Graco Inc. 231-553 Paint Sprayer User Manual
Contents
1. 19 Sprayer Parts List 0 00 02 teieni 35 Motor Brush eetos arn EN ENEAN ANAE EAN 20 Technical Data 0 cece eee eee 36 Displacement Pump Repair 0 22 DIMENSIONS o cornered id ei Bek ee KEEA ES 36 MOTOT seco icc AEA eats AA cette he eee ating ae 26 Graco Warranty and Disclaimers 36 Motor Start Board 0 0 cece eee ee 27 Phone Number 00 0 cee e ee eee ees 36 Power Supply Cord 000 cece ee 27 Symbols Warning Symbol Caution Symbol A WARNING A CAUTION This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions 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 fthere is any static sparking or you feel an electric shock while using this equipment stop spraying 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 area2. 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 2 308 646 A WARNING INJECTION HAZARD Spray from the gun leaks or ruptured components can inject fluid into your body and cause ex tremely 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 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 9 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 Flui
3. To reduce the risk of serious injury whenever you are instructed to relieve pressure follow the Pressure Relief Procedure on page 9 1 Remove both inspection covers A and their gas kets See Fig 14 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 20 308 646 1 Motor lead do not disconnect Minimum 0 5 12 5 mm A Included in Brush Repair Kit 236 967 a f P X Tu Fig 15 D 03881 4 Inspect the commutator for excessive pitting burn ing or gouging A black color on the commutator 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 J SAS Se E 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 Motor Brushes 9 Test the brushes a Remove the pum
4. See page 30 7 Install the connecting rod 3 Turn the displacement pump rod 107 so the pin hole aligns with the bottom drive housing screw 19 See Fig 28 Remove the three drive housing screws and lockwashers 19 6 Also see Fig 29 on page 29 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 pas sages 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 19 5 and their lock washers 6 Torque to 80 in lb 9 N m 01074 Fig 28 4 Remove the two motor screws 19 and handle 24 See Fig 29 on page 29 12 Install the displacement pump See page 22 5 Tap the lower rear of the drive housing 11 with a plastic mallet to loosen the motor Pull the drive 13 housing straight off the motor 28 308 646 Install the pressure control 64 See page 30 Install the front cover 13 Drive Housing Connecting Rod Crankshaft 24 AN Torque to 80 in lb 9 N m A
5. 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 be fore operating the sprayer again Refer also to the Fig 5 Troubleshooting page 14 See Fig 4 01022A 308 646 7 Operation How to use the RAC IV tip guard A WARNING N INJECTION HAZARD To reduce the risk of serious injury whenever you are instructed to relieve spraying position pressure follow the Pressure Relief Procedure on page 9 Tip handle shown in AA Turn handle 180 trigger gun to clear clog Fig 6 04647 How to remove a tip clog 1 Release the gun trigger Lock the safety latch Ro The tip guard alerts you to the risk and helps prevent A tate the RAC IV tip handle 180 See Fig 6 placing any part of the body close to the spray tip The tip guard also adjusts the vertical or horizontal spray 2 pattern See Fig 8 The tip guard holds a reversing spray tip The tip is in the spraying position when the tip handle points forward See Fig 6 3 Lock the safety latch Rotate the tip handle to the spraying position Unlock the safety latch Trigger the gun into a pail or onto the ground to remove the clog 4 Ifthe tip is still clogged lock the
6. eee 1 2 npt f Fluid Outlet Size Sisto etorar A tecansestA so 2 1 4 npsm Greek 186 045 Wetted Parts Korean 186 049 Displacement Pump Stainless steel Carbon steel English 185 953 PTFE Aluminum Polyethylene Delrin Leather Delrin is a registered trademark of the DuPont Company Dimensions Graco Phone Weight dry w o packaging 35 Ib 16 kg N um ber Height fsa go Bat aha anes era A 18 in 457 mm a ke gth o annaia h uT E EEE 15 in 381 mm TO PLACE AN ORDER contact your Graco distrib Width esd 2c case is als ba eae teu lana 12 5 in 318 mm utor or call this number to identify the distributor closest to you 1 800 367 4023 Toll Free The Graco Warranty and Disclaimers Graco warrants all equipment manufactured by it 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 As purchaser s sole remedy for breach of this warranty Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment proven defective with the exception of defects in parts on the drive train gear box on EM and GM sprayers or power train on EH and GH sprayers which will be repaired or replaced for twenty four months from the date of sale for Gas Hydraulic GH and Gas Mechanical GM sprayers and for thirty six months from the date of sale for Electric Mechanical EM Electr
7. long 6 Check motor brushes See Electrical What To 6 See page 20 Check item 4 on page 14 7 Check motor start board 47 by substituting 7 Replace board See page 27 with a good board 5 Replace with a correct grounded exten sion cord 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 26 armature tester growler or perform motor test See page 18 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 32 Transducer leaks 1 Slight leakage from transducer is normal Periodically remove residue from its cyl inder port See page 31 No output motor runs and 1 Check paint supply 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 34 threads of adapter 38 4 Remove intake valve and clean Check 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 Replace packings See page 22 Also check piston valve seat for hardened paint or nicks and re
8. 189 932 BASE motor 1 67 238 350 FTx GUN 1 See manual 308 645 for parts 68 206 994 TSL 8 oz not shown 1 74 223 541 HOSE grounded nylon 1 4 ID 1 cpld 1 4 npsm f 50 ft 15 m spring guards both ends 79 103 473 STRAP tie 2 89 187 963 GASKET 1 A Extra warning labels available free of charge t Motor Brush and Spring Replacement Kit P N 236 967 is available Purchase separately MOTOR Wires i BLACK a J 47 GREEN GREEN 53 YELLOW BLACK WHITE 04720 308 646 35 Technical Data DANGER LABELS The English language DANGER label shown on Power Requirements 120 VAC 60HZz page 1 is also on your sprayer If you have paint G ie Wen TRIMUM ers who do not read English order one of the fol Wot Range eee es oe 0 2750 psi ies cen lowing labels to apply to your sprayer The draw MOU ee lett id O 1 2 hp ing below shows the best placement of these la Cycles Gallon liter 0c cece eee 620 164 bels for good visibility nat PaA T A An cscs eva we a6 0 33 gpm 1 25 Ipm Order the labels directly from Graco free of IP SIZO aise en aae i eip ae tag edd one gun to 0 019 new tip with latex at 2000 psi 138 bar charge 1 800 328 0211 Apply other Power Cord No 14 AWG 3 wire 6 1 8 m French 185 956 Inlet Paint Strainer 12 mesh 1525 micron Spanish 185 961 Stainless Steel Screen reusable German 186 041 Pump Inlet Size 1
9. HAZARD Proper electrical grounding 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 Flush the pump to remove the lightweight oil which was left in to protect pump parts after fac tory testing See page 13 Prepare the paint according to the manufactu ers s recommendations Remove any paint skin Strain the paint through a fine nylon mesh bag available at most paint dealers to remove par ticles that could clog the spray tip This is an im portant step toward trouble free paint spraying 05993 Operation How to use the gun trigger safety AX Open or drain position When engaged the gun safety latch prevents the gun AN Closed or spray position from accidental triggering See Fig 3 A WARNING INJECTION HAZARD If the gun still sprays when the gun trig ger safety is locked repair the gun See manual 308 235 supplied AN Gun safety latch shown engaged AN Gun safety latch shown disengaged How to use the pressure control X The pressure control controls the motor operation so the sprayer maintains constant fluid pressure at the pump outlet Turn the pressure control knob fully coun AN terclockwise to obtain the minimum setting Turn the A knob clockwise to increase pressure See Fig 5 Fig 3 i ae 05964 How to use the pressure drain valve
10. rettes arcs from connecting or disconnecting power cords or turn ing light switches on and off Failure to follow this warning can result in death or serious injury Liquids can be injected into the body by high pressure airless spray or leaks especially hose leaks Keep body clear of the nozzle Never stop leaks with any part of the body Drain all pressure before removing parts Avoid accidental trig gering of gun by always setting safety latch when not spraying Never spray without a tip guard In case of accidental skin Surgical Treatment Failure to follow this warning can result in amputation or serious injury injection seek immediate READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE 4 308 646 Component Function and Identification 05993 DC motor 120 Vac 15A 1 phase Transfers power from DC motor to the displacement pump Hose and spray gun is connected here Pressurizes fluid to be sprayed through spray gun 1 4 in ID grounded nylon hose with spring guards on both ends Reverse A Clean RAC tip guard reduces the risk of fluid injection inju ry High pressure spray gun with gun safety latch RAC switch tip atomizes fluid and removes clogs from spray tip without removing tip from spray gun Pressure Drain Valve Relieves fluid pressure when open Pressure Control Controls motor to maintain fluid pressure Works with pressure adjusting knob N Spray Gun Safety La
11. 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 screwdriver carefully try to rotate Slowly increase pressure setting to see if fan at back of motor by hand See page 18 motor starts If it doesn t see NOTE be low 2 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 22 3 Check for motor damage Remove drive hous 3 Replace motor 4 if fan won t turn See ing assembly 11 See page 28 Try to rotate page 26 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 27 4 Check motor brushes for the following 4 Refer to page 20 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 Clean
12. to the Technical Data on page 36 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 warn ings 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 ex pose 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 36 to order lt a FIRE AND SKIN INJECTION EXPLOSION HAZARD HAZARD Spray painting flushing or cleaning equipment with flammable liq uids in confined areas can result in fire or explosion Use outdoors or in extremely well ventilated areas Ground equip ment hoses containers and objects being sprayed Avoid all ignition sources such as static electricity from plastic drop cloths open flames such as pilot lights hot objects such as ciga
13. 08 646 05993 11 Shutdown and Care A WARNING INJECTION HAZARD 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 Shutdown and Care 1 Check the packing nut wet cup daily 102 Re lieve 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 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 31 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 detergent oil See Fig 11 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 13 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 dam age the sprayer or result in a loss of pressure or stalling 6 For very s
14. 26 Remove the two motor screws 19 and and re move the sprayer handle 24 Tap the lower rear of the drive housing 11 with a 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 28 Fig 26 26 308 646 8 Remove the two screws 46 and lift the motor off the base 66 9 Align the new motor with the base and reinstall the screws 46 10 Assemble the drive housing to the motor Follow steps 8 to 11 on page 28 11 Connect the wires in the junction box Refer to Fig 27 on page 27 Install the junction box 12 Connect the piston rod 107 to the drive housing see page 22 Installing the Pump Step 2 and the WARNING following it Fig 24 01068 Fig 25 01074 04656 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 Procedure on page 9 NOTE See Fig 27 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 con nector A from the motor start board 47 Ob serve 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 I
15. 6 Hand tighten the valve into the piston rod just until w the nut 110 contacts the rod See Fig 21 Fig 21 01071 7 Place the flats of the rod 107 in a smooth jaw 9 vise Stack these parts one at a time into the top of the manifold 101 the male gland 106 alternately three plastic packings 104 with two leather pack CAREFULLY tighten the nut 110 against the pis ton rod to 30 ft lb 40 N m See Fig 21 Use two wrenches to maintain the alignment men tioned in NOTE below Step 3 24 308 646 10 ings 105 and then the female gland 103 See Fig 23 Install the packing nut 102 and plug 124 but leave loose for now See Fig 23 A A A Fig 14 Displacement Pump Repair 15 Torque the cylinder jam nut 117 to 73 ft lb Place a new o ring 116 firmly in the cylinder groove See Fig 22 Coat the piston rod and packings with oil Carefully slide the assembly into the top of the cylinder 115 See Fig 22 Put the manifold upside down in a vise Fully thread the jam nut 117 onto the cylinder 115 Guide the rod cylinder assembly down through the manifold 101 Screw the cylinder 115 into the manifold See Fig 22 Torque jam nut 117 to 73 ft lb 98 N m Torque cylinder 115 Cc gt into manifold 101 to TA 53 ft lb 71 N m U Torque intake valve 116 into cylinder 115 to 53 ft lb 71 N m Piston assembly 22 Place the bal
16. 9 The lips of the throat V packings face down The lips of the piston V packings face up Incorrect installa tion damages the packings and causes pump leakage NOTE Soak the leather packings in oil before reas sembling the pump Fig 19 Check the outside of the piston rod 107 and the inside of the cylinder 115 for wear Replace worn parts to ensure a good seal with the new packings Stack these parts onto the piston valve 108 one at a time the female gland 114 alternately three plastic 112 with two leather packings 113 and the male gland 111 See Fig 19 A Throat packings Piston packings A Intake valve 123 7 as 01069A 308 646 23 Displacement Pump Repair 3 Tighten the nut 110 onto the piston valve 108 to i i Torque to 5 in Ib 0 57 N m See Fig 20 AX Toraue are 107 NOTE Note the alignment of the piston 108 to the P apa Sse nut 110 Maintain this alignment through Step 8 threads 4 Clean all residue from the piston valve threads Apply one drop of adhesive supplied to the AN threads KR 5 Place the ball 109 on the piston valve 108 See i Fig 20 Fig 20 108 P J oi A CAUTION AN Torque nut against rod to 30 ft lb 40 N m Step 6 tightening the piston valve into the rod is critical Follow the procedure carefully to avoid AN Do not allow nut 110 damaging the packings by overtightening nator Sawer tightening piston against rod
17. A 30 308 646 Pressure Transducer 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 31 for this procedure 1 Remove the displacement pump See page 22 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 Fig 31 peas 02817A guiding the o ring and backup ring into place Ig 31 M 6 Align the holes in the transducer as shown by the arrows in Fig 31 7 Install the displacement pump See page 22 308 646 31 Drain Valve 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 42a AN Apply thread sealant rA 42b AN Apply grease Pa to face of base A Te t O S p A EER ea m Handle shown in closed position 45 Fig 32 02819 1 Turn the handle 45 to the closed position Drive out the pin 44 Remove the handle 2 Remove the base 43 3 Unscrew the drain valve 42 The gasket 42a and seat 42b will stay in the valve Repair 1 Unscrew the spring retainer from the valve body Remove the spr
18. ER 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 parts on page 29 CAPSCREW 7 16 14 x 1 3 4 SCREW 5 16 18 x 1 1 4 HANDLE sprayer CAP tubing NIPPLE hex 1 4 npsm x 1 4 npt 1 3 16 PRESSURE TRANSDUCER CLIP 5 8 SCREW filh 8 32 x 1 1 4 SUCTION HOSE amp TUBE DRAIN TUBE SCREW filh 8 32 x 2 1 2 LABEL identification ELBOW drain LEG sprayer ADAPTER union 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 Qty owes Ss S Pp i l 6 ee e E E ee ee ee _ wR BRP a N WS HS SS a i a h h i h Ref No PartNo Description Qty 44 111 600 PIN grooved 3 32 x 1 1 45 187 625 HANDLE drain valve 1 46 110 997 SCREW washer hex hd 5 16 2 47 235 008 MOTOR START BOARD 1 484 186 620 LABEL ground terminal 1 49 110 037 SCREW mach pnhd 10 24 x 5 8 1 50 235 010 POWER CORD SET 1 51 111 617 STRAIN RELIEF BUSHING 1 3 8 18 npt 52 105 679 SWITCH ON OFF 1 53 235 035 GROUND HARNESS 1 54 105 658 LOCKING RING 1 55 105 659 BOOT switch 1 56 111 703 SCREW filh 10 24 x 3 4 58 100 035 SCREW pan hd 8 32 x 5 16 2 59 187 795 JUNCTION BOX 1 63 111 704 SCREW filh 10 24 x 1 5 8 2 64 224 828 PRESSURE CONTROL KIT 1 66
19. INSTRUCTIONS PARTS LIST svscx 308 646 e Rev B Le This manual contains important Supercedes Rev A gt warnings and information READ AND RETAIN FOR REFERENCE INSTRUCTIONS ELECTRIC 120 VAC GRON Performance 390 rless Paint Sprayer 19 5 bar Maximum Working Pressure Air 2750 psi Model 231 553 Series A Complete sprayer with hoses gun RAC IV DripLess Tip Guard and SwitchTip 05994 GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Pe COPYRIGHT 1996 GRACO INC Graco Inc is registered to I S EN ISO 9001 H003 Table of Contents WaAIMINGS esde epee aE Rak eau A A DE A 4 ON OFF Switch 0000 cee eee 27 Component Identification and Function 5 Drive Housing Connecting Rod Crankshaft 28 SEtUP a Malan eA wed Se Ses ek gana 6 Pressure Control 00 cece eee eee 30 Operatlon assented aie ane ae 7 Pressure Transducer 000 cece eee eee ee 31 SAMUP 24 eaten annette aac ae hake seat 9 Drain VANE a 22s Sects te etc mraka IERE eE BE 32 Shutdown and Care sssaaa cece ee eee 12 Inlet Strainer Installation Removal 32 FIUSHING esaer nee aes de ee ya Pee Nee 13 Displacement Pump Parts Drawing and List 33 Troubleshooting 0 0 cee eee 14 AccessorieS aE ees 33 Motor Test ecreug ee pea ree nee 18 Sprayer Parts Drawing 00eeeeee 34 General Repair Information
20. Quantity of three A Quantity of one 3 fl 0z 29 cc of A Apply a total of Pe gt i grease to gears ENS A N Fig 29 04657 308 646 29 Pressure Control A WARNING 7 Loosely install the screws 63 and then torque them to 21 in lb 2 4 N m INJECHON HAZARD 8 Install the front cover 13 Connect the harness 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 pinched against the motor or by the motor start board NOTE See Fig 30 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 pres sure 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 Torque to 6 Install the new pressure control Tip the pressure 5 21 nee Nm control down and back into the drive housing 11 Fig 30 astBA Do not pinch or damage the harness
21. See Fig 17 1 Flush the pump if possible Relieve pressure Stop the pump with the piston rod 107 in its lowest position if 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 NOTE If repairing only the intake valve assembly go to Intake valve repair page 23 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 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 If 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 con necting rod or drive housing 22 308 646 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 Reconne
22. aligns with the raised nub in the suction tube 32 A sudden re lease in turning resistance will be felt when the parts align 2 Pull or tap the strainer straight off the suction tube 32 308 646 32 04717 Fig 33 Displacement Pump Parts Drawing and List Model 236 787 Series A Includes items 101 to 127 Ref No PartNo Description Qty 101 187 611 MANIFOLD pump 102 176 758 PACKING NUT 103 176 757 104 176 997 105 176 755 106 176 754 GLAND female throat V PACKING plastic throat V PACKING leather throat GLAND male throat 107 187 613 DISPLACEMENT ROD 108 224 808 PISTON VALVE 109 105 444 BALL 5 16 piston 110 176 751 NUT hex 1 2 20 unf 2b 111 176 750 112 176 882 113 176 749 114 180 073 115 236 786 116 108 526 117 187 614 118 224 966 119 111 603 120 176 760 121 105 445 122 176 759 123 180 656 124 102 969 1274 188 663 GLAND male piston V PACKING plastic piston V PACKING leather piston GLAND female piston CYLINDER pump PACKING o ring PTFE NUT jam 1 3 8 18 unef 2b INLET VALVE PACKING o ring PTFE GUIDE ball BALL 1 2 inlet PIN ball stop PLUG SEALANT not shown LABEL Warning Supplied in Repair Kit 235 703 Keep a repair kit on hand to reduce down time ee nC Sn a a A S SO On On on On On ns S mG Men Gen Gane 118 01069A Accessoriese Fluid Filter Kit 235 677 Low Profile Cart Kit 235 710 Filters
23. 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 Replace 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 22 and or pressure transducer page 31 must be replaced 14 308 646 Basic 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 Electrical continued 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 26 to check See page 20 Check motor armature for shorts using arma ture tester growler or perform motor test See page 18 Replace motor See page 26 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 p
24. ct the suction and drain hoses 32 33 Install the front cover 13 4 Tighten the packing nut 102 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 q 50 ft lb 68 N m A Apply sealant 42d Fig 17 O Tl Torque to 50 ft lb 68 N m 3 102 Fig 18 005 Displacement Pump Repair Intake valve repair See Fig 17 i 1 Remove the suction hose See Step 2 Removing the pump 2 Unscrew the intake valve 118 Remove the 2 o ring 119 ball guide 120 stop pin 122 and ball 121 from the valve 3 Clean and inspect the parts for wear or damage Replace parts as needed Use a new o ring 119 If no further service is needed reassemble the pump Disassembling the pump See Fig 19 1 Remove the intake valve 118 See page 2 Loosen the packing nut 102 and plug 123 3 Use a plastic mallet to tap the piston rod 107 down and then pull the rod out through the bottom of the cylinder 4 Remove the packing nut 102 and throat pack ings 5 Loosen the jam nut 117 Remove the cylinder 115 and the o ring 116 6 Clamp the flats of the piston rod in a smooth jaw vise Use an open end wrench to loosen the nut 110 and then unscrew the piston valve 108 7 Remove all parts from the piston valve 108 Reassembling the pump NOTE Alternate plastic and leather packings See Fig 1
25. d 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 oe Moving parts can pinch or amputate your fingers e 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 308 646 3 WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury RA 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 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
26. e can burn out a good board Circuit breaker opens after 1 Check Basic Problems Electrical on page sprayer operates for 5 to 10 14 minutes Building circuit breaker Check ON OFF switch 52 Be sure sprayer is 1 Replace ON OFF switch See page 27 opens as soon as sprayer unplugged Disconnect wires from switch is plugged into outlet and Check switch with ohmmeter The reading sprayer is NOT turned on should be infinity with ON OFF switch OFF and zero with switch ON 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 Check the generator s peak voltage This sprayer will Use AC power or a different generator ator but does run on AC not run if the peak voltage is above 190V power 308 646 17 Motor Test 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 elec trical continuity Setup Remove the drive housing See page 28 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 junctio
27. er warranties express or implied including warranty of merchantability or warranty of fitness for a particular purpose and of any non contractual liabilities including product liabilities based on negligence or strict liability Every form of liability for direct special or consequential damages or loss is expressly excluded and denied In no case shall Graco s liability exceed the amount of the purchase price Any action for breach of warranty must be brought within two 2 years of the date of sale EQUIPMENT NOT COVERED BY GRACO WARRANTY Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose with respect to accesso ries equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motor 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 Sales Offices Atlanta Chicago Detroit Los Angeles Foreign Offices Belgium Canada England Korea Switzerland France Germany Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 PRINTED IN U S A 308 646 February 1996 Revised September 1996 36 308 646
28. essure transducer 29 for hardened Replace transducer See page 31 Thor paint or damaged or worn components See ough system flushing will help extend life page 31 of transducer 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 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 22 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 308 646 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 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 22 Check electrical supply with volt meter Meter 4 Reset building circuit breaker replace should read 105 125VAC building fuse Repair electrical outlet or try another outlet Check extension cord size and length must be at least 12 gauge wire and less than 150 ft 45 m
29. ge 31 3 Check pressure control 64 for smooth opera f3 Replace pressure control See page 30 tion 4 Check Low output section page 16 Motor Is Hot and Runs 1 Determine if sprayer was operated at high pres 1 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 26 Building Circuit Breaker J 1 Check all electrical wiring for damaged insula 1 Repair or replace any damaged wiring or Opens As Soon As Sprayer tion and all terminals for loose fit or damage terminals Securely reconnect all wires Switch Is Turned On Also check wires between pressure control and motor See page 26 Check for missing motor brush inspection plate f 2 Correct faulty conditions gasket see page 18 bent terminal forks or other metal to metal contact points which could cause a short Check motor armature for shorts Use an arma 3 Replace motor See page 26 ture tester growler or perform motor test See page 18 Inspect windings for burns Check motor start board 47 by substituting 4 Replace board See page 27 with a good board CAUTION Do not perform this check until motor armature is determined to be good A bad motor armatur
30. h so the internal tab of the anti rotation ring 54 en gages with the vertical groove in the threads of the switch and the external tab engages with the blind hole C of the junction box 6 Powder the inside of the rubber boot 55 with tal cum then shake the excess out of the boot Install the nut and rubber boot and tighten 7 Reconnect the ON OFF switch black wires 8 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 04720 308 646 27 Drive Housing Connecting Rod Crankshaft A WARNING CAUTION INJECTION HAZARD Do not allow the gear 16 to fall it may stay attached to the drive housing or to the motor To reduce the risk of serious injury whenever you are instructed to relieve pressure follow the Pressure Relief Procedure on page 9 Do not lose the thrust balls 11a or 4a or let them fall between the gears which will damage the drive housing if not removed The balls which are heav ily 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 NOTE Inspect parts as they are removed Replace parts that are worn or damaged te Remove ine displacement pump S96 Page gs 6 Remove and inspect the crankshaft 12 and the connecting rod 15 2 Remove the pressure control 64
31. hort 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 hose from kinking abrasion coupling damage etc 12 308 646 See the warning section INJECTION HAZARD on page 3 for information on the hazard of using damaged hoses Turn packing nut clockwise to tighten A 102 04650 Fig 10 A Vent hole ks 28 X e N l Z 04651 Fig 11 RE Flushing When to Flush 1 A CAUTION Before using a new sprayer flush out the oil which was left in to protect pump parts Before using water base paint flush with min eral spirits followed by soapy water and then a clean water flush Before using oil base paint flush with mineral spirits only Changing colors flush with a compatible solvent such as mineral spirits or water Changing from water base to oil base paint flush with warm soapy water and then mineral spirits Changing from oil base to water base paint flush with mineral spirits then warm soapy water and then a clean water flush 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 Never a
32. ic Hydraulic EH 390st and 490st sprayers 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 any malfunction damage or wear caused by faulty installation misapplication abra sion 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 with Graco equipment of structures accessories equipment or mate rials 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 claim If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the origi nal 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 DISCLAIMERS AND LIMITATIONS The terms of this warranty constitute purchaser s sole and exclusive remedy and are in lieu of any oth
33. ing washers and stem ball Clean any debris from the ball or seat area 2 If replacing the gasket 42a or seat 42b pry out the gasket NOTE Whenever the gasket 42a is removed re place it with a new one 3 Coat the o ring 42d with grease Press the stem into the valve body Install the spring washers and spring retainer into the valve body 4 Place the seat 42b in the valve body so the lapped side is toward the ball Apply a small amount of grease to the new gasket 42a and in stall it in the valve body NOTE The gasket will protrude from the end of the valve until the valve is tightened into pump which cor rectly seats the gasket Replacement 1 Apply a small amount of thread sealant 42e onto the valve 42 threads Tighten the valve into the pump manifold to 185 in lb 21 N m 2 Lightly grease the face of the base 43 and install the base Turn the stem so the pin hole is vertical 3 Securely install the handle 45 and drive pin 44 Inlet Strainer Installation Removal Installation Fig 33 1 Align the keyway in the strainer 39 with the small nub near the end of the suction tube 32 2 Push the strainer over the nub and up to the suc tion tube s raised band While holding the strainer against the band rotate it about 1 2 turn in either direction a wrench may be necessary Removal 1 With a wrench or the hand turn the strainer 39 in either direction until the keyway
34. l guide 120 stop pin 122 and ball 121 in the cylinder 115 Screw the intake valve into the cylinder and torque to 53 ft lb 71 N m This will also properly torque the cylinder into the manifold See Fig 23 01072A 16 A A A 98 N m See Fig 22 Install the pump See page 22 Lips of V packings must face up AN Torque to 53 ft lb Lips of V packings 71 N m must face down Leather packings Poly packings 01073 308 646 25 Motor 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 except where noted a A Torque to 80 in lb 9 N m A Quantity of three A Quantity of one Relieve pressure 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 24 Remove the screws 56 and lower the junction box 59 Disconnect the motor wires and the pres sure control wire A from the motor start board Refer to Fig 27 on page 27 Remove the front cover 13 Turn the displacement pump rod 107 so the pin hole aligns with the bottom drive housing screw 19 See Fig 25 Remove the three drive housing screws and lockwashers 19 6 Also see Fig
35. llow water to freeze in the pressure control Doing so prevents the sprayer from being started and may cause serious damage Push the water out with mineral spirits 6 Startup after storage Before 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 How to Flush 1 Follow the Pressure Relief Procedure on page 9 2 Remove the spray tip and clean it separately 3 10 11 Pour one half gallon 2 liters of compatible solvent into a grounded metal flushing pail Put the suction hose in the pail Open the pressure drain valve See Fig 4 page 7 To save the paint still in the pump and hose 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 re lease the trigger Continue with Step 6 A WARNING FIRE AND EXPLOSION HAZARD To reduce static sparking and splashing 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 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 trig gered until the solvent flows freely from the g
36. ly to the side of a grounded metal pail before triggering the gun 6 To prime the hose lower the pressure to reduce splashing Hold a metal part of the gun firmly NOTE Spray patterns will change as tips wear against and aimed into a grounded metal pail See Change the spray tip if adjusting the pressure will not the preceding WARNING Hold the gun trigger improve the spray pattern open and slowly increase the pressure until 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 7 Check all fluid connections for leaks Relieve pressure before tightening the connections 8 Engage the gun safety latch 9 Install the spray tip and tip guard Install the spray tip If you are using the RAC IV tip guard a refer to manual 307 848 for installation instruc tions j For a vertical 10 Adjust the spray pattern A o ee a Increase the pressure until spray from the gun is completely atomized To avoid excessive AA ael n l overspray and fogging and to extend tip and k A A i sprayer life always use the lowest pressure Fig 8 oaaae needed to get the desired results 10 308 646 AN 1 4 npsm m fluid outlet A Do not install any shutoff device here AN Rotate clockwise to increase pressure A Shown in closed or spray position A Fill 1 3 full with TSL Fig 9 Startup 3
37. n box screws 56 Lower the junc tion box Disconnect the two leads C from the motor to the board 47 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 26 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 20 If there is still uneven or no turning resistance replace the motor See page 26 18 308 646 Fig 12 MOTOR BLACK WHITE BLACK Fig 13 04652 04720 General Repair Information 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 Tool List These are the tools required to service all parts of the sprayer 3 16 Allen wrench gear ho
38. necting wires in the junction box assembly use needle nose pliers to separate mat ing connectors 2 When reconnecting the wires be sure the flat blade of the insulated male connector is centered in the wrap around blade of the female connector CAUTION Improper wire routing can result in poor sprayer performance or damage to the pressure control 3 Route wires carefully through the drive housing and motor Avoid pinching the wires between the junction box and the motor or pressure control 4 Keep all screws nuts washers gaskets and electrical fittings removed during repair proce dures These parts are not normally provided with replacement assemblies 5 Test your repair before regular operation to be sure the problem is corrected 6 Ifthe sprayer does not operate properly verify that everything was done correctly Also refer to the Troubleshooting Guide pages 14 18 to help identify other possible problems and solutions 308 646 19 Motor Brushes NOTE Replace brushes when worn to about 0 5 in 12 5 mm Always check both brushes Brush Repair Kit 236 967 which includes spring clip 112 766 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
39. nstall the new motor start board Reconnect all 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 A CAUTION Be sure the flat blade of the insulated male con nector 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 27 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 5 Install the new cord 50 in the reverse order of disassembly 6 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 27 for this procedure 1 Relieve pressure 2 Remove the junction box screws 56 and lower the junction box 59 3 Remove the nut and rubber boot 55 4 Disconnect the black wires from the ON OFF switch 52 and remove the switch 5 Place the ring terminal of the ground wire 53 over the barrel of the new switch Install the switc
40. p connecting rod pin 17 See Fig 18 page 22 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 d Inspect the brush and commutator contact area for excessive arcing Arcs should not trail or circle around the commutator surface A WARNING MOVING PARTS HAZARD Do not touch the brushes leads springs or brush holders while the sprayer is plugged in to reduce the risk of electric shock and serious injury 10 Install the brush inspection covers and gaskets 11 Break in the brushes Operate the sprayer for at least one hour with no load Install the pump connecting rod pin See Fig 18 page 22 308 646 21 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 235 703 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 20 and clean the transducer see page 31 whenever you re pack the pump Replace these parts as needed Removing the pump
41. particles from fluid stream Includes manifold Converts sprayer to low profile wheeled cart filter fittings and installation instructions Upright Cart Kit 236 328 Converts sprayer to tall wheeled cart 308 646 33 Sprayer Parts Drawing Model 231 553 Series A HOSE AND GUN NOT SHOWN IN PROPORTION TO SPRAYER AN Label See detail on page 31 35 OUT SIDE LABEL 14 INSIDE LABEL 04658 34 308 646 Sprayer Parts List Model 231 553 Series A Includes items 3 to 89 as listed below Ref No 4t 42a 42b 42c 42d 42e 43 Part No 236 965 100 069 111 616 107 503 107 267 187 784 187 791 187 975 105 510 224 965 100 069 111 726 224 803 180 131 107 434 188 366 177 762 218 359 218 364 176 818 176 817 103 345 236 787 111 706 111 715 190 337 112 759 162 453 235 009 190 464 108 850 237 684 190 336 111 705 290 237 237 696 190 334 190 451 237 820 235 014 111 699 187 615 224 968 168 110 110 110 224 807 Description MOTOR KIT Includes items 4a to 4g BALL sst 1 4 dia TERMINAL flat 1 4 f 18 awg TERMINAL 3 16 m 16 awg TERMINAL 3 16 f LABEL DANGER French LABEL DANGER English LABEL WARNING electric shock LOCKWASHER 1 4 DRIVE HOUSING KIT Includes item 11a 11b BALL stainless steel 1 4 dia PLUG CRANKSHAFT Includes items 12a 12b BEARING thrust BEARING COV
42. place if necessary Tighten packing nut wet cup 4 Check to see if intake valve ball and piston ball are seating properly See page 22 Check for leaking around throat packing nut which may indicate worn or damaged packings See page 22 6 Release gun trigger Observe resting position of 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 22 No output motor runs but Check displacement pump connecting rod pin 1 Replace pin if missing Be sure retainer pump does not stroke 17 See Fig 18 page 22 spring 18 is fully in groove all around connecting rod Check connecting rod assembly 15 for dam 7 Replace connecting rod assembly See age See page 28 page 28 Be sure crank in drive housing rotates plugin 48 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 28 page 28 16 308 646 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 pa
43. roperly mated and firmly connected to mating part Check motor start board 47 by substituting Replace board See page 27 with a good board See page 27 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 Check power supply cord 50 Disconnect Replace power supply cord See page black and white power cord terminals connect 27 volt meter to these leads Plug in sprayer Meter should read 105 125VAC Unplug sprayer Check ON OFF switch 52 Disconnect the Replace ON OFF switch See page 27 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 Check motor thermal cutout switch Connect 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 12 Remove pressure control 64 and check mi 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 Replace pressure control See page 30 Check pr
44. safety latch shut Clean the front of the tip frequently during the day s off and unplug the sprayer and open the pressure operation First follow the Pressure Relief Procedure drain valve to relieve pressure Clean the spray tip on page 9 as shown in manual 307 848 supplied 8 308 646 Startup A WARNING INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally Fluid under high pressure can be injected through the skin and cause serious injury To reduce the risk of an injury from injection splashing fluid or moving parts follow the Pressure Relief Procedure whenever you e are instructed to relieve the pressure e stop spraying e 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 loo
45. sen completely Now clear the tip or hose obstruction PON gt on Startup Procedure Use this procedure each time you start the sprayer to help ensure the sprayer is ready to operate and that you start it safely NOTE If this is a first time startup flush the sprayer See page 13 NOTE Refer to Fig 9 and the other figures referenced in the text as you start the sprayer 1 Open the pressure drain valve 42 See Fig 7 2 Don t install the spray tip until the pump is primed AN Open or drain position N _ A e ar 3 Turn the pressure knob 64 to the minimum setting 4 Disengage the gun trigger safety See Fig 3 page 7 CAUTION Do not run the sprayer dry for more than 30 sec onds to avoid damaging the pump packings 5 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 308 646 9 Startup b If more coverage is needed use a larger tip A WARNING rather than increasing the pressure FIRE AND EXPLOSION HAZARD To tedlibe the Tsk oF Stahespargng And c Adjust the direction of the spray pattern See Fig 8 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 splashing when priming or flushing the system hold a metal part of the gun firm
46. tch Inhibits accidental triggering of spray gun 308 646 5 Setup 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 at least 2750 psi 195 bar Working Pressure 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 To avoid damaging the pressure control which may result in poor equipment performance and component damage follow these precautions 1 Always use a nylon spray hose at least 50 ft 15 m long Never use a wire braid hose as it is too rigid to act as a pulsation dampener Never install any shutoff device between the filter and the hose See Fig 2 1 Connect the hose 74 and gun 67 and screw it onto the outlet nipple 28 Don t use thread sealant and don t install the spray tip yet AN 1 4 npsm m fluid outlet AA Do not install any shutoff device here A Rotate clockwise to increase pressure Shown in closed or spray position A Fill 1 3 full with TSL Fig 2 6 308 646 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 Plug in the sprayer Be sure the ON OFF switch 52 is OFF Plug the cord into a grounded outlet at least 20 feet away from the spray area A WARNING FIRE AND EXPLOSION
47. un Circulate the solvent to thoroughly clean the spray er Release the gun trigger Engage the gun trigger safety Open the drain valve and circulate the solvent 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 pres sure Remove and clean the inlet strainer Wipe paint off the suction hose and drain tube Refer to When To Flush Step 1 again Relieve pressure Leave the drain valve open until you use the sprayer again 308 646 13 Troubleshooting 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 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
48. using legs handle 3 8 Allen wrench pump manifold 1 Phillips screwdriver junction box pressure control front cover 3 8 socket wrench motor mount 5 8 socket wrench drain valve outlet fittings on off switch boot piston 13 16 socket wrench drain valve 1 1 4 socket wrench pump inlet valve 1 2 open end wrench pump rod 11 16 open end wrench piston jam nut 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 3 needle nose pliers wiring on off switch Hammer amp punch packing nut Torque wrenches various fasteners A WARNING MOVING PARTS HAZARD o reduce the risk of serious injury includ ing electric shock DO NOT touch any moving parts or electrical parts with your fingers or a tool while inspecting the repair Shut off the sprayer and unplug it as soon as you complete the inspection Reinstall all covers gaskets screws and washers before operating the sprayer A WARNING HOT SURFACE HAZARD During operation the motor and drive housing become very hot and could burn your skin if touched Flammable materi als spilled on the hot bare motor could cause a fire or explosion CAUTION To reduce the risk of a pressure control malfunc tion be sure to properly mate connectors and never pull on a wire to disconnect it Pulling on a wire could loosen the connector from the wire 1 When discon
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