Graco 238-590 Operation manual

308–722
Rev. A


Part No. 238–590
Part No. 238–613
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
HIGH VOLUME
Air Control Kits
250 psi (1.7 MPa, 17.2 bar) Maximum Air Inlet Pressure
Part No. 238–590, Series A
Air Filter/Regulator/Lubricator Kit
For King  , Bulldog  , and Senator  airless pumps.
Part No. 238–613, Series A
Air Filter/Regulator/Lubricator Kit
For Bulldog  and Senator  air-assisted airless pumps.
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco W arranty 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toll-Free Graco Phone Numbers 12. . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1996, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

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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.
 Check equipment daily . Repair or replace worn or damaged parts immediately .
 Follow the Pressure Relief Procedure on page 4 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
 Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
T echnical Data on page 1 1 for the maximum working pressure of this equipment.
 Always wear protective eyewear when operating or servicing this equipment.
 Comply with all applicable local, state, and national fire, electrical, and safety regulations.
Installation
Prepare the Site
NOTE: Always use Genuine Graco Parts and Acces -
sories, available from your Graco distributor . If you
supply your own accessories, be sure they are ade -
quately sized and pressure rated for your system.
Bring a compressed air supply line from the air com -
pressor to the pump location. Be sure all air hoses are
properly sized and pressure-rated for your system.
Use only electrically conductive hoses. The air hose
should have a 3/4 npsm(m) thread.
Before installing any air line components, blow out the
air lines to remove scale and other debris. Use pipe
compound or tape sparingly and only on male threads.
Install a bleed-type shutof f valve in the air line up -
stream from all other air line components, to isolate
them for servicing.
CAUTION
Do not hang the air control kit directly of f the pump
air motor inlet, which could be damaged by the
weight and operating stress. Use a bracket to mount
the kit to a cart or to the wall.

 
Installation
Kit Components (see page 9)
WARNING
A red-handled bleed-type master air valve (5) is
supplied. This valve relieves air trapped between it
and the pump when the valve is closed, to help
reduce the risk of serious injury , including fluid
injection and splashing of fluid in the eyes or on the
skin, and injury from moving parts if you are adjust -
ing or repairing the pump.
 The red-handled bleed-type master air valve (5)
is supplied to relieve air trapped between it and the
air motor when the valve is closed (see the WARN-
ING
above). Be sure the bleed valve is easily
accessible from the pump, and is located down-
stream from the air filter/regulator (1).
The
air filter/regulator (1) controls pump speed
and outlet pressure by adjusting the air pressure to
the pump. It also removes harmful dirt and moisture
from the compressed air supply . Locate the regula -
tor as close as possible to the equipment it serves,
but upstream from the bleed-type master air valve
(5). Install the regulator in the air line so the air flow
is in the direction of the arrow stamped on the body .
The
gun air regulator (18, included in Kit
238–613 only)
adjusts the air pressure to an air-
assisted airless spray gun.
The air manifold (13) provides ports for connect -
ing lines to air-powered accessories.
 The air line lubricator (2) provides automatic air
motor lubrication.
The air line couplers (6 and 7) connect the main
air supply line to the air control kit.
Connecting the Air Line Couplers
Screw the female coupler (6) onto the main air hose.
Leave the male coupler (7) attached to the air filter/
regulator (1). Do not connect the couplers until you are
ready to operate the pump.
Connect the female coupler to the male coupler and
twist with a wrench to lock. Secure with the clip pins
(P). See Fig. 1.

Fig. 1
P
6
7
Using the Quick Connectors
To open the quick connector (12), loosen the captive
screw (S) and open the connector . Slide the desired
component into the connector , close, and tighten the
screw . See Fig. 2.

Fig. 2
S
12

4 308-722
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.
Close all bleed-type master air valves, including
the red-handled bleed-type master air valve (5,
supplied in your system).
3. Turn the regulator T -handle all the way counter -
clockwise if you are removing the air filter/regulator
(1) bowl, or servicing the air regulators (1 and 18).
4. Open any fluid shutof f valves.
5. Unlock the gun trigger safety .
6. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and trigger the gun to relieve
pressure.
7.
Lock the gun trigger safety .
8. Open any fluid drain valves (required in your
system), having a container ready to catch the
drainage.
9.
Leave the drain valve(s) open until you are ready
to spray again.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, very slowly loosen the
tip guard retaining nut or hose end coupling and relieve
pressure gradually , then loosen completely . Now clear
the tip or hose.
Adjusting the Air Regulator
1. To increase the regulated air pressure, turn the
T-handle clockwise.
2. T o decrease the regulated air pressure, turn the
T-handle counterclockwise.
3. T o lock the regulator setting, tighten the jam nut.
4. Open the air filter/regulator (1) slowly . Use the
filter/regulator to control pump speed and fluid
pressure. Always use the lowest air pressure
necessary to get the desired results. Higher pres -
sures cause premature tip and pump wear .
WARNING
COMPONENT RUPTURE HAZARD
T o reduce the risk of overpressurizing
your system, which could cause compo -
nent rupture and serious injury , never
exceed the specified Maximum Incoming Air Pres -
sure to the pump (see the T echnical Data, on
page 1
1).
Air-Assisted Airless Kit 238–613
Use the gun air regulator (18) to control the air pres -
sure to the gun.
Spray some test patterns before doing any finished
work. Refer to your separate gun manual for detailed
information on correct spraying technique.

308-722 5
Operation
Lubricator Operation
The lubricator meters oil into the moving air stream to
automatically lubricate air-operated motors. A manual
adjustment in the housing sets the oil drip rate into the
air stream, which can be monitored through a sight
glass. One to two drops of oil per minute is common.
Use an oil rated at 50 to 200 SUS (ISO grade 7 to 46)
at 100 F (38 C), such as Graco motor oil, Part No.
202–659.
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 4.
T o refill, unscrew the fill plug (F , page 8) and pour in
the oil. The lubricator ’ s capacity is 7 oz (0.2 liter).
Check the oil level with the sight glass. The lubricator
can be refilled with the system pressurized. However ,
always relieve the system pressure before removing
the bowl for any reason.
Service
Air Filter Service
Repair Kits are available. Refer to page 6.
Every day , drain contaminants from the bowl before
reaching the baf fle level by opening the drain (D) at the
bottom of the bowl (B).
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 4.
Clean the air filter regularly to maximize filtering ef fi-
ciency and to avoid excessive pressure drop. Fully
relieve pressure to remove the bowl (B).
Clean the filter element (1
1 1) and bowl using house -
hold soap and water or denatured alcohol. Use com -
pressed air to blow out the filter body . Blow the filter
element out from the inside.
Clean the sight glass (109) thoroughly . Do not leave
solvent residue in the sight glass as it may attack or
weaken the glass. If the sight glass appears damaged,
replace it immediately .
Regulator Service
Repair Kits are available. Refer to pages 6 and 7.
If the regulator fails to operate, operates roughly , or
vibrates, service it as follows.
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 4.
Fully relieve pressure and remove the regulator from
the air line.
Refer to pages 6 and 7. Disassemble the regulator .
If it is a filter/regulator , clean the filter bowl and ele -
ment as described under Air Filter Service.
Clean the parts with household soap and water or
denatured alcohol. Wipe dry with a clean, soft cloth.
Use compressed air to blow dirt and contaminants out
of the regulator body .
Inspect all parts for wear or damage. Replace dam -
aged parts.
Lubricate the bearing area, all o-rings, adjusting screw
threads, and spring ends with no. 2 lithium-base
grease. Reassemble the regulator .

6 308-722
Service
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101*
102*
103*
104*
105*
106*
108
109
107*
110
111
Model 1 13–494
Air Filter/Regulator Shown
1Lubricate
with no. 2
lithium-base grease.
1
1
1
1
1
1
1
B
D
Repair Kit 238–915 (includes items 101 to
107). For Part No. 113–494 Air
Filter/Regulator (shown).
Kit parts are marked with an asterisk (101*). Individual
parts are not available separately .
Ref.
No. Part No. Description Qty.
101* N/A DIAPHRAGM 1
102* N/A VALVE ASSEMBLY 1
103* N/A O-RING, valve 1
104* N/A SPRING, valve 1
105* N/A O-RING, center post 1
106* N/A O-RING, bowl assembly 1
107* N/A O-RING, drain 1
Repair Kit 238–912 (includes items 105 to
107). For Part No. 113–434 Air Filter.
Kit parts are marked with an asterisk (105*). Individual
parts are not available separately .
Ref.
No. Part No. Description Qty.
105* N/A O-RING, center post 1
106* N/A O-RING, bowl assembly 1
107* N/A O-RING, drain 1
Sight Glass Kit 238–913 (includes items
106 to 110). For Part Nos. 113–494 Air
Filter/Regulator (shown) and 113–434 Air
Filter.
Kit parts are marked with a symbol (108  ). Individual
parts are not available separately .
Ref.
No. Part No. Description Qty.
106N/A O-RING, bowl assembly 1
108N/A SCREW 2
109N/A LENS, sight glass 1
110N/A
SEAL, lens 1
Filter Element Kit 238–914 (includes item
111). For Part Nos. 113–494 Air
Filter/Regulator (shown) and 113–434 Air
Filter.
Kit parts are marked with a symbol (1 11 ). Individual
parts are not available separately .
Ref.
No. Part No. Description Qty.
111N/A ELEMENT
, 40 micron; polypropylene 1

 
Service

101*
102*
103*
104*
106*
Model 113–549
Air Regulator Shown
1Lubricate
with no. 2
lithium-base grease.
1
1
1
Repair Kit 238–916 (includes items 101 to
106). For Part No. 113–433 Air Regulator.
Kit parts are marked with an asterisk (101*). Individual
parts are not available separately .
Ref.
No. Part No. Description Qty.
101* N/A DIAPHRAGM 1
102* N/A VALVE ASSEMBLY 1
103* N/A O-RING, valve 1
104* N/A SPRING, valve 1
106* N/A O-RING, plug 1
Repair Kit 238–917 (includes items 101 to
106). For Part No. 113–549 Air Regulator
(shown).
Kit parts are marked with an asterisk (101*). Individual
parts are not available separately .
Ref.
No. Part No. Description Qty.
101* N/A DIAPHRAGM 1
102* N/A VALVE ASSEMBLY 1
103* N/A O-RING, valve 1
104* N/A SPRING, valve 1
106* N/A O-RING, plug 1

 
Service
Lubricator Service
Repair Kits are available.
T o drain the bowl, open the drain (D) at the bottom of
the bowl (B).
Clean the lubricator regularly to maximize ef ficiency.
Fully relieve pressure and remove the lubricator from
the air line.
Disassemble the lubricator .
Clean the parts with household soap and water or
denatured alcohol. Wipe dry with a clean, soft cloth.
Use compressed air to blow dirt and contaminants out
of the lubricator body .
Inspect all parts for wear or damage. Replace dam -
aged parts.
Clean the sight glass (109) thoroughly . Do not leave
solvent residue in the sight glass as it may attack or
weaken the glass. If the sight glass appears damaged,
replace it immediately .
Reassemble the lubricator .
Repair Kit 238–918 (includes items 101 to
106). For Part No. 113–435 Lubricator.
Kit parts are marked with an asterisk (101*). Individual
parts are not available separately . The kit includes
some parts not used on this lubricator .
Ref.
No. Part No. Description Qty.
101* N/A
O-RING, fill plug 1
102* N/A
SEAL, sight dome 1
106* N/A O-RING, bowl assembly 1
107* N/A O-RING, drain 1
Sight Glass Kit 238–913 (includes items
106 to 110). For Part No. 113–435
Lubricator.
Kit parts are marked with a symbol (108  ). Individual
parts are not available separately .
Ref.
No. Part No. Description Qty.
106N/A O-RING, bowl assembly 1
108N/A SCREW 2
109N/A LENS, sight glass 1
110N/A
SEAL, lens 1

*101 102*
106*
108
109
107*
110
D
B
F

 
Air Control Kit Parts
Part No. 238–590, Series A (includes items 1 to 13)
Ref.
No. Part No. Description Qty.
1 113–494
AIR FIL TER/REGULATOR;
3/4 npt(f) inlet and outlet;
5–150 psi (.03–0.1 MPa, 0.3–10 bar)
pressure range;
40 micron polypropylene filter 1
2 113–435 LUBRICAT
OR, air line 1
3 100–549 ELBOW
, street, 90  ; 3/4 npt (m x f) 1
4 238–374
HOSE, air; 19 mm (3/4 in.) ID;
3/4 npt (mbe); 559 mm (22 in.) long;
(not shown) 1
5 113–218 BLEED VAL
VE, red-handled;
3/4 npt (m x f) 1
6 113–430
COUPLER, air line; 3/4 npt(f) 1
7 113–429
COUPLER, air line; 3/4 npt(m) 1
8 113–432 BRACKET
, mounting 2
9 101–689 GAUGE, air 1
10 100–721
PLUG, pipe; 1/4 npt 3
11 113–444 ELBOW
, 45  ; 1/4 npt (m x f) 1
12 113–431 CONNECTOR, quick 2
13 113–442
MANIFOLD, air; 1/4 npt(f) 1

1
3
5
9
13
8
12
12
11
10
2
76

10 308-722
Air Control Kit Parts
Part No. 238–613, Series A (includes items 1 to 19)
Ref.
No. Part No. Description Qty.
1 113–494
AIR FIL TER/REGULATOR;
3/4 npt(f) inlet and outlet;
5–150 psi (.03–0.1 MPa, 0.3–10 bar)
pressure range;
40 micron polypropylene filter 1
2 113–435 LUBRICAT
OR, air line 1
3 100–549 ELBOW
, street, 90  ; 3/4 npt (m x f) 1
4 238–374
HOSE, air; 19 mm (3/4 in.) ID;
3/4 npt (mbe); 559 mm (22 in.) long
(not shown) 1
5 113–218 BLEED VAL
VE, red-handled;
3/4 npt (m x f) 1
6 113–430
COUPLER, air line; 3/4 npt(f) 1
7 113–429
COUPLER, air line; 3/4 npt(m) 1
8 113–432 BRACKET
, mounting 2
9 101–689 GAUGE, air 2
10 100–721
PLUG, pipe; 1/4 npt 2
11 113–630 ELBOW
, 45  ; 1/8 npt (m x f) 1
12 113–431 CONNECTOR, quick 2
13 113–442
MANIFOLD, air; 1/4 npt(f) 1
14 208–627 AIR BLOW GUN 1
15 162–453
NIPPLE; 1/4 npt x 1/4 npsm 1
16 156–823 ADAPTER, swivel;
1/4 npt(m) x 1/4 npsm(f) 1
17 113–548
TEE; 1/4 npt(m) 1
18 113–549 GUN AIR REGULATOR;
1/4 npt(f) inlet and outlet;
5–150 psi (.03–0.1 MPa, 0.3–10 bar)
pressure range 1
19 159–840 ADAPTER, increase;
1/8 npt(m) x 1/4 npt(f) 1
1
23
5
67
911
13
14
15
16
1718
81210
19 9
12
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