Graco Thermostat 203831 User Manual

Instructions–Parts List  
LOW PRESSURE  
306563K  
Fluid Regulator  
ENG  
For accurate, positive control of fluid pressure to one spray gun,  
dispensing valve, or atomizing head. For professional use only.  
250 psi (18 bar, 1.8 MPa) Maximum Inbound Pressure  
Important Safety Instructions  
Read all warnings and instructions in this manual.  
Save these instructions.  
Model 203831 Series H  
0–60 psi (0–4 bar, 0–0.4 MPa) Regulated Pressure  
Gives positive control of fluid pressures in most normal  
direct supply and circulating spray systems.  
Model 204500 Series H  
0–15 psi (0–1 bar, 0–0.1 MPa) Regulated Pressure  
Has a counterbalance spring for positive closure at  
extremely low pressures.  
Model 204501 Series H  
20–160 psi (1.5–11 bar, 0.15–1.1 MPa) Regulated  
Pressure  
Has a heavier spring for precise control of fluid in the  
regulated range.  
Model 205425 Series H  
0–60 psi (0–4 bar, 0–0.4 MPa) Regulated Pressure  
has a large valve for more viscous fluids. Not intended  
for use with standard paints and lighter viscosity fluids,  
as these fluids lower the sensitivity of this regulator.  
03367  
 
WARNING  
SKIN 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.  
D Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious  
injury. Get immediate surgical attention.  
D Do not stop or deflect leaks with your hand, body, glove or rag.  
D Always have the tip guard and the trigger guard on the gun when spraying.  
D Check the gun diffuser operation weekly. Refer to the gun manual.  
D Be sure the gun trigger safety operates before spraying.  
D Lock the gun trigger safety when you stop spraying.  
D Follow the Pressure Relief Procedure for your equipment if the spray tip clogs and before clean-  
ing, checking or servicing the equipment.  
D Tighten all fluid connections before operating the equipment.  
D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not  
repair high pressure couplings; you must replace the entire hose.  
D Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by  
kinks or bends near the couplings.  
MOVING PARTS HAZARD  
Moving parts can pinch or amputate your fingers.  
D Keep clear of all moving parts when starting or operating the pump.  
D Before checking or servicing the equipment, follow the Pressure Relief Procedure for your sys-  
tem to prevent the equipment from starting unexpectedly.  
306563  
3
 
WARNING  
FIRE AND EXPLOSION HAZARD  
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re-  
sult in a fire or explosion and serious injury.  
D 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.  
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid  
being sprayed.  
D Keep the spray area free of debris, including solvent, rags, and gasoline.  
D Before operating this equipment, electrically disconnect all equipment in the spray area.  
D Before operating this equipment, extinguish all open flames or pilot lights in the spray area.  
D Do not smoke in the spray area.  
D Do not turn on or off any light switch in the spray area while spraying or while operating if fumes  
are present.  
D 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.  
D Know the specific hazards of the fluid you are using.  
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,  
state and national guidelines.  
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and  
solvent manufacturer.  
4
306563  
 
Installation  
KEY  
A
B
C
D
E
F
Regulator  
Dispensing Unit  
Gauge  
Regulator Inlet  
Regulator Outlet  
Air Regulator  
Supply Line  
C
G
D
H
A
G
H
F
Accessory Outlet  
E
B
03363  
Fig. 1  
D Mount the regulator in an upright position so that  
TYPICAL INSTALLATION  
the gauge (C) can be easily read.  
D If turning the gauge, reapply sealer to the threads,  
and use a wrench on the inlet stud to turn gauge.  
Regulator inlet (D) is 3/8 npsm (f) swivel and outlet  
(E) is 3/8 npsm (m) rigid.  
CAUTION  
Before installing the regulator, check the tightness of  
the screws (1). Refer to Fig. 3 for the tightening  
sequence and the torque value. If the regulator leaks  
during operation, check and torque the screws again.  
D Connect a fluid hose to regulator outlet (E) and  
spray gun. Connect an air atomizing hose to the  
spray gun and air regulator (F) See Fig. 1.  
In order to prevent damaging the regulator, blow out  
and flush the supply line to remove any particles.  
D To mount the regulator in a circulating system  
supply line (G), install an accessory outlet (H). One  
outlet (H) and air regulator (F) are required for each  
spray gun. The accessory outlet (Part No. 204819)  
may be ordered separately.  
D Install regulator (A) in fluid supply line as close as  
possible to spray gun or dispensing valve (B) for  
easy operator control.  
306563  
5
 
Operation  
CLEANING THE REGULATOR  
WARNING  
Note: Flush the regulator every four weeks, or as  
To reduce the risk of component rupture, which  
can cause a fire or explosion and result in  
serious bodily injury, including splashing in the  
eyes, never exceed 250 psi (18 bar, 1.8 MPa)  
Maximum Inbound Fluid Pressure to this regula-  
tor.  
necessary for the amount and type of use.  
1. Clear regulator of paint or other fluid by blowing  
back fluid through the gun and hose.  
2. Shut off supply pump and relieve line pressure by  
opening back pressure regulator or other by-pass  
valve.  
CAUTION  
Do not pressure test the regulator with air; use  
solvent. Air may cause leaks between the fluid seals  
and result in fluid leaks during normal operation.  
3. Open regulator valve by screwing the threaded  
portion of key (25) as far as possible into the cap.  
See Fig. 2.  
4. Loosen air cap ring of spray gun three turns, hold  
a rag firmly over the end of the cap and trigger the  
gun. Air will force fluid back through the gun, hose  
and regulator.  
If the rest of the system must be pressure tested  
with air, loop past the regulator during the test.  
1. Insert hex end of key (25) in adjusting screw (20)  
and turn counterclockwise until spring tension is  
relieved. See Figs 2 and 3.  
5. After blow-back, remove the adjusting key (25)  
Note: Do not use the threaded end of key (25) to  
adjust pressure.  
2. Start pump and open shutoff valve of outlet (H) to  
admit fluid to regulator. Turn key (25) clockwise  
until desired fluid pressure shows on gauge.  
6. Flush regulator until clean.  
25  
CAUTION  
Do not exceed the Regulated Pressure specification  
of your regulator. Pressures higher than specified  
can damage the gauge.  
Blow Back Position  
Fig. 2  
Regulating Position  
Note: When reducing pressure, relieve pressure in gun  
and supply line to ensure a correct gauge reading.  
03369  
6
306563  
 
Troubleshooting  
Problem  
Cause  
Solution  
No pressure regulation  
Fluid leaks under cap  
Damaged diaphragm  
Loose cap, worn gasket  
Replace diaphragm (31).  
Tighten screws (1), replace gasket  
(32).  
Damaged diaphragm  
Loose cap  
Replace diaphragm (31).  
Tighten screws (1).  
Pressure creeps above setting  
Pressure drops below setting  
Worn gasket  
Replace gasket (32).  
Replace diaphragm (31).  
Damaged diaphragm  
Worn or held open fluid valve  
Flush regulator, replace fluid  
valves (26 & 27) if worn excessively.  
Loose cap  
Tighten screws (1).  
Replace gasket (32).  
Worn gasket  
Blocked fluid supply line or valve  
Flush supply line and valve,  
service if necessary.  
Using regulator beyond capacity  
Do not use regulator beyond its rated  
capacity.  
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7
 
Service  
Regulator Disassembly  
See TOP VIEW for tightening sequence.  
1
Lubricate with oil.  
Shut off pump, close shutoff valve and relieve pressure  
in regulator by triggering the spray gun. Remove the  
regulator from the system.  
2
3
Lubricate with grease.  
Torque to 20 ft-lb (27 NSm).  
Hanger must be parallel  
to diaphragm holes.  
Torque to 120–130 in-lb  
(13.6–14.7 NSm).  
4
5
6
1. Using the hex end of key (25), adjust screw (20) all  
the way counterclockwise to relieve regulator  
spring tension.  
4
10  
2. Remove outlet bushing (15) and counter-balance  
spring (29) (Model 204500 only) from the body.  
3. Unscrew valve stem (27) from diaphragm hanger  
(28) with adjusting key. See Fig. 3.  
25  
03371  
5
4. Remove screws (1), regulator cap (17), spring  
adjusting screw (20), spring (13), and spring  
cap (30) (Model 204500 only).  
28  
5. Lift diaphragm (31) and hanger from body. Disas-  
semble the hanger and diaphragm only if dam-  
aged.  
17  
3
20  
6. Unscrew valve seat (26) from body with a 9/16”  
socket wrench. See Fig. 3.  
1
1
6
12  
13 3  
32  
7. Thoroughly inspect all parts and inspect for wear  
or damage, replacing as necessary.  
30  
CAUTION  
Use special care in handling the valve stem and seat  
to avoid damaging the hard carbide parts.  
27  
Regulator Reassembly  
2
31  
Reassemble regulator in reverse order of Disassem-  
bly. When inserting the diaphragm and hanger, be  
sure that all surfaces are clean and smooth. Any dirt or  
roughness could damage the diaphragm.  
26  
28  
15  
Note: Hold hanger (28) and valve stem (27) in place  
with a finger so that the valve stem is correctly lined up  
with the valve seat (26).  
29  
03372  
5
The hanger should be in line with one set of holes and  
the nut should be torqued to 20 ft-lb (27 NSm). Turn the  
valve stem snugly against the seat and then back off  
1/2 turn on model 204500 and 3/4 turn on other mod-  
els to set valve clearance. When installing the  
cap (17), line up finger of spring adjusting nut (12) with  
the groove in the cap (17) . Torque the six screws (1)  
evenly to 120–130 in-lb (13.6–14.7 NSm) three times  
consecutively, in the order shown in the TOP VIEW, to  
compensate for diaphragm relaxation. See Fig. 3.  
3
2
4
Gauge  
1
03370  
TOP VIEW  
6
Fig. 3  
Note: If further service is needed, see notes on lu-  
brication, thread sealant, and torque values in Fig. 4.  
8
306563  
 
Notes  
306563  
9
 
Parts  
1
2
3
4
5
See torque sequence in Fig. 3.  
Lubricate with grease.  
side down.  
PTFE  
Apply sealant to threads.  
Torque to 70–80 in-lb (8–9 NSm).  
Lubricate with oil.  
21  
9
6
7
Torque to 30–35 ft-lb (41–47 NSm)  
6
3
31  
25  
17  
33*  
1 1  
4 *5  
32*  
28*  
27*  
11  
34  
2 4  
3
20  
16  
14  
12  
13  
4
2
5
26  
29  
2 30  
*7  
22*  
10  
7
15  
19  
4
4
03374  
Fig. 4  
10  
306563  
 
Parts  
Ref  
No.  
Ref  
Part No.  
Description  
Qty.  
No.  
Part No.  
Description  
Qty.  
1
2
3
4
101682  
101754  
101971  
101972  
187875  
SCREW, soc hd cap; 1/4–20 x 5/8  
PLUG, pipe; hex soc; 3/8 npt  
RACE, thrust; adjusting nut  
BEARING, needle thrust  
GAUGE, fluid pressure; 0–30 psi  
(0–2 bar) (Model 204500 only)  
GAUGE, fluid pressure; 0–200 psi  
(0–13 bar) (Model 204501 only)  
GAUGE, fluid pressure; 0–60 psi  
(0–4 bar) (Models 205425 &  
203831 only)  
GASKET, copper  
SEAL, o-ring; thiokol  
NUT, lock; diaphragm  
TUBE, gauge mounting  
NUT, spring adjusting  
SPRING, flat compression (Models  
203831 & 205425 only)  
SPRING, helical compression (Model  
204500 only)  
SPRING, helical compression (Model  
204501 only)  
6
1
1
1
17  
19  
20  
21*  
22*  
25  
171194  
162485  
164863  
164864  
171198  
204522  
204523  
CAP, regulator  
ADAPTER; 3/8 npt x 3/8 npsm  
SCREW, adjusting  
PLATE, diaphragm  
GASKET, acetal  
KEY, regulating (removable)  
SEAT, valve (Models 203831 &  
204501 only)  
SEAT, valve (Model 204500 only)  
SEAT, valve (Model 205425 only)  
STEM, valve (Model 204500 only)  
STEM, valve (Models 204501 &  
203831 only)  
STEM, valve (Model 205425 only)  
HANGER, diaphragm  
SPRING, helical compression (Model  
204500 only)  
CAP, spring (Model 204500 only)  
DIAPHRAGM  
GASKET; cellulose fiber  
GASKET; cellulose fiber  
WASHER, plain  
1
1
1
1
1
1
5*  
1
1
101180  
101176  
26*  
1
1
1
1
206523  
212030  
206920  
204524  
1
1
1
1
1
1
27*  
7*  
9*  
10  
11  
12  
13  
150670  
157277  
160741  
160745  
161349  
161351  
1
1
1
205183  
206921  
153996  
28*  
29  
1
1
1
1
1
1
1
30  
31*  
32*  
33*  
34  
*
166618  
172193  
171912  
171913  
171193  
166617  
160034  
161889  
1
1
14  
UNION 45_ swivel; 3/8 npt(m) x  
Recommended “tool box” spare parts. Keep on hand to  
reduce down time.  
3/8 npsm(f)  
1
1
1
15  
16  
161357  
161358  
BUSHING, fluid outlet  
BODY, regulator  
Dimensions  
5.5” (140 mm)  
Weight:  
Model 204500: 4 lb (1.7 kg)  
Model 203831: 5 lb (2.3 kg)  
Model 204501: 5 lb (2.3 kg)  
Model 205425: 5 lb (2.3 kg)  
Model 204500:  
11.25” (285.8 mm)  
Models 203831,  
204501, & 205425  
9.75” (247.7 mm)  
.62” (15.8 mm)  
3/8 NPSM (M) OUTLET  
3/8 NPSM (F) INLET  
Fig. 5  
306563  
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 defec-  
tive. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written rec-  
ommendations.  
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 im-  
proper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not sup-  
plied 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 prop-  
erty, 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 assis-  
tance in making any claim for breach of these warranties.  
For Sales to Canadian Customers:  
Except as expressly stated herein, Graco makers no representations, warranties or conditions, express, implied or collateral, con-  
cerning 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 equip-  
ment 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 Information  
TO PLACE AN ORDER, contact your Graco distributor or call to identify the distributor closest to you:  
Phone: 612–623–6921 or Toll Free: 1–800–328–0211 Fax: 612–378–3505  
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.  
Original instructions. This manual contains English. MM 306563  
Graco Headquarters: Minneapolis  
International Offices: Belgium, China, Japan, Korea  
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441  
Copyright 1996, Graco Inc. is registered to ISO 9001  
Revised 01/2010  
12  
306563  
 

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