Graco 20:1 KING 231131 Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
20:1 KINGtCARBON STEEL
Cart–Mounted Zinc Spray
Package
Part No. 231131, Series C
2000 psi (14 MPa, 138 bar) Maximum Fluid Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure
308081L
Read warnings and instructions.
See page 2 for Table of Contents.
TI1605A
Parts

2 308081
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 18. . . . . . . . . . . . . . . . . . . . . .
Graco Information 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 16 for the maximum working pressure of this equipment.
DUse fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DDo not use hoses to pull equipment.
DRoute 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).
DWear hearing protection when operating this equipment.
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.

308081 3
WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely
serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also
cause serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
DDo not point the gun at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DDo not “blow back” fluid; this is not an air spray system.
DAlways have the tip guard and the trigger guard on the gun when spraying.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DBe sure the gun trigger safety operates before spraying.
DLock the gun trigger safety when you stop spraying.
DFollow the Pressure Relief Procedure on page 9 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
Do not repair high pressure couplings; you must replace the entire hose.
DUse only Graco approved hoses. Do not remove the spring guard that is used to help protect the
hose from rupture caused by kinks or bends near the couplings.
MOVING PARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore servicing the equipment, follow the Pressure Relief Procedure on page 9 to prevent the
equipment from starting unexpectedly.

4 308081
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
DGround the equipment and the object being sprayed. Refer to Grounding on page 6.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing immediately. Do not use the equipment until you identify and correct the problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
DKeep the spray area free of debris, including solvent, rags, and gasoline.
DElectrically disconnect all equipment in the spray area.
DExtinguish all open flames or pilot lights in the spray area.
DDo not smoke in the spray area.
DDo not turn on or off any light switch in the spray area while operating or if fumes are present.
DDo not operate a gasoline engine in the spray area.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

308081 5
Setup
General Information
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
NOTE: Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor. Refer to
the Product Data Sheet for your pump, Form No.
305789. If you supply your own accessories, be sure
they are adequately sized and pressure rated for your
system.
Fig. 2 is only a guide for selecting and installing sys-
tem components and accessories. Contact your Graco
distributor for assistance in designing a system to suit
your particular needs.
Prepare the Operator
All persons who operate the equipment must be
trained in the safe, efficient operation of all system
components as well as the proper handling of all fluids.
All operators must thoroughly read all instruction
manuals, tags, and labels before operating the equip-
ment.
Prepare the Site
The King pump requires 180 scfm (5.0 m#/min) of
compressed air while operating at 90 psi (0.6 MPa, 6
bar) air pressure and 60 cycles per minute. Ensure
that you have an adequate compressed air supply.
Refer to Fig. 2. Bring a compressed air supply line (A)
from the air compressor to the pump location. Be sure
all air hoses (A) 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.
Install a bleed-type shutoff valve (B) in the air line to
isolate the air line components for servicing. Install an
air line moisture trap and drain valve (C) to help re-
move moisture from the compressed air supply.
Keep the site clear of any obstacles or debris that
could interfere with the operator’s movement.
Have a grounded, metal pail available for use when
flushing the system.

6 308081
Setup
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE OR EXPLOSION HAZ-
ARD on page 4.
1. Pump: use the ground wire and clamp (supplied)
as shown in Fig. 1. Remove the ground screw (Z)
and insert through the eye of the ring terminal at
end of ground wire (Y). Fasten the screw back
onto the pump and tighten securely. Connect the
other end of the wire to a true earth ground.
Fig. 1 TI1052
Y
Z
2. Air and fluid hoses: use only electrically conductive
hoses.
3. Air compressor: follow manufacturer’s recommen-
dations.
4. Spray gun: ground through connection to a prop-
erly grounded fluid hose and pump.
5. Fluid supply container: follow your local code.
6. Object being sprayed: follow your local code.
7. Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continu-
ity.
8. To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray
gun firmly to the side of a grounded metal pail,
then trigger the gun.

308081 7
Setup
Supplied Components
Refer to Fig. 2.
WARNING
A red-handled bleed-type master air valve (F) and
a fluid return line valve (7) are supplied. These
components 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 adjusting or repairing the pump.
The bleed-type master air valve relieves air trapped
between this valve and the pump after the air is
shut off. Trapped air can cause the pump to cycle
unexpectedly. Locate the valve close to the pump.
The fluid return line valve acts as a fluid drain valve
to assist in relieving fluid pressure in the displace-
ment pump, hose, and gun. Triggering the gun to
relieve pressure may not be sufficient.
DThe red-handled bleed-type master air valve (F)
is required in your system to relieve air trapped
between it and the air motor when the valve is
closed (see the WARNING above). Be sure the
bleed valve is easily accessible from the pump, and
is located downstream from the air filter/regulator
(H).
DThe air relief valve (38) opens automatically to
prevent overpressurization of the pump.
DThe fluid return line valve (7) is required in your
system to relieve fluid pressure in the hose and gun
(see the WARNING at left).
DThe suction hose (24) and tube (26) allow the
pump to draw fluid from a 5 gallon (19 liter) pail (E).

8 308081
Setup
TI1606A
KEY
SUPPLIED COMPONENTS
1 Pump
2 Cart
7 Fluid Return Line Valve
9 Fluid Return Line
10 Fluid Return Tube
12 Electrically Conductive Fluid Supply Hose
13 Coupling
14 Electrically Conductive Fluid Whip Hose
15 Gun Swivel
17 Airless Spray Gun
24 Suction Hose
26 Suction Tube
27 Air Regulation Kit (includes items
F and G)
F Red-Handled Bleed-Type Master
Air Valve (required, for pump)
G Air Line Inlet Swivel
35 Ground Wire (required; see page 6
for installation instructions)
38 Air Relief Valve (partially hidden)
39 Pump Air Hose
COMPONENTS YOU MUST SUPPLY
A Electrically Conductive Air Supply Hose
B Bleed-Type Master Air Valve
(for accessories)
C Air Line Moisture Trap and Drain Valve
E Grounded 5 Gallon (19 Liter) Pail
Detail of Air Line Connection
and Air Regulation Kit (27)
Fig. 2
12
12
35
15
17
E
9
F
A
B
G
38
C
7
13
14
24
26
10
F
39
39

308081 9
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. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray tips.
1. Lock the gun trigger safety.
2. Close the red-handled bleed-type master air valve
(F, supplied in your system).
3. Unlock the gun trigger safety.
4. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and trigger the gun to relieve
pressure.
5. Lock the gun trigger safety.
6. Open the return line valve (7, supplied in your
system), to relieve fluid pressure in the hose and
gun.
7. Leave the return line 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.
Flush the Pump Before First Use
The pump is tested with lightweight oil, which is left in
to protect the pump parts. If the fluid you are using
may be contaminated by the oil, flush it out with a
compatible solvent. See Flushing on page 11.
Packing Nut/Wet-Cup
Before starting, fill the packing nut (K) 1/3 full with
Graco Throat Seal Liquid (TSL) or compatible solvent.
See Fig. 3.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
The packing nut is torqued at the factory and is ready
for operation. If it becomes loose and there is leaking
from the throat packings, relieve pressure, then
torque the nut as specified in Fig. 3, using the supplied
wrench. Do this whenever necessary. Do not overtigh-
ten the packing nut.
Using the Airless Spray Gun
Before operating the equipment, read the instruction
manual supplied with the gun.
Spray some test patterns before doing any finished
work. Refer to the gun manual for detailed information
on correct spraying technique.
Circulating Zinc Fluids
1. When spraying zinc fluids, close the return line
valve (7). Circulation is not required when spray-
ing.
2. To circulate fluid back to the supply container while
you are not spraying, open the return line valve (7)
and lock the gun trigger safety. The pump will
continue to run.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
3. Always relieve pressure before overnight shut-
down, when changing spray tips, or when checking
or servicing any part of the system. During circula-
tion, some fluid will be present in the gun line and
must be relieved.

10 308081
Operation
CAUTION
To avoid tip-over, the cart must be on a flat and level
surface. Failure to follow this caution could result in
injury or equipment damage.
Prime the Pump
1. See Fig. 3. Remove the tip guard and spray tip
from the gun (17). See the gun instruction manual.
2. Close the air filter/regulator (H) and bleed-type air
valves (B, F).
3. Close the return line valve (7).
4. Connect the air line to the air inlet swivel (G).
5. Check that all fittings throughout the system are
tightened securely.
6. Place the pump suction tube (26) and the fluid
return tube (10) into the fluid supply container.
7. Open the bleed-type air valves (B, F).
8. Hold a metal part of the gun (17) firmly to the side
of a grounded metal pail and hold the trigger open.
9. Slowly open the air filter/regulator (H) until the
pump starts.
10. Cycle the pump slowly until all air is pushed out
and the pump and hoses are fully primed.
11. Release the gun trigger and lock the trigger safety.
The pump should stall against pressure.
Set the Air and Fluid Pressure
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
1. Relieve the pressure. Install the tip guard and
spray tip in the gun, as explained in the gun manu-
al.
2. Open the air filter/regulator (H) slowly. Use the
regulator to control pump speed and fluid pres-
sure. Always use the lowest air pressure neces-
sary to get the desired results. Higher pressures
cause premature tip and pump wear.
NOTE: To open the air filter/regulator, turn the
T-handle in (clockwise). To close the regulator, turn the
handle counterclockwise. To lock the regulator setting,
tighten the jam nut.
WARNING
COMPONENT RUPTURE HAZARD
To 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 Technical Data, on
page 16).
3. With the pump and lines primed, and with ade-
quate air pressure and volume supplied, the pump
will start and stop as you open and close the gun.
CAUTION
Do not allow the pump to run dry. It will quickly
accelerate to a high speed, causing damage. If your
pump is running too fast, stop it immediately and
check the fluid supply. If the container is empty and
air has been pumped into the lines, refill the con-
tainer and prime the pump and the lines, or flush and
leave it filled with a compatible solvent. Eliminate all
air from the fluid system.