Graco T Series Operation manual

306–667
Rev. G
Supersedes Rev E
and PCN F
First choice when
quality counts. 
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Airless Spray Gun
21.0 MPa, 210 bar (3000 psi) Maximum Working Pressure
Model 205–591, Series T
For non-circulating system
* Spray tip not included. Order separately .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
http://www.graco.com
COPYRIGHT
1997, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

306–667
Table of Contents
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
corresponding instructions.
WARNING
INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an
extremely serious injury
, including the need for amputation. Splashing fluid in the eyes or on the skin
can also cause a 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 spray gun at anyone or at any part of the body .

Do not put hand or fingers over the spray tip.
 Do not stop or deflect fluid 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 spray gun when spraying.
 Be sure the gun trigger safety operates before spraying.
 Lock the gun trigger safety when you stop spraying.
 Check gun dif fuser operation weekly .

Follow the Pressure Relief Procedure on page 5 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 the 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.
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the
skin, swallowed, or inhaled.
 Know the specific hazards of the fluid you are using. Read the fluid manufacturer ’ s warnings.
 Store hazardous fluid in an approved container . Dispose of the hazardous fluid according to all
local, state, and national guidelines.
W ear appropriate protective clothing, gloves, eyewear , and respirator .

3306–667
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in fire or explosion and serious injury .
D
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvent or the fluid being
sprayed.
D
Extinguish all the open flames or pilot lights in the spray area.
D Electrically disconnect all the equipment in the spray area.
D Keep the dispensing area free of debris, including solvent, rags, and gasoline.
D Do not turn on or of f any light switch in the spray area while operating or if fumes are present.
D Do not smoke in the spray area.
D Do not operate a gasoline engine in the spray area.
D If there is any static sparking while using the equipment, stop spraying immediately . Identify and
correct the problem.
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result
in a serious injury .
D This equipment is for professional use only .
D
Read all the 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 the equipment daily . Repair or replace worn or damaged parts immediately .
D
Do not exceed the maximum working pressure of this equipment. This system has a 21.0 MPa,
210 bar (3000 psi) maximum working pressure.
D Use fluids that are compatible with the equipment wetted parts. See the T echnical Data section of
all the equipment manuals. Read the fluid manufacturer ’ s warnings.
D Route the 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).
D
Do not use the hoses to pull equipment.
DW ear hearing protection when operating this equipment.
D Comply with all applicable local, state, and national fire, electrical, and other safety regulations.

4306–667
Installation
General
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury whenever you
are instructed to relieve the pressure, always follow
the Pressure Relief Procedure on page 5.
NOTE: Numbers and letters in parentheses in the text
refer to reference numbers in the Figures and Parts
Drawing.
WARNING
INJECTION HAZARD
B e s ur e y our syste m h a s a b leed-typ e m aster air
valve
( pneumati c v alve s o nly ) a n d a f lui d d rain v alve.
These
t w o a ccessorie s h elp reduc e t he ris k o r
serious
i njury , i ncluding f lui d i njection , s plashin g i n t he
eyes
o r o n t h e s kin , o r i njur y f ro m m ovin g p art s i f y ou
are
a djustin g o r repairin g t h e p um p o r gun.

The bleed-type master air valve relieves air
trapped between this valve and the pump after
the air regulator is shut of f. T rapped air can
cause the pump to cycle unexpectedly .

The fluid drain valve assists in relieving fluid
pressure in the displacement pump, hose, and
gun; triggering the gun to relieve pressure may
not be suf ficient.
1. Connect a grounded fluid hose to the gun inlet.
2. With no tip installed, start the pump/sprayer . Flush
it according to the instructions supplied with it.
Prime the system with the fluid you are using.
3. Relieve the pressure.
4. With the gun safety latch engaged, unscrew the tip
guard (25) and install the tip (B) and gasket (17) in
the nut of the tip guard. Screw the assembly firmly
onto the gun. T ighten with a wrench. See Fig. 1.
Fig. 1
25 B17 23
D
E
NOTE: Failure to install the tip gasket (17) will result in
leaking.
5.
Strain the fluid you are spraying if it contains
particles which could clog the spray tip.

5306–667
Operation
Grounding
T o reduce the risk of static sparking, ground the pump,
object being sprayed, and all other spray equipment
used or located in the spray area. Check your local
electrical code for detailed grounding instructions for
your area and type of equipment. Be sure to ground all
of this spray equipment.
 Pump or sprayer: as instructed in your separate
pump or sprayer manual.
 Air compressor or hydraulic power supply: accord-
ing to local code.
 Fluid hoses: use only grounded hoses with a maxi -
mum of 500 feet (150 m) combined hose length to
ensure grounding continuity .

Spray gun: obtain grounding through connection to
a properly grounded fluid hose and sprayer or
pump.

Fluid supply container: according to local code.
 Object being sprayed: according to local code.
 All solvent pails used when flushing, according to
local code. Use only metal pails, which are conduc -
tive. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which inter -
rupts the grounding continuity .

T o maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
gun firmly to the side of a metal pail, then trigger
the gun.
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 tips.
1. Engage the spray gun safety latch.
2. Shut of f the power supply to the pump and close
any bleed-type master air valves in the air supply .
3.
Disengage the gun safety latch.
4. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and trigger the gun into the
pail to relieve pressure.
5. Engage the spray gun safety latch.
6. Open the pump fluid 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.

6306–667
Operation
Using the Gun
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury whenever you
are instructed to relieve the pressure, always follow
the Pressure Relief Procedure on page 5.
WARNING
INJECTION HAZARD
T o avoid fluid injection from accidental spray ,
engage the gun safety latch. See Fig. 2.
1. Start the pump. Adjust the fluid pressure so the
spray is completely atomized. Always use the
lowest pressure necessary to get the desired
results. Higher pressure may not improve the
spray pattern and will cause premature tip and
pump wear .
2. I
f a djustin g t h e p ressur e d oe s n o t g iv e a g oo d s pray
pattern
, t r y a nother ti p s ize . B e s ur e to relieve the
pressure
c ompletel y b efor e c hangin g t ips.
3. Use a full-open, full-close trigger action. Hold the
gun about 350 mm (14 in.) from, and at right
angles, to the work surface. Do not swing the gun
in an arc. Practice to find the best length and
speed of the stroke.
Fig. 2
T o lock trigger safety
(on safe), pull out
latch and turn to right
angle with body .
Protect openings
in tip guard from
damage.
T
o unlock trigger safety
(of f safe), turn latch
parallel to body

7306–667
Operation
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury whenever you
are instructed to relieve the pressure, always follow
the Pressure Relief Procedure on page 5.
Adjust the Spray Pattern
1. To adjust the spray pattern direction, relieve the
pressure . Engage the safety latch and loosen the
tip guard retaining nut. T urn the spray tip so the
groove is horizontal for a horizontal spray pattern,
and vertical for a vertical spray pattern. T ighten the
retaining nut.
2. The spray tip orifice size and spray angle deter -
mines the coverage and size of the pattern. When
more coverage is needed, use a larger spray tip
rather than increasing fluid pressure.
WARNING
INJECTION HAZARD
T o reduce the risk of an injection injury , never use
the gun with the tip guard or trigger guard removed.
CAUTION
Openings in the tip guard are designed to reduce
paint buildup on the guard while spraying. Any dam -
age to the sharp edges of the openings causes paint
to collect at that area. T o reduce the risk of damage,
never hang the gun by the tip guard.
Cleaning and Clearing the Spray Tip
WARNING
INJECTION HAZARD
T o reduce the risk of fluid injection or splashing in
the eyes or on the skin, do not hold your hand,
body , or a rag in front of the spray tip when clean -
ing or checking a clogged tip. Always point the gun
toward the ground or into a waste container when
checking to see if the spray tip is cleared. Relieve
the pressure before wiping vbuildup of f the gun or
spray tip.
Clean of f the front of the tip frequently during the day’ s
operation and at the end of the work day. Relieve the
pressure, then use a solvent soaked brush to clean
the spray tip and to keep fluid buildup from drying and
clogging the spray tip.
If the spray tip clogs while spraying, release the spray
gun trigger , engage the trigger safety , shut of f the
pump, and relieve the pressure. Then remove the
spray tip and blow out the obstruction with air from the
front of the spray tip, or let the spray tip and gun
nozzle soak long enough 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.

8306–667
Operation
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury whenever you
are instructed to relieve the pressure, always follow
the Pressure Relief Procedure on page 5.
Flushing the Gun
WARNING
FIRE AND EXPLOSION HAZARD
Before flushing, be sure the entire system and
flushing pails are properly grounded. Refer to
Grounding, on page 5. Relieve the pressure
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 pail during flushing to reduce the risk of a fluid
injection injury , static sparking, and splashing.
Relieve the pressure , remove the spray tip, and then
flush the gun and spray system with a compatible
solvent. Always flush the gun before the fluid being
sprayed can dry on it.
Fig. 3
Maintain firm
metal–to metal
contact between
gun and container .
Troubleshooting
If you r g un leak s a t the ti p w hen yo u r elease the
trigger
, th e n eedl e o r sea t i s w or n o r damage d a nd
mus
t b e repaired . S e e Gu n P acking s o n p ag e 1 1.
If the gun sprays with the trigger safety on, the
needle travel must be adjusted. See Adjusting the
Needle
on page 1 1.

9306–667
Notes

10 306–667
Service
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury whenever you
are instructed to relieve the pressure, always follow
the Pressure Relief Procedure on page 5.
NOTES:

A repair kit, Part No. 214–969, is available for
repairing the gun. Use all new parts in the kit for the
best results.
 Parts included in the kit are shown with a dagger ,
for example (24†), indicate that these parts are
included in the repair kit.
 Periodically disassemble the gun to clean and
inspect parts.
Needle
1. Relieve the pressure.
2. Screw out the spring retainer (19). Remove the
spring (7) and needle (24). Unscrew the seat (23).
See the Parts Drawing, page 12.
3. Soak parts in clean solvent. Use the brushes
supplied to clean the parts and gun body passage -
ways. Replace worn or damaged parts.
4. If installing a new needle (24), remove the two nuts
(20, 21) from the old needle, counting the number
of turns needed to remove them. Screw the nuts
onto the new needle the same number of turns
and lock them together . Not that the thickest nut
(21) goes on first.
5. Adjust the needle as instructed below before
operating the gun.

11306–667
Service
Adjusting the Needle
WARNING
INJECTION HAZARD
Proper adjustment of the needle is essential to be
sure the trigger safety latch makes the gun inop -
erative when engaged. Improper adjustment may
result in serious injury , including fluid injection and
splashing in the eyes or on the skin.
1. T ighten the seat (23) to 23 N  ym (200 in-lb).
2. Install the needle and spring in the gun and hold
them in place with your thumb. See Fig. 4.
3. Check the travel of the trigger from the free posi -
tion to when it stops against the safety latch (15).
The travel should be about 8.1 mm (0.32 in.).
4. T o adjust the travel, turn the two nuts (20 and 21)
toward the front (clockwise) to increase travel, or
toward the back to decrease travel.
5. Connec t t h e h ose.
6. Instal
l t h e t i p g uar d a n d p rim e t h e s ystem.
7. Trigger th
e g u n a nd releas e i t. Th e f lui d f lo w s hould
sto
p i mmediately . N o w e ngag e t h e s afet y l atc h a nd
tr
y t o t rigger th e g un . N o f lui d s houl d f low . If t h e g un
fails
e ithe r t est , reliev e t h e p ressure , d isconnec t t he
hose,
a nd readjus t t h e n eedle.
Gun Packings
1. Remove the trigger (14) and screws (1). See the
Parts Drawing on page 12.
2. Remove the packing nuts (13) on both sides of the
gun.
3.
Remove the packings (10), glands (9† and 1) and
camshaft (12).
Fig. 4
Fig. 5
24
23
21
20
15
0.32” (8.1 mm)
PRESS NEEDLE AGAINST SEA T T O CHECK TRAVEL
11 109
12 13
CAM LEVER
4. Soak the new leather packings (10*) in oil until
they are pliable, then install the packing, glands
(9† and 11†) and camshaft (12).
5. Install the packing nuts (13) and tighten snugly .
6.
Install the trigger (14) and screws (1). If the cam -
shaft is too tight, loosen the spring retainer (19).

12 306–667
Parts
*
25
†17
†23
†18
SPRAY TIP
(Not included)
13 11†10†
9†
22 8
1
14
12*
†9
10† 11† 13
3
4
5
(left)
(right)
15
16 2†24†21
†20
†7†6 †19
Ref.
No. Part No. Description Qty. Ref. No. Part No. Description Qty.
1* 101–890 SCREW
, fill hd mach;
no. 6–32 x 7/16 2
2 101–965 NUT, lock 1
3 102–817 SCREW
, type “u” drive; no. 0 x 3/16 6
4 164–108 PLA
TE, name 1
5 164–109 PLA
TE, serial 1
6† 164–111 GASKET
, Delrin
1
7† 164–112 SPRING, compression 1
8 164–114 LEVER, cam 1
9† 164–115 GLAND, packing (inner) 2
10† 164–116 P
ACKING, cam shaft leather 4
11† 164–117 GLAND, packing (outer) 2
12* 164–118 SHAFT
, cam 1
13 164–119 NUT
, cam shaft packing 2
14 164–123 TRIGGER 1
15 164–822 STOP
, trigger 1
16 166–938 SPRING, compression 1
17† 166–969 GASKET
, flat Delrin

; 1/16 thick 1
18† 167–730 GASKET
, copper; dif fuser-seat 1
19† 168–330 RETAINER, spring 1
20† 171–240 NUT, lock 1
21† 171–241 NUT
, adjusting 1
22 205–598 BODY
, gun 1
23† 214–966 DIFFUSER SEAT 1
24† 208–137
NEEDLE, fluid valve 1
25* 220–222 TIP GUARD 1
* Recommended “T ool Box” spare parts. Keep on hand to
reduce down time.
† Supplied in Repair Kit 214–969.

13306–667
Technical Data
Category Data
Maximum fluid working pressure 21.0 MPa, 210 bar (3000 psi)
Fluid passage orifice size 3.18 mm (0.125 in.) dia.
W etted parts Cast Manganese Bronze, Stainless Steel, T ungsten Carbide,
Delrin , Thiokol Impregnated leather
Sound pressure level* 78 dB(A)
Sound power level* 87 dB(A)
Delrin is a registered trademark of the DuPont Company .
* Measured while spraying water-base paint, gravity 1–36, through a 517 tip at 21.0 MPa, 210 bar (3000 psi) per ISO 3744.

14 306–667
Notes

15306–667
Notes

16 306–667
Graco W arranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the
date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited
warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment
determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accor -
dance with Graco’
s written recommendations.
This warranty does not cover , and Graco shall not be liable for general wear and tear , or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub -
stitution
of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with 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 reasonable charge, which charges may include the costs of parts, labor , and
transportation.
THIS
W ARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER W ARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED T O WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s
sole obligation and buyer ’ s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property , or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
Graco makes no warranty , and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty , if any , of their manufacturer . Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty , the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais -
sent
avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Graco Phone Number
TO PLACE AN ORDER , contact your Graco distributor , or call this number to identify the distributor closest to you:
1–800–367–4023 T oll Free.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis, Detroit, Los Angeles
Foreign Offices: Belgium, Canada, England, Korea, France, Germany , Hong Kong, Japan
http://www.graco.com
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN U.S.A. 306–667 October 1959, Revised January 1998