Graco 308559B 590st Airless Paint Sprayer, Electric, 100VAC. 50 or 60 Hz Owner's Manual

INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
308–559
First choice when
quality counts.
Rev. B
Supersedes Rev A
and PCN B
ELECTRIC, 100 VAC, 50 or 60 Hz
590st Airless Paint Sprayer
195 bar Maximum Working Pressure
Model 231–347, Series A
Basic sprayer
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN
COPYRIGHT 1995, GRACO INC.
55440–1441
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Shutdown and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Repair Information . . . . . . . . . . . . . . . . . . . . . 18
Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . . 20
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Motor Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing, Connecting Rod, Crankshaft . . . . . .
Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Parts . . . . . . . . . . . . . . . . . . . . . .
Complete Sprayer Parts . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty and Disclaimers . . . . . . . . . . . . . . . . . . . . . .
27
28
30
31
32
33
34
36
36
36
36
Symbols
Warning Symbol
Caution Symbol
WARNING
CAUTION
his symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
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.
If there 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 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.
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.
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.
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.
Before servicing the equipment, follow the Pressure Relief Procedure on page 9 to prevent the
equipment from starting unexpectedly.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call Graco Technical Assistance at 1–800–543–0339.
D Do not alter or modify this equipment.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not exceed the maximum working pressure of the lowest rated system component. Refer to
the Technical Data on page 36 for the maximum working pressure of this equipment.
D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
D 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.
D Do not use hoses to pull equipment.
D 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).
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
NOTE: This is an example of the English language DANGER label on your sprayer. This label is supplied with the sprayer
in other languages. Before operating the sprayer, apply a DANGER label in the appropriate language for your
operators, according to the separate instructions supplied with it.
FIRE AND
EXPLOSION HAZARD
SKIN INJECTION
HAZARD
Spray painting, flushing or cleaning equipment with flammable liquids in
confined areas can result in fire or explosion.
Liquids can be injected into the body by high pressure airless spray or
leaks – especially hose leaks.
Use outdoors or in extremely well ventilated areas. Ground equipment,
hoses, containers and objects being sprayed.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts.Avoid accidental triggering 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,
arcs from connecting or disconnecting power cords or turning light
switches on and off.
Failure to follow this warning can result in death or serious injury.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical Treatment”.
Failure to follow this warning can result in amputation or serious injury.
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
4
308-559
Major Components
B
C
A
D
E
J
H
G
F
Fig. 1
04785
A
Motor
DC motor, 100 Vac, 13A, 1 phase
B
Drive Assembly
Transfers power from DC motor to the displacement pump
C
Pressure Adjusting Knob
Controls fluid outlet pressure
D
Fluid Filter
Filters fluid between source and spray gun
E
Fluid Outlet
Hose and spray gun is connected here
F
Displacement Pump
Pressurizes fluid to be sprayed through spray gun
G
Pressure Drain Valve
Relieves fluid pressure when open
H
Motor Control
Controls motor to maintain fluid pressure. Works with pressure
adjusting knob.
J
ON/OFF Switch
Power switch that controls 100 Vac power to sprayer
Setup
IMPORTANT: The model 231–347 sprayer is shipped
without a spray gun or hose. When a spray gun and
hose are referred to throughout this manual, the
instructions and figures depict a Graco) product. Your
gun and hose may be different.
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 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:
2. Never use a wire braid hose as it is too rigid to
act as a pulsation dampener.
3. Never install any shutoff device between the
filter and the hose. See Fig. 3.
1. Plug the power cord (57) into the inlet receptacle
located below the motor. Tighten the screw (A) of
the cord clamp (65) securely. See Fig. 2.
65
57
308-559
4. 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 seal.
5. Check the electrical service. It must be 100 VAC,
50/60 Hz, 10 Amp (minimum) and must be
protected by a fuse or circuit breaker with a rating
of not more than 16 amps.
7. Plug in the sprayer. Be sure the ON/OFF switch
(52) is OFF. Plug the cord into a grounded outlet at
least 6 m away from the spray area.
1. Always use a nylon spray hose at least 15 m
(50 ft) long.
6
3. Connect the hose and gun and screw it onto the
outlet nipple (28). Don’t use thread sealant, and
don’t install the spray tip yet!
6. You may use a 3-wire, 2.0 mm2 (14 AWG) (minimum) extension cord up to 45 m long. Longer
lengths affect sprayer performance.
CAUTION
Fig. 2
2. Attach the fluid filter (85) to the sprayer.
A
03174
WARNING
FIRE AND EXPLOSION 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.
8. Flush the pump to remove the oil which was left in
to protect pump parts after factory testing. See
page 12.
9. Prepare the paint according to the manufacturer’s
recommendations. Remove any paint skin. Stir the
paint to mix pigments. Strain the paint through a
fine nylon mesh bag to remove particles that could
clog the gun filter or spray tip. This is an important
step toward trouble–free paint spraying.
Setup
A
1/4 npsm(m):
Do not install any shutoff device here
B
Fill 1/3 full with TSL
85
A
28
52
102
B
04785
Fig. 3
Operation
Refer to the IMPORTANT note on page 6.
How to use the pressure drain valve
How to use the gun safety latch
Use the pressure drain valve (45) to relieve fluid pressure from the pump and to help prime the pump. If the
valve senses an overpressure condition, it opens
automatically to relieve fluid pressure. If this happens,
stop spraying immediately, shut off and unplug the
sprayer. Correct the problem before using the sprayer
again. Refer to Troubleshooting, page 13. See Fig. 5.
When engaged, the gun safety latch (A) prevents the
gun from accidental triggering. See Fig. 4.
WARNING
INJECTION HAZARD
If the gun still sprays when the gun trigger safety is locked, repair the gun.
See the spray gun instruction manual.
A
Safety latch shown
in “ON SAFE” position
B
Safety latch shown
in “OFF SAFE” position
A
Fig. 4
A
B
A
Closed (spray) position
B
Open (drain) position
45
A
01020
A
45
B
02825A
Fig. 5
308-559
7
Operation
How to use the pressure control
The pressure control controls the motor operation so
the sprayer maintains constant fluid pressure at the
pump outlet. Turn the pressure control knob (64) fully
counterclockwise to obtain the minimum setting. Turn
the knob clockwise to increase pressure. See Fig. 6.
64
A
A
Clean the front of the tip frequently during the day’s
operation. First, follow the Pressure Relief Procedure
on page 9.
A
A
Rotate clockwise to
increase pressure
B
Turn handle 180,
trigger gun to clear clog
04647
01022A
How to use the RAC IV tip guard
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 page 10. The tip guard holds a reversing
spray tip. The tip is in the spraying position when the
tip handle (B) points forward. See Fig. 7.
Tip handle shown in
spraying position.
Fig. 7
Fig. 6
B
How to remove a tip clog
1. Release the gun trigger. Engage the gun safety
latch. Rotate the RAC IV tip handle 180. See Fig.
7.
2. Disengage the gun safety latch. Trigger the gun
into a pail or onto the ground to remove the clog.
3. Engage the gun safety latch. Rotate the tip handle
(B) to the spraying position.
4. If the tip is still clogged, engage the gun safety
latch, shut off and unplug the sprayer, and open
the pressure drain valve to relieve pressure. Clean
the spray tip as shown in your gun manual.
Startup
Refer to the IMPORTANT note on page 6.
NOTE: If this is a first–time startup, flush the sprayer.
See page 12.
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tip.
NOTE: Refer to Fig. 10 and the other figures referenced in the text as you start the sprayer.
1. Open the pressure drain valve (45). See Fig. 8.
2. Don’t install the spray tip until the pump is primed!
3. Put the suction hose (32) into the paint.
4. Turn the pressure control (64) to minimum.
5. Disengage the gun safety latch. See Fig. 4, page
7.
CAUTION
Pressure Relief Procedure
To reduce the risk of damage to the displacement
pump packings, never run the pump without fluid in
it for more than 30 seconds.
1. Engage the gun safety latch.
2. Turn the ON/OFF switch to OFF.
3. Unplug the power supply cord.
4. Disengage the gun safety latch. Hold a metal part
of the gun firmly to a grounded metal pail. Trigger
the gun to relieve pressure.
5. 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 loosen the tip guard retaining nut or hose end coupling to
relieve pressure gradually, then loosen completely.
Now clear the tip or hose obstruction.
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.
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.
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.
A
Open (drain) position
7. To prime the hose, lower the pressure to reduce
splashing. Hold a metal part of the gun firmly
against and aimed into the side of a grounded
metal pail. See the WARNING, above. Hold the
trigger 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.
8. Check all fluid connections for leaks. Relieve
pressure before tightening any connections.
45
Fig. 8
A
03034
9. Install the spray tip. Engage the gun safety latch
first! Refer to your gun manual on how to install
the tip.
Startup
10. Adjust the spray pattern.
a. Increase the pressure just until spray 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.
b. If more coverage is needed, use a larger tip
rather than increasing the pressure.
c.
A
Tip guard; shown in
vertical position
B
Tip guard: shown in
horizontal position
A
Test the spray pattern. To adjust the direction
of the spray pattern, engage the gun safety
latch and loosen the retaining nut. Position the
tip guard horizontally for a horizontal pattern or
vertically for a vertical pattern. Hold the tip
guard in place while tightening the retaining
nut. See Fig. 9.
B
NOTE: Spray patterns will change as tips wear.
Change the spray tip if adjusting the pressure will not
improve the spray pattern.
Fig. 9
01025
32
A
33
Rotate clockwise to increase pressure
A
64
52
45
Fig. 10
10
308-559
04785
Shutdown and Care
Refer to the IMPORTANT note on page 6.
WARNING
8. Coil the hose when storing it, even for overnight, to
help protect the hose from kinking, abrasion,
coupling damage, etc.
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.
1. Check the packing nut/wet–cup (102) daily. 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.
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. 11.
INJECTION HAZARD
See the warning section INJECTION
HAZARD on page 3 for information on
the hazard of using damaged hoses.
A
With pressure relieved,
turn packing nut
clockwise to tighten
A
102
3. Clean the gun’s fluid filter (if present) often and
whenever the gun is stored. Relieve pressure first.
4. Periodically clean paint residue from the pressure
transducer vent hole (A) area. See Fig. 12. Replace the transducer when leakage is excessive.
See page 31.
5. Lubricate the bearing housing after every 100
hours of operation. Remove the front cover. Fill the
bearing housing cavity (B) with several drops of
SAE 10 non–detergent oil. See Fig. 12.
Fig. 11
A
0317
B
6. 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.
CAUTION
To prevent pump corrosion, and to reduce the
chance of fluid freezing in the pump in cold weather,
never leave water or any type of paint in the sprayer
when it is not in use. Freezing can seriously damage the sprayer or result in a loss of pressure or
stalling.
7. For very short shutoff periods, leave the suction
hose in the paint, relieve pressure, and clean the
spray tip.
Fig. 12
02827A
308-559
11
Flushing
Refer to the IMPORTANT note on page 6.
How to flush
When to flush
1. Follow the Pressure Relief Procedure on
page 9.
1. Before using a new sprayer, flush out the oil which
was left in to protect pump parts.
Before using water–base paint, flush with mineral
spirits followed by soapy water, and then a clean
water flush.
Before using oil–base paint, flush with mineral
spirits only.
2. Remove the spray tip and clean it separately.
Unscrew the bowl (A) and remove the filter screen.
Then reinstall the bowl, hand tight, without the
screen. Clean the screen.
A
B
2. When changing colors, flush with a compatible
solvent such as mineral spirits or water.
3. When changing from water–base to oil–base paint,
flush with warm, soapy water, and then mineral
spirits.
4. When changing from oil–base to water–base paint,
flush with mineral spirits, then warm, soapy water,
and then a clean water flush.
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.
CAUTION
Never allow 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 a clean water flush. When using oil-base
paint, flush out the mineral spirits with the paint to
be sprayed.
12
308-559
Fig. 13
02828
3. Pour 2 liters of compatible solvent into a grounded
metal flushing pail. Put the pump in the pail.
4. Open the pressure drain valve.
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.
5. If you have been spraying and want to save the
paint still in the pump and hose, follow Step 5,
except put the drain tube in the paint container. As
soon as solvent appears, close the drain valve.
Move the drain tube to the flushing pail. Trigger the
gun into the paint pail. As soon as solvent appears, release the trigger. Continue with Step 6.
Flushing
7. Lower the pressure setting. Turn on the sprayer.
Maintaining metal–to–metal contact, trigger the
gun into the flushing pail. Slowly increase the
pressure just until the pump operates. 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
safety latch.
8. Open the drain valve and circulate the solvent
through the drain tube to thoroughly clean it. Close
the drain valve.
CAUTION
9. Remove the pump from the pail. Disengage the
gun safety latch. Trigger the gun to force solvent
from the hose and run the sprayer a few seconds
more to push air into the hose. Relieve pressure.
10. Remove the filter bowl and reinstall the clean filter
screen. Hand tighten the bowl.
11. Remove the inlet strainer and clean it thoroughly.
Wipe paint off the suction hose and drain hose.
12. If you flushed with mineral spirits and are going to
use a water–base paint, flush with soapy water
followed by a clean water flush. Relieve pressure.
To reduce the risk of damage to the displacement
pump packings, never run the pump without fluid in
it for more than 30 seconds.
13. Leave the drain valve open.
Troubleshooting
Refer to the IMPORTANT note on page 6.
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
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
Fluid Pressure
1. Check pressure control knob setting. The pump
won’t develop much pressure if it is at minimum
setting (fully counterclockwise).
1. Slowly increase pressure setting to see if
motor starts.
2. Check for a clogged spray tip (see page 8) or
a clogged fluid filter (see page 12 ).
2. If tip is still clogged, relieve pressure; refer to separate gun or tip instruction manual for tip cleaning. Clean or replace the
filter element.
1. Check for frozen or hardened paint in pump
(20). Using a screwdriver, carefully try to rotate
fan at back of motor by hand. See page 19.
1. Thaw. Plug in sprayer and turn on.
Slowly increase pressure setting to see if
motor starts. If it doesn’t, see NOTE 1,
below.
Mechanical
NOTE 1: Thaw sprayer if water or water–based paint has frozen in it, due to exposure to low temperatures, by placing it in a
warm area. Do not try to start sprayer until it has thawed completely or damage to motor and/or start board may occur. If paint
hardened (dried) in sprayer, the pump packings and/or pressure transducer must be replaced. See page 23 (pump) or 31 (pressure transducer).
308-559
13
Troubleshooting
Basic Problem Solving (continued)
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
Mechanical (continued)
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 connecting rod groove. See page 23.
Electrical
WHAT TO DO
When check is not OK, refer to this column
3. Check for motor damage. Remove drive housing assembly (11). See page 28. Try to rotate
motor fan by hand.
3. Replace motor (4) if fan won’t turn. See
page 26.
1. Check electrical supply with volt meter. Meter
should read 90–110 VAC.
1. Reset building circuit breaker; replace
building fuse. Try another outlet.
2. Check extension cord for visible damage. Use
a volt meter or test lamp at extension cord outlet to check.
2. Replace extension cord.
3. Check sprayer power supply cord (57) for
visible damage such as broken insulation or
wires.
3. Replace power supply cord.
4. Check motor brushes for the following:
a. Loose terminal screws.
4. Refer to page 20.
a. Tighten.
b.
Broken or misaligned brush springs.
c.
Brushes binding in holders.
d.
Broken leads.
e.
Worn brushes.
NOTE: The brushes do not wear at same rate on
both sides of motor. Check both brushes.
b.
Replace broken spring and/or align
spring with brush
c.
Clean brush holders. Remove
carbon with small cleaning brush.
d.
Replace brushes
e.
Replace brushes if less than 10 mm
long.
5. Check motor armature commutator for
burn spots, gouges and extreme roughness.
Remove motor cover and brush inspection
plates to check. See page 20.
5. Remove motor and have motor shop
resurface commutator if possible. See
page 26.
6. Check motor armature for shorts
using armature tester (growler) or perform
motor test. See page 19.
6. Replace motor. See page 26.
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 seBe 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
with a good board. See page 27.
8. Replace board. See page 27.
CAUTION: Do not perform this check until motor armature is determined to be good. A bad
motor armature can burn out a good board.
9. Check power supply cord (57). Disconnect
9. Replace power supply cord.
cord from inlet filter (51). Connect voltmeter
to cord’s receptacle and plug into wall
outlet. Meter should read 90–110 VAC. Unplug
sprayer.
10. Check inlet filter (51). Disconnect black and
white power inlet filter terminals;
connect volt meter to these leads. Plug in
sprayer. Meter should read 90–110 VAC. Unplug sprayer.
14
308-559
10. Replace inlet filter.
Troubleshooting
Basic Problem Solving (continued)
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
Electrical, continued
11. Check ON/OFF switch (52). Disconnect the
wire labeled ”L”, between motor start
board (47) and switch. Connect volt meter between exposed terminal on switch and white
wire on inlet filter (51). Plug in sprayer and turn
ON. Meter should read 90–110 VAC. Turn off
and unplug sprayer.
11. Replace ON/OFF switch. See page 25.
12. Check motor thermal cutout switch. Connect
ohmmeter between motor’s red leads. Meter
should read 1 ohm maximum.
12. Allow motor to cool. Correct cause of
overheating. If switch remains open after
motor cools, replace motor.
13. Remove pressure control (64) and check microswitch operation with ohmmeter:
a. With pressure knob at lowest setting and
stem pushed into control, readings should
be: white & black = 1 ohm max.
white & red = open.
13. Replace pressure control. See page 30.
b.
With pressure knob at highest setting,
readings should be: white & black = open;
white & red = 1 ohm max.
14. Check pressure transducer (29) for hardened
paint or damaged or worn components. See
page 31.
14. Replace transducer. See page 31. Thorough system flushing will help extend life
of transducer.
Intermediate Problem Solving
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Low Output
1. Check for worn spray tip.
1. Follow Pressure Relief Procedure on
page 9 then replace tip. See your separate gun or tip manual.
2. Be sure pump does not continue to stroke
when gun trigger is released. Plug in and turn
on sprayer. Prime with paint. Trigger gun momentarily, then release and engage safety
latch. Relieve pressure, turn off and unplug
sprayer.
2. Service pump. See page 22.
3. Release gun trigger. Observe resting position of 3. If pump consistently comes to rest with rod
pump rod (107).
(107) fully extended, the piston packings
and/or piston valve may be worn. Service
the pump. See page 23.
4. Check electrical supply with volt meter. Meter
should read 90–110 VAC.
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 2.0 mm2 gauge wire and less than
45 m.
5. Replace with a correct, grounded extension cord.
308-559
15
Troubleshooting
Intermediate Problem Solving
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
6. Check motor brushes. See What To Check,
item 4, on page 14.
6. See page 20.
7. Check motor start board (47) by substituting
with a good board.
7. Replace board. See page 27.
CAUTION: Do not perform this check until motor armature is determined to be good. A bad
motor armature can burn out a good board.
8. Check motor armature for shorts by using an
armature tester (growler) or perform motor
test. See page 19.
8. Replace motor. See page 26.
Drain Valve Leaks
1. Check for correct torque and/or worn parts.
Check for debris trapped on seat.
1. Tighten to 21 N.m. Clean valve and replace with new gasket (42a) and sealant
(42e). See page 32.
Transducer Leaks
1. Slight leakage is normal.
1. Periodically remove residue from its cylinder port. See page 31.
No Output: Motor Runs
And Pump Strokes
1. Check paint supply.
1. Refill and reprime pump.
2. Check for clogged intake strainer.
2. Remove and clean, then reinstall.
3. Check for loose siphon tube or fittings. See
page 22.
3. Tighten; use thread sealant on npt
threads of inlet tube (38). Check for damaged o–ring (27).
4. Check to see if intake valve ball and piston ball
are seating properly. See page 22.
4. Remove intake valve and clean. Check
ball and seat for nicks; replace as needed. See page 22. Strain paint before using to remove particles that could clog
pump.
5. Check for leaking around throat packing nut
which may indicate worn or damaged packings.
See page 22.
5. Replace packings. See page 23. Also
check piston valve seat for hardened
paint or nicks and replace if necessary.
Tighten packing nut/wet-cup.
6. Release gun trigger. Observe resting position of 6. If pump consistently comes to rest with
pump rod (107).
rod (107) fully extended, the piston
packings and/or piston valve may be
worn. Service the pump. See page 23.
No Output: Motor Runs
But Pump Does Not
Stroke
1. Check displacement pump connecting rod pin
(17). See page 22.
1. Replace pin if missing. Be sure retainer
spring (18) is fully in groove all around
connecting rod.
2. Check connecting rod assembly (15) for damage. See page 28.
2. Replace connecting rod assembly. See
page 28.
3. Be sure crank in drive housing rotates; plug in
sprayer and turn on briefly to check. Turn off
and unplug sprayer. See page 28.
3. Check drive housing assembly for damage and replace if necessary. See page
28.
Troubleshooting
Intermediate Problem Solving
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
Spray Pattern Variations
1. Spray tip worn beyond sprayer pressure capability.
1. Replace spray tip.
NOTE: A smaller size tip will provide longer
life.
2. Check transducer (29) for wear or damage.
2. Replace transducer. See page 31.
3. Check pressure control (64) for smooth operation.
3. Replace pressure control. See page 30.
4. Check LOW OUTPUT section, page 15.
Motor Is Hot and Runs
Intermittently
Building Circuit Breaker
Opens As Soon As Sprayer
Switch Is Turned On.
1. Determine if sprayer was operated at high pres- 1. Decrease pressure setting or increase tip
size.
sure with small tips, which causes excessive
heat build up.
2. Be sure ambient temperature where sprayer is
located is no more than 32C and sprayer is
not located in direct sun.
2. Move sprayer to shaded, cooler area if
possible.
3. Check motor. (See NOTE 1, page 13.)
3. Replace motor. See page 26.
1. Check all electrical wiring for damaged insulation, and all terminals for loose fit or damage.
Also check wires between pressure control
and motor. See page 35.
1. Repair or replace any damaged wiring or
terminals. Securely reconnect all wires.
2. Check for missing motor brush inspection plate
gasket (see page 20), 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 armature tester (growler) or perform motor test. See
page 19. Inspect windings for burns.
3. Replace motor. See page 26.
4. Check motor start board (47) by substituting
with a good board.
4. Replace board. See page 27.
CAUTION: Do not perform this check until
motor armature is determined to be good.
A bad motor armature can burn out a good
board.
Circuit breaker opens after
sprayer operates for 5 to
10 minutes.
1. Check ‘Basic Problems – Electrical’ on page
13.
Building circuit breaker
opens as soon as sprayer
is plugged into outlet and
sprayer is NOT turned on.
1. Check wiring for correct connections.
1. Correct improper connections.
2. 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.
CAUTION: A short in motor circuit can damage
switch and/or motor start board (47).
2. Replace ON/OFF switch. See page .
3. Check power supply cord (57). Disconnect
black and white power inlet filter terminals;
connect volt meter to these leads. Plug in
sprayer. Meter should read 90–110 VAC. Unplug sprayer.
3. Replace power supply cord.
General Repair Information
Refer to the IMPORTANT note on page 6.
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
Used for:
3/8” Allen wrench
pump manifold
3/16” Allen wrench
gear housing, legs, handle
#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 & punch
packing nut
Torque wrenches
various fasteners
1. When disconnecting wires in the junction box
assembly, use needle nose pliers to separate
mating connectors.
CAUTION
To reduce the risk of a pressure control malfunction, 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.
308-559
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.
Required Tool List
18
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.
4. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair procedures. These parts are not normally provided with
replacement assemblies.
5. Reinstall all covers, gaskets, screws and washers
before operating the sprayer.
WARNING
MOVING PARTS HAZARD
To reduce the risk of serious injury, including electric shock, DO NOT touch
any moving parts or electrical parts with
your fingers or a tool while inspecting the repair.
WARNING
HOT SURFACE HAZARD
During operation, the motor and drive
housing become very hot and could burn
your skin if touched. Flammable materials spilled on the hot, bare motor could cause a fire
or explosion.
6. Test your repair before regular operation to be sure
the problem is corrected.
7. Shut off the sprayer and unplug it as soon as you
complete the inspection.
8. If the sprayer does not operate properly, verify that
everything was done correctly. Also refer to
Troubleshooting, starting on page 13, to help
identify other possible problems and solutions.
Motor Test
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.
B
For checking armature, motor winding and brush
electrical continuity.
A
Setup
1. 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.
2. Remove the junction box screws (56). Lower the
junction box. Disconnect the two leads (C) from
the motor to the board (47). See Fig. 15.
Fig. 14
Armature Short Circuit Test
1. Remove the fan cover (B). See Fig. 14.
2. 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 replaced. See page 26.
MOTOR
RED
GREEN/
YELLOW
BLACK
Armature, Brushes, and Motor Wiring
Open Circuit Test (Continuity)
BLACK/
WHITE
1. Connect the two black motor leads together with a
test lead. Turn the motor fan by hand at about two
revolutions per second.
59
C
BLACK
2. When turning the fan on a DC motor, normally you
sense an even, pulsing resistance. If there is
irregular turning resistance, or no turning resistance, remove the motor brush inspection covers
(A). See Fig. 14. Check and repair the following as
needed: broken brush springs, brush leads, motor
leads; loose brush terminal screws, motor lead
terminals; worn brushes. See page 20.
3. If there is still uneven or no turning resistance,
replace the motor. See page 26.
WHITE
54
47
10
Fig. 15
03177
308-559
19
Motor Brush Replacement
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.
1
Motor lead; do not disconnect
2
Minimum 0.5” (12.5 mm)
3
Included in Brush Repair
Kit 236–967
2
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).
3
1
H C
G
F
B
E
WARNING
D
Fig. 17
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
03881
4. Inspect the commutator for excessive pitting,
burning 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.
1. Remove both inspection covers (A) and their
gaskets. See Fig 16.
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.
1
F
G
A
Fig. 16
C
04653
Fig. 18
2. Push in the spring clip (F) and release its hook (G)
from the brush holder (B). Pull out the spring clip.
See Fig 17.
3. Slide off the brush lead terminal (E) off the blade
connector. Remove the old brush (C). See Fig 17.
E
03881
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. 18. 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 pump connecting rod pin (17).
See Fig. 20, page 23.
b. With the sprayer OFF, turn the pressure control 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.
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. 20, page 23.
308-559
21
Displacement Pump
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.
Reference numbers of parts included in the kit are
marked with an asterisk, i.e., (121*). Use all the new
parts in the kit.
NOTE: Check the motor brushes (see page 20) and
clean the transducer (see page 31) whenever you
repack the pump. Replace these parts as needed.
Intake Valve Repair (See Fig. 19)
1. Unscrew the intake valve (118) with swivel (82)
attached. Remove the o-ring (119*), ball guide
(120), stop pin (122*) and ball (121*) from the
valve.
2. Clean and inspect the parts for wear or damage.
Replace parts as needed. Use a new o–ring
(119*). Reassemble the pump, or for additional
pump repair, go to page 23.
Installing the Pump (See Fig. 19 and 20)
1. Mount the pump on the drive housing. Tap it into
the alignment pins with a soft hammer. Tighten the
screws (21) to 68 N.m.
A
Torque to 68 N.m
B
Apply sealant (42e)
Removing the Pump (See Fig. 19)
13
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 manually, rotate the motor fan blades.
2. Loosen the swivel nut on adapter (82) and remove
suction hose (32).
17
18
20
3. While pushing in on the collar of the elbow (36),
pull out and remove drain tube (33).
NOTE: If repairing only the intake valve assembly, go
to Intake valve repair, at right.
A
21
33
32
4. Use a screwdriver to push the retaining spring (18)
up and push out the pin (17).
107
120
*122
36
*121
118 *119
82
B
5. Loosen the screws (21) and remove the pump
(20).
Fig. 19
04654
Displacement Pump
15
2. Unscrew the packing nut (102) and plug (123).
17
3. Use a plastic mallet to tap the piston rod (107)
down, and then pull the rod out through the bottom
of the cylinder.
123
4. Remove the throat packings (104*,105*) and
glands (103*,106*).
18
5. Loosen the jam nut (117). Remove the cylinder
(115) and the o-ring (116*).
WARNING
MOVING PARTS HAZARD
Be sure the retaining spring (18) is firmly
in the groove all the way around, to prevent the pin (17) from working loose due
to vibration. See Fig. 20.
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 connecting rod or bearing housing.
3. Reconnect the drain hose (33).
4. Tighten the packing nut (102) enough to stop
leakage, but no tighter. Fill the wet-cup 1/3 full with
TSL. Push the plug (123) into the wet-cup.
7. Remove all parts from the piston valve (108).
123
102
107
*103
*104
*106
105*
109*
110
111
*113
112*
101
114*
125*
PISTON
2. Align the hole in the rod (107) with the connecting
rod assembly (15). Use a screwdriver to push the
retaining spring up and push in the pin (17). Push
the retaining spring (18) into place around the
connecting rod.
6. Clamp the flats of the piston rod in a smooth jaw
vise. Use an open-end wrench to loosen the
retaining nut (110) and then unscrew the piston
valve (108) from the rod (107).
117
*116
126*
108
115
Disassembling the pump
118
INTAKE
VALVE
Fig. 20
01068
THROAT
102
(See Fig. 21 except where noted)
1. Remove the intake valve (118). See page 22.
Fig. 21
03148A
Displacement Pump
Reassembling the pump
7. Place the flats at the top of the rod in a vise.
NOTE: Alternate plastic and leather packings. See Fig.
21. The lips of the throat V-packings face down,
against pressure. The lips of the piston V-packings
face up, against pressure. The lips of the u–cup face
down. Incorrect installation damages the packings and
causes pump leaking.
8. Carefully tighten the nut (110) against the piston
rod to 40 N.m. See Fig. 23.
NOTE: Soak the leather packings in oil before reassembling the pump.
Use two wrenches to maintain the alignment
mentioned in the NOTE, at left.
A
Torque to 0.57 N.m
B
Apply one drop of
sealant to these
threads
1. 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.
2. Stack these parts onto the piston valve (108) one
at a time: the backup washer (126*) and u–cup
(125*), female gland (114*), alternately three
plastic (112*) with two leather packings (113*),
and the male gland (111*). See Fig. 22.
3. Tighten the nut (110) onto the piston valve (108) to
0.23 N.m. See Fig. 22.
NOTE: Note the alignment of the piston (108) to the
nut (110). Maintain this alignment through Step 8.
CAUTION
Step 6, tightening the piston valve into the rod, is
critical. Follow the procedure carefully to avoid
damaging the packings by overtightening.
6. Hand tighten the valve into the piston rod just until
the nut (110) contacts the rod. See Fig. 23.
24
308-559
109*
A
110
*111
*113
*125
B
112*
114*
*126
108
Fig. 22
A
B
03178
Torque nut against
rod to 40 N.m
Do not allow nut (110) to
move relative to piston
(108) when tightening piston
against rod
A
4. Clean all residue from the piston valve threads.
Apply one strip of adhesive, supplied, to the
threads.
5. Place the ball (109*) on the piston valve (108). See
Fig. 22.
107
B
107
110
108
Fig. 23
B
03179
9. 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
packings (105*), and then the female gland (103*).
See Fig. 24.
10. Install the packing nut (102) and plug (124), but
leave loose for now. See Fig. 24.
11. Place a new o–ring (116*) firmly in the cylinder
groove. See Fig. 25.
Displacement Pump
12. Coat the piston rod and packings with oil. Carefully
slide the assembly INTO THE TOP OF THE
CYLINDER (115). See Fig. 24.
13. Put the manifold 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.
14. Place the ball guide (120), stop pin (122) and ball
(121*) in the cylinder (115). Screw the intake valve
into the cylinder and torque to 71 N.m. This will
also properly torque the cylinder into the manifold.
See Fig. 25.
15. Tighten the cylinder jam nut (117) to 98 N.m. See
Fig. 24.
16. Install the pump. See page 22.
Leather throat packings:
lips must face down
E
F
Leather piston packings:
lips must face up
G
Torque to 71 N.m
H
Plastic throat packings:
lips must face down
J
Plastic piston packings:
lips must face up
107
A
Torque cylinder (115) into manifold (101)
to 71 N.m
B
Torque jam nut (117) 98 N.m
C
Torque intake valve (118) into cylinder
(115) to 71 N.m
D
Piston assembly
123
102
102
101
*103
104*
*105
E
*116
H
106*
101
107
110
*111
116*
117
F
B
*113
D
115
108
A
115
120
118
C
*119
G
Fig. 24
01072A
117
112*
J
114*
125*
126*
122*
121*
118
Fig. 25
03147
Motor
6. Turn the displacement pump rod (107) so the pin
hole aligns with the bottom drive housing screw
(19). See the DETAIL below. Remove the three
drive housing screws and lockwashers (19,6).
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.
7. Remove the two motor screws and lockwashers
(5,6).
8. 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. Do not allow the
gear (16) to fall. Read the CAUTION on page 28.
1. Relieve pressure.
2. 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. 26.
9. Remove the two screws (46) and lift the motor off
the base (66).
10. Align the new motor with the base and reinstall
the screws.
3. Remove the screws (56) and lower the junction
box (59). Disconnect the motor wires and the
pressure control wire (A) from the motor start
board. Refer to Fig. 27 on page 27.
11. Assemble the drive housing to the motor. Follow
Steps 8 to 10 on page 28.
12. Connect the wires in the junction box. Refer to Fig.
27 on page 27. Install the junction box.
4. Remove the drive housing cover (13).
13. Reconnect the piston rod (107) to the drive housing; see page 23, Installing the Pump, Step 2 and
the Warning that follows the step.
5. Remove the pressure control (69) while guiding the
harness (A) through the motor.
A
DETAIL
107
A
Torque to
9 N.m
19,6
11
11a
12a
16
12
B
4a
12b
C
5
4
6
64
01074
6
A
19
13
59
31
46
56
34 (x 3)
Fig. 26
03180
Motor Start Board
4. Install the new motor start board. Reconnect all
wires. Mount the junction box. See Fig. 27.
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.
1. Remove the junction box screws (56) and lower
the junction box (59). See Fig. 26.
2. Disconnect the motor wires (B) and the 3-wire
connector (A) from the motor start board (47).
Disconnect the wire from the ON/OFF switch.
Observe where connections are made. See Fig.
27.
3. Remove the screws (58) and motor start board
(47). Transfer the white thermal paste from the old
board to the new board. See Fig. 27.
NOTE: Route wires through the gasket (50) before
making connections.
CAUTION
Be sure the flat blade of the insulated male connector 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.
On/Off Switch
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.
6. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board.
MOTOR
48
GREEN/
YELLOW
BLACK
1. Remove the junction box screws (56) and lower
the junction box (59). See Fig. 26.
WHITE
52
BLACK/
WHITE
2. Remove the nut and rubber boot (55).
3. Disconnect the wires from the ON/OFF switch (52)
and replace the switch. See Fig. 27.
49
B
50
59
58
4. 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.
C 55
47
A
RED
NOTE: Route wires through any gaskets before
making connections.
5. Reconnect the ON/OFF switch wires.
Fig. 27
03177
Drive Housing, Connecting Rod, Crankshaft
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.
5. 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.
6. Remove and inspect the crankshaft (12) and the
connecting rod (15).
7. Install the connecting rod.
NOTE: Inspect parts as they are removed. Replace
parts that are worn or damaged.
1. Remove the displacement pump. See page 22.
2. Remove the pressure control (64). See page 30.
NOTE: The gears and bearings between the drive
housing (11) and motor front end bell (C) should contain a total of 90 ml of grease.
3. Remove the three drive housing screws and
lockwashers (19,6).
8. Lubricate the inside of the drive housing bearing
with SAE 10 non-detergent oil. Pack the roller
bearing and gears with the grease supplied.
4. Remove the two motor screws and lockwashers
(5,6).
9. Place the large washer (12a) and then the small
washer (12b) on the crankshaft (12).
CAUTION
Do not allow the gear (16) to fall; it may stay
attached to the drive housing or to the motor.
Do not lose the thrust balls (11a or 4a) or allow
them to fall between the gears, which will seriously
damage the drive housing 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.
10. Lift the crank to the top of the stroke and insert the
crankshaft (12). Align the drive housing and motor
with the locating pins. Push the drive housing onto
the motor. Install the screws (5,19) and lockwashers (6) and tighten evenly to 9 N.m.
11. Install the pressure control (64). See page 30.
12. Install the displacement pump. See page 22.
13. Install the front cover (13).
Drive Housing, Connecting Rod, Crankshaft
A
A Torque to 9 N.m
64
DETAIL
15
16
REF A
17
12a
12
6
5
4a
12b
11a
18
A
01068
47
59
56
31
6
15
13
Fig. 28
11
19 A
34 (x 3)
03181
Pressure Control
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.
8. Install the front cover (13). Connect the harness
(A) to the motor start board (47).
9. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board.
B
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).
64
63
2. Disconnect the harness connector (A) from the
motor start board (47). Turn the pressure adjustment knob (B) fully counterclockwise.
A
11
13
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.
A Torque to 2.4 N.m
A
5. Guide the harness of the new pressure control
through the drive housing and motor passages.
6. Install the new pressure control. Tip the pressure
control down and back into the drive housing (11).
Do not pinch or damage the harness (A).
7. Loosely install the screws (63) and then torque
them to 2.4 N.m.
59
56
Fig. 29
03182
Pressure Transducer
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.
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.
29
4. Lightly apply oil to the o–ring of the new transducer.
101
5. Install the transducer in the pump manifold, while
guiding the o–ring and backup ring into place.
6. Align the holes in the transducer as shown by the
arrows in Fig. 30.
7. Install the displacement pump. See page 22.
04715
Fig. 30
308-559
31
Drain Valve
42a
WARNING
42b
A
42d
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
42c
43 B
D
1. Turn the handle (45) to the closed position. Drive
out the pin (44). Remove the handle.
42
A
Apply thread sealant (42e)
B
Apply grease to face of base
C
Handle shown in closed position
D
Torque into pump manifold to 21 N.m
44
45
Fig. 31
C
02819
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 spring, 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, replace 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
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
correctly 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 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 the pin
(44).
Displacement Pump Parts
Model 235–699, Series A
123
Includes items 101 to 126
102
Ref
No.
Part No.
Description
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
187–611
176–758
176–757*
176–997*
176–755*
176–754*
235–709
218–197
105–444*
176–751
176–750*
176–882*
176–749*
180–073*
235–708
108–526*
187–614
224–966
111–603*
176–760
105–445*
176–759*
180–656
102–969*
105–522*
MANIFOLD, pump
NUT, packing
GLAND, female. throat
V–PACKING, plastic, throat
V–PACKING, leather, throat
GLAND, male. throat
ROD, displacement
PISTON, valve
BALL, 5/16”, piston
NUT, hex, 1/2–20 unf–2b
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
VALVE, inlet
PACKING, o–ring, PTFE GUIDE, ball
BALL, 1/2”, inlet
PIN, ball stop
PLUG 1
SEALANT (not shown)
PACKING, u–cup
polyurethane
WASHER, backup, steel
126
186–652*
*Supplied in Repair Kit 235–703.
Keep a repair kit on hand to reduce
down time.
Qty.
1
1
1
3
2
1
1
1
1
1
1
3
2
1
1
1
1
1
1
1
1
1
103*
107
109*
*105
104*
110
111*
101
106*
*113
112*
114*
125*
1
1
1
126*
117
*116
115
108
*122
120
121*
119*
118
03148A
Complete Sprayer Parts
68
30
39
24
4e
74
REF 32
6
5
4
64
4a
REF 33
63 6
15 19
84
4d LABEL
16 12b
28
85
LABEL
3
11
12
12a
11b
50
SEE DETAIL
ON PAGE 33
57
17
11a
35,14
LABELS
18
26
66
56
REF 24
31
42a
42b
42d
28
13
29
34
21
20
62
36
LABEL
32
33
46
23
23
42
43
44
45
37
27
38
42c
82
25
04786
34
308-559
Complete Sprayer Parts
Model 231–347, Series A
Includes items 3 to 85 as listed below
Ref.
No.
Part No.
Description
3
4
4a
4b
4c
4d
4e
5
6
10
11
111–700
237–465
100–069
111–616
107–503
189–699
189–702*
100–643
105–510
187–962
224–965
11a
11b
12
12a
12b
13
14
15
16
17
18
19
20
21
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
42
42a
42b
42c
42d
42e
43
44
45
46
47
100–069
111–726
224–803
181–131
107–434
187–789
189–700*
218–359
218–364
176–818
176–817
103–345
235–699
111–706
111–715
187–631
112–759
235–307
104–938
162–453
235–009
111–602
108–850
237–687
190–336
111–705
290–075
190–454
187–895
187–627
235–004
235–014
111–699
187–615
224–968
168–110
110–110
224–807
111–600
187–625
110–997
235–707
47a
47b
107–260
107–267
1
GRIP, handle
1
MOTOR KIT Includes 4a to 4e
. BALL, SST, 1/4” dia.
1
. TERMINAL, 1/4” F, 16 AWG
2
. TERMINAL, 3/16” M, 18 AWG
2
1
. LABEL, Warning, Shock
. LABEL, DANGER, Japanese
1
2
SCREW, sch, 1/4–20 x 1”
5
LOCKWASHER, spring, 1/4”
1
GASKET, inlet filter
DRIVE HOUSING KIT
Includes 11a, 11b
1
. BALL, stainless steel, 1/4” dia.
1
. PLUG
1
1
CRANKSHAFT Includes 12a, 12b
. BEARING, thrust
1
. BEARING
1
COVER, front
1
LABEL, Warning
1
ROD, CONNECTING
1
GEAR REDUCER
1
PIN, straight, hdls, 3/8” dia. x 1”
1
SPRING, retaining
1
3
SCREW, sch, 1/4–20 x 1–1/4”
1
PUMP KIT see parts on page 33
2
CAPSCREW, sch, 7/16–14 x 1–3/4”
6
SCREW, special, 5/16–18 x 1–1/4”
HANDLE, sprayer
1
4
CAP, tubing
LEG, w/gusset
1
O–RING
1
NIPPLE, 1/4 npsm x 1/4 npt
2
PRESSURE TRANSDUCER
1
1
CLIP, 3/4”
1
SCREW, filh, 8–32 x 1–1/4”
SUCTION HOSE & TUBE
1
DRAIN TUBE
1
3
SCREW, filh, 8–32 x 2–1/2”
LABEL, identification
1
1
ELBOW, drain
LEG, sprayer
1
TUBE, inlet
1
STRAINER
1
DRAIN VALVE KIT Includes 42a–42e 1
. GASKET, valve seat
1
1
. SEAT, drain valve
. STEM, drain valve
1
. O–RING, stem
1
1
. SEALANT, pipe (not shown)
BASE, valve
1
PIN, grooved, 3/32 x 1”
1
HANDLE, drain valve
1
2
SCREW, washer/hex hd, 5/16”
MOTOR START BOARD
Includes 47a, 47b
1
1
. TERMINAL, 1/4” F, 16 AWG
1
. TERMINAL, 3/16” F, 16 AWG
Qty.
48
49
50
51
51a
51b
52
53
54
55
56
57
58
59
62
63
64
65
66
68
73
186–620*
110–037
187–963
236–524
107–262
107–504
105–679
111–840
105–658
105–659
111–703
235–981
100–035
187–958
189–698*
111–704
224–828
112–402
189–932
206–994
111–839
74
82
84
85
103–473
156–684
100–721
235–677
LABEL, ground terminal
SCREW, mach, pnhd, 10–24 x 5/8”
GASKET, junction box
FILTER, power inlet
TERMINAL, 1/4” F, 18 AWG
TERMINAL, 3/16” F, 18 AWG
SWITCH, ON/OFF
SCREW, panhead, M3 x 10 mm
RING, locking
BOOT, switch
SCREW, filh, 10–24 x 3”
POWER CORD with IEC–320 Connector
SCREW, panhd, 8–32 x 5/16”
JUNCTION BOX
LABEL, Warning
SCREW, filh, 10–24 x 1–5/8”
PRESSURE CONTROL KIT
CLAMP, power cord
BASE, motor
TSL, 8 oz.
SCREW, panhead w/lockwasher,
6–32 x .375”
STRAP, cable
FITTING, swivel
PLUG, 1/4 npt
FLUID FILTER
See manual 308–249 for parts
1
1
1
1
1
1
1
2
1
1
4
1
2
1
1
2
1
1
1
1
2
2
1
1
1
*Extra warning labels available free of charge.
Motor Brush and Spring Replacement Kit,
P.N. 236–967 is available. Purchase separately.
MOTOR
48
RED
GREEN/
YELLOW
47b
BLACK
BLACK/
WHITE
4c
49
51b
47a
WHITE
52
4b
54
50
51a
59
58
BLACK
53
47b
Ref 57
65
55
47
73
10
51
03177
Technical Data
Dimensions
Power Requirements . . . . . . . . . . . 100 VAC, 50/60 Hz,
1 phase, 13 amp minimum
Working Pressure Range . . . . . . . . . . . . . . . 0 – 195 bar
Cycles/Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Power Cord . . . . . . . . . . . . . . . . 2.0 mm2, 3 wire, 2.0 m
Inlet Paint Strainer . . . . . . . . . . . . . . . . . . . . 1525 micron
Stainless Steel Screen, reusable
Pump Inlet Size . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt(f)
Fluid Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npsm
Wetted Parts:
Displacement Pump . . Stainless steel, Carbon steel,
Aluminum, Polyethylene, Delrin, Leather
NOTE: Delrin
Weight (dry w/o packaging) . . . . . . . . . . . . . . . . . 16.6 kg
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483 mm
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381 mm
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356 mm
Accessories
FLUID HOPPER KIT
236–342
(Includes hopper, lid, screen, and Installation Kit.)
WHEELED LO–CART KIT
235–710
WHEELED UPRIGHT CART KIT
236–328
The Graco Warranty and Disclaimers
Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. 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. 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.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties
reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures
judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
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, Los Angeles
Foreign Offices: Belgium, Canada, England, Korea, France, Germany, Hong Kong, Japan
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN
PRINTED IN U.S.A.
36
308-559
55440–1441
308–559 February 1995, Revised June 1997

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