INSTRUCTIONS-PARTS LIST

This manual contains important warnings and information.

READ AND KEEP FOR REFERENCE.

INSTRUCTIONS

HIGH VOLUME

Air Control Kits

250 psi (1.7 MPa, 17.2 bar) Maximum Air Inlet Pressure

Part No. 238–980, Series A

Air Regulator Kit

For President and Monark airless pumps.

Part No. 238–939, Series A

Air Filter/Regulator Kit

For President and Monark air-assisted airless pumps.

Table of Contents

Warnings

Installation

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Operation

Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

11

Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Toll-Free Graco Phone Number . . . . . . . . . . . . . . . . .

12

12

5

6

2

3

Part No. 238–980

308–686

Rev. A

Part No. 238–939

GRACO INC.

P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

COPYRIGHT 1997, GRACO INC.

Graco Inc. is registered to I.S. EN ISO 9001

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.

INSTRUCTIONS

WARNING

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.

Follow the Pressure Relief Procedure on page 5 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

Technical Data on page 11 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 Accessories, available from your Graco distributor. If you supply your own accessories, be sure they are adequately sized and pressure rated for your system.

Bring a compressed air supply line from the air compressor to the pump location. Be sure all air hoses are properly sized and pressure-rated for your system.

Use only electrically conductive hoses.

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 shutoff valve in the air line upstream from all other air line components, to isolate them for servicing.

CAUTION

Do not hang the air control kit directly off 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.

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 at left). Be sure the bleed valve is easily accessible from the pump, and is located down-

stream from the air regulator (3).

The air regulator (3) controls pump speed and outlet pressure by adjusting the air pressure to the pump. Locate the regulator 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 filter/regulator (8, included in Kit

238–939 only) adjusts the air pressure to an airassisted airless spray gun. It also removes harmful dirt and moisture from the compressed air supply.

The air manifold (7, included in Kit 238–939

only) provides ports for connecting lines to air-powered accessories.

Using the Quick Connectors

To open a quick connector (2), loosen the captive screw (S) and open the connector. Slide the desired component into the connector, close, and tighten the screw. See Fig. 1.

S

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 adjusting or repairing the pump.

06278

Fig. 1

2

4 308-686

Notes

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: 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 counterclockwise if you are removing the air filter/regulator

(8) bowl, or servicing the air regulators (3 and 8).

4.

Open any fluid shutoff 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.

Operation

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.

To decrease the regulated air pressure, turn the

T-handle counterclockwise.

3.

To lock the regulator setting, tighten the jam nut.

4.

Open the air regulator slowly. Use it to control pump speed and fluid pressure. Always use the lowest air pressure necessary to get the desired results. Higher pressures cause premature tip and pump wear.

WARNING

COMPONENT RUPTURE HAZARD

To reduce the risk of overpressurizing your system, which could cause component rupture and serious injury, never exceed the specified Maximum Incoming Air Pres sure of the equipment (see the Technical Data on page 11 and in your separate component manuals).

Air-Assisted Airless Kit 238–939

Use the gun air filter/regulator (8) to control the air pressure 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.

308-686 5

Air Filter Service

Repair Kits are available. Refer to page 7.

Service

Air Regulator Service

Repair Kits are available. Refer to pages 7 and 8.

If the regulator fails to operate, operates roughly, or vibrates, service it as follows.

Every day, drain contaminants from the bowl before reaching the baffle level by opening the drain (D) at the bottom of the bowl (B).

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 5.

Clean the air filter regularly to maximize filtering efficiency and to avoid excessive pressure drop. Fully relieve pressure to remove the bowl (B).

Clean the filter element (111) and bowl using household soap and water or denatured alcohol. Use compressed 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.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 5.

Fully relieve pressure and remove the regulator from the air line.

Refer to pages 7 and 8. Disassemble the regulator.

If it is a filter/regulator, clean the filter bowl and element 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 damaged parts.

Lubricate the bearing area, all o-rings, adjusting screw threads, and spring ends with no. 2 lithium-base grease. Reassemble the regulator.

B

D

1

1

1

Lubricate with no. 2 lithium-base grease.

101*

102*

103* 1

104*

1

105* 1

111

}

Service

Model 113–765

Air Filter/Regulator Shown

Repair Kit 239–383 (includes items 101 to

107). For Part No. 113–765 Air

Filter/Regulator.

Kit parts are marked with an asterisk (101*). Individual parts are not available separately.

Ref.

No.

Part No.

Description

101* N/A

102* N/A

103* N/A

104* N/A

105* N/A

106* N/A

107* N/A

DIAPHRAGM

VALVE ASSEMBLY

O-RING, valve

SPRING, valve

O-RING, center post

O-RING, bowl assembly

GASKET, drain

Sight Glass Kit 239–385 (includes items

106 to 110). For Part No. 113–765 Air

Filter/Regulator.

Kit parts are marked with a symbol (108

{

). Individual parts are not available separately.

Qty.

1

1

1

1

1

1

1

Ref.

No.

Part No.

Description

106 { N/A

108 { N/A

109 { N/A

110 { N/A

O-RING, bowl assembly

SCREW

LENS, sight glass

SEAL, lens

Filter Element Kit 239–384 (includes item

111). For Part Nos. 113–765 Air

Filter/Regulator.

Kit parts are marked with a symbol (111 } ). Individual parts are not available separately.

Qty.

1

1

1

2

Ref.

No.

Part No.

Description

111 } N/A ELEMENT, 40 micron; polypropylene

Qty.

1

106* {

1

110 {

109

{

108

{

107*

1 05998

308-686 7

Service

Model 113–764

Air Regulator Shown

1

Lubricate with no. 2 lithium-base grease.

Repair Kit 238–917 (includes items 101 to

105). For Part No. 113–764 Air Regulator.

Kit parts are marked with an asterisk (101*). Individual parts are not available separately.

Ref.

No.

Part No.

Description

101* N/A

102* N/A

103* N/A

104* N/A

105* N/A

DIAPHRAGM

VALVE ASSEMBLY

O-RING, valve

SPRING, valve

O-RING, plug

Qty.

1

1

1

1

1

101*

102*

103*

1

104*

1

105* 1

4

5

6

Air Control Kit Parts

Part No. 238–980, Series A

(includes items 1 to 6)

Part No. 238–939, Series A

(includes items 1 to 13)

1

2

3

Ref.

No.

6

Part No.

Description

113–911 GAUGE, air

113–763 CONNECTOR, quick

113–764 AIR REGULATOR;

3/8 npt(f) inlet and outlet;

5–150 psi (.03–0.1 MPa, 0.3–10 bar) pressure range

113–630 ELBOW, 45 ; 1/8 npt (m x f)

113–333 BLEED VALVE, red-handled;

3/8 npt (m x f)

113–767 ADAPTER, pipe; 3/8 npt(f)

Qty.

1

2

1

1

1

2

2

Part No. 238–980

2 6

3

1

4

5

06948

6

7

8

4

5

1

2

3

Ref.

No.

9

10

11

12

13

Part No.

Description Qty.

113–911 GAUGE, air

113–763 CONNECTOR, quick

113–764 AIR REGULATOR;

3/8 npt(f) inlet and outlet;

5–150 psi (.03–0.1 MPa, 0.3–10 bar) pressure range

113–630 ELBOW, 45 ; 1/8 npt (m x f)

113–333 BLEED VALVE, red-handled;

3/8 npt (m x f)

113–767 ADAPTER, pipe; 3/8 npt(f) 2

113–762 MANIFOLD, air; four 3/8 npt(f) ports 1

113–765 AIR FILTER/REGULATOR;

3/8 npt(f) inlet and outlet;

5–150 psi (.03–0.1 MPa, 0.3–10 bar) pressure range;

40 micron polypropylene filter 1

113–766

100–040

162–453

CONNECTOR, quick

PLUG, pipe; 3/8 npt

NIPPLE; 1/4 npt x 1/4 npsm

217–430 ADAPTER, swivel, 90 ;

3/8 npt(m) x 1/2 npt(f)

164–259 ELBOW, street, 90 ;

1

1

1

1

1

2

3

1

2

3/8 npt(m) x 1/4 npt(f) 1

13 8

6

11

4

1

10

7

2 3

9

1

4

Part No. 238–939

6

2 5

12

2

06947

308-686 9

10 308-686

Notes

Category

Maximum air input pressure

Air inlet size

Technical Data

Air outlet size (air regulator)

Gauge port size (air regulator)

Manual drain thread size (air filter/regulator)

Air filter/regulator element

Maximum operating temperature

Data

250 psi (1.7 MPa, 17.2 bar)

Part No. 238–980: 3/8 npsm(f)

Part No. 238–939: 1/2 npt(f) swivel

3/8 npt(f)

1/8 npt(f)

7/16–24 uns(m)

40 micron polypropylene screen

79 _ C (175 _ F)

MODEL 113–765 AIR FILTER/REGULATOR FLOW CURVE psi bar

MPa

100

7.0

0.7

80

5.6

0.56

60

4.2

0.42

40

2.8

0.28

20

1.4

0.14

scfm m

#

/ min

0

0 10

0.280

20

0.560

30

0.840

40

1.120

50

1.400

60

1.680

AIR FLOW AT INLET PRESSURE OF 100 PSI (0.7 MPa, 7 BAR) psi bar

MPa

100

7.0

0.7

MODEL 113–764 AIR REGULATOR FLOW CURVE

80

5.6

0.56

60

4.2

0.42

40

2.8

0.28

20

1.4

0.14

scfm m

#

/ min

0

0 10

0.280

20

0.560

30

0.840

40

1.120

50

1.400

60

1.680

AIR FLOW AT INLET PRESSURE OF 100 PSI (0.7 MPa, 7 BAR)

308-686 11

The Graco Warranty and Disclaimers

WARRANTY

Graco warrants all equipment listed in this manual which is 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. 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 accordance 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 substitution 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 WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING

BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PUR-

POSE.

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.

For Sales to Canadian Customers:

Except as expressly stated herein, Graco makes no representations, warranties or conditions, express, implied or collateral, concerning any goods or services sold, and GRACO SHALL NOT BE LIABLE IN ANY MANNER FOR any other representation, warranty or condition of any kind, whether arising by operation of law or otherwise, including but not limited to, WARRANTIES OF

MERCHANTABLE QUALITY OR FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF LIABILITY

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or for 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.

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 Toll 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: Atlanta, Detroit, Los Angeles

Foreign Offices: Belgium, Canada, England, Korea, Switzerland, France, Germany, Hong Kong, Japan

GRACO INC.

P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

PRINTED IN U.S.A. 308–686 January 1997

12 308-686