Hitachi ULTRA MAX 695 232133 User's Manual
Contents
1. Ae Gi A 7 Q EE K SEQ FSS SSS SSS gt gt Vi SS SSS Sage A DSSS SSS TS YANS AN GEE ZES OATES if AL ALEER 7727A Fig 1 A Motor Under shield shown DC motor permanent magnet totally enclosed fan cooled B Pressure Adjusting Knob Controls fluid outlet pressure C ON OFF Switch Power switch that controls 120 VAC main power to sprayer D Drive Assembly Transfers power from DC motor to the displacement pump E Fluid Filter Filter of fluid between source and spray gun F Fluid Outlet Main hose to spray gun is connected here G Pail Hanger Container for fluid to be sprayed may be hung here H Displacement Pump Transfers fluid to be sprayed from source through spray gun J 50 ft 15 m Main Hose 1 4 in ID grounded nylon hose with spring guards on both ends K RAC IV Tip Guard Reverse A Clean RAC tip guard reduces the risk of fluid injection injury Contractor Gun High pressure spray gun with gun safety latch M RAC IV Switch Tip RAC switch tip uses high pressure fluid to remove clogs from spray tip without removing tip from spray gun N 3 ft 0 9 m Hose 3 16 in ID grounded nylon hose used between 50 ft hose and spray gun to allow more flexibility when spraying P Pressure Drain Valve Relieves fluid outlet pressure when open diverts fluid to drain line Pressure Control Controls motor speed2. Coil hose when storing it even for overnight to help protect hose from kinking abrasion coupling damage etc Turn packing nut clockwise to tighten Fig 10 fiai 308801 11 Flushing When to flush Determine material to spray from column 1 Flush with A CAUTION material in column 2 Then follow recommendations in one of next three columns Do not leave water or water based fluids in sprayer if it could freeze Push water out with mineral spirits Frozen fluid in sprayer prevents starting and may Cause serious damage If you are going to Y Flush with Y Prime with Y Clean with W Store unit with vy Spray latex paint Warm soapy water Latex base paint Warm soapy water Mineral spirits then clean water then clean water Spray oil paint Mineral spirits Oil base paint Mineral spirits Mineral spirits Change latex to oil paint Warm soapy water Mineral spirits Mineral spirits Mineral spirits then clean water Change oil to latex paint Mineral spirits Latex Warm soapy water Mineral spirits soapy water and then clean water clean water Change colors same base Compatible solvent such as water or mineral spirits How to flush A WARNING INJECTION HAZARD To reduce the risk of serious injury when 4 Pour one half gallon 2 liters of compatible solvent instructed to relieve pressure follow the into a grounded metal flushing pail Put suction Pr
3. Installing pump See Fig 17 and 18 201 Fig 18 78408 1 Lightly grease or oil transducer 67 See Fig 24 Guide pump over alignment pins and pressure transducer Tap it into position with a soft hammer Tighten screws 17 to 50 ft lb 68 N m 2 Align hole in rod 222 with connecting rod assem bly 12 Use screwdriver to push retaining spring 15 up and push in pin 14 Push retaining spring into place around connecting rod A WARNING MOVING PARTS HAZARD Be sure retaining spring 18 is firmly in groove all around to prevent pin 14 from working loose See Fig 18 If pin works loose parts including pump connect ing rod or bearing housing could project into the air and cause serious injury or property damage 3 Replace o ring 45 if worn or damaged See page 29 Reconnect suction and drain hoses 47 50 Install front cover 11 4 Tighten packing nut 202 enough to stop leakage but no tighter Fill packing nut full with Graco TSL Push plug 201 into packing nut Motor 9 Remove four screws 75 and lift motor off cart A WARNING 70 INJECTION HAZARD 10 Align new motor with cart and reinstall screws 75 To reduce the risk of serious injury when instructed to relieve pressure follow the 11 Assemble drive housing to motor Follow steps 9 Pressure Relief Procedure on page 8 to 15 on page 26 Install junction box NOTE See Fig 21 except where noted 12 Connect
4. Be careful not to cause kinks or bends in packing during installation Fig 25 oR Suction Hose Models 232132 and 232133 A WARNING INJECTION HAZARD Misalignment or cross threading will damage the To reduce the risk of serious injury when parts and or create shavings which can cause the instructed to relieve pressure follow the o ring 45 to leak Pressure Relief Procedure on page 8 1 Relieve pressure 2 Remove drain hose 50 from clip 3 Pull upward on suction hose 47 while unscrewing it from inlet tube 43 The hose coupling A threads will engage and the hose will separate from the tube 4 Replace o ring 45 if it is worn or damaged 5 Lubricate o ring 45 and inlet tube 43 threads with light grease 6 Align suction hose coupling A with threads of inlet tube 43 Tighten hose onto tube at least 4 A A fae sdi turns to ensure that threads have disengaged and 43 l can function as a swivel joint Fig 26 MAAR 308801 29 Drain Valve Repair A WARNING INJECTION HAZARD To reduce the risk of serious injury when instructed to relieve pressure follow the Pressure Relief Procedure on page 8 1 Relieve pressure 2 Turn handle 54 to closed position Drive out pin 53 Remove handle 3 Remove base 52 4 Unscrew drain valve assembly 51 gasket 55 and seat 56 will stay in valve 55 Fi 56 L 51 N g A N Torque into pump manifold
5. PIN straight SPRING retaining SCREW sch 1 4 20 x 1 25 SCREW mach sch 7 16 x 1 75 KIT pump displacement Manual 308815 SCREW 10 24 x 0 250 HOUSING junction box GASKET motor HEAT SINK does not include 22a KIT board control motor SCREW filh 10 24 x 0 75 GASKET heatsink SCREW panh 10 24 x 3 5 SCREW panh 8 32 x 0 5 KNOB potentiometer LABEL pressure adjust BUSHING strain relief CORD power set SCREW trusshead 8 32 KIT shield motor U 695 includes 9 31 amp 37 33 amp 57 LABEL DANGER French SCREW filh 8 32 x 1 0 LABEL cover front NUT self retaining CAP hub WHEEL semi pneumatic RING retaining wheel BALL thrust PLUG tube TUBE suction STRAINER 1 2 nosm SCREW 8 32 x 38 NIPPLE 1 4 npt x 1 4 npsm HANGER pail FILTER fluid Manual 308249 Qty et WOO OCF S O ON N a PO PMO PO A a P VMN NNNNN HA AND Ref No 49 51s Part No 192648 235014 224807 111600 187625 111699 187615 187791 187975 206994 114296 112396 240514 189269 104319 240007 110243 111590 239998 192027 110997 112382 236352 110037 183350 111930 105658 105659 240017 240035 114420 240495 192840 114271 214701 220955 223541 193072 192838 114422 240498 Description Qty CLIP spring 1 ASSEMBLY drain valve 1 includes 55 and 56 VALVE base PIN grooved HANDLE drain valve GASKET sea
6. The balls which are heavily covered with grease usually stay in the gear re cesses but could be dislodged If the balls are not in place the bearings will wear prematurely 26 308801 10 Tap lower rear of drive housing 2 with a plastic mallet to loosen motor Pull drive housing straight off motor Remove and inspect crankshaft 5 and connecting rod 12 Replace all damaged or worn parts Install connecting rod Lubricate inside of connecting rod bearing with SAE non detergent oil Pack roller bearing and gears with grease supplied NOTE The gears and bearings between the drive housing 2 and motor front end bell C should contain a total of 3 fl oz 89 cc of grease 11 12 13 14 15 16 17 Place large washer 6 and then small washer 7 on crankshaft 5 Rotate crank to top of stroke and insert crankshaft 5 Align gears and push drive housing 2 straight onto motor and locating pins Install screws 16 3 and their lockwashers 4 Torque to 80 in lb 9 N m Plug in pressure transducer See page 28 Install displacement pump See page 22 Install front cover 11 Replace shroud 32 Replace heat sink 22 Drive Housing Connecting Rod Crankshaft ALR SS q VZ 16 Note Filter not shown S N Torque to 80 in lb 9 N m zZ Fig 23 A 308801 27 Pressure Transducer NOTE See Fig 23 and 24 for this procedure NOTE The pressure trans
7. 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 308801 3 4 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 e lf 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 Use only with a grounded outlet that matches the grounded plug of this equipment MOVING PARTS HAZARD Moving parts can pinch or amputate your fingers Keep clear of all moving parts when starting or operating the pump Before servicing the equipme
8. sprayer and turn ON Meter should read 105 125 VAC Turn off and unplug sprayer 11 Check motor thermal cutout switch Connect ohm meter between motor s red leads Meter should read 1 ohm maximum 12 Check the transducer 67 by replacing it with a new one 13 Check pressure adjustment potentiometer 77 by replacing it with a new one with small cleaning brush Align brush leads with slot in brush holder to as sure free vertical brush movement d Replace brushes e Replace brushes if less than 0 5 in 12 5 mm long f Correctly route the wires See page 21 Remove motor and have motor shop resurface commutator if possible See page 23 6 Replace motor See page 23 Replace loose terminals crimp to leads Be sure male terminal blades are straight and firmly connected to mating part Replace board See page 24 Replace power supply cord See page 25 Replace ON OFF switch See page 25 11 Allow motor to cool Correct cause of overheating If switch remains open after motor cools replace motor 12 Replace pressure transducer See page 28 13 Replace potentiometer 308801 15 Intermediate Problem Solving TYPE OF WHAT TO CHECK WHAT TO DO PROBLEM If check is OK go to next check When check is not OK refer to this column Follow Pressure Relief Procedure Warning on page 8 then replace tip See your separate gun or tip manual 1 1 Low Output Check for
9. 0 6 gpm 2 3 Ipm Tip Size 1 ee eee one gun to 0 026 new tip with latex at 2000 psi 138 bar 13 8 MPa Power Cord 14 AWG 3 wire 15 ft 4 5 m Inlet Paint Strainer 16 mesh 975 micron Stainless Steel Screen reusable Outlet Filter 60 mesh 238 micron Pump Inlet Size 0 0 0 eee 3 4 npt f Fluid Outlet Size 2 eee eee 1 4 npsm Wetted Parts Zinc plated carbon steel Aluminum Stainless steel Polyethylene Delrin Leather Tungsten carbide Chrome plating Polyurethane Delrin is a registered trademark of the DuPont Company Dimensions Models 232132 and 232133 Weight dry w o packaging 61 Ib 27 7 kg Length noses gstetcaesaneuge nee ss 25 5 in 648 mm Width 2 2 24 Soca daeneeetetendaetad 15 in 881 mm MGN aa sete ee yan eee ger yecsse 20 in 508 mm Accessories DANGER LABELS The English language DANGER label shown on page 4 is also on your sprayer If you have painters who do not read English order one of the following labels to apply to your sprayer The drawing below shows the best place ment of these labels for good visibility Order the labels directly from Graco free of charge 1 800 328 0211 Apply other language here_ 187784 i 185956 185961 186041 186045 187791 French Spanish German Greek Korean English Models 232130 and 232131 Weight dry w o packaging 73 Ib 33 1 kg
10. EONO ooo224 oeeqaeeeneneeesesases 21 in 533 mm Width 24 b2ee4netee lt 5ecacenee ese 20 5 in 521 mm Height Handle Down 28 5 in 711 mm 308801 31 Complete Sprayer Parts Model 232132 and 232133 Series A Pressure Control Box Bottom View o T 7 30 29 78 8 P 7869B 32 308801 Ref sab OONOAaBRWN N Part No 240057 100069 101682 105510 239979 180131 107434 189270 108865 193718 236366 240519 218364 176818 176817 103345 111706 239769 112620 189105 112158 192844 240168 112379 112159 112381 114417 114273 193056 108295 239995 114053 240318 187784 114406 192617 111612 114052 112612 112607 109570 100069 112759 192808 235004 104938 192644 187624 Complete Sprayer Parts Model 232132 and 232133 Series A Description KIT housing drive U 695 BALL thrust SCREW sch 1 4 20 x 625 LOCKWASHER 1 4 hi collar CRANKSHAFT U 695 BEARING thrust front BEARING thrust rear BRACKET sh
11. 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 sub stitution 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
12. drive housing 3 Remove motor brush inspection covers A See 7 80 107 Fig 12 4 Remove screws 25 26 Lower control board Se 108 22a Disconnect two leads C from motor to black gt board See Fig 13 green 7869B Fig 13 2 When turning the fan on a DC motor normally you sense an even pulsing resistance If there is irregular turning resistance or no turning resis tance check and repair the following as needed broken brush springs brush leads motor leads loose brush terminal screws or motor lead termi nals worn brushes See page 21 Fig 12 02991 3 If there is still uneven or no turning resistance replace motor See page 23 20 308801 Motor Brushes NOTE Replace brushes when worn to about 12 5 mm 0 5 in Always check both brushes Brush Repair Kit 236967 is available for motor brush repair NOTE Replacement brushes may last only half as long as the original ones To maximize brush life break in new brushes by operating the sprayer with no load as instructed in this procedure NOTE To minimize down time and for best sprayer performance check motor brushes and clean trans ducer see page 28 whenever pump is repacked A WARNING INJECTION HAZARD To reduce the risk of serious injur
13. for shorts by using an arma ture tester growler or perform motor test See page 20 Replace motor See page 23 l Drain Valve Leaks Check drain valve for correct torque and or worn parts Check for debris trapped on seat Tighten to 185 in lb 21 N m Clean valve and replace with new gasket 55 and sealant 110 110 See page 30 l No Output Motor Runs And Pump Strokes Check paint supply Refill and reprime pump 2 Check for clogged intake strainer 2 Remove and clean then reinstall 3 Check for loose suction tube or fittings See 3 Tighten use thread sealant on page 29 npt threads of suction tube 43 Check for damaged o ring 45 4 Check to see if intake valve ball and piston ball are 4 Remove intake valve and clean Check seating properly See page 22 ball and seat for nicks replace as need ed See page 22 Strain paint before us ing to remove particles that could clog pump 5 Check for leaking around throat packing nut 5 Replace packings See page 22 Also which may indicate worn or damaged packings check piston valve seat for hardened See page 22 paint or nicks and replace if necessary Tighten packing nut wet cup 6 Release gun trigger Observe resting position of 6 If pump consistently comes to rest pump rod 222 with rod 222 fully extended the piston packings and or piston valve may be worn Service the pump See page 22 No Output Motor 1 C
14. spraying position 10 If tip is still clogged engage safety latch shut off and unplug sprayer and open pressure drain valve to relieve pressure Clean spray tip as shown in manual 308644 supplied Startup Use this procedure each time you start the sprayer to 4 Turn pressure knob E to minimum setting help ensure the sprayer is ready to operate and that you start it safely 5 Disengage gun safety latch See Fig 4 NOTE If this is a first time startup flush the sprayer See page 12 A CAUTION 1 Open pressure drain valve A See Fig 8 To reduce the risk of damage to the displacement pump packings never run the pump without fluid in it 2 Don t install spray tip until pump is primed for more than 30 seconds 3 Put suction hose or tube C into paint If you 6 To prime pump turn sprayer ON OFF switch F are pumping from a 1 gallon 5 liter pail push ON Slowly increase pressure until sprayer starts drain hose D down below top of pail to avoid When fluid comes from pressure drain valve close splashing paint when drain valve is opened valve A N Shown in closed or spray position E A Open or drain position PNT Pe Model 232133 Shown 7728A Fig 8 308801 9 Startup NOTE Spray patterns will change as tips wear A WARNING Change spray tip if adjusting pressure will not improve spray pattern FIRE AND EXPLOSION HAZARD To reduce static sparking and splashin
15. the Pressure Relief Procedure on page 8 1 Relieve pressure 2 Check packing nut daily Keep packing nut full of TSL at all times to help prevent fluid buildup on piston rod and premature wear of packings 3 If pump begins to leak loosen packing nut and remove throat nut spacer 228 Tighten packing nut just snug Over tightening causes binding and excessive packing wear Use a round punch or brass rod and light hammer to adjust nut Refer to Fig 10 When leakage occurs again repack pump 4 Clean gun s fluid filter often and whenever gun is stored Relieve pressure first Refer to manual 307614 5 Lubricate bearing housing after every 100 hours of operation Remove front cover Apply several drops of SAE 10 non detergent oil in bearing housing cavity B See Fig 10 44 CAUTION To prevent pump corrosion and to reduce the chance of fluid freezing in the pump in cold weather never leave water or any type of paint in the sprayer when it is not in use Freezing can seriously damage the sprayer or result in a loss of pressure or stalling A Flush sprayer at end of each work day and fill it with mineral spirits to help prevent pump corrosion and freezing See page 12 For very short shutoff periods leave suction hose in paint relieve pressure and clean spray tip A WARNING INJECTION HAZARD See the warning section INJECTION HAZARD on page 3 for information on the hazard of using damaged hoses
16. to 53 185 in lb 21 N m 54 N A N Apply thread sealant A A Apply grease to face of base 52 3 N Handle shown in closed position Fig 27 7839A 30 308801 1 Unscrew spring retainer from valve body Remove spring washers and stem ball Clean any debris from ball or seat area If replacing gasket 55 or seat 56 pry out gas ket NOTE Whenever gasket 55 is removed replace it with a new one Place seat 56 in drain valve assembly 51 so lapped side is toward ball Apply a small amount of grease to new gasket 55 and install it in drain valve assembly NOTE The gasket will protrude from the end of the valve until the valve is tightened into pump which correctly seats the gasket Replacement 1 Apply a small amount of thread sealant 110110 onto drain valve assembly 51 threads Tighten the valve into the pump manifold 229 to 185 in lb 21 N m Lightly grease face of base 52 and install base Turn stem so pin hole is vertical Securely install handle 54 and drive pin 53 Technical Data Power Requirements 120 VAC 60 Hz 1 phase 15A minimum Generator 0 000 cee eae 3000W minimum Working Pressure Range 0 3000 psi O 210 bar 21 MPa MOTO siia aiia aoe hone doh ope ae wt wan R E pe Hae ey aa 0 9 HP with latex at 2000 psi 138 bar 13 8 MPa Cycles Gallon liter 00 4 566 150 Maximum Delivery Rating
17. to maintain fluid outlet pressure at displacement pump outlet Works with pressure adjusting knob sS Spray Gun Safety Latch Inhibits accidental triggering of spray gun 308801 5 2 Fill packing nut D Fill packing nut full with Graco Throat Seal Liquid TSL 64 supplied A WARNING If you supply your own hoses and spray gun be sure the hoses are electrically conductive that the A WARNING FIRE AND EXPLOSION HAZARD Proper electrical grounding is essential gun has a tip guard and that each part is rated for at least 3000 psi 210 bar 21 MPa Working Pres sure This is to reduce the risk of serious injury caused by static sparking fluid injection or over pressurization and rupture of the hose or gun CAUTION To avoid damaging the pressure control which may 3 Plug in sprayer Be sure ON OFF switch E is result in poor equipment performance and compo OFF Plug cord into grounded outlet at least 20 ft nent damage follow these precautions 6 m away from spray area to reduce the risk of fire or explosion which can result in serious injury and property damage Read FIRE OR EX PLOSION HAZARD on page 4 and Grounding page 7 e Do not allow material to freeze in sprayer 4 Flush pump to remove oil installed to protect pump parts after factory testing See page 12 e Use nylon spray hose at least 50 ft 15 m long 5 Prepare paint according to manufacturer s recom e Do not use wire braid hos
18. transducer Replace pressure transducer repeatedly to blink three times repeatedly is faulty or missing Four times Sprayer shuts down and LED continues Run away pressure Replace motor control board repeatedly to blink four times repeatedly Pressure greater than See preceding Motor control 4500 psi board removal procedure Five times Sprayer shuts down and LED continues Locked rotor Motor Clear obstruction and replace repeatedly to blink five times repeatedly can not turn because broken parts preventing motor of some mechanical from turning condition 24 308801 Power Supp y Cord A WARNING INJECTION HAZARD To reduce the risk of serious injury when instructed to relieve pressure follow the Pressure Relief Procedure on page 8 1 Relieve pressure 2 Remove screws 25 26 and lower heat sink 22 See Fig 21 Disconnect power supply cord leads 30 including green wire to grounding screw 78 See Fig 13 Loosen strain relief bushing 29 Remove power supply cord 30 Install new cord 30 in reverse order of disassem bly Install heat sink 22 Be sure no leads are pinched between heat sink and junction box 20 On Off Switch A WARNING INJECTION HAZARD To reduce the risk of serious injury when instructed to relieve pressure follow the Pressure Relief Procedure on page 8 1 Relieve pressure 2 Remove screws 25 26 and lower heat sink 22 See Fig 23 3 Remove r
19. 220955 223541 193072 114422 240498 Description FILTER fluid see manual 308249 CLIP spring HOSE drain assy ASSEMBLY drain valve includes 55 and 56 VALVE base PIN grooved HANDLE drain valve GASKET seat valve SEAT valve lapped LABEL DANGER English LABEL WARNING elec shock LIQUID throat seal GROMMET cable RING external retaining TRANSDUCER pressure control SPACER transducer PACKING o ring PTFE FRAME cart U 695 PIN spring straight BUTTON spring HANDLE cart BUSHING sleeve molded SCREWS 1 4 20 x 625 NUT shaft sealing POTENTIOMETER pressure adj Qty BH PO VY SH MH l Ha VS VS SBS aMi POD SH aM M IM St SCREW sltd hex hd 10 24 x 375 1 SWITCH toggle RING locking BOOT toggle KIT motor electric DC SCREW WIRE electrical 5 F 18 AWG LABEL warning STRAP hose HOSE whip 3 16 x 3 SPRAY GUN contractor see manual 307614 HOSE 1 4 x 50 LABEL pressure SCREW pnhd WIRE ground Not supplied with sprayer Model 232132 AExtra Warning Labels available free i i 3 4 i 2 i i 3 i Replace Ref No 45 with 114048 and o ring 169110 in Ret No 51 assembly 235014 with 112319 if using severe solvents such as lacquer thinner and acetone 308801 33 Complete Sprayer Parts Model 232130 and 232131 Series A 73 70 GEER Lok fr is AS SNS XS SS
20. 4 Refer to page 21 continued a Loose terminal screws a Tighten b Broken or misaligned brush springs b Replace broken spring and or align spring with brush c Brushes binding in holders c Clean brush holders Remove carbon d Broken leads e Worn brushes f Brush leads snagged on spring clip NOTE The brushes do not wear at same rate on both sides of motor Check both brushes Check motor armature commutator for burn spots gouges and extreme roughness Remove motor cover and brush inspection plates to check See page 21 Check motor armature for shorts using armature tester growler or perform motor test See page 20 Check leads from pressure transducer and motor to motor control board 22a to be sure they are securely fastened and properly mated Check motor control board 22a by performing motor control board diagnostics on page 24 If diagnostics indicate substitute with a good board CAUTION Do not perform this check until motor armature is determined to be good A bad motor armature can burn out a good board Check power supply cord 30 Disconnect black and white power cord terminals connect volt meter to these leads Plug in sprayer Meter should read 105 125 VAC Unplug sprayer 10 Check ON OFF switch 80 Disconnect black wire 96 between motor control board 22a and switch and connect volt meter between exposed terminal switch and power cord s white wire Plug in
21. INSTRUCTIONS PARTS LIST C 3083801 9 This manual contains important GRACO Rev E e warnings and information eee READ AND KEEP FOR REFERENCE quality counts INSTRUCTIONS ELECTRIC 120 VAC ULTRA MAX 695 3000 psi 210 bar 21 MPa Maximum Working Pressure Models 232133 and 232131 Series A Complete sprayer with hoses gun RAC IV DripLess Tip Guard and SwitchTip Model 232132 and 232130 Series A Basic sprayer only X N PEER lg Fosse N SSA AN SA Sas NOS SS WAN SAN a SSS Ree eas ARS SSN SO SS SSS SS SNS TEs SSS lt lt lt x aS lt S LZZ ZS LZ ALE ZS BEES LEE ZA oe GLE LALA PA LLLE Model 232131 Related Manuals 7728A 7727A Displacement Pump 308815 Fluid Filter 02056040Feeceeen ees ae ees 308249 Spray GU s sapik arate mon ee Nk atte 307614 Sera e EE cases 308644 GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1997 GRACO INC Graco Inc is registered to l S EN ISO 9001 Table of Contents Warnings ee ancace deen ch be ceetank Ws ass ach mane de aceee a 2 Power Supply Cord 0 ccc eee eee eee 25 Component Function and Identification 5 OMOR SWNGCH 64 4 6 254c coded toda nee seacaae eee 25 2 0 6 a ee ar ee ne ee re eee re eee ee 6 Drive Housing Connecting Rod Crank
22. 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 PURPOSE 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 mak ing any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or 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 FOR GRACO CANADA CUSTOMERS The parties acknowledge
23. SS SS a SSNS SAS TSS SSS SS G SSS SSS SN SSSR ae SS aS LEE ioe CO A RES h OOOO AEG Pressure Control Box f A Bottom View le va 30 29 78 ip 34 308801 Ref sab OON DWAR ONN Part No 240057 100069 101682 105510 239979 180131 107434 189270 108865 236366 240519 218364 176818 176817 103345 111706 239769 109032 189105 112158 192844 240168 112379 112159 112381 114417 114273 193056 108295 239995 114053 240318 187784 114406 192617 114052 104811 106062 101242 100069 108691 192809 187190 112777 193718 190321 240038 Complete Sprayer Parts Model 232130 and 232131 Series A Description KIT housing drive U 695 BALL thrust SCREW sch 1 4 20 x 625 LOCKWASHER 1 4 hi collar CRANKSHAFT U 695 BEARING thrust front BEARING thrust rear BRACKET shield SCREW panh KIT cover front U 695 CONNECTING rod assy GEAR assy 2nd stage
24. a wire to disconnect it A WARNING A FIRE HAZARD During operation the motor and drive housing become very hot and could burn your skin if touched Flammable materi 2 When reconnecting wires center flat blade of als spilled on the hot bare motor could cause a fire male connector in blade of female connector or explosion 1 When disconnecting wires use needle nose pliers to separate mating connectors 308801 19 Motor Test A WARNING Armature Short Circuit Test 1 Remove fan cover B See Fig 12 INJECTION HAZARD To reduce the risk of serious injury when instructed to relieve pressure follow the Pressure Relief Procedure on page 8 2 Spin motor fan by hand If there are no shorts the motor will coast two or three revolutions before coming to a complete stop If the motor does not spin freely the armature is shorted and the motor must be replaced See page 23 For checking armature motor winding and brush electrical continuity Setup Armature Brushes and Motor Wiring Open Circuit Test Continuity 1 Unplug sprayer 1 Connect red and black motor leads C together 2 Remove drive housing See page 26 This is to with a test lead Turn motor fan by hand at about ensure that any resistance you notice in armature two revolutions per second See Fig 13 test is due to motor and not to worn gears in
25. arate gun or tip instruction manual for tip cleaning Clean or replace filter element See manual 308249 Mechanical 1 Check for frozen or hardened paint in pump 18 Thaw After thawing plug in sprayer and Using a screwdriver carefully try to rotate fan at turn it on Slowly increase pressure set back of motor by hand See page 23 ting to see if motor starts If it doesn t start see CAUTION above 2 Check pump connecting rod pin 14 It must be Push pin into place and secure with completely pushed into connecting rod 12 and spring retainer retaining spring 15 must be firmly in connecting rod groove See Fig 18 page 22 3 Check for motor damage Remove drive housing Replace motor 85 if fan won t turn See assembly 2 See page 26 Try to rotate motor page 23 fan by hand Electrical 1 Check electrical supply with volt meter Meter 1 Reset building circuit breaker replace should read 105 125 VAC building fuse Try another outlet 2 Check extension cord for visible damage Use a 2 Replace extension cord voltmeter or test lamp at extension cord outlet to check 3 Check sprayer power supply cord 30 for visible 3 Replace power supply cord See page damage such as broken insulation or wires 25 14 308801 Basic Problem Solving TYPE OF WHAT TO CHECK WHAT TO DO PROBLEM If check is OK go to next check When check is not OK refer to this column Electrical 4 Check motor brushes for the following
26. d commutator surface 10 Install brush inspection covers and gaskets 11 Break in brushes Operate sprayer for at least one hour with no load Install pump connecting rod pin AN Motor lead do not disconnect A N Minimum 12 5 mm 5 in Fig 15 Fig 16 03881 308801 21 Displacement Pump NOTE Packing Repair Kit 235703 is available Refer ence numbers of parts included in the kit are marked with an asterisk i e 223 Removing pump See Fig 17 A WARNING INJECTION HAZARD To reduce the risk of serious injury when instructed to relieve pressure follow Pressure Relief Procedure on page 8 AX Torque to 50 ft lb 68 N m 2N Apply pipe sealant 110110 Fig 17 7736A 1 Relieve pressure 2 Flush pump if possible Relieve pressure Stop pump with piston rod 222 in its lowest position if possible To lower piston rod manually rotate motor fan blades 3 Remove filter 48 4 Models 232132 and 232133 While pulling upward on suction hose 47 unscrew hose from inlet tube 43 Unscrew drain hose 50 from displacement pump nipple 36 5 Models 232130 and 232131 Remove suction tube 43 Unscrew drain tube 84 from displace ment pump nipple 36 22 308801 6 Use a screwdriver to push retaining spring 15 up and push out pin 14 7 Loosen screws 17 Remove pump 18 Repairing pump See manual 308815 for displacement pump repair instructions and parts
27. ducer 67 cannot be re paired or adjusted If it malfunctions replace it Removal A WARNING INJECTION HAZARD To reduce the risk of serious injury when instructed to relieve pressure follow the Pressure Relief Procedure on page 8 1 Relieve pressure 2 Remove displacement pump 18 See page 22 3 Remove front cover 11 Remove screws 25 26 Lower motor control card 4 Disconnect harness connector from motor control board 22a Remove grommet 65 5 Remove retaining ring 66 Pull pressure trans ducer down and out past drive housing 2 6 Guide harness A through motor and drive hous ing and remove pressure transducer 7 Inspect spacer 68 and seal 69 for damage Replace seal 69 only if it is cut nicked or if leakage occurred See page 28 Installation 1 Using a small piece of solid copper or mild steel wire approximately 12 in form a small hook and place it in the passage of bottom of the motor Guide it up and out the hole in the drive housing 2 Fig 24 Pass a spacer 68 over harness connector A and down into position at bottom of transducer 67 Guide harness up through leg and notch of drive housing 2 Secure guide wire over connector While pulling guide wire out through bottom of motor guide harness through drive housing and motor castings Place grommet 65 over harness and push into position in drive housing hole Feed excess harness cable thro
28. e mendations Remove any paint skin Stir paint to mix pigments Strain paint through a fine nylon e Do not install shutoff device between sprayer and mesh bag available at most paint dealers to gun See Fig 2 remove particles that could clog gun filter or spray tip This is an important step toward trouble free 1 Connect hose B and gun C and screw it onto paint spraying outlet nipple A Don t use thread sealant and don t install spray tip yet continued on next page AN Do not install any shutoff device here IX Fill full with TSL Shown in closed or spray position Model 232133 Shown 7728A Fig 2 6 308801 Setup Grounding A WARNING Improper installation or alteration of the grounding plug will result in a risk of electric shock fire or explosion that could cause serious injury or death 1 This equipment requires a 120 Vac 60 Hz 15A circuit with a grounding receptacle See Fig 3 P 6 Grounded Outlets Q Grounding n LPN 2 Do not alter the ground prong or use an adapter Fig 3 3 A 12 AWG 3 wire grounded 150 ft extension cord may be used with this equipment NOTE Long extension cords affect sprayer perfor mance How to use the gun safety latch When engaged the gun safety latch prevents the gun from accidental triggering See Fig 4 A WARNING If the gun still sorays when the gun safety latch is engaged adjust the g
29. ent through drain hose to thoroughly clean it Close drain valve 9 Remove suction hose from pail Disengage gun safety latch Trigger gun and run pump a few seconds to push air into hose Do not run pump dry for more than 30 seconds to avoid damaging Fig 11 7731A pump packings Relieve pressure Te 308801 13 Troubleshooting A WARNING A CAUTION i INJECTION HAZARD Thaw sprayer if water or water based paint has To reduce the risk of serious injury when frozen in it due to exposure to low temperatures by instructed to relieve pressure follow the placing it in a warm area Do not try to start sprayer Pressure Relief Procedure on page 8 until it has thawed completely or damage to motor and or control board may occur If paint hardened dried in sprayer the pump packings and or pres sure transducer must be replaced See page 22 pump or 28 pressure transducer Check everything in the troubleshooting tables before disassembling the sprayer Basic Problem Solving TYPE OF WHAT TO CHECK WHAT TO DO PROBLEM If check is OK go to next check When check is not OK refer to this column Fluid Pressure 1 Check pressure transducer knob setting The 1 Slowly increase pressure setting to see if pump won t develop much pressure if it is at mini motor starts mum setting fully counterclockwise 2 Check for a clogged spray tip or fluid filter if used If tip is still clogged relieve pressure See page 8 refer to sep
30. essure Relief Procedure on page 8 hose in pail 3 Remove filter screen and then reinstall bowl hand tight without screen Clean screen separately See manual 308249 5 Open pressure drain valve See Fig 11 1 Relieve pressure 6 To save paint still in pump and hose follow Step 7 except put drain hose in paint pail When solvent appears close drain valve Put drain hose 2 Remove spray tip and clean it separately If you in flushing pail Trigger gun into paint pail When are changing from water based to oil based paints solvent appears release trigger Continue with or solvents be sure that tip is cleaned thoroughly Step 7 12 308801 Flushing 10 Reinstall clean filter screen A WARNING FIRE AND EXPLOSION HAZARD 11 Remove and clean inlet strainer Wipe paint off To reduce static sparking and splashing suction hose and drain hose always remove the spray tip from the gun and hold a metal part of the gun firmly to the side of a grounded metal pail when flushing 12 Leave drain valve open until you use sprayer again 7 Lower pressure setting Turn on sprayer Maintain ing metal to metal contact trigger gun into flushing Open or _ pail Slowly increase sprayer pressure just until drani positon pump starts Keep gun triggered until solvent flows freely from gun Circulate solvent to thoroughly clean sprayer Release gun trigger Engage gun safety latch 8 Open drain valve and circulate solv
31. est your repair before regular operation to be 3 16 Allen wrench gear housing legs handle sure problem is corrected 5 64 Allen wrench pressure adjustment knob Phillips screwdriver junction box front cover motor 6 If sprayer does not operate properly verify that shield everything was done correctly Also refer to Trou 3 8 socket wrench motor mount bleshooting Guide page 14 to help identify other 5 8 socket wrench drain valve on off switch boot possible problems and solutions piston 5 8 open end wrench outlet fittings 13 16 socket wrench drain valve A WARNING 1 1 4 socket wrench pump inlet valve MOVING PARTS HAZARD BA To reduce the risk of serious injury in es 1 2 open end wrench pump rod 11 16 open end wrench piston jam nut cluding electric shock DO NOT touch 15 16 open end wrench flats of inlet tube 1 3 4 open end wrench pump jam nut any moving parts or electrical parts with 5 64 drive pin drain valve pin your fingers or a tool while inspecting the sprayer 3 needle nose pliers wiring on off switch Hammer amp punch packing nut Shut off the sprayer and unplug it as soon as you Torque wrenches various fasteners complete the inspection Pipe wrench suction tube 4 CAUTION Reinstall all covers gaskets screws and washers before operating the sprayer To reduce the risk of a pressure transducer malfunc tion properly mate connectors and never pull on
32. g when priming be sure the spray tip is not installed on the gun and hold a metal part of the gun firmly to the side of a grounded metal pail 7 To prime hose lower pressure to reduce splash ing Holding gun against pail trigger gun and slowly increase pressure until pump starts Keep gun triggered until all air is forced out of system and fluid flows freely from gun Release trigger and engage gun safety latch 8 Check all fluid connections for leaks Relieve pressure before tightening any connections 9 Install spray tip Engage gun safety latch first For a vertical See manual 308644 for how to install tip AN spray pattern 10 Adjust spray pattern e aa spray pattern a Increase pressure just until spray from gun is completely atomized To avoid excessive Fig 9 overspray and fogging and to extend tip and sprayer life always use lowest pressure needed to get desired results b If more coverage is needed use a larger tip rather than increasing pressure c Test spray pattern To adjust direction of spray pattern engage gun safety latch and loosen retaining nut B Position tip guard horizontally for a horizontal pattern or vertically for a verti cal pattern Hold tip guard in place while tight ening retaining nut See Fig 9 10 308801 Shutdown and Care A WARNING INJECTION HAZARD To reduce the risk of serious injury when instructed to relieve pressure follow
33. heck displacement pump connecting rod pin 14 11 Replace pin if missing Be sure retainer Runs But Pump See Fig 18 page 22 spring 15 is fully in groove all around Does Not Stroke connecting rod 2 Check connecting rod assembly 12 for damage 2 Replace connecting rod assembly See See page 26 page 26 3 Be sure crank in drive housing rotates plug in 3 Check drive housing assembly for dam sprayer and turn on briefly to check Turn off and age and replace if necessary See unplug sprayer See page 26 page 26 Spray Pattern 1 Spray tip worn beyond sprayer pressure capability 1 Replace spray tip Variations NOTE A smaller size tip will provide longer life 2 Check motor control board 22a by performing 2 Replace board See page 24 motor control board diagnostics on page 24 If diagnostics indicate substitute with a good board CAUTION Do not perform this check until motor armature is determined to be good A bad motor armature can burn out a good board 308801 17 Intermediate Problem Solving TYPE OF WHAT TO CHECK WHAT TO DO PROBLEM If check is OK go to next check When check is not OK refer to this column Spray Pattern 3 Check pressure adjustment potentiometer 77 by Variations replacing it with a new one continued 4 Check Low Output section page 16 Motor Is Hot and 1 Determine if sprayer was operated at high pressure 1 Decrease pressure setting or increase tip Runs Intermittently
34. ield SCREW panh NIPPLE 1 4 npt x 14 npsm KIT cover front U 695 CONNECTING rod assy GEAR assy 2nd stage PIN straight SPRING retaining SCREW sch 1 4 20 x 1 25 SCREW mach sch 7 16 x 1 75 KIT pump displacement see manual 308815 SCREW 6 32 x 0 187 HOUSING junction box GASKET motor HEAT SINK does not include 22a KIT board control motor see manual 308816 SCREW filh 10 24 x 0 75 GASKET heatsink SCREW panh 10 24 x 3 5 SCREW panh 8 32 x 0 5 KNOB potentiometer LABEL pressure adjust BUSHING strain relief CORD power set SCREW trusshead 8 32 KIT shield motor U 695 includes 9 31 amp 37 33 amp 57 LABEL DANGER French SCREW filh 8 32 x 1 0 LABEL cover front ADAPTER tube NUT self retaining CAP hub WHEEL semi pneumatic WASHER plain BALL thrust PLUG tube TUBE suction STRAINER 1 2 nosm PACKING o ring NIPPLE long 1 4 npt x 1 4 npt HOSE suction swivel Qty et WO e OF S OF DO mh i i a A at NV e VD PY N A ot PD PO PO POP AN Ref No 48 99 100 101 102 103A 107 108 Part No 240038 114026 187652 235014 224807 111600 187625 111699 187615 187791 187975 206994 114296 112396 240514 189269 104319 239999 109567 178565 189934 280290 110997 112382 236352 110037 111930 105658 105659 240035 114420 240495 192838 114271 214701
35. nt follow the Pressure Relief Procedure on page 8 to prevent the equipment from starting unexpectedly NOTE This is an example of the DANGER label on your sprayer This label is available in other languages free of re See page 31 to order a FIRE AND SKIN INJECTION EXPLOSION HAZARD HAZARD Spray painting flushing or cleaning equipment with flammable liquids in Liquids can be injected into the body by high pressure airless spray or confined areas can result in fire or explosion leaks especially hose leaks Use outdoors or in extremely well ventilated areas Ground equipment Keep body clear of the nozzle Never stop leaks with any part of the hoses containers and objects being sprayed body Drain all pressure before removing parts Avoid accidental trigger ing of gun by always setting safety latch when not spraying Avoid all ignition sources such as static electricity from plastic drop cloths open flames such as pilot lights hot objects such as cigarettes Never spray without a tip guard arcs from connecting or disconnecting power cords or turning light In case of accidental skin injection seek immediate switches on and off Surgical Treatment Pantie te ONGNE tois Waming can comin dator senigus Miur Failure to follow this warning can result in amputation or serious injury READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE 4 308801 Component Function and Identification
36. p spraying check or service any of the system equipment install or clean the spray tip 1 Engage gun safety latch 2 Turn ON OFF switch to OFF 3 Unplug power cord 4 Disengage gun safety latch Hold a metal part of gun against a grounded metal pail and trigger gun into pail to relieve pressure 5 Engage gun safety latch 6 Open any fluid drain valves in system Leave drain valve open until you are ready to dispense again How to use the RAC IV tip guard A WARNING INJECTION HAZARD To reduce the risk of serious injury when instructed to relieve pressure follow the preceding Pressure Relief Procedure 8 308801 The tip guard alerts you to the risk of injection and helps prevent placing any part of the body close to the spray tip The tip guard also adjusts the vertical or horizontal spray pattern See page 10 The tip guard holds a reversing spray tip The tip is in the spraying position when the tip handle points forward See Fig 7 Clean front of tip frequently during day s operation First follow preceding Pressure Relief Procedure Tip handle shown in spraying position Turn handle 180 trigger gun to clear clog 03008 Fig 7 How to remove a tip clog 7 Release gun trigger Engage safety latch Rotate RAC IV tip handle 180 See Fig 7 8 Disengage safety latch Trigger gun into a pail or onto ground to remove clog 9 Engage safety latch Rotate tip handle to
37. r Control Board Motor control board removal A WARNING 5 Remove four screws and motor control board 22a INJECTION HAZARD 6 Install new motor control board 22a with four To reduce the risk of serious injury when screws Reconnect all wires and secure heat sink instructed to relieve pressure follow the 22 to junction box 20 Pressure Relief Procedure on page 8 1 Relieve pressure A CAUTION To reduce the risk of a malfunction 2 Remove screws 25 26 and lower heat sink 22 and motor control board 22a See Fig 21 e Be sure the flat blade of the insulated male connector is centered in the wrap around blade of 3 Disconnect wires C D 96 E and 108 from the female connector when the connections are motor control board 22a See Fig 13 made 4 Disconnect potentiometer 77 and transducer 67 e Route all wires carefully to avoid interference with from motor control board 22a the motor control board or junction box Motor control board diagnostics 1 Relieve pressure 3 Turn ON OFF switch ON 2 Remove screws 25 26 and lower heat sink 22 4 Observe LED operation and reference following and motor control board 22a See Fig 21 table LED SPRAYER OPERATION INDICATES WHAT TO DO BLINKS Twice Sprayer shuts down and LED continues Line voltage is too Lower line voltage to 120 VAC repeatedly to blink twice repeatedly high Three times Sprayer shuts down and LED continues Pressure
38. roblems Electrical on page 14 Building circuit 1 breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on Check ON OFF switch 80 Be sure sprayer is unplugged Disconnect wires from switch Check switch with ohmmeter The reading should be infinity with ON OFF switch OFF and zero with switch ON Replace ON OFF switch See page 25 CAUTION A short in motor circuit can damage switch and or motor control board 22a 2 Check for damaged or pinched wires in junction 2 Replace damaged parts box 20 Unit will not run on 1 Check the generator s peak voltage This sprayer 1 Use AC power or a different generator generator but does will not run if the peak voltage is above 190V or run on AC power below 100V 18 308801 General Repair Information 3 Route wires carefully and avoid pinching any wires between covers A WARNING INJECTION HAZARD To reduce the risk of serious injury when instructed to relieve pressure follow the Pressure Relief Procedure on page 8 44 CAUTION Improper wire routing can result in poor sprayer performance or damage to the pressure transducer 4 Keep all screws nuts washers gaskets and electrical fittings removed during repair proce Tool List These service tools are required 12 adjustable wrench pump dures 1 4 Allen wrench filter plug 3 8 Allen wrench pump manifold 5 T
39. rom 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 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 medical 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 8 if the spray tip clogs and before cleaning checking or servicing the equipment Tighten all fluid connections before operating the equipment 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 Fluid hoses must have spring guards on both ends to help protect them from rupture caused by kinks or bends near the couplings TOXIC FLUID HAZARD Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin
40. se the equipment to rupture or malfunction and result in serious injury INSTRUCTIONS 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 distributor Do not alter or modify this equipment Use only genuine Graco parts 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 31 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 use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use could result ina chemical reaction with the possibility of explosion 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 Do not lift pressurized equipment Comply with all applicable local state and national fire electrical and safety regulations 2 308801 4 WARNING INJECTION HAZARD Spray f
41. shaft 26 a LOT o ate we ete te er eee Se ee Ged le Sores ne Bs we 9 Pressure TranSducer 0 cece eee eae 28 Shutdown and Care 0 cee ees 11 Pressure Transducer Seal 000005 28 PUSAN ree pe a ew Som hss Rw ase Seca cee Boer E west hoe ee 12 DUCION HOSE 34060030 csedacdedenencatecane cans 29 Troubleshooting ax 5 4au G eare cra Ong eae eee a eae os One 14 ROMA VOING a ii2 ate et eo gees Be eee 30 General Repair Information 004 19 Complete Sprayer Parts 0000000 32 Motor TeSt nos na yt ces he ateacaretanss ous os ones 20 Technical Data soc 0cnv es eadeunae cee oees oe ae be 31 Motor Brushes 000 eee ence eee eee 21 Dimensions sc od o2 tea doa oe oe dae dead Ge oa w 31 Displacement PUM 2 c2 lt e secseedtawsndawes 22 Accessories tnccosawlereioantey ees oh eorbea ais 31 MOLOI s2332t440cddestussneqia sae vend one d sana on 23 Graco Warranty y soxe dd aa aot eee enn ane Tae s 36 Motor Control Board 022 2222s0cectaeceoeeweas 25 Phone Number 2c lt tec needa di hsws dene eeseeenee 36 Sy Warning Symbol A WARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions bols Caution Symbol CAUTION This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions 4 WARNING EQUIPMENT MISUSE HAZARD e Equipment misuse can cau
42. t valve SEAT valve lapped LABEL DANGER English LABEL WARNING elec shock LIQUID throat seal GROMMET cable RING external retaining TRANSDUCER pressure control SPACER transducer PACKING o ring PTFE FRAME cart U 695 RING retaining handle BUTTON spring HANDLE cart SLEEVE cart SCREWS 1 4 20 x 625 NUT shaft sealing POTENTIOMETER pressure adj SCREW sltd hex hd 10 24 x 375 WASHER flat SWITCH toggle RING locking BOOT toggle TUBE drain KIT motor electric DC SCREW WIRE electrical 5 F 18 AWG LABEL WARNING finger pinch STRAP hose HOSE whip 3 16 x 3 SPRAY GUN contractor Manual 307614 HOSE 1 4 x 50 LABEL pressure LABEL WARNING French SCREW pnhd WIRE ground eb st Dat s PD S amp HRP PN SH HK HAH HAH HAH HAH SH AHN HSH AS SS SS aS ee ee eee Not supplied with sprayer Model 232130 AExtra Warning Labels available free Replace o ring 168110 in Ref No 51 assembly 235014 with 112319 if using severe solvents such as lacquer thinner and acetone 308801 35 Graco Standard Warranty Graco warrants all equipment referenced in this document 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 With the exception of any special extended or limited warranty published by Graco Graco will for
43. that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnais sent avoir convenu que la redaction du presente document sera en Anglais ainsi que tous documents avis et procedures judiciaires executes donn s ou intentes a la suite de ou en rapport directement ou indirectement avec les procedures concern es ADDITIONAL WARRANTY COVERAGE Graco does provide extended warranty and wear warranty for products described in the Graco Contractor Equipment Warranty Program Phone Number TO PLACE AN ORDER contact your Graco distributor or call this number to identify the distributor closest to you 1 800 690 2894 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 Minneapolis Detroit Foreign Offices Belgium Korea Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 http www graco com PRINTED IN U S A 308801 December 1997 Revised August 1999 36 308801
44. ubber boot 82 See page 32 Disconnect black wires from ON OFF switch 80 and remove switch See Fig 13 Install switch so internal tab of anti rotation ring 54 engages with vertical groove in threads of switch and external tab engages with slot of junction box See page 32 Powder inside of rubber boot 82 with talcum then shake excess out of boot Install nut and rubber boot and tighten Reconnect ON OFF switch black wires Install control card Be sure no leads are pinched between motor control board or other components 308801 25 Drive Housing Connecting Rod Crankshaft A WARNING INJECTION HAZARD To reduce the risk of serious injury when instructed to relieve pressure follow the Pressure Relief Procedure on page 8 NOTE Inspect parts as they are removed Replace parts that are worn or damaged 1 Relieve pressure 2 Remove displacement pump See page 22 3 Remove shroud 32 4 Lower heat sink 22 and remove pressure trans ducer 67 See page 28 4 N 16 oy Soy Fig 22 7840A 5 Remove three drive housing screws and lock washers 16 4 Also see Fig 23 6 Remove two motor screws and lockwashers 3 4 See Fig 23 44 CAUTION Do not allow the gear 13 to fall it may stay at tached to the drive housing or to the motor Do not lose the thrust balls 2a or 41 or let them fall between the gears which will damage the drive housing if not removed
45. ugh grommet and fully seat transducer body into hole in drive housing leg Secure it with retaining ring 66 Attach connector to motor control board 22a Replace cover 11 and heat sink 22 Ensure no wires are pinched between components N 65 A ai D 68 69 f Ol g 02996A Pressure Transducer Seal NOTE PTFE seal is unaffected by most solvents and materials Replace seal only when leakage occurs Removal A WARNING INJECTION HAZARD To reduce the risk of serious injury when instructed to relieve pressure follow the Pressure Relief Procedure on page 8 28 308801 Relieve pressure Remove displacement pump 18 See page 22 Remove seal 69 from recess in manifold 229 Clean manifold recess with solvent and cloth or cotton swabs Inspect for nicks or scratches Pressure Transducer Seal Installation 4 Lightly grease or oil transducer 67 and install pump 18 See page 22 1 Lightly coat cleaned packing recess in manifold with a light grease or oil 2 Heat seal 69 in hot water for several minutes CAUTION Excess pressure from the probes or fingernails will damage the packing and cause subsequent leakage 3 Use a blunt wooden or plastic probe and install seal 69 into recess in manifold 229
46. un See manual 307614 supplied How to use the pressure drain valve Use the pressure drain valve to relieve fluid pressure from the pump and to help prime the pump If the valve senses an over pressure condition it opens automati cally to relieve fluid pressure If this happens stop spraying immediately shut off and unplug the sprayer Determine the cause of the problem and correct it before operating the sprayer again Refer also to the Troubleshooting Guide page 14 See Fig 5 How to use the pressure control The pressure control controls the motor operation so the sprayer maintains constant fluid pressure at the pump outlet Turn the pressure control knob fully counterclockwise to obtain the minimum setting Turn the knob clockwise to increase pressure See Fig 6 A N Engaged X Disengaged Fig 4 Closed or spray position Open or drain position Fig 5 7731A or decrease pressure 7732A Fig 6 308801 7 Setup Pressure Relief Procedure A WARNING INJECTION HAZARD la 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 sto
47. wires to motor control board 22a Refer 1 Torque to 80 in lb 9 N m to Fig 13 Install motor control board Try to stop pump with piston rod 222 in lowest position To lower piston rod manually remove 13 Connect piston rod 222 to drive housing see shroud 32 and rotate motor fan blades Use a page 22 Installing Pump Step 2 and WARNING screwdriver to push retaining spring 15 up and following it push out pin 14 See Fig 19 14 Install shroud 82 and drive housing cover 11 Relieve pressure Remove motor shield 32 15 Lift connecting rod Remove screws 25 26 and S lower heat sink 22 and motor control board 22a SS 14 Disconnect motor wires and pressure transducer Me wire A from motor control board Remove heat Se ak sink 22 and motor control board 22a screws Fig 19 A a 23 and junction box 20 Refer to Fig 21 and 13 Remove drive housing cover 11 Turn displacement pump rod 222 so pin hole aligns with bottom drive housing screw 16 See Fig 20 Remove three drive housing screws and lockwashers 16 4 See Fig 20 and 21 Remove two motor screws and lockwashers 3 4 Tap lower rear of drive housing 2 with a plastic mallet to loosen motor Pull drive housing straight off motor while guiding pressure transducer wire A from motor Do not allow gear 13 to fall Read CAUTION on page 26 Fig 21 308801 23 Moto
48. with small tips which causes excessive heat build size up 2 Be sure ambient temperature where sprayer is lo 2 Move sprayer to shaded cooler area if cated is no more than 90 F 32 C and sprayer is possible not located in direct sun 3 Check motor 3 Replace motor See page 23 1 Building Circuit 1 Breaker Opens As Soon As Sprayer Switch Is Turned On Check all electrical wiring for damaged insulation and all terminals for loose fit or damage Also check wires between pressure transducer and motor See page 23 Repair or replace any damaged wiring or terminals Securely reconnect all wires Check for missing motor brush inspection plate gasket see page 21 bent terminal forks or other metal to metal contact points which could cause a short 2 Correct faulty conditions Check motor armature for shorts Use an armature tester growler or perform motor test See page 18 Inspect windings for burns 3 Replace motor See page 23 Check motor control board 22a by performing motor control board diagnostics on page 24 If diagnostics indicate substitute with a good board 4 Replace board See page 24 CAUTION Do not perform this check until motor armature is determined to be good A bad motor armature can burn out a good board Circuit breaker opens after sprayer operates for 5 to 10 minutes Check Basic P
49. worn spray tip 2 Be sure pump does not continue to stroke when gun trigger is released Plug in and turn on sprayer Prime with paint Trigger gun mo mentarily then release and engage safety latch Relieve pressure turn off and unplug sprayer Service pump See page 22 3 Release gun trigger Observe resting position of pump rod 222 lf pump consistently comes to rest with rod 222 fully extended the piston packings and or piston valve may be worn Service the pump See page 22 Reset building circuit breaker replace building fuse Repair electrical outlet or try another outlet 4 Check electrical supply with volt meter Meter should read 105 125 VAC 5 Check extension cord size and length Replace with a correct grounded exten sion cord Note that long lengths and or smaller gauges reduce performance 6 Check motor brushes See Electrical What To 6 See page 21 Check item 4 on page 15 16 308801 Intermediate Problem Solving TYPE OF WHAT TO CHECK WHAT TO DO PROBLEM If check is OK go to next check When check is not OK refer to this column Low Output continued 7 Check motor control board 22a by substituting with a good board 7 Replace board See page 24 CAUTION Do not perform this check until motor armature is determined to be good A bad motor armature can burn out a good board 8 Check motor armature
50. y when instructed to relieve pressure follow the Pressure Relief Procedure on page 8 1 Unplug sprayer 2 Remove both inspection covers A and their gaskets See Fig 14 Fig 14 ii 3 Push in spring clip F and release hooks G from brush holder B Pull out spring clip See Fig 15 4 Inspect commutator for excessive pitting burning or gouging A black color on commutator is normal Have commutator resurfaced by a qualified motor repair shop if brushes seem to wear too fast or arc excessively See Step 9 d also 5 Repeat for other side 6 Place a new brush C in holder B so ramp H faces spring See Fig 15 7 Holding spring clip F at a slight angle slide spring clip into brush holder and hook it over end of holder See Fig 16 Pull on spring clip to be sure it stays in place Connect brush lead to blade con nector E 8 Repeat for other side 9 Test brushes a Remove pump connecting rod pin 14 A WARNING ELECTRIC SHOCK HAZARD Do not touch the brushes leads springs Wy or brush holders while the sprayer is plugged in to reduce the risk of electric shock and serious bodily injury b With sprayer OFF turn pressure control knob fully counterclockwise to minimum pressure Plug in sprayer c Turn sprayer ON Slowly increase pressure until motor is at full speed d Inspect brush and commutator contact area for excessive arcing Arcs should not trail or circle aroun
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