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Hitachi 231580 User's Manual

1. 1 Remove both inspection covers A and their gaskets See Fig 14 7 gt L E AN 04653 Fig 14 2 Push in the spring clip F and release its hook G from the brush holder B Pull out the spring clip See Fig 15 3 Slide off the brush lead terminal E off the blade connector Remove the old brush C See Fig 15 Motor Brushes 1 Motor lead do not disconnect A N Minimum 0 5 12 5 mm AN Included in Brush Repair Kit236967 Fig 15 03881 4 Inspect the commutator for excessive pitting burning or gouging A black color on the commuta tor is normal Have the commutator resurfaced by a qualified motor repair shop if the brushes seem to wear too fast or arc excessively See Step 9 d also 5 Repeat for the other side NOTE The motor brushes on the other side are upside down 6 Place a new brush C in the holder B so the ramp H faces the spring See Fig 16 03881 Fig 16 7 Holding the spring clip F at a slight angle slide the spring clip into the brush holder and hook it over the end of the holder See Fig 16 Pull on the spring clip to be sure it stays in place Connect the brush lead to the blade connector E 8 Repeat for the other side 308715 19 Motor Brushes 9 Test the brushes A WARNING a Remove the pump connecting rod pin 17 See Fig 18 page 21 MOVING PARTS HAZARD Do not touch the brushes leads s
2. 38 42 42a 42b 42c Part No 111700 236965 237458 100069 111616 107503 107504 187784 187791 187975 114811 100721 224965 100069 111726 224803 180131 107434 187789 177762 218359 218364 176818 176817 235699 111706 111715 192166 112759 239054 239276 104938 162453 235009 111602 108850 187624 187652 111705 111612 187628 187895 192167 235004 235014 111699 187615 224968 Sprayer Parts List Model 231580 Series A Model 232654 Series A Description GRIP handle MOTOR KIT Includes items 4a to 4g Model 231580 Model 232654 BALL sst 1 4 in dia TERMINAL flat 1 4 in f 18 awg TERMINAL 3 16 in m 16 awg TERMINAL 3 16 in f LABEL DANGER French LABEL DANGER English LABEL WARNING electric shock SCREW socket head 1 4 20 x 1 1 8 in PLUG DRIVE HOUSING KIT Includes item 11a 11b BALL stainless steel 1 4 in dia PLUG CRANKSHAFT Includes items 12a 12b BEARING thrust BEARING COVER front LABEL WARNING CONNECTING ROD GEAR REDUCER PIN headless 3 8 in dia x 1 in SPRING retaining PUMP KIT See manual 308190 for parts CAPSCREW 7 16 14 x 1 3 4 in SCREW 5 16 18 x 1 1 4 in HANDLE sprayer CAP tubing LEG with gusset Model 231580 Model 232654 O RING NIPPLE hex 1 4 nosm x 1 4 npt 1 3 16 in PRESSURE TRANSDUCER CLIP 5 8 in SCREW filh 8 32 x 1 1 4 in SUCTION HOSE amp TUBE
3. Decrease pressure setting or increase tip Intermittently sure with small tips which causes excessive size heat build up 2 Be sure ambient temperature where sprayer is 2 Move sprayer to shaded cooler area if located is no more than 90 F 32 C and possible sprayer is not located in direct sun 3 Check motor 3 Replace motor See page 22 1 Check all electrical wiring for damaged insula 1 Repair or replace any damaged wiring or tion and all terminals for loose fit or damage terminals Securely reconnect all wires Also check wires between pressure control and motor See page 22 Building Circuit Breaker Opens As Soon As Sprayer Switch Is Turned On 2 Check for missing motor brush inspection plate gasket see page 17 bent terminal forks or other metal to metal contact points which could cause a short 2 Correct faulty conditions 3 Check motor armature for shorts Use an arma ture tester growler or perform motor test See page 17 Inspect windings for burns 3 Replace motor See page 22 4 Check motor start board 47 by substituting with a good board 4 Replace board See page 23 CAUTION Do not perform this check until motor armature is determined to be good A bad motor armature can burn out a good board 1 Check Basic Problems Electrical on page 13 Circuit breaker opens after sprayer operate
4. See Fig 13 Armature Short Circuit Test Remove the fan cover B See Fig 12 Spin the 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 re placed See page 22 Armature Brushes and Motor Wiring Open Circuit Test Continuity Connect the two black motor leads together with a test lead Turn the motor fan by hand at about two revolu tions per second When turning the fan on a DC motor normally you sense an even pulsing resistance If there is irregular turning resistance or no turning resistance check and repair the following as needed broken brush springs brush leads motor leads loose brush terminal screws or motor lead terminals worn brushes See page 19 If there is still uneven or no turning resistance replace the motor See page 22 Motor Test Q UJ w 06975 Fig 12 Model 231580 shown MOTOR Fig 13 ili 308715 17 General Repair Information A WARNING A WARNING m hice eae HOT SURFACE HAZARD O reduce the risk of Serious Injury During operation the motor and drive whenever you are instructed to relieve iy housing become very hot and could burn SSA pressure follow the Pressure Relief Procedure on page 9 your skin if touched Flammable materi als spilled on the hot bare motor cou
5. DRAIN TUBE SCREW filh 8 32 x 2 1 2 in TUBE adapter LEG sprayer Model 231580 Model 232654 TUBE inlet STRAINER DRAIN VALVE KIT Includes items 42a to 42e GASKET valve seat SEAT drain valve STEM drain valve Qty 1 orn p gt SS SS WD NM KR AN ee i i b i i M d h ee ee ee Ref No PartNo Description Qty 42dm 168110 O RING stem 1 42e 110110 SEALANT pipe not shown 1 43 224807 BASE valve 1 44 111600 PIN grooved 3 32 x 1 in 1 45 187625 HANDLE drain valve 1 46 110997 SCREW washer hex hd 5 16 in 2 47 MOTOR START BOARD 235008 Model 231580 1 235707 Model 232654 1 484A 186620 LABEL ground terminal 1 49 110037 SCREW mach pnhd 10 24 x 5 8 in 1 50 235010 POWER CORD SET 1 51 111617 STRAIN RELIEF BUSHING 1 3 8 18 npt 52 105679 SWITCH ON OFF 1 53 235035 GROUND HARNESS 1 54 105658 LOCKING RING 1 55 105659 BOOT switch 1 56 111703 SCREW filh 10 24 x 3 in 4 58 100035 SCREW pan hd 8 32 x 5 16 in 2 59 187795 JUNCTION BOX 1 63 111704 SCREW filh 10 24 x 1 5 8 in 2 64 239515 PRESSURE CONTROL KIT 1 66 189932 BASE motor 1 67 238350 CONTRACTOR FTx GUN 1 See manual 308645 for parts 68 206994 TSL 8 oz not shown 1 74 238361 HOSE grounded nylon 1 4 in ID 1 cpld 1 4 npsm f 50 ft 15 m spring guards both ends 85 239447 FILTER fluid 1 89 187963 GASKET 1 A Extra warning labels available free of charge t Motor Brush and Sprin
6. 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 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 gas engines 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 LIMITATION OF LIABILITY 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 ot
7. and the external tab engages with the blind hole C of the junction box Powder the inside of the rubber boot 55 with talcum then shake the excess out of the boot Install the nut and rubber boot and tighten Reconnect the ON OFF switch black wires Install the junction box Be sure no leads are pinched against the motor or by the motor start board Also be sure the gasket 89 is installed MOTOR GREEN 53 YELLOW 50 51 39 04720 308715 23 Drive Housing Connecting Rod Crankshaft A WARNING INJECTION HAZARD To reduce the risk of serious injury whenever you are instructed to relieve pressure follow the Pressure Relief Procedure on page 9 NOTE Inspect parts as they are removed Replace parts that are worn or damaged 1 Remove the displacement pump See page 21 2 Remove the pressure control 64 See page 26 3 Turn the displacement pump rod 107 so the pin hole aligns with the bottom drive housing screw 5 See Fig 23 Remove the three drive housing screws 5 Also see Fig 24 on page 25 01074 Fig 23 4 Remove the two motor screws 5 See Fig 24 on page 25 5 Tap the lower rear of the drive housing 11 witha plastic mallet to loosen the motor Pull the drive housing straight off the motor 24 308715 4 CAUTION Do not allow the gear 16 to fall it may stay at tached to the drive housing or to the motor Do not lose the thrust balls 11a or 4a or let
8. box and the motor or pressure control 4 Keep all screws nuts washers gaskets and MOVING PARTS HAZARD n l electrical fittings removed during repair proce aR To reduce the risk of serious injury in dures These parts are not normally provided with i cluding electric shock DO NOT touch replacement assemblies any moving parts or electrical parts with your fingers or a tool while inspecting the repair 5 Test your repair before regular operation to be l sure the problem is corrected Shut off the sprayer and unplug it as soon as you complete the inspection 6 If the sprayer does not operate properly verify l that everything was done correctly Also refer to Reinstall all covers gaskets screws and washers the Troubleshooting Guide pages 13 17 to help before operating the sprayer identify other possible problems and solutions 18 308715 NOTE Replace brushes when worn to about 0 5 in 12 5 mm Always check both brushes Brush Repair Kit 236967 which includes spring clip 112766 is available for motors manufactured by Pacific Scientific 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 for at least one hour with no load remove the pump connecting rod pin A WARNING INJECTION HAZARD To reduce the risk of serious injury whenever you are instructed to relieve pressure follow the Pressure Relief Procedure on page 9
9. controls 120 Vac power to sprayer E Fluid Outlet Hose and spray gun is connected here G 50ft 15m Main Hose 1 4 in ID grounded nylon hose with spring guards on both ends H RAC IV Tip Guard Reverse A Clean RAC tip guard reduces the risk of fluid injection injury J FTx Gun High pressure spray gun with gun safety latch K RAC IV Switch Tip RAC switch tip atomizes fluid and removes clogs from spray tip without removing tip from spray gun L Pressure Drain Valve Relieves fluid pressure when open M Pressure Control Controls motor to maintain fluid pressure Works with pressure adjusting knob N Spray Gun Safety Latch Inhibits accidental triggering of spray gun 308715 5 Setup 2 Fill the wet cup 102 Pry off the wet cup seal Fill the cup 1 3 full with Graco Throat Seal Liquid TSL supplied Install the wet cup seal A WARNING If you supply your own hoses and spray gun be sure the hoses are electrically conductive that the gun has a tip guard and that each part is rated for 3 Plug in the sprayer Be sure the ON OFF switch at least 3000 psi 210 bar 21 MPa Working Pres 52 is OFF Plug the cord into a grounded outlet at sure This is to reduce the risk of serious injury least 20 feet away from the spray area caused by static sparking fluid injection or over pressurization and rupture of the hose or gun A WARNING FIRE AND EXPLOSION HAZARD Proper electrical grou
10. motor start Fig 19 board Refer to Fig 22 on page 23 01068 Remove the front cover 13 Turn the displacement pump rod 107 so the pin hole aligns with the bottom drive housing screw 5 See Fig 20 Remove the three drive housing screws 5 Also see Fig 21 Remove the two motor screws 5 01074 Tap the lower rear of the drive housing 11 with a Fig 20 plastic mallet to loosen the motor Pull the drive housing straight off the motor while guiding the harness A from the motor Do not allow the gear 16 to fall Read the CAUTION on page 24 Remove the two screws 46 and lift the motor off the base 66 im A A 31 05119 22 308715 Motor Start Board A WARNING INJECTION HAZARD To reduce the risk of serious injury whenever you are instructed to relieve pressure follow the Pressure Relief Ha Procedure on page 9 NOTE See Fig 22 for this procedure 1 Relieve pressure 2 Remove the junction box screws 56 and lower the junction box 59 3 Disconnect the motor wires B and the 3 wire connector A from the motor start board 47 Observe where connections are made 4 Remove the screws 58 and motor start board 47 Transfer the white thermal paste from the old board to the new board 5 Install the new motor start board Reconnect all 4 CAUTION wires Install the junction box Be sure no leads are pinche
11. necessary Tighten packing nut wet cup 6 Release gun trigger Observe resting position of 6 If pump consistently comes to rest with pump rod 107 rod 107 fully extended the piston pack ings and or piston valve may be worn Service the pump See page 21 No output motor runs but 1 Check displacement pump connecting rod pin 1 Replace pin if missing Be sure retainer pump does not stroke 17 See Fig 18 page 21 spring 18 is fully in groove all around connecting rod 7 Check connecting rod assembly 15 for dam 7 Replace connecting rod assembly See age See page 24 page 24 8 Be sure crank in drive housing rotates plug in 8 Check drive housing assembly for sprayer and turn on briefly to check Turn off damage and replace if necessary See and unplug sprayer See page 24 page 24 308715 15 Intermediate Problem Solving TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK go to next check When check is not OK refer to this column Spray Pattern Variations 1 Spray tip worn beyond sprayer pressure capa 1 Replace spray tip bility NOTE A smaller size tip will provide longer life 2 Check transducer 29 for wear or damage 2 Replace transducer See page 27 3 Check pressure control 64 for smooth opera f3 Replace pressure control See page 26 tion 4 Check Low output section page 15 m E Motor Is Hot and Runs 1 Determine if sprayer was operated at high pres f 1
12. screwdriver carefully try to rotate Slowly increase pressure setting to see if fan at back of motor by hand See page 17 motor starts If it doesn t see NOTE be low Check pump connecting rod pin 17 It must be 2 Push pin into place and secure with completely pushed into connecting rod 15 spring retainer and retaining spring 18 must be firmly in con necting rod groove See Fig 18 page 21 3 Check for motor damage Remove drive hous 3 Replace motor 4 if fan won t turn See ing assembly 11 See page 24 Try to rotate page 22 motor 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 2 Replace extension cord a volt meter or test lamp at extension cord out let to check 3 Check sprayer power supply cord 50 for vis 3 Replace power supply cord ible damage such as broken insulation or wires See page 23 4 Check motor brushes for the following 4 Refer to page 19 a Loose terminal screws Tighten b Broken or misaligned brush springs Replace broken spring and or align spring with brush c Brushes binding in holders Clean brush holders Remove carbon with small cleaning brush Align brush leads with slot in brush holder to as sure free vertical brush movement d Broken leads d Replace brushes e Worn brushes e Repla
13. them fall between the gears which will damage the drive hous ing if not removed The balls which are heavily covered with grease usually stay in the gear recesses but could be dislodged If the balls are not in place the bearings will wear prematurely 6 Remove and inspect the crankshaft 12 and the connecting rod 15 7 Install the connecting rod 8 Lubricate the inside of the drive housing bearing with SAE non detergent oil Pack the roller bearing and gears with the grease supplied NOTE The gears and bearings between the drive housing 11 and motor front end bell C should con tain a total of 3 fl oz 29 cc of grease 9 Route the wire harness A through the motor passages to the junction box 59 10 Place the large washer 12a and then the small washer 12b on the crankshaft 12 11 Lift the crank to the top of the stroke and insert crankshaft 12 Align the gears and push the drive housing 11 straight onto the motor and the locat ing pins Install the screws 5 Torque to 80 in Ib 9 N m 12 Install the displacement pump See page 21 13 Install the pressure control 64 See page 26 Install the front cover 13 Drive Housing Connecting Rod Crankshaft AN Torque to 80 in Ib 9 N m A N Quantity of three AN Quantity of one AAN Apply a total of 3 fl oz 29 cc of grease to gears EN Note Filte
14. trigger safety when you stop spraying e Follow the Pressure Relief Procedure on page 9 if the spray tip clogs and before cleaning checking or servicing the equipment Tighten all fluid connections before operating the equipment e 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 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 MOVING PARTS HAZARD Moving parts can pinch or amputate your fingers Keep clear of all moving parts when starting or operating the pump e Before servicing the equipment follow the Pressure Relief Procedure on page 9 to prevent the equipment from starting unexpectedly 308715 3 WARNING RA EQUIPMENT MISUSE AM Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury INSTRUCTIONS This equipment is for professio
15. using water base paint flush out the mineral spirits with soapy water and then clean water When using oil base paint flush out the mineral spirits with the paint 9 Remove and clean the inlet strainer Wipe paint off the suction hose and drain tube How to Flush 10 Refer to When To Flush Step 1 again Relieve 1 Follow the Pressure Relief Procedure on pressure page 9 11 Leave the drain valve open until you use the 2 Remove the spray tip and clean it separately sprayer again 12 308715 Troubleshooting A WARNING INJECTION HAZARD Ea To reduce the risk of serious injury whenever you are instructed to relieve pressure follow the Pres sure Relief Procedure on page 9 Basic Problem Solving Check everything in the troubleshooting table before disassembling the sprayer TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK go to next check When check is not OK refer to this column Fluid pressure 1 Check pressure control knob setting The pump 1 Slowly increase pressure setting to see if won t develop much pressure if it is at minimum motor starts setting fully counterclockwise 2 Check for a clogged spray tip or fluid filter if 2 If tip is still clogged relieve pressure re used See page 8 fer to separate gun or tip instruction man ual for tip cleaning Clean the filter if used Mechanical 1 Check for frozen or hardened paint in pump 1 Thaw Plug in sprayer and turn on 20 Using a
16. valve to relieve pressure Clean the spray tip as shown in manual 308644 supplied Startup 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 stop spraying check or service any of the system equipment or install or clean the spray tip Pressure Relief Procedure Engage the gun safety latch Turn the ON OFF switch to OFF Unplug the power supply cord Disengage the gun safety latch Hold a metal part of the gun firmly to a grounded metal pail Trigger the gun to relieve pressure Engage the gun safety latch 6 Open the pressure drain valve Leave the pressure drain valve open until you are ready to spray again If you suspect that the spray tip or hose is completely clogged or that pressure has not been fully relieved after following the steps above VERY SLOWLY loos en the tip guard retaining nut or hose end coupling to relieve pressure gradually then loosen completely Now clear the tip or hose obstruction oe SS on Startup Procedure Use this procedure each time you start the sprayer to help ensure the sprayer is ready to operate and that yo
17. 3 new tip Korean 186049 with latex at 2000 psi 138 bar 13 8 MPa English 185953 Power Cord 14 AWG 1 5mm 3 wire 6 ft 1 8 m Inlet Paint Strainer 12 mesh 1525 micron Stainless Steel Screen reusable G 2 h Pump INe SIZE suvo duns teotnevaue andes ene eas 1 2 npt f raco O ne Fluid Outlet Size nnana cacdceescesacesscded 1 4 npsm Wened PANS 2 cass teheceeu es Stainless steel Carbon steel N U m be r PTFE Aluminum Polyethylene Delrin Leather TO PLACE AN ORDER contact your Graco distrib utor or call this number to identify the distributor closest to you 1 800 690 2894 Toll Free Dimensions Delrin is a registered trademark of the DuPont Company Model 231580 Model 232654 Model 232655 Weight dry w o packaging 35 lb 16 kg 37 Ib 17 kg 47 lb 21 4 kg Height 18 in 457 mm 19 in 483 mm 29 5 in 749 mm Handle down 39 5 in 1003 mm Handle up Length 15 in 381 mm 15 in 381 mm 21 in 533 mm Width 14 in 356mm 14 in 356 mm 20 5 in 521 mm 308715 29 Sprayer Parts Drawing Model 231580 Series A HOSE AND GUN NOT SHOWN Model 232654 Series A IN PROPORTION TO SPRAYER Label See detail on page 31 14 SIDE Te LABEL 30 308715 Ref No 9 4t 4a 4b 4c 4d 4e 4f A 40 A 10 11 ia 11b 12 12a 12b 144A 15 16 17 20 21 23 24 26
18. A WARNING INJECTION HAZARD To reduce the risk of serious injury whenever you are instructed to relieve pressure follow the Pressure Relief Procedure on page 9 NOTE See Fig 26 for this procedure 1 Remove the displacement pump See page 21 2 Use a pull twist motion to remove the transducer 29 from the pump manifold 101 3 Clean paint residue from the hole in the manifold do not scratch the surface of the hole Lightly apply oil to the o ring of the new transducer Install the transducer in the pump manifold while guiding the o ring and backup ring into place 02817A Fig 26 6 Align the holes in the transducer as shown by the arrows in Fig 26 7 Install the displacement pump See page 21 Suction Hose A WARNING 4 CAUTION INJECTION HAZARD Misalignment or cross threading will damage the parts and or create shavings which can cause the o ring 27 to leak To reduce the risk of serious injury whenever you are instructed to relieve pressure follow the Pressure Relief Procedure on page 9 AS Lubricate Note Filter 1 Remove the drain hose 33 from the clip Remove not shown the front cover 13 43 2 Pull upward on the hose 32 while unscrewing it from the inlet tube 38 The hose coupling A threads will engage and the hose will separate from the tube 3 Replace the o ring 27 if it is worn or damaged A S AL 26 4 Lubricate t
19. EXPLOSION HAZARD HAZARD Spray painting flushing or cleaning equipment with flammable liquids in f 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 W eoo In case of accidental skin injection seek immediate Surgical Treatment AUTE O AAE AE L AE E RE A Failure to follow this warning can result in amputation or serious injury READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE 4 308715 Component Function and Identification Model 231580 shown 06973 Fig 1 A Motor DC motor 120 Vac 15A 1 phase B Drive Assembly Transfers power from DC motor to the displacement pump c Pressure Adjusting Knob Controls fluid outlet pressure D ON OFF Swith Power switch that
20. INSTRUCTIONS PARTS LIST 2z20x 308715 This manual contains important Rev E warnings and information READ AND KEEP FOR REFERENCE INSTRUCTIONS DURON Airless Paint Sprayers ELECTRIC 120 VAC 3000 psi 210 bar 21 MPa Maximum Working Pressure Performance 395 Model 231580 Series A Standard mount complete sprayer with hoses gun RAC IV DripLess Tip Guard and SwitchTip TM Performance 495 Model 232654 Series A a Standard mount complete sprayer with hoses gun RAC IV DripLess N Tip Guard and SwitchTip IN Model 232655 Series A Upright cart complete sprayer with hoses gun RAC IV DripLess Tip Guard and SwitchTip S gt ae 06973 Model 231580 DY 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 WarmingS seis iiae gai dak stoat aai dae hen aan daw R Byori 2 Component Identification and Function 5 DOD agers oasis op eh ee ee oa an ene re E 6 Operatii ssa sses ssi sarah k i aoka easi a aos gar as We 28 9 ot 7 AAU aie geo Opa ee eee EAR A 9 Shutdown and Care 2 cee ee ees 11 PISMO ise acc eare ee ee ee ae eee eee ae a oa 12 Troubleshooting 22 lt 6 02 2250 6442 0009 oo4 aeeeues 22 13 MOLOI TCG si rrena a N aA A a 17 General Repair Information 08 18 Molor BIUS sresr seriean Ages ones ea a S 19 Displacement
21. Pump Repair 000005 21 MOIO ay eee a ech a Ses r EEE aie ee ae 22 Motor Start Board nc icv nese ecae ba we gas eee gals 23 Power Supply Cord 0 0 0 cece eee eee 23 ON OFF Switch 626d cae cces ate can te oiea sa aton eat 23 Drive Housing Connecting Rod Crankshaft 24 Pressure Control cic vee cea cae 406 s40 PRO 4 aCe 26 Pressure TranSdUCer 0 000 cee eee ees 27 Drain Valve on cues eiceae bend oe eee meen eee eas 28 Technical Data 0 0 0 ee 29 DIMENSIONS occ o oo w Gwe caw he ote ne eee ewe 29 Phone Number atic ae 2 2 cn s gata easton sock anni ob 29 Sprayer Parts Drawing 00 cece eens 30 Sprayer Parts List 0 0 c cece eee eee 31 Graco Warranty and Disclaimers 34 Symbols Warning Symbol A 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 A 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 a
22. W mach pnhd 10 24 x 5 8 1 50 235010 POWER CORD SET 1 5i 111617 STRAIN RELIEF BUSHING 1 3 8 18 npt 52 105679 SWITCH ON OFF 1 53 235035 GROUND HARNESS 1 54 105658 LOCKING RING 1 55 105659 BOOT switch 1 56 111703 SCREW filh 10 24 x 3 4 58 100035 SCREW pan hd 8 32 x 5 16 2 59 187795 JUNCTION BOX 1 62 110243 RING retaining 2 63 111704 SCREW filh 10 24 x 1 5 8 2 64 239515 PRESSURE CONTROL KIT 1 65 104811 HUBCAP 4 66 238669 FRAME cart 1 67 238350 CONTRACTOR FTx GUN 1 See manual 308645 for parts 68 206994 TSL 8 oz not shown 1 72 111590 BUTTON spring 2 73 183350 WASHER 1 74 238361 HOSE grounded nylon 1 4 ID 1 cpld 1 4 npsm f 50 ft 15 m spring guards both ends 85 239425 FILTER fluid 1 See Manual 308249 for parts 88 181102 CLIP spring 1 89 187963 GASKET 1 A Extra warning labels available free of charge t Motor Brush and Spring Replacement Kit 236967 is available Purchase separately m Replace Ref No 42d with 112319 if using severe solvents such as lacquer thinner and acetone MOTOR gt GREEN AR 49 GREEN y p O amp 03 YELLOW 4c IA oN 50 Ss BLACK WHITE 52 gt gt BLACK gt 54 59 i i uf D WA Veg e SSS 0 p 3 e SY lt 2 P 3 ies Ns ry Ns Ns ey ES res Ns SS 3 pa S 04720 308715 33 Graco Warranty Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free f
23. at 1 4 f 18 awg TERMINAL 3 16 m 16 awg LABEL DANGER French LABEL DANGER English LABEL WARNING electric shock SCREW socket head 1 4 20 x 1 LOCKWASHER 1 4 PLUG 1 4 18 npi f DRIVE HOUSING KIT Includes item 11a 11b BALL stainless steel 1 4 dia PLUG CRANKSHAFT Includes items 12a 12b BEARING thrust BEARING COVER front LABEL WARNING CONNECTING ROD GEAR REDUCER PIN headless 3 8 dia x 1 SPRING retaining SCREW socket head 1 4 20 x 1 1 4 PUMP KIT See manual 308190 for parts CAPSCREW 7 16 14 x 1 3 4 SCREW 10 32 x 0 25 HANDLE sprayer PLUG tubing WHEEL sprayer NIPPLE hex 1 4 nosm x 1 4 npt 1 3 16 PRESSURE TRANSDUCER CLIP spring SCREW filh 8 32 x 1 1 4 SUCTION TUBE DRAIN TUBE SCREW filh 8 32 x 2 1 2 LABEL identification CONNECTOR tube RING retaining wheel STRAINER DRAIN VALVE KIT Includes items 42a to 42e GASKET valve seat SEAT drain valve STEM drain valve O RING stem SEALANT pipe not shown BASE valve PIN grooved 3 32 x 1 HANDLE drain valve SCREW washer hex hd 5 16 Qty ek U W OND NO as ma OI SS a Set st es MNN amp PY lt a N ea WH Ss Ss Ss i N e SS SS Sst St Ref No PartNo Description Qty 47 235707 MOTOR START BOARD 1 includes items 47a to 47c 484 186620 LABEL ground terminal 1 49 110037 SCRE
24. ce brushes if less than 0 5 in long NOTE The brushes do not wear at same rate on both sides of motor Check both brushes NOTE Thaw sprayer if water or water based paint has frozen in it due to exposure to low temperatures by placing in a warm area Do not try to start sprayer until completely thawed or damage to motor and or start board may occur If paint hardened dried in sprayer the pump packings page 21 and or pressure transducer page 27 must be replaced 308715 13 TYPE OF PROBLEM Electrical continued TYPE OF PROBLEM Low output 14 308715 Basic Problem Solving WHAT TO CHECK WHAT TO DO If check is OK go to next check When check is not OK refer to this column 5 Check motor armature commutator for burn 5 Remove motor and have motor shop spots gouges and extreme roughness Re resurface commutator if possible See move motor cover and brush inspection plates page 22 to check See page 19 6 Check motor armature for shorts using arma 6 Replace motor See page 22 ture tester growler or perform motor test See page 17 7 Check leads from pressure control and motor to 7 Replace loose terminals crimp to leads motor start board 47 to be sure they are se Be sure male terminal blades are straight curely fastened and properly mated and firmly connected to mating part 8 Check motor start board 47 by substituting 8 Replace board See page 23 with a good board See
25. d against the motor or by the motor start board Also be sure the gasket 89 is installed Be sure the flat blade of the insulated male connec tor is centered in the wrap around blade of the female connector when the connections are made Route all wires carefully to avoid interference with the motor start board or junction box These precautions are essential to reduce the risk of a malfunction Power Supply Cord NOTE See Fig 22 for this procedure 1 Relieve pressure 2 Remove the junction box screws 56 and lower the junction box 59 3 Disconnect the power supply cord leads including the green wire to the grounding screw 49 4 Loosen the strain relief bushing 51 Remove the power supply cord 50 Install the new cord 50 in the reverse order of disassembly Install the junction box Be sure no leads are pinched against the motor or by the motor start board Also be sure the gasket 89 is installed On Off Switch NOTE See Fig 22 for this procedure 1 2 Relieve pressure Remove the junction box screws 56 and lower the junction box 59 Remove the nut and rubber boot 55 Disconnect the black wires from the ON OFF switch 52 and remove the switch Place the ring terminal of the ground wire 53 over the barrel of the new switch Install the switch so the internal tab of the anti rotation ring 54 en gages with the vertical groove in the threads of the switch
26. e page 27 of transducer Intermediate Problem Solving WHAT TO CHECK WHAT TO DO If check is OK go to next check When check is not OK refer to this column 1 Check for worn spray tip 1 Follow Pressure Relief Procedure then replace tip See your separate gun or tip manual 2 Be sure pump does not continue to stroke 2 Service pump See page 21 when gun trigger is released Plug in and turn on sprayer Prime with paint Trigger gun mo mentarily then release and lock safety latch Relieve pressure turn off and unplug sprayer Intermediate Problem Solving TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK go to next check When check is not OK refer to this column Low output continued 3 Release gun trigger Observe resting position of 3 If pump consistently comes to rest with pump rod 107 rod 107 fully extended the piston pack ings and or piston valve may be worn Service the pump See page 21 4 Check electrical supply with volt meter Meter should read 105 125VAC 4 Reset building circuit breaker replace building fuse Repair electrical outlet or try another outlet 5 Check extension cord size and length must be at least 12 gauge wire and less than 150 ft 45 m long 5 Replace with a correct grounded exten sion cord 6 Check motor brushes See Electrical What To 6 See page 19 Check item 4 on page 13 7 Check motor start board 47 by s
27. e to water base paint gun and hold a metal part of the gun flush with mineral spirits then warm soapy water firmly to the side of a grounded metal pail when and then a clean water flush flushing 5 Storage after using water base paint flush with water and then mineral spirits Leave the system filled with mineral spirits Relieve pressure Leave the drain valve open Storage after using oil base paint flush with mineral spirits Relieve pressure Leave the drain valve open Lower the pressure setting Turn on the sprayer Maintaining metal to metal contact trigger the gun into the flushing pail Slowly increase the sprayer pressure until the pump starts Keep the gun triggered until the solvent flows freely from the gun Circulate the solvent to thoroughly clean the sprayer Release the gun trigger Engage the gun trigger safety Open the drain valve and circulate the solvent A CAUTION Never allow water to freeze in the pressure control Doing so prevents the sprayer from being started g through the drain tube to thoroughly clean it Close the drain valve Remove the suction hose from the pail Disengage the gun trigger safety Trigger the gun and run the pump a few seconds to push air into the hose Do not run the pump dry for more than 30 seconds to avoid damaging the pump packings Relieve pressure and may cause serious damage Push the water out with mineral spirits 6 Startup after storage Before
28. f possible To lower the piston rod manu ally rotate the motor fan blades 2 Loosen the swivel nut on adapter 38 and remove suction hose 32 While pushing in on the collar of elbow 36 pull out and remove drain tube 33 3 Use a screwdriver to push the retaining spring 18 up and push out the pin 17 4 Loosen the screws 21 Remove the pump 20 Repairing the pump See manual 308190 for pump repair instructions Installing the pump See Fig 18 and 19 1 Mount the pump on the drive housing Tap it into the alignment pins with a soft hammer Tighten the screws 21 to 50 ft lb 68 N m A WARNING MOVING PARTS HAZARD Be sure the retaining spring 18 is firmly in the groove all the way around to pre vent the pin 17 from working loose due to vibration See Fig 18 oa lf the pin works loose it or other parts could break off due to the force of the pump action These parts could be projected into the air and result in serious injury or property damage including the pump connecting rod or drive housing 2 Align the hole in the rod 107 with the connecting rod assembly 15 Use a screwdriver to push the retaining spring 18 up and push in the pin 17 Push the retaining spring 18 into place around the connecting rod 3 Replace the o ring 27 if it is worn or damaged Reconnect the suction and drain hoses 82 33 Install the front cover 13 4 Tighten the packing nut 102
29. g Replacement Kit 236967 is available Purchase separately m Replace Ref No 27 with 114048 and Ref No 42d with 112319 if using severe solvents such as lacquer thinner and acetone MOTOR GREEN 48 wr AR GREEN j Lr CD amp 53 YELLOW c fh PN 0 os we Lage 52S BLACK W iS 7 se L Sa 0 55 D 04720 308715 31 Sprayer Parts Drawing Model 232655 Series A N O i ws Ze EEE Pm SIN SS 4 Ss Z SAN NN SAAS PEON XY Z SSS SSS SSK SN Sas Y N gt DS SSS m 7 O1 D A e AA N A E ROO SSS i rt A LEE ZEZE LES Ss Cee ZO 30 25 pp ee A 39 u 14 Dy AN Label See page 33 for detail 05121B 32 308715 Sprayer Parts List Model 232655 Series A Ref No 9 4t 4a 4b 4c 4dA 4e 4A 5 6 10 11 11a 11b 12 Part No 192027 237 458 100069 111616 107503 187784 187791 187975 100643 105510 100721 224965 100069 111726 224803 180131 107434 187789 177762 218359 218364 176818 176817 103345 235699 111706 109032 224554 105521 106062 162453 235009 186245 108850 192169 186549 111705 194671 108982 101242 183770 235014 111699 187615 224968 168110 110110 224807 111600 187625 110997 Description SLEEVE cart MOTOR KIT Includes items 4a to 4f BALL sst 1 4 dia TERMINAL fl
30. he o ring 27 and the inlet tube 38 threads with light grease 5 Align the suction hose coupling with the threads of the inlet tube 38 Tighten the hose onto the tube at least 4 turns to ensure that the threads have disen gaged and can function as a swivel joint Fig 27 OOOO O OO 308715 27 Drain Valve A WARNING Repair 1 Unscrew the spring retainer from the valve body INJECTION HAZARD Remove the spring washers and stem ball Clean la To reduce the risk of serious injury any debris from the ball or seat area whenever you are instructed to relieve pressure follow the Pressure Relief Procedure on page 9 2 If replacing the gasket 42a or seat 42b pry out the gasket NOTE Whenever the gasket 42a is removed re Apply thread sealant place it with a new one Apply grease to face of base 3 Coat the o ring 42d with grease Press the stem TA nin eap E into the valve body Install the spring washers and Bina spring retainer into the valve body Aedes ee 4 Place the seat 42b in the valve body so the P lapped side is toward the ball Apply a small amount of grease to the new gasket 42a and install it in the valve body NOTE The gasket will protrude from the end of the valve until the valve is tightened into pump which 4 4 7 correctly seats the gasket N45 Replacement Fig 28 _ 1 Apply a small amount of thread sealant 42e onto 1 Turn the handle 45 to the closed position Drive the val
31. henever you are instructed to relieve Z HAZARD on page 3 for information on pressure follow the Pressure Relief the hazard of using damaged hoses Procedure on page 9 Shutdown and Care AN nut clockwise to ighten 1 Check the packing nut wet cup daily 102 Relieve pressure first Keep the wet cup 1 3 full of TSL at all times to help prevent fluid buildup on the piston rod and premature wear of packings J 102 2 Tighten the packing nut wet cup 102 just enough to stop leakage Over tightening causes binding and excessive packing wear Use a round punch or brass rod and a light hammer to adjust the nut See Fig 10 3 Periodically clean paint residue from the pres sure transducer 29 vent hole area See Fig 11 Replace the transducer when leakage Is exces sive See page 27 Fig 10 04650 4 Lubricate the bearing housing after every 100 hours of operation Remove the front cover Fill the bearing housing cavity A with SAE 10 non AN ende detergent oil See Fig 11 A 5 Flush the sprayer at the end of each work day and fill it with mineral spirits to help prevent pump corrosion and freezing See page 12 4 CAUTION gt To prevent pump corrosion and to reduce the chance of fluid freezing in the pump in cold weather never Y leave water or any type of paint in the sprayer when it is not in use Freezing can seriously damage the X DN Ay sprayer or resul
32. herwise ADDITIONAL WARRANTY COVERAGE Graco does provide extended warranty and wear warranty for products described in the Graco Contractor Equipment Warranty Program 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 England Korea France Germany Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 PRINTED IN U S A 308715 January 1997 Revised May 1999 34 308715
33. ir 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 2 308715 A WARNING INJECTION HAZARD Spray from the gun leaks or ruptured components can inject fluid into your body and cause extremely serious injury including the need for amputation Fluid splashed in the eyes or on the skin can also Cause serious injury e 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 e Do not point the gun at anyone or at any part of the body e Do not put your hand or fingers over the spray tip e Do not stop or deflect leaks with your hand body glove or rag e 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 e Check the gun diffuser operation weekly Refer to the gun manual Be sure the gun trigger safety operates before spraying Lock the gun
34. just enough to stop leakage but no tighter Fill the packing nut wet cup 1 3 full with Graco TSL Push the plug 123 into the wet cup 27 2 Torque to AA 50 ft lb 68 N m 38 A N Apply anaerobic E pipe Fig 17 sealant 02832B 15 L AI K i LH 18 Torque to 50 ft lb 68N m 2 gt 102 Fig 18 04655 308715 21 Motor 9 Align the new motor with the base and reinstall the screws 46 A WARNING To reduce the risk of serious injury steps 8 to 11 on page 24 l INJECTION HAZARD 10 Assemble the drive housing to the motor Follow NOTE See Fig 21 except where noted 1 2 AN Torque to 80 in lb 9 N m A N Quantity of three AN Quantity of one Fig 21 whenever you are instructed to relieve pressure follow the Pressure Relief Procedure on page 9 11 Connect the wires in the junction box Refer to Fig 22 on page 23 Install the junction box 12 Connect the piston rod 107 to the drive housing see page 21 Installing the Pump Step 2 and the Relieve pressure WARNING following it Try to stop the pump with the piston rod 107 in its lowest position To lower the piston rod manually rotate the motor fan blades Use a screwdriver to push the retaining spring 18 up and push out the pin 17 See Fig 19 Remove the screws 56 and lower the junction box 59 Disconnect the motor wires and the pressure control wire A from the
35. ld cause a fire or explosion Tool List These are the tools required to service all parts of the A CAUTION ae l To reduce the risk of a pressure control malfunction be sure to properly mate connectors and never pull 3 16 Allen wrench gear housing legs handle on a wire to disconnect it Pulling on a wire could 3 8 Allen wrench pump manifold loosen the connector from the wire 1 Phillips screwdriver junction box pressure control front cover 1 When disconnecting wires in the junction box 3 8 socket wrench motor mount assembly use needle nose pliers to separate 5 8 socket wrench drain valve outlet fittings mating connectors on off switch boot piston 13 16 socket wrench drain valve 2 When reconnecting the wires be sure the flat 1 1 4 socket wrench pump inlet valve blade of the insulated male connector is centered 1 2 open end wrench pump rod in the wrap around blade of the female 11 16 open end wrench piston jam nut connector 15 16 open end wrench flats of inlet tube 1 3 4 open end wrench pump jam nut 5 64 drive pin drain valve pin A CAUTION 3 needle nose pliers wiring on off switch i l Hammer amp punch packing nut Improper wire routing can result in poor sprayer Torque wrenches various fasteners performance or damage to the pressure control 3 Route wires carefully through the drive housing and motor Avoid pinching the wires between the A WARNING junction
36. nal 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 29 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 in a 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 NOTE This is an example of the DANGER label on your sprayer This label is available in other languages free of re See page 29 to order a FIRE AND SKIN INJECTION
37. nding is essential to reduce the risk of fire or explosion which can result in serious injury and property damage Also read FIRE OR EXPLOSION HAZARD on page 2 To avoid damaging the pressure control which may result in poor equipment performance and compo nent damage follow these precautions 1 Always use a nylon spray hose at least 50 ft 15 m long 4 Flush the pump to remove the lightweight oil Never use a wire braid hose as it is too rigid to which was left in to protect pump parts after fac act as a pulsation dampener tory testing See page 12 Never install any shutoff device between the filter and the hose See Fig 2 5 Prepare the paint according to the manufacturer s recommendations Remove any paint skin Strain the paint through a fine nylon mesh bag available 1 Connect the hose 74 and gun 67 and screw it at most paint dealers to remove particles that onto the outlet nipple 28 Don t use thread could clog the spray tip This is an important step sealant and don t install the spray tip yet toward trouble free paint spraying AN 1 4 nosm m fluid outlet Do not install any shutoff device here L gt AN Rotate clockwise to increase pressure 33 N Shown in closed or spray position 3 64 7 AN Fill 1 3 full with TSL D 102 A 2 Dy D Dy Model 231580 shown 06973 Fig 2 6 308715 setup Grounding A WARNING Improper installation or alteration of the gr
38. ounding 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 Grounded Outlets Grounding Prong Fig 3 2 Do not alter the ground prong or use an adapter 3 A12 AWG gauge 50 ft extension cord may be used with this equipment Operation How to use the gun trigger safety When engaged the gun safety latch prevents the gun from accidental triggering See Fig 4 A WARNING INJECTION HAZARD If the gun still sorays when the gun trigger safety is locked repair the gun See manual 308645 supplied AN Gun safety latch shown engaged A N Gun safety latch showndisengaged Fig 4 05964 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 page 13 See Fig 5 AN Open or drain position Closed or spray position How to use the pressure control The pressure control controls the motor operation so the sprayer maintains constant fl
39. page 23 CAUTION Do not perform this check until mo tor armature is determined to be good A bad motor armature can burn out a good board 9 Check power supply cord 50 Disconnect 9 Replace power supply cord See page black and white power cord terminals connect 2d volt meter to these leads Plug in sprayer Meter should read 105 125VAC Unplug sprayer 10 Check ON OFF switch 52 Disconnect the 10 Replace ON OFF switch See page 23 motor start board 47 and switch and connect volt meter between exposed terminal on switch and power cord s white wire Plug in sprayer and turn ON Meter should read 105 125VAC Turn off and unplug sprayer 11 Check motor thermal cutout switch Connect 11 Allow motor to cool Correct cause of ohmmeter between motor s red leads Meter overheating If switch remains open after should read 1 ohm maximum motor cools replace motor Remove pressure control 64 and check mi Replace pressure control See page 26 croswitch operation with ohmmeter 1 With pressure knob at lowest setting and stem pushed into control readings should be white amp black 1 ohm max white amp red open 2 With pressure knob at highest setting read ings should be white amp black open white amp red 1 ohm max Check pressure transducer 29 for hardened Replace transducer See page 27 Thor paint or damaged or worn components See ough system flushing will help extend lif
40. prings or brush holders while the sprayer is plugged in to reduce the risk of electric shock and serious injury b With the sprayer OFF turn the pressure con trol knob fully counterclockwise to minimum pressure Plug in the sprayer c Turn the sprayer ON Slowly increase the pressure until the motor is at full speed 10 Install the brush inspection covers and gaskets d Inspect the brush and commutator contact area 11 Break in the brushes Operate the sprayer for at for excessive arcing Arcs should not trail or least one hour with no load Install the pump circle around the commutator surface connecting rod pin See Fig 18 page 21 20 308715 Displacement Pump Repair A WARNING INJECTION HAZARD To reduce the risk of serious injury whenever you are instructed to relieve pressure follow the Pressure Relief Procedure on page 9 NOTE Packing Repair Kit 235703 is available Refer ence numbers of parts included in the kit are marked with an asterisk i e 121 For the best results use all the new parts in the kit even if the old ones still look good NOTE To minimize down time and for the best sprayer performance check the motor brushes see page 19 and clean the transducer see page 27 whenever you repack the pump Replace these parts as needed Removing the pump See Fig 17 1 Flush the pump if possible Relieve pressure Stop the pump with the piston rod 107 in its lowest position i
41. r not shown 34 AA 02815 Fig 24 308715 25 Pressure Control 7 Loosely install the screws 63 and then torque them to 21 in lb 2 4 N m A WARNING INJECTION HAZARD 8 Install the front cover 13 Connect the harness la To reduce the risk of serious injury A to the motor start board 47 whenever you are instructed to relieve pressure follow the Pressure Relief 9 Install the junction box Be sure no leads are Procedure on page 9 Siia against the motor or by the motor start oard NOTE See Fig 25 for this procedure NOTE The pressure control 64 cannot be repaired or adjusted If it has malfunctioned replace it 1 Remove the front cover 13 Remove the screws 56 Lower the junction box 59 2 Disconnect the harness connector A from the motor start board 47 3 Remove the screws 63 Pull forward on the pressure adjusting knob and tip the pressure control 64 forward and up to detach it from the drive housing 11 4 Guide the harness A through the motor and drive housing and remove the pressure control 5 Guide the harness of the new pressure control through the drive housing and motor passages 3 3 bs 59 Torque to 3 6 Install the new pressure control Tip the pressure 5 56 21 in lb 2 4 N m control down and back into the drive housing 11 Do not pinch or damage the harness A Fig 25 eee 02816A 26 308715 Pressure Transducer
42. rom 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 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 or 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
43. s for 5 to 10 minutes iP 1 Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on Check ON OFF switch 52 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 23 CAUTION A short in motor circuit can damage switch and or motor start board 47 2 Check electrical supply with volt meter Meter 2 If voltage is too high do not operate should read 105 125 VAC sprayer until corrected Unit will not run on gener ator but does run on AC power Check the generator s peak voltage This sprayer will Use AC power or a different generator not run if the peak voltage is above 190V 16 308715 A WARNING INJECTION HAZARD To reduce the risk of serious injury whenever you are instructed to relieve pressure follow the Pressure Relief Procedure on page 9 For checking armature motor winding and brush electrical continuity Setup Remove the drive housing See page 24 This is to ensure that any resistance you notice in the armature test is due to the motor and not to worn gears in the drive housing Remove the motor brush inspection covers A See Fig 12 Remove the junction box screws 56 Lower the junction box Disconnect the two leads C from the motor to the board 47
44. t in a loss of pressure or stalling 6 For very short shutoff periods leave the suction tube in the paint relieve pressure and clean the spray tip 7 Coil the hose and hang it on a hose rack when storing it even for overnight to help protect the Fig 11 hose from kinking abrasion coupling damage etc 308715 11 Flushing When to Flush 3 Pour one half gallon 2 liters of compatible solvent into a grounded metal flushing pail Put the suction 1 Before using a new sprayer flush out the oil hose in the pail which was left in to protect pump parts 4 Open the pressure drain valve See Fig 5 page Before using water base paint flush with min Z eral spirits followed by soapy water and then a clean water flush 5 To save the paint still in the pump and hose Before using oil base paint flush with mineral spirits only follow Step 6 except put the drain tube in the paint pail When solvent appears close the drain valve Put the drain tube in the flushing pail Trigger the gun into the paint pail When solvent appears 2 Changing colors flush with a compatible solvent release the trigger Continue with Step 6 such as mineral spirits or water 3 Changing from water base to oil base paint A WARNING flush with warm soapy water and then mineral FIRE AND EXPLOSION HAZARD SPS To reduce static sparking and splashing always remove the spray tip from the 4 Changing from oil bas
45. til the pump starts Keep the gun triggered until all air is forced out of the system and the fluid flows freely from the gun Release the trigger and engage the gun safety latch Check all fluid connections for leaks Relieve pressure before tightening the connections Engage the gun safety latch Install the spray tip and tip guard Install the spray tip If you are using the RAC IV tip guard refer to manual 308644 for installation instructions Adjust the spray pattern a Increase the pressure until soray from the gun is completely atomized To avoid excessive overspray and fogging and to extend tip and sprayer life always use the lowest pressure needed to get the desired results 10 308715 b If more coverage is needed use a larger tip rather than increasing the pressure c Adjust the direction of the spray pattern See Fig 9 Engage the gun safety latch Loosen the retaining nut A Position the tip guard for a horizontal or vertical pattern Hold the tip guard in place and tighten the retaining nut NOTE Spray patterns will change as tips wear Change the spray tip if adjusting the pressure will not improve the spray pattern For a vertical AN spray pattern A For a horizontal spray pattern Fig 9 Shutdown and Care A WARNING A WARNING INJECTION HAZARD INJECTION HAZARD la To reduce the risk of serious injury See the warning section INJECTION w
46. u start it safely NOTE If this is a first time startup flush the sprayer See page 12 NOTE Refer to Fig 2 and the other figures referenced in the text as you start the sprayer 1 Open the pressure drain valve 42 See Fig 8 2 Don t install the spray tip until the pump is primed 3 Put the suction tube 32 into the paint If you are pumping from a pail push the drain hose 33 down below the top of the pail to avoid splashing paint when the drain is opened AN Open or drain position Fig 8 04648 4 Turn the pressure knob 64 to the minimum setting 5 Disengage the gun trigger safety See Fig 4 page 7 CAUTION Do not run the sprayer dry for more than 30 seconds to avoid damaging the pump packings 6 To prime the pump turn the sprayer switch 52 on Slowly increase the pressure until the sprayer starts When fluid comes from the pressure drain valve close the valve 308715 9 T 11 Startup A WARNING FIRE AND EXPLOSION HAZARD To reduce the risk of static sparking and splashing when priming or flushing the system hold a metal part of the gun firmly to the side of a grounded metal pail before triggering the gun To prime the hose lower the pressure to reduce splashing Hold a metal part of the gun firmly against and aimed into a grounded metal pail See the preceding WARNING Hold the gun trigger open and slowly increase the pressure un
47. ubstituting 7 Replace board See page 23 with a good board CAUTION Do not perform this check until mo tor armature is determined to be good A bad motor armature can burn out a good board 8 Check motor armature for shorts by using an 8 Replace motor See page 22 armature tester growler or perform motor test See page 17 Drain valve leaks 1 Check drain valve for correct torque and or 9 Tighten to 185 in lb 21 N m Clean worn parts Check for debris trapped on seat valve and replace with new gasket 42a and sealant 42d See page 28 Transducer leaks 1 Slight leakage from transducer is normal 1 Periodically remove residue from its cyl inder port See page 27 No output motor runs and f 1 Check paint supply 1 Refill and reprime pump pump strokes 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 npt page 30 threads of adapter 38 4 Check to see if intake valve ball and piston ball 4 Remove intake valve and clean Check are seating properly See page 21 ball and seat for nicks replace as need ed See page 21 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 21 Also which may indicate worn or damaged packings check piston valve seat for hardened See page 21 paint or nicks and replace if
48. uid 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 co oy a 308715 7 Fig 6 Operation How to use the RAC IV tip guard A WARNING INJECTION HAZARD To reduce the risk of serious injury whenever you are instructed to relieve pressure follow the Pressure Relief Procedure on page 9 The tip guard alerts you to the risk 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 Fig 9 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 the front of the tip frequently during the day s operation First follow the Pressure Relief Procedure on page 9 8 308715 Tip handle shown in spraying position Turn handle 180 trigger gun to clear clog 04647 Fig 7 How to remove a tip clog 1 Release the gun trigger Lock the safety latch Rotate the RAC IV tip handle 180 See Fig 7 2 Unlock the safety latch Trigger the gun into a pail or onto the ground to remove the clog 3 Lock the safety latch Rotate the tip handle to the spraying position 4 Ifthe tip is still clogged lock the safety latch shut off and unplug the sprayer and open the pressure drain
49. ve 42 threads Tighten the valve into the out the pin 44 Remove the handle pump manifold to 185 in lb 21 N m 2 Remove the base 43 2 Lightly grease the face of the base 43 and install l the base Turn the stem so the pin hole is vertical 3 Unscrew the drain valve 42 The gasket 42a and seat 42b will stay in the valve 3 Securely install the handle 45 and drive pin 44 28 308715 Technical Data DANGER LABELS The English language DANGER label shown on Power Requirements 0 08 120 VAC 60Hz page 1 is also on your sprayer If you have paint Corea l are Leetsdale ers who do not read English order one of the Working Pressure Range 0 3000 psi 0 210 bar 21 MPa deak labels to apply to your sprayer The Motor rawing below shows the best placement of these Model 231580 0 ccc eee c eee cece eee e ees 1 2 hp labels for good visibility Pitas 232654 202000 eeee duns teeergeen coarse 3 4 hp Order the labels directly from Graco free of ycles Gallon liter 0 0 0 cece ee 620 164 h 4 800 328 0211 Delivery charge 1 800 Apply other Model 231580 0005 0 33 gpm 1 25 Ipm French 185956 anguagehere Models 232654 amp 232655 0 50 gpm 1 9 Ipm Spanish 185961 Tip Size Model 231580 0000 one gun to 0 019 new tip German 186041 with latex at 2000 psi 138 bar 13 8 MPa Greek 186045 Models 232654 amp 232655 one gun to 0 02

Hitachi 231580 User's Manual

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