bined hose length to ensure grounding continuity .
3. Air compressor : according to manufacturer ’ s
recommendations.
4.
Fluid supply container: according to local code.
5. All solvent pails used when flushing , according to
local code. Use only metal pails, which are con -
ductive. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which inter -
rupts the grounding continuity .

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System Component Information
I. How to use the air–assisted airless
spray gun.
With an air-assisted airless spray gun, the spray tip
shapes the fluid into a fan pattern. Air from the air cap
further atomizes the fluid and completes the atomiza -
tion of the paint tails into the pattern to produce a more
uniform pattern.
The spray gun has a built-in lead and lag operation.
When triggered, the gun emits air before the fluid is
discharged. When the trigger is released, the fluid
stops before the air flow stops. This helps assure the
spray is atomized and prevents fluid buildup on the air
cap.
NOTE:
The gun air and fluid inlets have 1/4–18 npsm
(R1/4–19) compound male threads that are compatible
with NPSM and BSP female swivel
connectors.
1.
The fan pattern valve (E) can be used to reduce
the pattern by about 25% of the total pattern width.
As the valve is opened, the pattern will reduce
slightly . The tip used designates the total width of
the spray pattern.
2. T o unlock the gun trigger safety, turn the safety so
it is parallel with the trigger . T o lock the gun trigger
safety , turn the safety to a right angle with the trig -
ger
. See Fig. 2.
Fig. 2
UNLOCKED gun trigger safety
LOCKED gun trigger safety
0795A
1
2
1
2
E
II. How to change the spray pattern
direction.
1. Relieve the air and fluid pressure.
2. Install a spray tip in the gun. Rotate the air cap
(the spray tip rotates with it) to determine the
direction of the spray pattern. See Fig. 3.
Fig. 3
V
ertical Spray Pattern Horizontal Spray Pattern
0791
III. How to adjust the air regulators.
See Fig. 4.
As you look at the system, the air regulator (8a) on the
left regulates air to the gun and the air regulator (8b)
on the right regulates air to the pump.
1. Always open air regulators slowly to prevent surg -
ing during startup.
2. T o open the regulator , which allows air to flow , turn
the T–handle IN (clockwise). T urn the T–handle
OUT (counterclockwise) to close off the air flow .
Be sure the jam nut under the T–handle does not
interfere with your adjustments. T ighten the jam
nut to lock in the setting, if desired.
Fig. 4
8a 8b
CW
CCW
04069

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Operation
I. Pressure relief procedure
The system remains pressurized until pressure is
manually relieved. To reduce the risk of serious
injury , including skin injection from pressurized fluid
or accidental spray from the gun, or injury due to
splashing fluid in the eyes or on the skin, follow this
procedure whenever you:
D are told to relieve pressure;
D stop spraying;
D check or service any system equipment;
D install, clean or change spray tips.
WARNING
1. Lock the gun trigger safety .
2.
Close the bleed-type master air valves (A,14).
3. Close the air regulators (8a,8b).
4. Unlock the gun trigger safety .
5.
Hold the gun firmly against a grounded metal
waste pail. T rigger the gun to relieve pressure.
6. Lock the gun trigger safety .
7.
Open the filter drain valve (26), having a container
ready to catch the drainage. Close the drain valve.
If you suspect that the spray tip or hose is completely
clogged or that pressure has not been fully relieved,
very slow loosen the tip retaining nut or hose end cou -
pling and relieve pressure gradually . Clean the tip or
hose obstruction.
II. Flush the pump before the first use.
Flush with a solvent compatible to your fluid. Consult
the fluid manufacturer ’ s literature for recommenda -
tions. See Flushing on page 10.
III. Prime the system.
See Fig. 5.
1. Remove the air cap and spray tip from the gun.
2. Close the filter drain valve (26).
3. Put the suction tube into the fluid supply container .
4.
Make sure the air regulators (8a,8b) are closed.
5. Open the master air valves (A,14).
NOTE: In the next steps, the pump will cycle quickly
until air is purged.
6. Slowly turn on the pump air regulator (8a) until the
pump cycles slowly .
7.
Hold a metal part of the gun firmly against and
aimed into the grounded metal waste pail. T rigger
the gun while increasing pressure at the pump air
regulator (8a) just enough to purge the air and
storage solvent from the system. When new fluid
comes from the gun, release the trigger . Lock the
gun trigger safety .
Fig. 5
A
C
8b 8a
04072
KEY
A Bleed-type
master air valve
3 Air-assisted airless spray gun
8a Pump air regulator
8b Gun air regulator
14 Bleed–type air valve
26 Filter drain valve
3
14
26

9
308-457
Operation
IV. Set the fluid and air pressure.
1. Install the spray tip and air cap on the gun.
2. Adjust the pump air pressure regulator until the
pressure shown on the fluid filter gauge is about
800 psi (56 bar). This should require approximately
35 psi (2.4 bar) air pressure to the pump.
3. T est spray a pass or stationary horizontal pattern.
Hold the gun 10 to 12 in. (250 to 300 mm) from the
paper . Stripes in the outer edges of the pass or
spots at the ends of the stationary pattern are
likely at this point.
NOTE: If there are no stripes or spots, lower the
fluid pressure until they appear before turning on
the air to the gun.
4. Partially trigger the gun so only air is emitted. Set
the gun air regulator to 20 psi (1.4 bar).
5. Retest the spray pattern. T rigger the gun and
adjust the gun’ s air control valve (C) to add air to
the aircap and to eliminate stripes or spots. If there
are no stripes or spots, you are ready to start
spraying.
6.
If there are stripes or spots in the spray pattern,
raise the pump air pressure until you raise the fluid
outlet pressure by about 100 psi (6.9 bar) and try
again. Continue to raise the fluid pressure in
100 psi (6.9 bar) increments until the pattern is full
and clean. Do not exceed 120 psi (8.3 bar)
incoming air pressure or 2760 psi (190 bar) fluid
working pressure.
NOTE: Always use the lowest fluid and air pres -
sure required for good atomization and spray pat -
tern for maximum fluid ef ficiency . Air pressure over
approximately 30 psi (2.1 bar) will cause turbu -
lence in the fan pattern, dirty air caps and slower
production capability .
WARNING
This system has a maximum air working pressure
of 120 psi (8.3 bar) which produces a maximum
fluid working pressure of 2760 psi (190 bar). Higher
pressure can cause the system to rupture or mal -
function and result in serious injury .
V. You are now ready for production
spraying.
CAUTION
When using catalyzed fluids, observe the pot life
as recommended by the fluid manufacturer . Always
flush the system before the pot life has expired to
prevent dried fluid which may be dif ficult to clean
out and may damage the system.
VI. When to shut down the system.
Shut down the system at the end of the work shift and
before checking, adjusting, cleaning or repairing the
system. Always follow the Pressure relief procedure
on page 8.

10 308-457
Flushing
I. When to flush.
DBefore the first time use
D When changing colors
D Before fluid can dry or settle out in a dormant sys -
tem (observe the recommended fluid pot life on cat -
alyzed fluids)
D Before storing the system
II. How to flush.
See Fig. 6.
1. Relieve pressure. See page 8.
2. Remove the air cap and spray tip before flushing.
3. Unscrew the fluid filter (5) bowl. Remove the
screen. See manual 307–273. Reinstall the bowl
without the screen.
4. Put the suction tube into a grounded metal pail with
about 1/2 gallon (2 liters) of a compatible solvent.
5. Make sure the air regulators (8a,8b) are closed.
NOTE: The gun air regulator (8b) always stays closed
during flushing.
6. Open the master air valves (A,14).
7. Slowly turn on the pump air regulator (8a) until the
pump cycles slowly .
8.
Hold a metal part of the gun firmly against the
grounded metal waste pail. T rigger the gun. Slowly
increase the pump air regulator setting until the
fluid flows freely . (Some air will spit from the gun
until the fluid arrives.)
9. Keeping the gun triggered, decrease the pump air
regulator (8a) pressure as much as possible
without stalling the pump, and pump out the
solvent until air comes through the gun.
10. Repeat the procedure with clean solvent, if needed.
11. Release the trigger and lock the gun trigger safety .
12.
Close the master air valves (A,14). Fully close the
pump air regulator (8a).
13.
Open the drain valve (26), having a container
ready to catch the drainage.
14. Remove the suction hose from the solvent and
place it in an empty container
.
15. Clean the filter screen, air cap and spray tip sepa -
rately
. Reinstall the filter screen.
16. Thoroughly clean the inside and outside of the
suction tube .
Fig. 6
C
8b 8a
04072
KEY
A Bleed-type
master air valve
3 Air-assisted airless spray gun
5 Fluid filter
8a Pump air regulator
8b Gun air regulator
14 Bleed–type air valve
26 Filter drain valve
3
14 5
26
A