Graco MONARK 222-617 Operation manual

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
 COPYRIGHT 1988 GRACO INC.
MODEL 222–617 SHOWN
(without gun & gun hoses)


INSTRUCTIONS–PARTS LIST 307–946
This manual contains IMPORT ANT
W
ARNINGS AND INSTRUCTIONS
READ AND RET AIN FOR REFER -
ENCE
Rev. E
Supersedes D
HIGH EFFICIENCY LOW
PRESSURE SYSTEM 2500
AIR–ASSISTED AIRLESS
10:1 RATIO MONARK SPRAYER
950 psi (66 bar) MAXIMUM WORKING FLUID PRESSURE
95 psi (6.5 bar) MAXIMUM WORKING AIR PRESSURE*
10 psi (0.7 bar) MAXIMUM OPERA TING AIR PRESSURE**
Model 222–617
5 Gallon Pail-Mounted Sprayer with Fluid Regulation
Model 223–825
Wall-Mount Sprayer with Fluid Regulation
Model 231–165
Cart-Mounted Sprayer with Fluid Regulation
WARNING
Hazard of Using Fluids Containing
Halogenated Hydrocarbons
Never use 1,1,1–trichloroethane, methylene chloride, other
halogenated hydrocarbon solvents or fluids containing such
solvents
in this equipment. Such use could result in a serious
chemical reaction, with the possibility of explosion, which could
cause death, serious bodily injury and/or substantial property
damage.
Consult
your fluid suppliers to ensure that the fluids being used
are compatible with aluminum parts.
*The MAXIMUM WORKING AIR PRESSURE indicates the maximum air pressure the gun was designed to operate
safely under .
**The
MAXIMUM OPERA TING AIR PRESSURE indicates the maximum air pressure the air cap supplied with this gun
was designed to operate at or below to comply with California Wood Rule 1 136 . T o guarantee compliance to rule 1 136,
the gun must be used with
Air Regulator Part No. 1 10–776 . This regulator limits the operating pressure to 10 psi
(0.7 bar)
, using an air supply pressure of 100 psi (7 bar).


SAFETY W ARNINGS
HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY.
FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS
Read and understand all instruction manuals before operating equipment.
FLUID INJECTION HAZARD
General Safety
This equipment generates very high fluid pressure. Spray from the gun,
leaks or ruptured components can inject fluid through your skin and into
your body and cause extremely serious bodily injury , including the need
for amputation. Also, fluid injected or splashed into the eyes or on the skin
can cause serious damage.
NEVER point spray gun at anyone or at any part of the body .
NEVER put hand or fingers over the spray tip.
NEVER try to “blow back” paint; this is NOT an air spray gun.
ALWAYS follow the Pressure Relief Procedure, at right, before cleaning
or removing the spray tip or servicing any system equipment.
NEVER try to stop or deflect leaks with your hand or body .
CHECK operation of all equipment safety devices before each use.
Medical Alert – Airless Spray W ounds
If any fluid appears to penetrate your skin, get EMERGENCY MEDICAL
CARE A T ONCE. DO NOT TREA T AS A SIMPLE CUT . T ell the doctor
exactly what fluid was injected.
Note to Physician: Injection into the skin is a traumatic injury . It is im -
portant
to treat the injury surgically as soon as possible. Do not
delay treatment to research toxicity . T oxicity is a concern with some ex -
otic
coatings injected directly into the blood stream. Consultation with a
plastic surgeon or reconstructive hand surgeon may be advisable.
Spray Gun Safety Devices
Be sure all gun safety devices are operating properly before each use. Do
not remove or modify any part of the gun; this can cause a malfunction
and result in serious bodily injury .
Safety Latch
Whenever you stop spraying, even for a moment, always set the gun
safety
latch in the closed or “safe” position, making the gun inoperative.
Failure to set the safety latch can result in accidental triggering of the gun.
Diffuser
The gun dif fuser breaks up spray and reduces the risk of fluid injection
when the tip is not installed. Check dif fuser operation regularly . Follow the
Pressure Relief Procedure , below , then remove the spray tip. Aim the
gun into a grounded metal pail, holding the gun firmly to the pail. Using the
lowest possible pressure, trigger the gun. If the fluid emitted is not dif -
fused into an irregular stream, replace the dif fuser immediately .
Spray T ip Safety
Use extreme caution when cleaning or changing spray tips. If the spray
tip clogs while spraying, engage the gun safety latch immediately . AL -
WAYS
follow the Pressure Relief Procedure, below , and then remove
the spray tip to clean it.
NEVER wipe of f build–up around the spray tip or air cap until pressure is
fully relieved and the gun safety latch is engaged.
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including fluid injection, splash -
ing
in the eyes or on skin, or injury from moving parts, always follow this
procedure whenever pump is shut of f, when checking or servicing any
part of system, when installing or changing spray tips and whenever you
stop spraying.
1. Engage the spray gun safety latch.
2. Shut of f the power to the pump.
3. Close the bleed–type master air valve (required in system).
4. Disengage the gun safety latch.
5. Hold a metal part of the gun firmly to the side of a grounded metal
waste container and trigger the gun to relieve fluid pressure.
6. Engage the gun safety latch again.
7. Open the drain valve connected to the fluid pressure gauge to help
relieve fluid pressure in the pump, hose and gun. T riggering the gun to
relieve pressure may not be suf ficient. Have a container ready to
catch
the drainage.
8. 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 hose end coupling and relieve pressure
gradually,
then loosen completely . Now clear the tip or hose obstruction.
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the equipment or accessories, such as overpressurizing,
modifying parts, using incompatible chemicals and fluids, or using worn
or damaged parts, can cause them to rupture and result in serious bodily
injury, including fluid injection and splashing fluid in the eyes or on the
skin, or in fire, explosion or property damage.
NEVER alter or modify any part of this equipment; doing so could cause it
to malfunction.
CHECK the gun and all spray equipment regularly and repair or replace
worn or damaged parts immediately .
Read
and follow the fluid and solvent manufacturer ’ s literature regarding
the use of protective eyewear , gloves, clothing, respirator and other
equipment.
System Pressure
The 10:1 Ratio Monark pump develops 950 psi (66 bar) MAXIMUM
FLUID
WORKING PRESSURE at 95 psi (6.5 bar) MAXIMUM WORK -
ING
AIR PRESSURE. The AA2000 Spray Gun has a 950 psi (66 bar)
MAXIMUM FLUID WORKING PRESSURE. NEVER exceed 95 psi (6.5)
air pressure to the pump or spray gun. T o guarantee compliance to Cali-
fornia
Wood Rule 1 136 , the supply air to the gun must be regulated down
to 10 psi (0.7 bar) MAXIMUM OPERA TING PRESSURE, using Air Regu -
lator Part No. 1 10–776. Be sure that all spray equipment and accessories
added to the sprayer are properly rated to withstand the maximum work -
ing
pressure of the sprayer . DO NOT exceed the maximum working pres -
sure
of any component or accessory used with the sprayer .
Fluid Compatibility
BE SURE all fluids and solvents used are chemically compatible with the
“Wetted Parts” shown in the TECHNICAL DA TA on page 17. Always
read the fluid and solvent manufacturer ’ s literature before using them in
this sprayer .


FIRE OR EXPLOSION HAZARD
Static electricity is created by the flow of fluid through the pump and hose.
If every part of the equipment is not properly grounded, sparking may oc -
cur, and the system may become hazardous. Sparks may also occur
when
plugging in or unplugging a power supply cord. Sparks can ignite
fumes from solvents and the fluid being sprayed, dust particles and other
flammable substances, whether you are pumping indoors or outdoors,
and cause a fire or explosion, serious bodily injury , and property damage.
Do not plug in or unplug any power supply cords in the spray area when
there is any chance of igniting fumes still in the air .
If
you experience any static sparking or feel even a slight shock while us -
ing this equipment, STOP SPRA YING IMMEDIA TELY . Check for proper
grounding of the entire system. Do not use the system again until the
cause
of the problem is identified and corrected.
Grounding
To reduce the risk of static sparking, ground the pump and all other equip -
ment
used or located in the spray area. CHECK your local electrical code
for detailed grounding instructions for your area and type of equipment
and be sure to ground all of the following equipment:
1. Pump : use a ground wire and clamp as shown in Fig 1.
2. Fluid hoses connected to the pump : use only grounded hoses with a
maximum of 500 feet (150 m) combined hose length to ensure
grounding
continuity . Refer also to Hose Grounding Continuity , be -
low.
3.
Air compressors: ground according to the manufacturer ’s recom-
mendations.
4.
Spray gun: obtain grounding through connection to a properly
grounded
fluid hose and pump.
5. Fluid supply container: according to local code.
6. Object being sprayed: according to local code.
7. All solvent pails used when flushing , according to local code. Use
only
metal pails, which are conductive. Do not place the pail on a non–
conductive surface, such as paper or cardboard, which interrupts the
grounding continuity .
8.
To maintain grounding continuity when flushing or relieving pressure,
always hold a metal part of the gun firmly to the side of a grounded
metal pail, then trigger the gun.
To ground the pump, loosen the grounding lug locknut (A) and washer
(B). Insert one end of a 12 ga (1.5 mm) minimum, ground wire (D) into the
slot in lug (C) and tighten the locknut securely . See Fig 1. Refer to page 16
for ordering a ground wire and clamp. Connect the clamp end of the
ground
wire to a true earth ground.
Fig 1
C
B
A
D
Flushing Safety
Before flushing , be sure the entire system and flushing pails are properly
grounded. Refer to Grounding , above. Follow the Pressure Relief Pro -
cedure
on page 2, and remove the spray tip from the gun. Always use the
lowest possible fluid pressure, and maintain firm metal–to–metal contact
between the gun and the grounded metal pail during flushing to reduce
the risk of fluid injection injury , static sparking and splashing.
Ventilate the Spray Area
To prevent hazardous concentrations of toxic and/or flammable vapors,
spray only in a properly ventilated spray area.
HOSE SAFETY
High pressure fluid in the hoses can be very dangerous. If the hose devel -
ops
a leak, split or rupture due to any kind of wear , damage or misuse, the
high pressure spray emitted from it can cause a fluid injection injury or
other serious bodily injury or property damage.
ALL FLUID SPRA Y HOSES MUST HA VE A SPRING GUARD ON
BOTH ENDS! The spring guards help protect the hose from kinks or
bends
at or close to the coupling which can result in hose rupture.
TIGHTEN all fluid connections securely before each use. High pressure
fluid can dislodge a loose coupling or allow high pressure spray to be
emitted
from the coupling.
NEVER use a damaged hose. Before each use, check the entire hose for
cuts, leaks, abrasion, bulging cover , or damage or movement of the hose
couplings. If any of these conditions exist, replace the hose immediately .
DO
NOT try to recouple high pressure hose or mend it with tape or any
other device. A repaired hose cannot contain the high pressure fluid.
HANDLE AND ROUTE HOSES CAREFULL Y . Do not pull on hoses to
move equipment. Do not use fluids or solvents which are not compatible
with the inner tube and cover of the hose. DO NOT expose Graco hose to
temperatures above 180  F (82  C) or below –40  F (–40  C).
Fluid Hose Grounding Continuity
Proper hose grounding continuity is essential to maintaining a grounded
spray system. Check the electrical resistance of your fluid hoses at least
once a week. If your hose does not have a tag on it which specifies the
maximum electrical resistance, contact the hose supplier or manufac -
turer
for the maximum resistance limits. Use a resistance meter in the ap -
propriate
range for your hose to check the resistance. If the resistance
exceeds the recommended limits, replace it immediately . An ungrounded
or poorly grounded fluid hose can make your system hazardous. Also
read FIRE OR EXPLOSION HAZARD , above.
MOVING P ARTS HAZARD
Moving parts can pinch or amputate your fingers or other body parts.
KEEP CLEAR of moving parts when starting or operating the pump.
NEVER
operate the pump with any part removed to reduce the risk of
pinching or amputating your fingers on moving parts. Before checking or
servicing the gun, pump, or any other system component follow the Pres-
sure
Relief Procedure on page 2, to prevent the pump from starting ac -
cidentally.
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards – particularly the Gen -
eral
Standards, Part 1910, and the Construction Standards, Part 1926 – should be consulted.


TERMS
Be sure you read and understand each of these terms before reading the
rest of the manual.
WARNING Alerts user to avoid or correct conditions which could cause
bodily injury .
CAUTION
Alerts user to avoid or correct conditions which could cause
damage to or destruction of equipment.
PRESSURE RELIEF PROCEDURE A safety procedure for relieving air
and fluid pressure in the system.
FOR YOUR SAFETY Alerts user to read the additional safety warnings
on the page indicated.
FLUID INJECTION INJUR Y A serious injury , which may appear to be a
simple cut, caused by high pressure injection of fluid directly into the
body.
INSTALLATION
NOTES:
1. The numbers and letters in parentheses in the text
refer
to callouts in the drawings.
2. The circled letters in the drawings, such as
J
show
hose connections.
3. Accessories are shown on page 16.
4. The following manuals are supplied with your
sprayer.
MANUAL COMPONENT
307–595 10:1
Ratio Monark Pump 217–523
307–946 High Ef ficiency Low Pressure System 2500
10:1 Ratio Monark Air–Assisted
Airless Spray System 222–617
307–947 High Ef ficiency Low Pressure System 2500
AA2000 Air–Assisted Airless
Spray Gun 222–615
308–024 Gun Air Regulator 1 10–776
308–167 Pump Air Regulator 104–267
307–273 Fluid Filter 218–029
306–861 Ball V alve 210–657
307–886 Fluid Pressure Regulator 222–121
WARNING
For your safety in installing, operating and servicing
this system, thoroughly read and follow all warnings
and instructions given in this manual and in any
other
manuals supplied with this system or any ac -
cessories you add to the system. If a manual is
missing or you need additional copies, they are
available
from Graco at no charge.
WARNING
The wallet sized warning card 179–960, provided
with
the gun, should be available and easily accessi -
ble
at all times for anyone operating or servicing this
equipment. The card contains important information
on what to do if a fluid injection injury occurs. Addi-
tional
cards are available at no charge from Graco.
Assembling the Sprayer
Locate your sprayer model on page 5, 6, or 7 and as-
semble
the sprayer as instructed there. Then continue on
with Setting Up the System . Keep the following points in
mind as you assemble your sprayer .
1.
DO NOT install a spray tip in the gun yet.
2. Instructions for installing the air line filter and for con -
necting
the air hose grounding clamp are included in
Setting Up the System .


01105
01102
Fig 2
KEY
AGun Air Inlet
B Gun Fluid Inlet
CBleed–T ype Master
Air V alve (required)
D Main Air Supply Line
E Pail Clamp
F Fill Port
G Pump Ground Wire
(required)
H Air Line Filter
1 Air Inlet Swivel
7 Pump Air Regulator
23 Fluid Filter
24 Filter Ball V alve
60b
Gun Air Regulator
60d Adapter
71
Gun Air Hose
72 Grounded Fluid Hose
75 Fluid Regulator Kit
H
A
B
Ref
72
Ref 71
60b
60d
1
7
D
23
24
C
E
F
DET AIL B DET AIL C
DET AIL A
See
DET AIL C
75
See
DETAIL
A & B
G
75d
75h
75b
75i
75a
75r
75g
75f
75p
75c
75k
75j
75m
75n
Ref 75
Ref 75c
Ref 23
Ref 24
WARNING
NEVER connect a spray hose to this valve.
This valve is only to be used as a drain valve.
Ref 75h
01103 01104
TYPICAL INSTALLATION
75b
71
72
Ref 75a
H
Ref 75a
HF
F
J
J
G
G
75b
AIR
SHUTOFF
VALVE
Ref 75b
75h
Model
222–617
Connect the gun air supply hose (71) between the air inlet
(A) of the gun and the air regulator adapter (60d).
Assemble the fluid regulator kit (75) as shown in Detail A
and Detail B. Connect the fluid regulator (75d) to the top
of the pail cover using the lockwasher (75m) and nut
(75n) provided. Connect the hose (75a) to filter ball valve
(24).
Connect the grounded fluid hose (72) between the gun
fluid
inlet (B) and the nipple (75b) near the fluid regulator
gauge (75h).


TYPICAL INSTALLATION
01108
Fig 3
KEY
AGun Air Inlet
B Gun Fluid Inlet
CBleed–T ype Master
Air V alve (required)
D Main Air Supply Line
E Pump Ground Wire
(required)
15 Fluid Filter
16 Filter Ball V alve
19
Air Manifold
21 Pump Air Regulator
32 Filter Nipple
43 Air Shut-of f V alve
45
Suction T ube
47
Gun Air Regulator
47c Regulator Elbow
49 Gun Air Hose
50 Grounded Fluid Hose
51 Air Line Filter
52 Fluid Regulator Kit
DETAIL B
DET AIL A
52
See
DETAIL
A
& B
52d
52h
52b
52i
52b
52a
52r
52g
52f
52p
52c
52k
52j
52m
52n
Ref 52
Ref 52c
B
A
J
H
G
H
D
51
E
15
16
19
F
F
21
45
47
50
49
WARNING
NEVER connect a spray hose
to this valve. This valve is only
to be used as a drain valve.
G
J
47c
32
Ref 52b
01106
01107
G
H
H
Ref 52h
C
Ref 50
Ref 49
Ref 45
AIR
SHUT-
OFF
VALVE
Model 223–825
Connect the gun air supply hose (49) between the air inlet
(A) of the gun and the air regulator elbow (47c).
Assemble the fluid regulator kit (52) as shown in Detail A
and Detail B. Connect the fluid regulator (52d) to the side
of the wall bracket using the bracket (52j), screw (52k),
lockwasher (52m), and nut (52n). Connect the hose
(52a)
to the filter nipple (32).
Connect the grounded fluid hose (50) between the gun
fluid
inlet (B) and the nipple (52b) near the fluid regulator
gauge (52h).


TYPICAL INSTALLATION
67
KEY
AGun Air Inlet
B Gun Fluid Inlet
CBleed–T ype Master Air V alve
(required)
D Main Air Supply Line
E Pump Ground Wire
(required)
23 Suction T ube
25
Fluid Filter
26 Gun Air Regulator
26c Regulator Elbow
29 Air Manifold
31 Pump Air Regulator
41 Filter Nipple
51 Air Line Filter
62 Air Shut-of f V alve
65
Filter Ball V alve
67
Gun Air Hose
68 Grounded Fluid Hose
70 Fluid Regulator Kit
Fig 4
D
DET AIL B
DET AIL A
70
See
DETAIL
A
& B
E
25
65
29
31
23
26
J
F
F
H
G
H
Ref 70
Ref 70c
70d
70h
70b
70i
70b
70a
70r
70g
70f
70p
70c
70k
70j
70m 70n
G
J
WARNING
NEVER connect a spray hose
to this valve. This valve is only
to be used as a drain valve.
Ref 70b
26c
41
01109
01110
01111
E
G
68
B
A
C
H
51
AIR
SHUTOFF
VALVE
Ref 67
Ref 68
H
Ref 70h
Model 231–165
Connect the gun air supply hose (67) between the air inlet
(A) of the gun and the air regulator adapter (26c).
Assemble the fluid regulator kit (70) as shown in Detail A
and Detail B. Connect the fluid regulator (70d) to the side
of the cart using the bracket (70j), screw (70k), lock-
washer
(70m), and nut (70n). Connect the hose (70a) to
filter nipple (41).
Connect the grounded fluid hose (68) between the gun
fluid
inlet (B) and the nipple (70b) near the fluid regulator
gauge (70h).


TYPICAL INSTALLATION
Setting Up the System
Grounding
Read the warning section FIRE OR EXPLOSION
HAZARD
on page 3 of this manual and ground the pump,
and system as instructed there.
Flushing
Read
the warning section Flushing and Cleaning Safety ,
under
FIRE OR EXPLOSION HAZARD on page 3 of this
manual. Then flush the pump as instructed in manual
307–595,
supplied, to remove the oil left in the pump after
factory testing.
Air Line
Always use
an air line filter (H or 51) to remove harmful
dirt
and contaminants from your compressed air supply .
Within
easy reach of the pump, install a bleed–type mas -
ter
air valve (C).
WARNING
The
bleed–type master air valve (C) is required in
your system to shut of f and relieve air pressure
that
may be trapped in the air motor . This air could
cause the pump to cycle unexpectedly , which
could
result in serious bodily injury , including am -
putation of a limb, or splashing in the eyes.
CAUTION
To avoid contaminating the air supply to the gun,
do
not use an automatic air line oiler; lubricate the
motor manually , instead. See the OPERA TION
section.
Fluid
Supply (Refer to the drawing for your sprayer)
For pail-mounted sprayers, fill the 5–gallon pail with fluid.
Be sure you engage the pail clamps (E) securely . The pail
has an inspection/fill port (F) for replenishing the fluid
supply.
For cart-mounted and wall-mounted sprayers, place the
suction tube (23 or 45) in the fluid container .
Hoses
Secure the air and fluid hoses together with plastic ties
spaced
about 18 to 24 in. (0.5 to 0.6 m) apart.


OPERATION
WARNING
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including
fluid injection, splashing in the eyes or on skin, or in -
jury
from moving parts, always follow this procedure
whenever pump is shut of f, when checking or serv -
icing
any part of system, when installing or changing
spray tips and whenever you stop spraying.
1. Engage the spray gun safety latch.
2. Shut of f the power to the pump.
3. Close the bleed–type master air valve (required
in system).
4. Disengage the gun safety latch.
5. Hold a metal part of the gun firmly to the side of
a grounded metal waste container and trigger
the
gun to relieve fluid pressure.
6. Engage the gun safety latch again.
7. Open the drain valve connected to the fluid
pressure
gauge to help relieve fluid pressure in
the pump, hose and gun. T riggering the gun to
relieve pressure may not be sufficient. Have a
container
ready to catch the drainage.
8. Leave the drain valve open until you are ready
to spray again.
If you suspect that the spray tip or hose is com-
pletely clogged or that pressure has not been fully
relieved after following the steps above, V
ERY
SLOWLY
loosen the hose end coupling and relieve
pressure gradually, then loosen completely . Now
clear
the tip or hose obstruction.
NOTE: Contact your Graco distributor for information
on
training aids which are available from Graco.
To Operate the Pump
Open the bleed–type master air valve. Adjust the pump
air
regulator until the pump is running smoothly .
With no spray tip installed, hold a metal part of the gun
firmly
to the side of a grounded metal pail. Disengage the
gun’s safety latch and trigger the gun into a pail to prime
the pump. See Fig 5. Be sure to remove all air from the
fluid
line. Release the trigger and engage the gun safety
latch.
0794
ÄÄÄÄÄ
ÄÄÄÄÄ
ÄÄÄÄÄ
ÄÄÄÄÄ
Fig 5
Ground
Wire
Maintain firm
metal–to–metal
contact between
gun and
grounded
metal container
AA2000 Spray Gun Operation
Refer to the OPERATION section of manual 307–947,
supplied, for installing the spray tip, adjusting the spray
pattern
and using the spray gun.
Control air to the gun with the gun air regulator .
Control the fluid to the gun with the fluid pressure
regulator.
Manual Air Motor Lubrication
To lubricate the air motor manually , first follow the Pres -
sure Relief Procedure W arning, at left. Then remove
the
air inlet fitting from the motor . Place 10–15 drops of oil
in the inlet, reinstall the air inlet fitting and apply air to the
motor. Do this daily for the best corrosion protection.


75p
01112
23
28
50
24
24
Ref 75a
14
9
10
11 8
7
49
1
3
4
5
31
32
33
34
Ref 5
20
22 21
16
17
19
18
Ref 17
6
15
75d
75h
75b
75i
75f
75c 75b 75a
43
75r75k
39
40 41 42
45
44
46
47
30
12
35
60c
60a 61
60b
60d
70
71
72
36
75g
Ref No. 75
Fluid Regulator Assy .
Includes items 75a–75r
Ref No. 60
Air Regulator Assy.
Includes items 60a–60d
A
A
B
B
C
C
D
D
PARTS DRA WING
75j
75n
75m


PARTS LIST
Part No. 222–617
H.E.L.P. 2500 10:1 Ratio Monark Pail-Mounted Sprayer
REF
NO. P ART NO. DESCRIPTION QTY
1 162–505 UNION, swivel;
3/8 npt(m) x 1/2 npsm(f) swivel 1
3 171–987
TEE; 3/8 npt(f) x 1/4 npt(f) run;
3/8 npt(f) branch 1
4 156–823 UNION, swivel;
1/4 npsm(f) swivel x 1/4 npt(m) 1
5 202–812 HOSE, air
, neoprene; 1/4” ID;
cpld 1/4 npt(mbe); 1.2’ (0.36 m) long 1
6 101–180
GAUGE, air pressure; 0–200 psi
(0–44 bar) range 1
7 104–267 AIR REGULATOR
See 308–167 for parts 1
8 158–256 UNION, straight swivel;
1/2 npt(m) x 3/8 npsm(f) swivel 1
9 103–347 AIR PRESSURE RELIEF VALVE 1
10 100–176
BUSHING, hex; 1/4 npt(f) to 3/8 npt(m) 1
11 108–066
TEE, pipe; two 3/8 npt(m);
one 3/8 npt(f) 1
12 104–765
PLUG, pipe, hdls; 1/8–27 npt(f) 1
14 217–523
10:1 RA TIO MONARK PUMP;
See 307–595 for parts 1
15 104–429 CAPSCREW
, hex hd;
1/4–20 x 2.25’ ’ long 2
16 165–198
NIPPLE, rdcg; 3/8 x 1/4 npt 1
17 206–966
HOSE, fluid, r ; 1/4’ ’ ID; cpld
1/4 npsm(fbe); 12.5’ ’ (317.50 mm) long 1
18 162–453
NIPPLE; 1/4 npt x 1/4 npsm 1
19 164–259 ELBOW
, str; 3/8 npt(m) x
1/4 npt(f) 1
20 166–031 ELBOW
, outlet; 3/4 npt x 3/8 npt 1
21 161–800
ADAPTER; 3/8 npsm x 3/4 npt 1
22 155–665
UNION, adapter; 3/8 npt(m) x
3/8 npsm(f) 1
23 218–029 FIL
TER, fluid
See 307–273 for parts 1
24 210–657
BALL V AL VE; 1/4 npt(mbe)
See 306–861 for parts 2
28 104–813
PLUG, pipe, sq hd; 3/8 npt 1
30 218–693
BASE, mounting, pump 1
31 100–933 SCREW
, type “F” self–tapping;
No. 8–32 x 3/16” 2
32 206–755
CORD, wire; 5.5” (140 mm) long 2
33 164–726
PLUG, inspection hole 1
34 156–593
O–RING, nitrile rubber 1
35 101–962 SCREW
, cup pt soc hd set;
1/4–20 x 3/8” 2
36 179–917 COVER, pail 1
39 161–395
PIN, pivot; 0.25’ ’ (6.4 mm) dia;
2.0’ ’ (51 mm) long 2
40 204–535 HANDLE, latch, cover 2
41 204–534 HOOK, latch, cover 2
42 158–223 WASHER, steel 2
43 100–063
PIN, cotter; 0.06’ ’ (1.6 mm) dia;
0.5’ ’ (12.7 mm) long 2
44 100–016 LOCKW
ASHER, spring; 1/4’ ’2
45 100–015 NUT
, hex; 1/4–20 2
46 185–347 P
AIL, 5 gallon (U.S.) 1
47 185–348 LABEL 1
49 159–239
NIPPLE, pipe, reducing; 1/2 to 3/8 npt 1
50 100–721
PLUG, slotted hd pipe; 1/4 npt 1
55* 206–994 THROAT SEAL LIQUID, 8 oz. 1
REF
NO. P ART NO. DESCRIPTION QTY
56* 101–380 BUTTON, plug 1
57* 160–516 O–RING, nitrile rubber 1
58* 165–096
PLUG, inspection hole 1
60 223–594 AIR REGULATOR ASSEMBLY
Includes items 60a–60d 1
60a 110–232 S
UNION, adapter , 45 _ swivel;
1/4–18
npt (m x f) 1
60b 110–776 SREGULATOR, air pressure
See 308–024 for parts 1
60c 159–842 S ADAPTER; 1/4 npt(m) x 1/2 npt(f) 1
60d 110–249 SELBOW
, 90 _ street; 1/4–18 npt(m) 1
61 185–350 GAUGE, air pressure 1
70 222–615
High Ef ficiency Low Pressure System
2500 AA2000 AIR–ASSISTED AIRLESS
SPRA Y GUN; See 307–947 for parts 1
71 185–353 HOSE, air
, buna; 3/8” ID; cpld
1/4 npsm(fbe) swivel; 25’ (7.6 m) long 1
72 214–698
HOSE, fluid, grounded, nylon; 3/16’ ’ ID;
cpld 1/4 npsm(f) swivel x 1/4 npt(m);
25’ (7.6 m) lg; spring guards both ends 1
73* 182–513 SPRA
Y TIP 1
75 222–564 FLUID REGULATOR ASSEMBLY
Includes items 75a–75r 1
75a 110–192
.HOSE, coupled 1
75b 162–453 .NIPPLE, 1/4 npt x 1/4 npsm
(only qty . of 2 used with this sprayer) 3
75c 100–840 .ELBOW , street; 1/4 npt (m x f)
(only qty . of 1 used with this sprayer 2
75d 222–121 .REGULAT
OR, fluid pressure
See Manual 307–886 for parts. 1
75e* 110–220
.UNION, adapter , swivel
(not used with this sprayer) 1
75f 156–971 .NIPPLE, short; 1/4 npt x 1–3/8’ ’ long 1
75g 102–959
.CROSS, pipe; 1/4 npt 1
75h 802–072 .GAUGE, pressure, fluid;
0–1000 psi (0–69 bar) range 1
75i 210–657 .VAL VE, ball 1
75j 185–251 .BRACKET , regulator 1
75k 100–469 .SCREW
, cap, hex hd; 1
75m 100–133 .WASHER, lock 1
75n 100–307 .NUT
, full, hex 1
75p 100–270 .SCREW , cap, hex hd 2
75r 100–016 .WASHER, lock 2
306, 307, & 308 Numbers in the description refer to separate instruction
manuals.
*These
items are not shown in the Parts Drawing.
HOW T O ORDER REPLACEMENT P ARTS
1.To be sure you receive the correct replacement parts,
kits or accessories, always give all of the information
requested in the chart below .
2. Check the parts list to identify the correct part number;
do not use the ref. no. when ordering.
3. Order all parts from your nearest Graco distributor .
6 digit
Part
Number Qty
Part Description
PTFE

12ą307946E
Ref No. 52
Fluid Regulator Assy .
Includes items 52a–52r
Ref No. 47
Air Regulator Assy.
Includes items 47a–47c
Ref 7
13
14
15
16
17
1920 21
22
23
Ref 23
24
29
31
32
14
40
20
42
43
44
45
47a
47c
47b
48
45
50
51
52a
52b
52c
52d
52h 52f
52r
52p
52k
52j
52m 52n
52i
52g
52b
A
A
B
B
C
C
D
E
D
E
PARTS DRA WING
01113
17
PART OF
ITEM 7
7
5
P ART OF
ITEM 7
Ref 52a
49
25
A


PARTS LIST
Part No. 223–825
H.E.L.P. 2500 10:1 Ratio Monark W all-Mounted Sprayer
REF
NO. P ART NO. DESCRIPTION QTY
5 217–523 10:1 RATIO MONARK PUMP;
See 307–595 for parts 1
7 207–365 BRACKET , self-mounting;
Includes mounting hardware;
See 306–783 for parts 1
8* 206–994 THROAT SEAL LIQUID, 8 oz. 1
13 103–347 AIR PRESSURE RELIEF VALVE 1
14 156–850
NIPPLE, adapter; 3/8 npt; 2.5” long 2
15 218–029 FIL
TER, fluid;
See 307–273 for parts 1
16 210–658
BALL V ALVE 1
17 100–509 PLUG, pipe; 1/4 ” 3
19 179–749
MANIFOLD, air; two 1/2 npt(f) 1
20 156–877
NIPPLE; 1/2 npt 2
21 104–267 AIR REGULATOR;
See 308–167 for parts 1
22 171–987 TEE; 3/8 npt(f) x 1/4 npt(f) run;
3/8 npt(f) branch 1
23 204–560 HOSE, air buna-N; 3/8” ID, cpld 3/8
npt(m), 1.5’ (460 mm) long 1
24 161–037 ADAPTER, union; 1/2 npt(m) x
3/8 npsm(f) swivel 1
25 101–180
GAUGE, air pressure; 0–200 psi
(0–44 bar) range 1
29 102–254 SCREW
, sems hex head; 1/4-20 x 7/8” 2
31 185–350 GAUGE, air pressure 1
32 162–453
NIPPLE; 1/4 npsm x 1/4 npt 1
40 222–297 UNION, swivel adapter;
1/2-14 npsm x 1/2-14 nptf 1
42 100–122
NIPPLE, close; 1/2-14 npt 1
43 107–142 VAL VE, shut-of f; 1/2-14 npt 1
44 150–286
ADAPTER; 3/8” (m x f) std. pipe thd. 1
45 208–259 SUCTION KIT 1
46* 110–110 SEALANT
, stainless steel pipe 1
REF
NO. P ART NO. DESCRIPTION QTY
47 223–938 AIR REGULATOR ASSEMBLY;
Includes items 47a to 47c 1
47a 110–776 REGULATOR, air pressure;
See 308–024 for regulator instructions 1
47b 159–842 
ADAPTER; 1/4 npt(m) x 1/2 npt(f) 1
47c 110–249 ELBOW
, 90  ; 1/4–18 npt(m) 1
48 222–615
High Ef ficiency Low Pressure System
2500 AA2000 AIR–ASSISTED AIRLESS
SPRA Y GUN; See 307–947 for parts 1
49 185–353 HOSE, air
, buna; 3/8” ID; cpld
1/4 npsm(fbe) swivel; 25’ (7.6 m) long 1
50 214–698
HOSE, fluid, grounded, nylon; 3/16’ ’ ID;
cpld 1/4 npsm(f) swivel x 1/4 npt(m);
25’ (7.6 m) lg; spring guards both ends 1
51 106–148
AIR FIL TER; 3/8 npt(f) 1
52 222–564 FLUID REGULATOR ASSEMBLY
Includes items 52a–52r 1
52a 110–192
.HOSE, coupled 1
52b 162–453
.NIPPLE, 1/4 npsm x 1/4 npt
(only qty . of 2 used with this sprayer) 3
52c 100–840 .ELBOW
, street; 1/4 npt (m x f)
(only qty . of 1 used with this sprayer) 2
52d 222–121 .REGULAT
OR, fluid pressure
See Manual 307–886 for parts. 1
52e* 110–220
.UNION, adapter , swivel
(not used with this sprayer) 1
52f 156–971
.NIPPLE, short; 1/4 npt x 1–3/8’ ’ long 1
52g 102–959
.CROSS, pipe; 1/4 npt 1
52h 802–072 .GAUGE, pressure, fluid;
0–1000 psi (0–69 bar) range 1
52i 210–657 .VAL
VE, ball 1
52j 185–251 .BRACKET
, regulator 1
52k 100–469 .SCREW
, cap, hex hd; 1
52m 100–133 .WASHER, lock 1
52n 100–307 .NUT
, full, hex 1
52p 100–270 .SCREW
, cap, hex hd 2
52r 100–016 .WASHER, lock 2
306, 307, & 308 Numbers in the description refer to separate
instruction
manuals.
*These items are not shown in the Parts Drawing.
HOW T O ORDER REPLACEMENT P ARTS
1.To be sure you receive the correct replacement parts,
kits or accessories, always give all of the information
requested in the chart below .
2. Check the parts list to identify the correct part number;
do not use the ref. no. when ordering.
3. Order all parts from your nearest Graco distributor .
6 digit
Part
Number Qty
Part Description


01114
Ref No. 70
Fluid Regulator Assy .
Includes items 70a–70r
Ref No. 26
Air Regulator Assy.
Includes items 26a–26c
A
A
C
D
E
E
D
70h
70b
70g
70i
70f
70d
70r
70p
70k
70j
70c
70b
70a
70m 70n
7
1
4
3
5
21
24
25
26a
26c
26b
27
34
38
41
52
57
60
61
62
64
65
66
68
67
30
30
28
31 32
33
23
22
29
24
PARTS DRA WING
C
Ref 70a
D
A
Ref 33
27
51

307946Eą15
PARTS LIST
Part No. 231–165
H.E.L.P. 2500 10:1 Ratio Monark Cart-Mounted Sprayer
REF
NO. P ART NO. DESCRIPTION QTY
1 100–016 LOCKWASHER, spring; 1/4’ ’2
3 100–022 CAP SCREW
; 1/4-20 x 3/4” 2
4 100–015 NUT
, hex; 1/4–20 2
5 217–523
10:1 RA TIO MONARK PUMP;
See 307–595 for parts 1
7 224–044 UNIVERSAL CART
;
See 308–136 for parts 1
21 100–349 ELBOW
, 90  ; 3/4 npt 1
22 214–960
HOSE, suction; 3/4” ID; 3-1/2” (1 m) lg;
cpld 3/4 npt(mbe); with spring guard 1
23 165–767 TUBE, suction 1
24 156–850
NIPPLE, adapter; 3/8 npt; 2.5” long 2
25 218–029 FIL
TER, fluid;
See 307–273 for parts 1
26 223–938 AIR REGULATOR ASSEMBLY;
Includes items 26a to 26c 1
26a 110–776 REGULATOR, air pressure;
See 308–024 for regulator instructions 1
26b 159–842 
ADAPTER; 1/4 npt(m) x 1/2 npt(f) 1
26c 110–249 ELBOW
, 90  ; 1/4–18 npt(m) 1
27 100–509
PLUG, pipe; 1/4 ” 3
28 185–350 GAUGE, air pressure 1
29 179–749
MANIFOLD, air; two 1/2 npt(f) 1
30 156–877
NIPPLE; 1/2 npt 2
31 104–267 AIR REGULATOR;
See 308–167 for parts 1
32 161–037
ADAPTER, union; 1/2 npt(m) x
3/8 npsm(f) swivel 1
33 204–560
HOSE, air buna-N; 3/8” ID, cpld 3/8
npt(m), 1.5’ (460 mm) long 1
34 101–180
GAUGE, air pressure; 0–200 psi 1
38 102–254 SCREW
, sems hex head; 1/4-20 x 7/8” 2
41 162–453
NIPPLE; 1/4 npsm x 1/4 npt 1
42* 206–994 THROAT SEAL LIQUID, 8 oz. 1
51 106–148
AIR FIL TER; 3/8 npt(f) 1
52 103–347 AIR PRESSURE RELIEF VALVE 1
57 171–987
TEE; 3/8 npt(f) x 1/4 npt(f) run;
3/8 npt(f) branch 1
60 222–297 UNION, swivel adapter;
1/2-14 npsm x 1/2-14 nptf 1
REF
NO. P ART NO. DESCRIPTION QTY
61 158–491 NIPPLE; 1/2 npt 1
62 107–142 VAL
VE, shut-of f; 1/2-14 npt 1
64 150–286
ADAPTER; 3/8” (m x f) std. pipe thd. 1
65 210–658
BALL V ALVE 1
66 222–615
High Ef ficiency Low Pressure System
2500 AA2000 AIR–ASSISTED AIRLESS
SPRA Y GUN; See 307–947 for parts 1
67 185–353 HOSE, air
, buna; 3/8” ID; cpld
1/4 npsm(fbe) swivel; 25’ (7.6 m) long 1
68 214–698
HOSE, fluid, grounded, nylon; 3/16’ ’ ID;
cpld 1/4 npsm(f) swivel x 1/4 npt(m);
25’ (7.6 m) lg; spring guards both ends 1
70 222–564 FLUID REGULATOR ASSEMBLY
Includes items 70a–70r 1
70a 110–192
.HOSE, coupled 1
70b 162–453
.NIPPLE, 1/4 npsm x 1/4 npt
(only qty . of 2 used with this sprayer) 3
70c 100–840 .ELBOW
, street; 1/4 npt (m x f)
(only qty . of 1 used with this sprayer) 2
70d 222–121 .REGULAT
OR, fluid pressure
See Manual 307–886 for parts. 1
70e* 110–220
.UNION, adapter , swivel
(not used with this sprayer) 1
70f 156–971
.NIPPLE, short; 1/4 npt x 1–3/8’ ’ long 1
70g 102–959
.CROSS, pipe; 1/4 npt 1
70h 802–072 .GAUGE, pressure, fluid;
0–1000 psi (0–69 bar) range 1
70i 210–657 .VAL
VE, ball 1
70j 185–251 .BRACKET
, regulator 1
70k 100–469 .SCREW
, cap, hex hd; 1
70m 100–133 .WASHER, lock 1
70n 100–307 .NUT
, full, hex 1
70p 100–270 .SCREW
, cap, hex hd 2
70r 100–016 .WASHER, lock 2
306, 307, & 308 Numbers in the description refer to separate
instruction
manuals.
*These items are not shown in the Parts Drawing.
HOW T O ORDER REPLACEMENT P ARTS
1.To be sure you receive the correct replacement parts,
kits or accessories, always give all of the information
requested in the chart below .
2. Check the parts list to identify the correct part number;
do not use the ref. no. when ordering.
3. Order all parts from your nearest Graco distributor .
6 digit
Part
Number Qty
Part Description

16ą307946E
ACCESSORIES
Accessories must be purchased separately .
Use only GENUINE GRACO PARTS AND ACCESSORIES.
BLEED–TYPE MASTER AIR VALVE
300 psi (21 bar) MAXIMUM WORKING PRESSURE
Relieves air trapped in the air line between the pump air
inlet and this valve when closed.
107–141 3/4 npt(m x f) inlet & outlet
107–142 1/2 npt(m x f) inlet & outlet
AIR LINE FILTER
250 psi (17.5 bar) MAXIMUM WORKING PRESSURE
106–148 3/8 npt(f)
106–149 1/2 npt(f)
AIR SUPPLY HOSE
175 psi (12 bar) MAXIMUM WORKING PRESSURE
205–418 6 ft (1830 mm)
205–216 15 ft (4.6 m)
205–273 25 ft (7.6 m)
208–594 50 ft (15.2 m)
GROUND WIRE 208-950
25 ft (7.6 m) lg, 12 ga.
GROUNDING CLAMP 103–538
THROAT SEAL LIQUID
Non–evaporating solvent for wet–cup
206–995 1 quart (0.9 liter)
206–996
1 gallon (3.8 liter)


TECHNICAL DA TA
Recommended Air
Operating Range 20–95 psi (1.5–6.3 bar) . . . . . . .
Maximum Pump Fluid
W orking Pressure 950 psi (66 bar) . . . . . . . . . . . .
Maximum Recommended Pump Speed
for Continuous Operation 60 cycles/min: . . . . . . .
1 gpm (3.8 liter/min) delivery
Air Consumption Approximately 15 SCFM per . . . . . .
gallon at 95 psi (6.3 bar)
Air Inlet Size 1/2 npt(f); use 1/2 in. ID air hose . . . . . . .
Fluid Filter 60 mesh (250 micron) screen . . . . . . . . . . .
Wetted Parts See component instruction. . . . . .
manuals
SPRAYER DIMENSIONS
Sprayer
Model
Overall
Height
Overall
Width
Overall
Depth
Ap-
prox.
Net
Weight
222–617 30
in.
(762 mm)
15.5 in.
(394 mm)
14.75 in.
(375 mm)
52 lb
(24 Kg)
223–825
30.37 in.
(771 mm)
20.75 in.
(526 mm)
15.25 in.
(387 mm)
49 lb
(22 Kg)
231–165
42.25 in.
(1 149 mm)
27.75 in.
(705 mm)
27.50 in.
(699 mm)
140 lb
(60 Kg)
SERVICE INFORMATION
This manual was revised to add Sprayer Model 231–165,
which uses the universal cart.


NOTES:


NOTES:


THE GRACO W ARRANTY AND DISCLAIMERS
WARRANTY
Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and work -
manship
on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser ’ s sole
remedy for breach of this warranty , Graco will, for a period of twelve months from the date of sale, repair or replace
any part of the equipment proven defective. This warranty applies only when the equipment is installed, operated
and maintained in accordance with Graco’ s written recommendations.
This warranty does not cover , and Graco shall not be liable for , any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tam -
pering,
or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear
caused by the incompatibility with Graco equipment of structures, accessories, equipment or materials not supplied
by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories,
equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco
distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If
inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a rea -
sonable
charge, which charges may include the costs of parts, labor and transportation.
DISCLAIMERS AND LIMIT ATIONS
THE TERMS OF THIS W ARRANTY CONSTITUTE PURCHASER’S SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF
ANY OTHER W ARRANTIES (EXPRESS OR IMPLIED), INCLUDING W ARRANTY OF MERCHANT ABILITY OR W ARRANTY
OF
FITNESS FOR A P AR TICULAR PURPOSE, AND OF ANY NON–CONTRACTUAL LIABILITIES, INCLUDING PRODUCT LI -
ABILITIES, BASED ON NEGLIGENCE OR STRICT LIABILITY . EVER Y FORM OF LIABILITY FOR DIRECT , SPECIAL OR CON -
SEQUENTIAL
DAMAGES OR LOSS IS EXPRESSL Y EXCLUDED AND DENIED. IN NO CASE SHALL GRACO’S LIABILITY EX -
CEED THE AMOUNT OF THE PURCHASE PRICE. ANY ACTION FOR BREACH OF W ARRANTY MUST BE BROUGHT
WITHIN
TWO (2) YEARS OF THE DA TE OF SALE.
EQUIPMENT NOT COVERED BY GRACO W ARRANTY
GRACO MAKES NO W ARRANTY , AND DISCLAIMS ALL IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR
A P AR TICULAR PURPOSE, WITH RESPECT T O ACCESSORIES, EQUIPMENT , MA TERIALS, OR COMPONENTS SOLD BUT
NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motor ,
switches,
hose, etc.) are subject to the warranty , if any , of their manufacturer . Graco will provide purchaser with rea -
sonable
assistance in making any claim for breach of these warranties.
IMPORTANT PHONE NUMBERS
TO PLACE AN ORDER , contact your Graco distributor ,
or call this number to identify the distributor closest to
you:
1–800–328–0211 T oll Free
FOR TECHNICAL ASSISTANCE , service repair infor-
mation
or assistance regarding the application of Graco
equipment: 1–800–543–0339 T oll Free
Factory Branches: Atlanta, Chicago, Dallas, Detroit, Los Angeles, W est Caldwell (N.J.)
Subsidiary and Affiliate Companies: Canada; England; Switzerland; France; Germany; Hong Kong; Japan; Korea
GRACO INC. P .O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN U.S.A. 307–946 12–88 Revised 1–92