Graco 231161 Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1988, Graco Inc. is registered to I.S. EN ISO 9001
PORTABLE, AIR-ASSISTED AIRLESS
10:1 Ratio Monark
Hydra-Spray Pumps
95 psi (0.66 MPa, 6.6 bar) MAXIMUM AIR INLET PRESSURE
950 psi (6.6 MPa, 66 bar) MAXIMUM FLUID WORKING PRESSURE
Model 231158
For cold spray applications. Includes pump, cart, hose, gun and tip
Model 231162, Series B
For cold spray applications. Includes pump, cart,
fluid regulation kit 222564, hose, gun and tip
Model 224629, Series A
For heated spray applications. Includes pump, cart,
Viscon heater, heater mounting kit 222262,
and circulating kit 222436
Model 231161
For heated spray applications. Includes pump, cart,
Viscon heater, heater mounting kit 222262,
circulating kit 222436, hose, gun and tip
307929J
Read warnings and instructions.
See page 2 for table of contents.
Model 231158 Shown
Parts

2 307929
Table of Contents
Warnings 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 14–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawings and Lists 16–21. . . . . . . . . . . . . . . . . . .
Conversion Kits 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
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 uncertain about usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 23 for the maximum working pressure of this equipment.
Use 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.
Do not exceed the maximum working pressure of the lowest rated system component. This equip-
ment has a 950 psi (6.6 MPa, 66 bar) maximum working pressure.
Do not use hoses to pull equipment.
Route 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).
Wear hearing protection when operating this equipment.
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.

3307929
WARNING
INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause
extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause 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 gun at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip.
Do not stop or deflect 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 gun when spraying.
Check the gun diffuser operation weekly. Refer to the gun manual.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 14 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
Tighten all 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.
Use only Graco approved hoses. Do not remove any 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.
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the Pressure Relief Procedure on page 14 to prevent the
equipment from starting unexpectedly.

4 307929
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.
Ground the equipment and the object being sprayed. Refer to Grounding on page 5.
If 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.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do 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.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

5307929
Installation
General
Be sure that all operators read and understand this
entire manual and the separate manuals supplied with
components and accessories before using this equip-
ment.
Reference numbers and letters in parentheses refer to
the illustrations and the parts lists on pages 16–23.
Accessories mentioned in the text are available from
your Graco distributor. If you supply your own acces-
sories, be sure they are adequately sized to meet your
system’s requirements.
The Typical Installation shown in Fig. 2 is only an
example. For assistance in designing a system to meet
your particular needs, contact your Graco distributor.
System Accessories
Refer to Fig. 2. Install an air line filter (A) in the main
air line (B), to remove harmful dirt and moisture from
the compressed air supply. To provide automatic
lubrication of the air motor, install an air line lubricator
(C) downstream from the pump air regulator (31).
Install a second bleed valve (G) in the main air line, to
isolate the accessories for servicing.
Grounding
To 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.
1. Pump: loosen the grounding lug locknut (W) and
washer (X). Insert one end of a 1.5 mm2 (12 ga)
minimum ground wire (Y) into the slot in lug (Z)
and tighten the locknut securely. See Fig. 1. Con-
nect the other end of the wire to a true earth
ground. Order Part No. 237569 Ground Wire and
Clamp.
2. Air hoses: use only electrically conductive air
hoses.
3. Fluid hoses: use only electrically conductive fluid
hoses.
4. Heater, if used: refer to the Viscon2Heater manu-
al, 307805.
5. Air compressor: follow manufacturer’s recommen-
dations.
6. Spray gun: grounding is obtained through connec-
tion to a properly grounded fluid hose and pump.
7. Fluid supply container: according to your local
code.
8. Object being sprayed: according to your local
code.
9. All solvent pails used when flushing, according to
local code. Use only metal pails, which are con-
ductive, placed on a grounded surface. Do not
place the pail on a non-conductive surface, such
as paper or cardboard, which interrupts the
grounding continuity.
10. To maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
spray gun firmly to the side of a grounded metal
pail, then trigger the spray gun.
Fig. 1
W
X
Y
Z
0864

6 307929
Installation
0972A
KEY
AAir Line Filter
BMain Air Line
CAir Line Lubricator
DFluid Hose
ESpray Gun
FGun Air Supply Hose
GBleed-Type Master Air Valve
(for accessories)
YGround Wire (required)
5Pump
22 Suction Hose
23 Suction Tube
25 Fluid Filter
31 Air Regulators
52 Air Relief Valve
62 Bleed-Type Master Air Valve
(for pump)
65 Fluid Drain Valve
A
B
C
D
E
F
G
Y
22
25
31 31
52
62
65
5
23
Fig. 2
WARNING
Three required components are supplied in your
system, to help reduce the risk of serious injury
including fluid injection, splashing in the eyes or on
the skin, overpressurization, or injury from moving
parts if you area adjusting or repairing the pump.
The bleed-type master air valve (62) relieves air
tapped between this valve and the pump. Trapped
air can cause the pump to cycle unexpectedly. To
bleed air from the pump, the pump air regulator
must be open when you close this valve.
The air relief valve (52) opens automatically to
relieve air pressure to the pump if the the pressure
exceeds a preset level. This vale prevents over-
pressurization of the spray gun.
The fluid drain valve (65) assists in relieving fluid
pressure in the displacement pump, hose, and gun;
triggering the gun to relieve pressure may not be
sufficient.
Hose and Gun Connections
Refer to the Typical Installation drawing (Fig. 2). Con-
nect one end of the fluid hose (D) to the filter (25)
outlet and the other to the fluid inlet of the gun (E). Do
not install the spray tip in the gun yet. To use a second
gun with the sprayer, refer to pages 11–13.
Close the bleed-type master air valve (62) and both
the air regulators (31). Connect the main air line (B) to
the bleed valve. Connect an air supply hose (F) to the
outlet nipple of the gun (left) air regulator. Connect the
other end of the hose to the gun’s air inlet.

7307929
Installation
Installing Fluid Regulation Kit 222564
(Pump Model 231162)
WARNING
Before installing the fluid regulation kit, follow the
Pressure Relief Procedure on page 14. Discon-
nect all hoses from the pump.
Assemble the fluid regulation kit (66) as shown in
Detail A of Fig. 3. (Refer to the parts list on page 19.)
Install the mounting bracket (66k) on the regulator
(66f) using the two screws (66p) and lockwashers
(66q). Connect the fluid regulator and bracket to the
side of the cart (7) using the screw (66l), lockwasher
(66m) and nut (66n). Connect the 22” (560 mm) hose
(66h) to the outlet of the fluid filter (25).
Connect the gun air supply hose (F) between the air
inlet of the gun (E) and the outlet nipple of the gun
(left) air regulator. See Fig. 2.
Connect the fluid hose (D) between the gun fluid inlet
and the outlet nipple (66b) of the fluid regulation kit.
Fig. 3
DETAIL A
66d
66a
66b
7
7
25
66h (REF)
(SEE DETAIL A)
21
22
24
66b
66c
66e66f
66h 66j
66k
66l
66m 66n
66p66q
Fluid Regulation Kit 222564
includes items 66a–66q.
26
0973B
1Connect fluid hose here.
1

8 307929
Installation
Converting the Pump to a Heated
Circulating System
To convert pump Model 231162 to a heated circulating
unit, order the following:
VisconFluid Heater, Model 220522
Heater Mounting Kit 222262
Circulating Kit 222436
Hose Kit 222264
WARNING
The Viscon2Heater must be installed by a qualified
electrician in compliance with all state and local
codes and regulations, to reduce the risk of electric
shock or other serious injury during installation or
operation.
The heater requires a 120 VAC, single-phase, 16.7
Amp power supply. Refer to the Viscon2 Heater
Manual 307805 for further information.
Do not plug or unplug the power cord in any area
containing flammable materials or fumes to avoid
fire or explosion, which can result in serious injury.
Installing Heater Mounting Kit 222262
WARNING
Before installing the heater, heater mounting kit
and circulating kit, follow the Pressure Relief
Procedure on page 14. Disconnect all hoses from
the pump.
NOTE: Reference numbers marked with an asterisk
(for example, 68*) are included in kit 222262.
Apply 110110 pipe sealant (included in the kit) to all
male threads, except at swiveling connections.
1. Remove the cover from the electrical box (H) at
the back of the heater (67). Screw the bushing
(74*) into the inlet of the electrical box. Install the
cord grip elbow (75*) in the bushing. See Fig. 4.
2. Thread the cord (76*) through the elbow (75*) and
into the electrical box. Attach the black lead to the
leftmost terminal, the white lead to the center
terminal, and the green ground wire to the right-
most terminal. Tighten all terminal nuts to 30 in–lb
(3.4 N.m). Tighten the nut on the cord grip elbow
(75*) to secure the cord. See Fig. 4.
WARNING
The electrical cord (76*) is rated for 105 C (221
F). Do not substitute a lower temperature rated,
generally available cord.
NOTE: Mount the heater (67) on the back of the cart
as follows. Two people are required to perform this
operation.
3. Align the heater (67) mounting posts with the four
holes at the back of the cart’s pump support brack-
et (J). See Fig. 5. Secure the heater to the bracket
with the M8 x 1.25 screws and lockwashers sup-
plied with the heater.
4. Unscrew the swivel adapter (26) and remove the
fluid filter (25) from the pump (5). Remove the
adapter from the filter, and remove the 3/8 npt
nipple (24) from the pump fluid outlet. See Fig. 3.
Fig. 4
1
GREEN
(GROUND)
WHITEBLACK
Tighten terminal nuts
to 30 in–lb (3.4 N.m).
H
*74
0867
*75
*76 1
1

25
63*
*72
67
74*75*
76*
73*
PART OF
ITEM 67
77
22
5
B
B
J
41
*70
40 82
83
81
38
41
80
REF)
41
23
C
C
40
79
78
*71
*73
(REF)
19*
J
7
82
80
40
40
Fig. 5
1Arrow on body must point away from pump.
1
0974
C
9307929
Installation
5. Screw the check valve (70*) into the pump’s fluid
outlet, making certain that the arrow on the check
valve points away from the pump. Screw the rigid
end of the adapter (71*) onto the check valve. See
Fig. 5.
6. Install the 3/8 npt nipple (63*) in the heater outlet.
Screw the male end of the 90swivel (19*) into the
inlet of the fluid filter (25). Screw the female end of
the swivel (19*) onto the nipple (63*) at the heater
outlet, and tighten securely.
7. Screw the elbow (72*) into the heater’s inlet.
Attach the 1/2” x 3’ (0.9 m) hose (73*) to the
elbow. Attach the other end of the hose to the
swivel of the adapter (71*) at the pump outlet.

10 307929
Installation
Installing Circulating Kit 222436
WARNING
Before installing the heater, heater mounting kit
and circulating kit, follow the Pressure Relief
Procedure on page 14. Disconnect all hoses from
the pump.
NOTE: Reference numbers marked with a symbol (for
example, 77), are included in kit 222436.
Apply 110110 pipe sealant (included in the kit) to all
male threads, except at swiveling connections.
1. Unscrew the suction hose (22) from the pump
intake elbow (21) and set the hose aside. Remove
the elbow (21) from the pump intake and discard.
See Fig. 3.
2. Screw the rigid end of the manifold (77) onto the
pump intake, and attach the suction hose (22) to
the swivel end of the manifold. See Fig. 5.
3. Place a washer (81) and insulator (82) on each
of the screws (38). Insert the screws through the
mounting holes on the left side of the pump sup-
port bracket (J), working from the inside. Place
another insulator (82) on each of the screws on
the outside of the bracket. Use the screws to
attach the back pressure regulator (83) to the
pump support bracket.
4. Screw one of the nipples (41) into the outlet in
the base of the back pressure regulator (83), then
screw one of the elbows (40) onto the nipple so
the male end of the elbow faces forward. Install
another elbow (40) in the inlet of the back pres-
sure regulator, then install the other nipple (41) in
the elbow. Install plugs in the other regulator
ports.
5. Screw an elbow (40) into the open port of the
pump fluid intake manifold (77), so the female
end of the elbow faces left. Install the CIRC end of
the three-way ball valve (78) in the elbow, so the
valve handle is at the front.
6. Screw a second elbow (40) onto the IN branch of
the three-way valve (78), so the elbow points
upward. Connect one end of the hose (80) to this
elbow, and the other end to the nipple (41) at the
outlet of the back pressure regulator.
7. Connect the drain hose (79) to the DRAIN end of
the three-way valve (78).
8. Connect the fluid return line to the nipple (41) at
the inlet of the back pressure regulator.
9. Connect the air and fluid hoses and gun as ex-
plained on page 6.
0975B
Fig. 6
1
2
29
30
NQ
T
SRP
M
L
M
N
31
Connect air hose for first gun here
Air Regulator Connections for a Two-Gun System (All Models)
Connect air hose for second gun here
1
2