Graco 308298B ELECTRIC, 230 VAC/50 HZ 490st Airless Paint Sprayer Owner's Manual

308 -298
INSTRUCTIONS-PARTS LIST
m
UIsTRuCnOHS
This manual contains important
warnings and information.
Rev. B
Supercedes Rev.A
and PCN B
GRACO
READ AND RETAIN FOR REFERENCE
ELECTRIC. 230 VAC/50 HZ
490s)Airless Paint Sprayer
-~~
~
195 bar Maximum Working Pressure
Model 231 -306, Series A
Complete sprayer with hose, gun,
RAC IV@Dripless”
Tip Guard and SwitchTip”
..
NOTE: This isan example of the English languageDANGER label on your sprayer. Thislabel is
supplied with the sprayerin 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.
I
FIRE AND
EXPLOSION HAZARD
SKIN INJECTION
HAZARD
Uquids can be injected into body
the by high pressure airieSS spray or
Spray painting. flushingor cleaning equipment with flammable liquids
leaks - especially hose leaks.
in fire or explosion.
in confined areas can result
Keep bodyclearofthenoule. Neverstop ieakswithanypaltofhe body.
Use outdoors or inextremelyweilventilated areas. Ground equipment,
Drain all pressure before removing parts.Avoid accidental triggering of
hoses, containers and objects being sprayed.
gun by always setting safety latch when
not Spraying.
Avoid ail ignition sources such
as static electricity from plastic drop
Never
spray
without
a
tip
guard.
cloths, open flames such as pilot lights, hot objectsas
such
Cigarettes,
accidental skin injection.
seek immediate
arcs from connecting or disconnecting power cords
or turning light In case of
switches on andoff.
“Surgical Treatment”.
Failure to follow this warning can result
in death or seriousinjuly.
Failure to follow this’ warning can result in amputation or serious
injury.
I
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
OCOPYRIGHT1993,GRACO INC.
I
High Pressure Spray Can Cause Serious
Injury. For Professional Use Only.
Observe All Warnings..Read and understandall instruction manuals before operating equipment.
FLUID INJECTION HAZARD
General Safety
This equipment generatesvery high fluid pressure. Sprayfrom
the gun, leaksor ruptured components can inject fluid through
yourskinandintoyourbodyandcauseextremeiyseriousbodily
injury, including the need for amputation. Also,
fluid injected or
splashedintotheeyesorontheskincancauseseriousdamage.
NEVERpointthespraygunatanyoneoratanypartofthebody.
NEVER put hand or fingers over the spray tip. NEVER try to
"blow b a c k paint; this is NOT an air spray system.
ALWAYS have the tip guard in piace on the spray gun when
spraying.
ALWAYS followthe Pressure Relief Procedure, below, before
cleaning or removing the spray tip or servicing any system
equipment.
NEVER try to stop or deflect leaks with your hand or body.
Besureequipmentsafetydevicesareoperatingproperlybefore
each use.
Medical Alert--Airless Spray Wounds
If any fluid appears to penetrate your skin, get
EMERGENCY
MEDICAL CAREAT ONCE. DO'NOT TREAT AS A SIMPLE
'CUT Tell the doctor exactly whatfluid was injected.
Note to Physician: Injection in the skin is a traumaticinjury
It is important to treat theinjury surgically as soon as possible. Do not delay treatmentto research toxiciv. Toxicity
is a concern with some exotic coatings
injected directly into
the blood stream. Consultation witha plastic surgeon or
reconstructive hand surgeon may be advisable.
Spray Gun Safety Devices
Safety Latch
Wheneveryoustopspraying,evenforamoment,aiwayssetthe
gun safety latch
in the closed or
"safe" position, makingthe gun
inoperative.Failuretosetthesafetylatchcanresuitinaccidenta1
triggering of the gun.
Diffuser
Thegundiffuserbreaksupsprayandreducestheriskoffluidinjection when thetip is not installed.Check diffuser operation
regularly. Follow the Pressure Relief Procedure, below, then
remove the spray tip. Aimthe gun into a metal pail,
holding the
gunfirmlytothepail.Usingthelowestpossiblepressure,trigger
the gun. If the fluid emitted is not diffused into an irregular
stream, replacethe diffuser immediately.
Tip Guard
ALWAYS have thetip guard in place on the spray gun while
spraying. Thetip guard alertsyou to the fluid injection hazard
and helps reduce, but does
not prevent, the risk
of accidentally
placing your fingers or any
part of your body close to the spray
tip.
Trigger Guard
Alwayshavethetriggerguardinpiaceonthegunwhenspraying
to reduce the risk of accidentallytriggering the gun if it is
dropped or bumped.
Spray Tip Safety
Useextremecautionwhenc1eaningorchangingspraytips.Ifthe
spray tip clogs while spraying, engage
the gun safetylatch immediately.ALWAYSfollowthePressureRelief Procedureand
then remove the spray tip to clean it.
Be sure all gun safety devices
are operating properly before
each use. Do not removemodify
or any part of the gun; this can NEVERwipeoffbuild-uparoundthespraytipuntilpressureis
cause a malfunctionand result in serious bodily injury.
fully relieved and the gun safety latch is engaged.
Pressure Relief Procedure
Toreducetheriskofseriousbodilyinjury,includingfluidinjection,splashingfluidorsolventintheeyesorontheskin,orinjury from moving parts or electric shock, always followthis
procedurewheneveryoushutoffthesprayer,whenchecking
or servicing any part of the spray system, when installing,
cleaning or changing spray tips, and whenever you stop
spraying.
1. Engage the gu'n safety latch.
2. Turn the ON/OFF switch to OFF.
3. Unplug the power supply cord.
2
308-298
4. Disengage the gun safety.latch. Hold a metalpart of the
gunfirmlytothesideofagroundedmetalpaii,andtrigger
the gunto relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve, having a container ready
to catch the drainage. Leave the valve open
until you are
ready to spray again.
lfyoususpectthatthespraytiporhoseiscompletelyclogged,
orthatpressurehasnotbeenfuliyrelievedafterfollowingthe
stepsabove.VERYSLOWLY1oosenthetipguardretainingnut
or hose end couolina to relieve
oressure ~.
oraduallv
-- --..,, then
. .-. .
:
,~
loosen completely. Now clear the
tip or hose.
.
/
I
~
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the spray equipment or accessories, such
as
overpressurizing, modifying parts,using incompatible chemicalsandfluids,orusingwornordamagedparts,cancausethem
toruptureandresultinfluidinjection,splashingintheeyesoron
theskin,orotherserious bodilyinjury, orfire,explosionorproperty damage.
NEVER alter or modify any part of this equipment; doingso
could cause it to malfunction. ture
CHECKallsprayequipmentregulariyandrepairorreplaceworn
or damaged parts immediately.
Aiwayswearprotectiveeyewear,gloves,clothingandrespirator
as recommended by the fluid and solvent manufacturer.
System Pressure
195 barMaximum Working Pressure.
This sprayer can develop
Besurethatallsprayequipmentandaccessoriesusedarerated
towahstandthis pressure. DONOTexceedthemaximumworking pressure of anypart used in the system.
Fluid and Solvent Compatibility
BE SUREthat all fluids and solvents used chemicallycomare
patiblewiththewettedpartsshownintheTECHNlCALDATAon
page36.Alwaysreadthefluidandsolventmanufacturer'siiterabefore using them in this sprayer.
Donotuse1,1.1-trichloroethane,methylenechloride,otherhalogenated hydrocarbonsolvents orfluids containing such solvents inthis equipment, which
aluminum
and/or zinc
parts. Suchusecould result in aseriouschemical reaction, with
the possibility of explosion, which
could cause death, serious
bodily injury andlor substantial property damage.
HOSE SAFETY
High pressure fluid in the hoses canbe very dangerous.If the
hose develops a leak, spiit
or rupture due to anykind of wear,
damageormisuse,thehighpressuresprayeminedfromitcan
cause a fluid injection injury
. . or
. . or other serious bodily. iniury
property damage.
and hot surfaces of thepump and gas engine.Do not use fluids
or solvents which are not compatible with the inner tube
and
coverofthehose.DONOTexposeGracohosetotemperatures
above 82°C or below -4oOC.
. -.
All fluid hoses must havespring guards on both ends1 The
spring guards help protect the hose from kinks or bendsorat
close to the coupling which can resultin hose rupture.
Proper hosegrounding continuity is essentialto maintaining a
grounded spray system. Checkthe electrical resistanceof
If your hose doesnot
your fluid hoses at least once a week.
have a tagon it which specifies the maximum electrical resistance, contactthe hose supplieror manufacturer forthe maximum resistance limits. Use
a resistance meterin the appropri..
.
ate range for your hoseto check the resistance.If the
resistance exceedsthe recommended limits, replace it immediately. An ungrounded or poorly grounded hose can make
your system hazardous, Also read
OR
~
~
~
~
~
Hose Grounding Continuity
TIGHTEN allfluid connections securely before each use.
High
oressurefluid can dislodae aloose couolino orallow hiah oressure sDrav
. . to be emittedfrom the couplina.
. NEVERuseadamagedhose.Beforeeachuse,checktheentire
hose for cuts, leaks, abrasion,bulging cover, or damage or
movementofthehosecoupiings.Ifanyoftheseconditionsexist,
replacethehoseimmediately.DON0TtrytorecouplehighpresHAZARD.
sure hose or mend it with taoe or anv other device. A reoaired
hose cannot contain thehigh pressirefluid.
.
I
".
HANDLE AND ROUTE HOSES CAREFULLYDo not pull on
hoses to move equipment. Keep hoses clear of moving parts
FIRE OR EXPLOSION HAZARD
Static electricityis created bythe flow of fluid through thepump
and hose. If every part of the spray equipmentis not properly
grounded, sparking may occur, and the system may become
hazardous. Sparking may also occur when
plugging in or unpluggingapowersupplycord.Sparkscanignitefumesfromsolvents and the
fluid beingsprayed, dust particles and
otherflammable substances, whether you are spraying indoors or
outdoors, and can cause afire or explosion and serious
bodily
injury and property damage. Plugthe sprayer into a grounded
outlet at least 6 m from the sprayer.
Ifyouexperienceanystaticsparkingorevenaslightshockwhile
using this equipment, Stop Spraying Immediately.Checkthe
entiresystemforpropergrounding.Donotusethesystemagain
until the problem has been identified and corrected.
Grounding
To reduce the risk of static sparking,ground the sprayer and all
other spray equipment used or located in the spray area.
CHECKyourlocalelectricaicodefordetaiiedgroundinginstructions for your area and type of equipment. BE SURE to ground
all of this spray equipment:
1. Sprayer:plugintoaproperlygroundedoutlet.Donotusean
adapter. Extensioncords must
havethreewiresandberated
for at least6 amps.
2. Fluid hoses: use only grounded hoses witha maximum of
150 m combined hose lengthtoensuregroundingcontinuity. SeeHose Grounding Continuity.
3. Spraygun: obtain grounding through connectionto a prop
erly grounded fluid hose and sprayer.
4. Object being sprayed: according to local code.
5. Fluid supply container: according
- to local code.
6. Nisolventpailsusedwhenflushing, accordingtolocalcode.
Useonlymetalpails,whichareconductive.Donotplacethe
pail on a non-conductive surface, suchas paper orcardboard, which interrupts the
grounding continuity.
7. To maintain gmunding continuity when flushing
orreiieving
pressure, alwayshold a metal partof the gun firmlyto the
side of a grounded metal pail, then trigger
the gun.
Flushing Safety
Reducetheriskoffluidinjectioninjury,staticsparking,orsplashingbyfollowingtheflushingproceduregivenonpage1Oofthis
manual.
MOVING PARTS HAZARD
Moving partscan pinch or amputate your fingers
or otherbody parts. KEEP CLEAR ofmoving parts when starting
or operating the
sprayer. FollowthePressureRellefProcedureonpage2beforecheckingorservicinganypartofthesprayer,topreventitfromstarting accidentally.
308-298
3
2. Attach thefluid filter (85) to the sprayer.
WARNING
If you supply your own hoses and spray gun, be
sure the hoses are electrically conductive, that the
gun has atip guard, and that each part is rated for
at least 195 bar Maximum Working Pressure. This
is to reduce the risk of serious bodily injury
caused by static sparking, fluid injection or overpressurization and rupture of the hose or gun.
CAUTION
~
To avoid damaging the pressure control,which
may resultin poor equipment performance and
component damage, follow these precautions:
1. Always usenylon spray hose at least
6m
long.
2. Never use a wirebraid hose as it is too rigid to
act as a pulsation dampener.
3. Never install any shutoff device between the
pump andthe hose. See Fig. 2.
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.1, If the
power cord youare using does not have a male
plug attached, have aqualified electrician install
an appropriate plug.
Fig. 1
4
308-298
,.
3. Connect the hose (74) and gun (67) and screw it
onto the outletnipple (28). Don't use thread
sealant, and don't install the spray tip yet!
4. Fill the wet-cup (102). Pryoff the wet-cup seal.
Liquid
Fill the cup 1/3 full with Graco Throat Seal
(TSL), supplied. Installthe seal.
5. Check the electrical service.
It must be 230 V/50
Hz, 6 Amp (minimum)and must be protected by
a fuseor circuit breaker with a ratingof not more
than 16 amps.
6. You may use a 3-wire,
1.O mm2 (16 AWG) (minimum) extensioncord up to45 m long. Longer
lengths affect sprayer performance.
7. Plug in the sprayer. Be sure the ON/OFF switch
(52) is OFF. Plug the cord into a grounded outlet
at least6 m away from thespray area.
WARNING
Proper electricalgrounding is essentialto reduce
the riskof fire or explosion which can result in
serious bodily injury and property damage. Also
read FIRE OR EXPLOSION HAZARDon page 3.
8. Flush the pump to remove theoil which was leftin
to protect pump parts afterfactory testing. See
page 7.
9. Prepare thepaint according to the manufacturarls
recommendations. Remove any
paint skin. Stir
the paintto mix pigments. Strain
the paint
through afine nylon meshbag to remove particles that could clog the gun filter or spray tip. This
is an important steptoward trouble-free paint
spraying.
A
A
1/4 npsm(8n):
Do not install any shutoff device here
Fill 1/3 full with TSL
1022
67
Operation
How to use thegun safety latch
When engaged, the gun safety latch (A) prevents the
gun from accidental triggering. See Fig. 3.
How to use the pressure drain valve
Use the pressuredrain valve (45) to relieve fluid pressure from thepump and tohelp prime the pump. If
the valve sensesan overpressure condition, it opens
automatically to relieve fluid pressure. If this happens,
stop spraying immediately, shut offand unplug the
sprayer. Correct theproblem before using the sprayer
again. Refer to Troubleshooting, page 11. See Fig. 4.
I
W
A
If the gun still sprays whenthe safety latchis engaged, adjust the gun. See manual 307-614.
A
Safety latch shown
In "ON SAFE" position
Closed (spray)position
Open (drain) position
Fig. 4
W
308-298
1022
5
Operation
How to use the pressure control
The pressure control controls the motor operation so
the sprayer maintainsconstant 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.5.
A
A
Clean the front of the tip frequently during the day's
operation. First, follow the
Pressure Relief Procedure Warning onpage 2.
,
Rotate clockwise to
increase pressure
. -
Fig.
How to use theRAC IV tip guard
WARNING
To reduce the risk of serious bodily injury from
from fluid injection:
Fig. 6
W
How to remove a tip clog
1. Release the gun trigger. Engagethe gun safety
latch. Rotate theRAC IV tip handle 180". See Fig,
6.
NEVER operate the spray gun with the tip guard
removed.
2.
DO NOT hold your hand, body, or a rag in front of
the spraytip when cleaning or checking a clogged
tip. Always point the gun toward the ground or
into a p&l when checking to see if the tip is clear.
3. Engage the gun safety latch. Rotate thetip handle
(6)
to the spraying position.
DO NOT try to "blow back" paint; this is NOT an
air spray sprayer.
6
The tip guard alerts you to the riskand helps prevent
placing any part of the body close to the spray tip.
The tip guard also adjuststhe vertical or horizontal
spray pattern.See page 8. The tip guard holds a
reversing spray tip. The tip is in the spraying position
when the tip handle (6)points forward. See Fig.6.
308-298
Disengage thegun safety latch. Triggerthe gun
into a pail or onto the ground to remove the clog.
4. If the tip is still clogged, engage thegun safety
latch, shut off and unplug the sprayer, and open
the pressure drain valve
to relieve pressure. Clean
the spraytip as shown in manual 307-848, supplied.
Startup
Use this procedure each time you start the sprayerto
3. Put the suction hose (32) into the paint.
help ensure the sprayer is ready to operate and that
you start it safely. 4. Turn
the pressurecontrol (64) to minimum.
5. Disengage the gun safety latch.See Fig. 3, page
5.
WARNING
follow the Pressure Relief Procedureon page 2
when instructed in this procedure to relieve
pressure.
CAUTION 1I
To reduce the risk of damage to the displacement
pump packings, never run the pump without fluid
in itfor more than 30 seconds.
I
Fig. 7
I
1022
NOTE: If this is a first-time startup, flush thesprayer.
See page 10.
NOTE: Refer to Fig. 9 and the other figures referenced in the text as you start the sprayer.
1. Open the pressure drain valve (45). See Fig.
7.
2. Don’t install the spraytip until the pump is
primed!
6. To prime the pump, turn the sprayerswitch (52)
on. Slowly increase the pressure
until the sprayer
starts. Whenfluid comes fromthe pressure drain
valve, close the valve.
I
I
WARNING
.......- ..- 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 priming orflushing.
I
I
7. To prime the hose, lower the pressure
to reduce
splashing. Hold a metal part of the gun firmly
against and aimed into the sideof a grounded
metal pail.See the WARNING, above. Hold the
trigger open and slowly increasethe pressure
until the pump starts. Keep thegun triggered until
all airis forced out of the systemand the fluid
flows freely from the
gun. Releasethe trigger and
engage the gun safety latch.
8. Check allfluid connections for leaks. Relieve pressure before tightening any connections.
9. Install the spray
tip. Engage thegun safety latch
first! See manual 307-848 for how to install the
tip.
308-298
7
Startup
10. Adjust the spray pattern,
a. Increase the pressure just until spray from the
gun is completely atomized. To avoid excessive oversprayand 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. Test the spray pattern. To adjust thedirection
of the spray pattern, engage thegun safety
latch and loosen the retaining nut. Position
the tip guard horizontally for a horizontalpattern or vertically for a vertical pattern.Hold the
tip guard in place while tightening the retaining nut. See Fig.8.
NOTE: Spray patterns will change as tips wear.
Change the spray tip if adjusting the pressure willnot
improve the spray pattern.
8
308-298
Fig. 8
Shutdown and Care
WARNING
To reduce the risk of serious bodily injury, always
follow the Pressure Relief Procedure on
page 2
when instructed in this procedure to relieve
See the warning section, HOSE SAFETY on page
3, for information on the hazard of using damI aged
Whoses.A
R
N
I
N
G
I. Check the packing nut/wet-cup (102) daily. Relieve pressure first. Keep thewet-cup 113 full of
TSL at all times to help prevent fluid buildup on
the piston rod and premature wear of packings.
1
Wlth pressure relieved.
turn packing nut
clockwise to tighten
2. Tighten the packing nut/wet-cup (102) just
enough to stop leakage. Over-tightening causes
binding andexcessive packing wear. Use a round
punch or brass rod and a light hammer to adjust
the nut. See Fig. 10.
3. Clean the gun'sfluid filter oftenand whenever the
gun is stored. Relieve pressure first.
Refer to manual307-614.
4.
Periodically clean paint residue from the pressure
transducer vent hole (A) area. See Fig. 11. Replace the transducer when leakageis excessive.
See page 29.
5. Lubricate the bearing housing after every100
hours of operation. Remove the
front cover. Fill
the bearing housing cavity (B) with SAE 10 nondetergent oil. See Fig. 11.
6.
Flg. 10
u
Flush the sprayer at the end of each workday
and fill it with mineral spirits to help prevent pump
corrosion and freezing. See page 10.
CAUTION 1I
r
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 itis not in use. Freezingcan seriously damage the sprayeror result in a loss of
pressure or stalling.
I
7. For very short shutoff periods,leave the suction
hose in the paint, relieve pressure,
and clean the
spray tip.
8. Coil the hose when storing it, even for overnight,
to help protect the hose from kinking, abrasion,
coupling damage, etc.
Fig. 11
1067
308-298
9
Flushing
How to flush
When to flush
1. Before using a new sprayer, flush out the oil
which was leftin toprotect pump parts.
Before using water-base paint, flush with mineral
spirits followed by soapy water, and then a clean
water flush.
1. Follow the Pressure Relief Procedure on page
n
L.
2. Remove the spraytip and clean it separately.
Unscrew thebowl (A) and remove the filter
screen. Then reinstallthe bowl, hand tight,
without the screen. Cleanthe screen.
Before using oil-base paint, flush with mineral
spirits only.
2. When changing colors, flush with acompatible
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 thena clean water flush.
5. Storage afterusing 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 afterusing oil-base paint: flush with minera1 spirits. Relieve pressure. Leave
the drain
valve open.
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
To reduce staticsparking and splashing, always
remove the spray tip from the gun, and holda
metal part of the gun firmly to the sideof a
grounded metal pail when priming or flushing.
CAUTION
NEVER,leave wateror water-based fluids in the
sprayer if there is a chance it could freeze. Push
the waterout with mineral spirits. Frozen
fluid in
the sprayer preventsit from being started and may
cause serious damage.
6.
10
Startup after storage. Before
using water-base
paint, flush out the mineral spirits with soapy water and then a clean water flush. When
using oilbase paint, flush out the mineral spirits with the
paint to be sprayed.
308-298
5. Ifyou have been spraying and want to save the
paint still in the pump and hose, follow Step 5,
except put the drain hosein the paint container.
As soon as solvent appears,close the drain valve.
Move thedrain hose to the flushing pail. Trigger
the gun into the paint pail.As soon as solvent appears, releasethe trigger. Continue with Step 6.
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 pumpoperates. Keep the
gun triggered until the solvent flows freely from
the gun. Circulate the solvent
to thoroughly clean
the sprayer. Releasethe gun trigger. Engagethe
gun safety latch.
8. Open thedrain valveand circulate the solvent
through thedrain hoseto thoroughly cleanit.
Close the drain valve.
CAUTION 1To reduce the risk of damage to the displacement
pump packings, neverrun the pump withoutfluid
in it for more than 30 seconds.
9. Remove theD u m from the oa141. Disengage the
gun safety latch. Trigger the'gun toforce solvent
from the hose and run the sprayer a few seconds
more to push airinto the hose. Relieve pressure.
10. Remove thefilter bowl and reinstallthe clean filter
screen. Handtighten the bowl.
11. Remove theinlet strainer and cleanit thoroughly.
Wipe paint off the suction hoseand drain hose.
12. If you flushed with mineral
spirits and are going to
use a water-basepaint, flush with soapy water
followed by a clean water
flush. Relieve pressure.
13. Leave the drain valve open.
Troubleshooting
WARNING
To reduce the risk of serious bodily injury, always
follow the Pressure Relief Procedureon page 2
when instructedin thisprocedure to relieve
pressure.
Check everything in the guide before disassembling
the sprayer.
Basic Problem Solving
TYPE OF PROBLEM
Fluid Pressure
WHATTO CHECK
If check is OK, go to next check
1. Check pressure control knob setting. The pump
1. Slowly increase pressure setting tosee if
won't develop muchpressure if it is at minimum
motor starts.
setting (fully counterclockwise).
2.
Mechanical
WHAT TO DO
When check is not OK, refer to this column
Check for a clogged spray tip (see page 6 ) or
a clogged fluid filter (see page 10 ).
1. Check for frozen or hardened paintin pump
(20). Using a screwdriver, carefully tryto rotate
fan at back of motor by hand. See page 16.
2. iftip is still clogged, relieve pressure; refer to separate gun or tip instruction manual for tip cleaning.Clean or replace the
filter element.
1.
Thaw. Plugin sprayer and turn on. Slowly
increase pressure setting to see if motor
starts. If it doesn't, see NOTE 1, below.
-
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 sprayeruntil it has thawed completelyor 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 21 (pump) or 29 (pressuretransducer).
308-298
11
Troubleshooting
Basic Problem Solving (continued)
YPE OF PROBLEM
lechanical (continued)
/HAT TOCHECK
check isOK, go to nexfcheck
.
.
ilectrical
,
,
.
.
Check pump connecting rod pin (17). It must be
completely pushed into connecting
rod (15),
and retainingspring (1 8) must befirmly in connecting rod groove. See page 21
(HAT TO DO
/hen check is not OK, refer to thiscolumn
,
Check for motor damage. Remove drive hous- . Replace motor (4) if fan won't turn. See
page 24.
ina assemblv (11).See .Dacre
- 26.Trv to rotate
m&or fan by hand.
Check electrical supply with volt
meter. Meter
should read 210-250 VAC.
Check extensioncord for visible damage. Use a
volt meter or test lamp at extension
cord outlet
to check.
Check sprayer power supply
cord (57) for visible damage suchas broken insulationor wires.
Check.motor brushes for the following:
a. Loose terminal screws.
. Reset buildingcircuit breaker; replace
building fuse. Try another outlet.
.
Replace extension cord.
.
Replace power supplycord.
. Refer to page 18.
a. Tighten.
b. Broken or misaligned brush springs.
b. Replace broken spring andlor align
spring with brush.
c. Brushes binding in holders.
c. Clean brush holders. Remove carbor
with small cleaningbrush. Align brust
leads with slotin brush holder to assure free verticalbrush movement.
d. Broken leads.
d. Replace brushes.
e. Replace brushes if less than 10 mm
long.
e. Worn brushes
iOTE: The brushes do not wear at same rate
on
0th sidesof motor. Check both brushes.
,
Push pin into place
and secure with
spring retainer.
Check motor armature commutator forburn
. Remove motor and havemotor shop
spots, gouges and extreme roughness. Remove resurface commutatorif possible. See
motor cover andbrush inspection platesto
page 24.
check. See page 18.
. Checkmotorarmatureforshorts using armature
tester (growler) or perform motor test. See page
.
Replace motor. Seepage 24.
16.
.
.
.
12
308-298
Check leadsfrom pressure control and motor
to
motor start board (47)to be sure they are securely fastened and properly mated.
.
Check motor startboard (47) by substituting
with a good board. See page 28.
. Replace board. Seepage 28.
CAUTION: Do not performthis check until motor armature is determined to
be good. A bad
motor armature canburn out a good board.
Check power supplycord (57). Disconnect
brown and blue power cord terminals; connect
volt meterto these leads. Plugin sprayer. Meter
should read 210-250VAC. Unplug sprayer.
.
Replace loose terminals;crimp to leads.
Be sure maleterminal blades are straighi
and firmly connectedto mating part.
Replace power supplycord,
Troubleshooting
Basic Problem Solving (continued)
YPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
:/electrical,continued
WHAT TO DO
When check is not OK, refer to this column
ON/OFFswitch (52). Disconnect red wire 10. Replace ON/OFF switch. See
page 25. 10. Check
from motor and brown wire from motor start
board (47) and connect volt meter between exposed terminals on switch. Plugin sprayer and
0-250 VAC. Turn
turn ON. Meter should read 21
off and unplug sprayer.
11. Checkmotor thermal cutout switch. Connect 11. Allow motorto cool. Correct cause of
ohmmeter betweenmotor's red leads. Meter
overheating. If switch remains
open after
should read 1 ohm maximum.
motor cools, replace motor.
I
12. Remove pressurecontrol (64) and check micro- 12. Replace pressurecontrol. See page 2 r
swltch operation with ohmmeter:
a. With pressure knob at lowest setting and
stem pushed into control, readings should
be: white &black = 1 ohm m a .
white &'red = open.
b. With pressure knob at highest setting,readings shouldbe: white&black = open: white
&red = 1 ohmmax.
-
13. Check pressuretransducer (29) for hardened
13. Replace transducer. See page 29. Thorpaint or damaged or worn components. See
ough systemflushing will help extendlife
page 29.
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 2 then replacetip. See your separate gun ortip manual.
I
to stroke when 2. Sewice pump. See page20.
2. Be sure pump does not continue
gun triggeris released. Plugin and turn on
sprayer. Primewith paint. Trigger gun momentarily, then release andengage safety latch.Re.
lieve dressure.turn off and unoluo soraver.
3. Release gun trigger. ObSeNe resting
position 01
pump rod (107).
4. Check electrical supply with volt
meter. Meter
should read 210-250VAC.
-
5. Check extensioncord size and length; must be
less than
at least 1.O mm2 gauge wire and
45 m.
1
(107) fully extended. the piston packings
and/or piston valve may be worn. Service
1. Reset building circuit breaker: replace
building fuse. Repair electrical outletor
try another outlet.
sion cord.
308-298
13
Troubleshooting
Intermediate Problem Solving
TYPE OF PROBLEM
WHAT TO DO
When checkis not OK, refer to this column
WHAT TO CHECK
If check is OK, go to nextcheck
6. Check motor brushes. See What
To Check, item 6. See page 18.
4, on page 12.
7. Check motor startboard (47) by substituting
with agood board.
7. Replace board. See page 28.
CAUTION: Do not performthis check until mo.
tor armature is determinedto be good. A bad
motor armature canburn out aaood board.
8. Replace motor. See page 24
8. Check motor armaturefor shorts by using an
armature tester (growler)or perform motor test
See page 16.
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 sealanl
(42e). See page 30.
Transducer Leaks
1. Slight leakage is normal.
1. Periodically remove residue from its cylin
der port. See page 29.
No Output: MotorRuns
And Pump Strokes
1. Check paint supply.
1. Refill and reprime pump.
2. Check forclogged intake strainer.
I
2. Remove and clean,then reinstall.
I
3. Check for loose siphon tube or fittinas.
See 13. Tiahten: use thread sealant
on not
page 20.
thyeads'of inlettube (38). Checkior dam
aged
O-ring- (27).
. .
I
l
4. Check to see if intake valveball and piston ball 14. Remove intake valve
and clean. Check
are seating properly.See page 20.
ball and seat for nicks: replace as needed. See page 20. Strainpaint before us.
ing to remove particles thatcould clog
.oumo.
,
5. Check for leaking around throat
packing nut . 5. Replace packings. See page 21. Also
which may indicate wornor damaged packings.
check piston valve seatfor hardened
See page 20.
paint or nicks and replace if necessary.
Tighten packing nuuwet-cup.
5. Release gun trigger. Observe restingposition of 6. If pump consistently comesto reit with
pump rod (107).
rod (107)fully extended, the piston pack
ings andlor piston valve may be worn.
Service the pump. See page 21.
No Output: MotorRuns
I. Check displacementpump connecting rod pin
But Pump Does Not Stroke (17). Seepage 20.
1. Replace pin if missing, Be sure retainer
spring (18) is fully in groove all around
connecting rod.
2. Check connectingrod assembly (15) for dam-
2. Replace connecting rod assembly. See
page 26.
3. Be sure crankin drive housing rotates: plug in
sprayer and turn on brieflyto check. Turn off
and unplug sprayer. See page 26.
3. Check drive housing assembly for dam-
age. See page 26.
14
308-298
age and replace if necessary. See page
26.
Troubleshooting
Intermediate Problem Solving
WHAT TO DO
When check is notOK, referto this column
If check is OK, go to next check
1. Replace spraytip.
NOTE A smaller sizetip will provide longer
life.
bility.
2. Check transducer (29) for wear or damage.
3. Replace pressure control. See
page 28.
tion.
Aotor Is Hot and Runs
ntermittently
I
I
I 1.
2. Replace transducer. See page 29.
Determine if sprayer was operated high
at pres- 1. Decrease pressuresetting or increase til
sure with small tips, which.causes excessive
size.
heat build up.
located is no mare than
32°C and sprayer isnot
located in direct sun.
3. Check motor. (See NOTE 1, .Daae
_ 11.I
2. Move sprayer to shaded, cooler areaif
possible.
3. Replace motor. See page 24.
3uilding Circuit Breaker 1. Check all electrical wiring for damaged insula-1. Repair or replace any damaged wiringa
tion, and all terminals for loose
fit or damage.
terminals. Securely reconnect ail wires.
)pens As Soon As
Also
check
wires
between
pressure
control
and
jprayer Switch
Is
motor. See Fig on page 25..
ixned On.
I
2. Check for missing motorbrush inspection plate 2. Correct faulty conditions.
gasket (see page 19), bent terminal forksor
other metalto metal contact points which
could
cause a short.
3. Check motor armature for shorts.
Use an a n a - 3. Replace motor.See page 24.
See
ture tester (growler) or perform motor test.
page 16. Inspect windings for burns.
4. Check motor start board(47) by substituting
with agood board.
4. Replace board. See page 28.
CAUTION: Do not perform this check
until
motor armature is determined
to be good. A
bad motor armature can
burn out agood
board,
-
:ircuit breaker opens 1. Check 'Basic Problems- Electrical' on page
11.
lfter sprayer operates
)r 5 to 10 minutes.
meter. Meter
ruilding circuit breaker 1. Check electrical supply with volt
should read 210-25OVAC.
lpens assoon as spray'r is plugged into outlet 2. Check tightness of pump packing nut. Over.nd sprayer is NOT
tightening tightens packingson rod, restricts
m e d on.
pump action, damages packings.
3. Check for damaged motor.
~
2. Loosen packing nut. Check for leaking
around throat. Replacepump packings, i
necessary. Seepage 21,
3. Replace motor. Seepage 24.
unplugged! Disconnect wires from switch.
Check switch with ohmmeter. The reading
should be infinity with ON/OFF switchOFF, and
zero with switchON.
CAUTION: A shortin motor circuit can damaae
switch and/or mator start
board (47).
I
1. Ifvoltage is too high, do not operate
sprayer until corrected.
t. Replace ON/OFF switch. See page 25.
-
308-298
15
Motor Test
1
WARNING
To reduce the risk of serious bodily injury, always
follow the Pressure Relief Procedureon page 2
when instructed in this procedure to relieve
pressure.
For checking armature, motor winding and brush
electrical continuity.
Setup
1, Remove the drive housing. See page 26. 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 themotor brush inspection covers (A).
See Fig. 13.
3.
Remove the junction box screws (56). Lower the
junction box. Disconnect the two leads (C) from
the motor to the board (47). See Fig. 14.
Armature Short CircuitTest
1.
Remove the fancover (B). See Fig. 13.
2. Spin the motor fan by hand. If there are no shorts,
the motor will coast two or three revolutionsbefore coming to a complete stop. If themotor does
not spin freely, the armatureis shorted and the
motor must be replaced. See page 24.
Armature, Brushes, and Motor Wiring
Open Circuit Test (Continuity)
1. Connect the two black motor leads togetherwith
a test lead.Turn the motor fan by hand at about
two revolutions per second.
2. When turning the fan on a DC motor, normally
you sense an even, pulsing resistance. If there is
irregular turning resistance, or noturning resistance, check and repair the following as needed:
broken brush springs, brush leads, motor leads;
loose brush terminal screws, motor lead terminals: worn brushes. Seepage 18.
3. If thereis still uneven or no turning resistance,
replace the motor. See page 24.
16
308-298
Fig. 13
1022
General Repair Information
I
To reduce the risk of serious bodily injury, always
on page 2
follow the Pressure Rellef Procedure
when instructed in this procedure to relieve
pressure.
3. Route wires carefullythrough the drive housing
and motor. Avoidpinching the wires betweenthe
junction box and the motor.
I
Improper wire routing can resultin poorsprayer
performance or damage to the pressure control.
Required Tool List
Tool
Used for:
I .DumD. manifold
316" Allen@ wrench
3116" Allen@ wrench
I1 gear
housing, legs,handle
#1 Phillips@ screwdriver junction box, pressure
control, front cover
318" socket wrench
motor mount
516" socket wrench
I drain valve, outlet fittings,
onloff switch, boot, piston
13/16 socket wrench
I drain valve
1-114" socket wrench
pump inlet valve
112" openend wrench
I DumD rod
"
I
11/16" open endwrench
15/16" open endwrench
piston jam nut
flats ofinlet tube
1-314" open end wrench pump jam nut
5/64" drive pin
drain valve pin
3" needle nose pliers
wiring. onloff switch
Hammer 8. punch
Toraue wrenches
CAUTION
packing nut
I various fasteners
1. When disconnecting wires in the junction box as-
sembly, use needle nose pliers to separate mating 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
To reduce the risk of a pressurecontrol malfunction, be sure to properly mate connectors,and
never pull on a wireto disconnect it. Pulling on a
wire could loosen the connector from the wire.
4. Keep all screws, nuts, washers, gaskets,
and
electrical fittings removed during repair procedures. These parts are
not normally provided with
replacement assemblies.
5. Test your repairbefore regular operation to be
sure theproblem is corrected.
6. If the sprayer doesnot operate properly, verify
that everything was done correctly. Also referto
the Troubleshooting Guide, starting
on page 11,
to help identify other Dossible Droblems
and sohtions.
WARNING
To reduce the riskof serious bodily injury, including electric shock,DO NOT touch any moving
parts or electrical parts with yourfingers or a tool
while inspecting the repair.
Shut off the sprayerand unplug it as soon as you
complete the inspection.
Reinstall all covers, gaskets, screwsand washers
before operating the sprayer.
During operation, the motor and drive housing
become very hot and could burn your skin if
touched. Flammable materialsspilled on the hot,
bare motor could cause a fire or explosion.
308-298
17
Motor Brush Replacement
NOTE Replace the brushes when they haveworn to
less than 10 mm. Refer to Fig. 16. Note that the
brushes wear differently on each side of the motor, so
check them both. Brush Repair Kit 235-980 is available.
NOTE: Replacement brushes may lastonly half as
long as the original ones. To maximize brush life,
break in the new brushes by operating the sprayer
with noload (remove thepump connecting rod pin)
for at least hour.
1
WARNING
To reduce the riskof serious bodily injury, always
follow the Pressure Relief Procedure
on page 2
when instructed in this procedure to relieve
1. Remove both inspection covers (A) and their gas
kets. See Fig. 15.
2. Push in the spring clip (G) and release its hooks
from the brush holder (B). Pull out the spring clip.
See Fig. 16.
3. Loosen thebrush lead terminal screw (E).Pull the
brush lead away, but leave the motor lead terminal (C) in place. Removeand discard the brush
(F). See Fig. 16.
4.
Inspect the commutator for excessive pitting,
burning or gouging. A black color on thecommutator 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
10.d. also.
5. Repeat for the other
side.
6. Place a newbrush (F) in the holder (B)so the
lead is closerto the fan-end of the motor.Slide
the terminalunder the terminal screw (E) washer.
Be sure themotor lead isstill connected at the
screw. See Fig. 16.
7. Holding the spring/clip (G) at aslight angle, slide
the spring/clip into the brush holder (B) and hook
it overthe end of the brush holder. See Fig. 17.
Pull on the spring/clip to be sure it staysin place.
Be surethe brush lead (D) is tucked under the
spring/clip tab.
8. Repeat for the other side.
Fig. 15
9. Continue on the next page.
C
Fig. 16
18
308-298
n/
Y
Motor Brush Replacement
10. Test the brushes.
a. Remove the pumpconnecting rod pin.
b. With the sprayer OFF, turn the pressurecontrol knobfully counterclockwise to minimum
pressure. Plug in ihe sprayer.
WARNING
Do not touch the brushes, leads,springs or brush
holders while the sprayeris plugged in to reduce
the risk of electric shockand serious bodily injury.
c. Turn the sprayer ON.Slowly increase the
pressure until the'motor is atfull speed.
11. Install the brush inspection covers and gaskets.
d. Inspect the brush and commutator contact
area for excessive arcing. Arcs
should not
"trail" or circle around the commutator sur..
face.
12. Break in the brushes. Operate the sprayer for at
least onehour with no load. Theninstall the pump
connecting rod pin.
308-298
19
Displacement Pump
WARNING
To reduce the risk of serious bodily injury, always
follow the Pressure Relief Procedure on
page 2
when instructed in this procedure to relieve
pressure.
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 18) and
clean the transducer (see page 29)whenever you repack the pump. Replace these parts
as needed.
Removing the Pump (See Fig. 18)
2. Clean and inspect the parts for wear or damage.
Replace parts as needed. Use a new O-ring
(1 19*). Reassemblethe pump, or for additional
pump repair, go topage 21..
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 68 N.m.
A
N.m
A ~ p p sealant
~y
Torque to 68
(4%)
1. Flush thepump, 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.
Remove the filter(85).While pulling upward on
the suction hose (32),unscrew thehose from the
inlet tube (38).
3.
Unscrew the drain hose (33)from the displace.
rnent pump nipple(36).
NOTE: If repairing only the intake valve assembly,go
to Intake valverepair, below.
4. Use a screwdriver to push theretaining spring
(18) up and push out the pin (17).
5.
Loosen the screws (21) and remove thepump
(20).
Intake Valve Repair (See Fig. 18)
1. Unscrew the intake valve (1
18). Remove theoring (119*), ball guide (120),stop pin (122*)and
ball (121 *) from the valve.
20
308-298
Fig. 18
1073
Displacement Pump
3. Use a plastic mallet
to tapthe piston rod (107)
down, and then pull the rod out through the bottom of the cylinder.
4. Remove thethroat packings (104*,105*) and
glands (103*,106*).
5.
Loosen the jam nut (1 17). Removethe cylinder
(115) andtheo-ring (116*).
6. Clamp the flats ofthe piston rod ina smooth jaw
vise. Use an open-end wrench to loosen the retaining nut (1 10)and then unscrew the piston
valve (108)from the rod (107).
Fig. 19
2. Align the hole in the rod (107) with theconnecting
rod assembly (15). Use a screwdriverto push the
retaining spring up and push in the pin (17). Push
the retaining spring (18) into place around the
connecting rod.
7. Remove all parts from thepiston valve (108).
WARNING
Be sure the retaining spring (18) is firmlyin the
groove all the way around,to prevent thepin (17)
from working loose due to vibration. See Fig. 19.
If the pin works loose, it or other partscould break
off due tothe force of the pump action. These
parts could be projected into the airand 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 notighter. Fill thewet-cup 1/3 full
with TSL. Push theplug (123) into the wet-cup.
Disassembling the pump
(See Fig. 20 except where noted)
1. Remove the intake valve (1 18). Seepage 20.
2. Unscrew the packing nut (102) and plug (123).
Fig. 20
1708
308-298
21
Displacement Pump
Reassembling the pump
NOTE: Alternate plastic and leather packings. See
Fig. 20. The lips of the throat V-packings face down,
against pressure. Thelips of the piston V-packings
face up, against pressure.
Incorrect installation damages the packings and causes pump leaking.
NOTE: Soak the leather packings in oil before reassembling the pump.
8. CAREFULLY tighten the nut (1 10)
against the piston rodto 25 N.m. See Fig.22.
Use two wrenches to maintain thealignment
mentioned in the NOTE, above.
A
1. Check the outside of the piston rod (107)and the
for wear. Replaceworn
inside of the cylinder (1 15)
parts to ensure agood seal with the newpackings.
2. Stack theseparts onto the piston valve (108)one
at a time:the backup washer (126*)and u-cup
(125*),female gland (1 14*),
alternately threeplastic (112*)with two leather packings (113*),and
the malegland (1 1 1 *). See Fig. 21.
3. Tighten thenut (110) onto the piston valve (108)
to 0.23 N.m. See Fig. 21.
NOTE: Note thealignment of the piston (108)to the
nut (1 10).Maintain this alignment through Step 8.
Torque to 0.23 N.m
Apply one dropof
sealant to these
threads
112*
114*
Fig..21
A
Y O 8
Torque nut against
rod to25 N.m
Do not allow nut(1 10)to
move relative to piston
(108) when tightening
.. piston
against rod
4. Clean all residue from the piston valve threads.
Apply one drop of adhesive, supplied, to the
threads.
5. Place the ball (log*)on the piston valve (108).
See Fig. 21.
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 (1 10)contacts the rod. See Fig.22.
7. Place the flatsat the top of the rod in avise.
22
308-298
9. Stack these parts one attime
a into the top of the
manifold (101):the malegland (106*),
alternately
three plasticpackings (104*)with two leather
and then the female gland
packings (105*),
(103*).See Fig.23.
10. Install thepacking nut (102)and plug(124),but
leave loose for now. See Fig. 23.
11. Place a new O-ring(116*) firmly in the cylinder
groove. See Fig. 24.
Displacement Pump
12. Coat the piston rod andpackings with oil. Carefully slide the assemblyINTO THE TOP OF THE
CYLINDER (115). See Fig. 23.
13. Put the manifold in a vise. Fully thread
the jam nut
(117) onto the cylinder (1 15). 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.24.
A
A
15. Tighten thecylinder jam nut (117) to 98 N.m. See
Fig. 23.
16. Install the pump. See page 20.
A
A
Leather throatpackings:
lips must face down
Leather piston packings:
lips must faceup
A
Torque to 71 N.m
Plastic throat packings:
Q lips must face down
A
Plastic piston packings:
lips must face
up
Torque cylinder (115) into manifold
(101) to 71 N.m
Torque jam nut (117)
98 N.m
Torque intake valve (1 18)
into cylinder
(115) to 71 N.m
Piston assembly
Fig. 23
Fig. 24
308-298
23
Motor
6.
F
To reduce the risk of serious bodily injuty, always
follow the Pressure Relief Procedure on
page 2
when instructed in this procedure to relieve
pressure.
W
A
R
N
I
N
G
1. Relieve pressure.
Turn the displacement pump rod (107)so the pin
hole aligns with thebottom drive housing screw
(19). See the DETAIL below. Remove thethree
drive housing screws and lockwashers (19.6).
1 7. Remove the twomotor screws and lockwashers
(5,6).
8. Tap the lower rearof the drivehousing (1 1)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 26.
2. Try to stop the pump with the piston rod (107) in
its lowestposition. To lower the piston rod manually, rotatethe motor fan blades.Use a screwdriver to pushthe retaining spring (18) up and
push out the pin (17). See Fig. 25.
9. Remove thetwo screws (46) and lift the motor off
the base (66).
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. 26 on page 25.
11. Assemble the drive
housing to the motor. Follow
Steps 8to 10 on page 26.
10. Align the newmotor with the base and reinstall
the screws.
4. Remove the drive housing cover (13).
12. Connect the wires in the
junction box. Referto
Fig. 26on page 25. Install the junction box.
5. Remove the pressure control (69) whileguiding
the harness (A) through the motor.
13. Reconnect thepiston rod (107) to the drive housing; see page 21, Installing the Pump, Step2 and
the Warning that follows thestep.
Motor Start Board
WARNING
To reduce the risk of serious bodily injury, always
follow the Pressure Relief Procedure
on page 2
when instructed in this procedure to relieve
1.
Remove the junction box screws (56) and lower
the junction box (59). See Fig. 25.
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 whereconnections are made. See Fig. 26.
3. Remove the screws (58) and motor startboard
(47). Transfer the white thermal paste from the
old
board to the new board.See Fig. 26.
4.
Install the new motor start board. Reconnect all
wires. Mount thejunction box. See Fig. 26.
NOTE: Route wiresthrough the gasket (50) before
making connections.
CAUTION
Be sure the flatblade 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
To reduce the risk of serious bodily injury, always
follow the Pressure Relief Procedure on
page 2
when instructed in this procedure to relieve
pressure.
1.
6. Install thejunction box. Be sure no leads are
pinched against themotor or by the motor start
board.
)
MOTOR
,
/
Remove the junction box screws (56) and lower
the junction box (59).See Fig. 25.
2. Remove the nut and rubber boot (55).
,
3. Disconnect the wires from the ON/OFF switch
(52) and remove the switch.See Fig. 26.
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.
NOTE: Route wiresthrough any gaskets before
making connections.
5. Reconnect the ON/OFF switch wires.
Fig. 26
v
308-298
25
,
I
Drive Housing, Connecting
Rod, Crankshaft
WARNING
To reduce the risk of serious bodily injury, always
follow the Pressure Relief Procedureon page 2
when instructed in this procedure to relieve
pressure.
NOTE: Inspect parts asthey are removed. Replace
parts that are worn ordamaged.
1. Remove the displacement pump. See page 20.
5. Tap the lower rearof 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.
2. Remove the pressure control (64). See page 28.
NOTE: The gears and bearings betweenthe drive
housing (11) and motor front end bell (C) should contain a total of 90ml of grease.
3. Turn the displacement pump rod(107) so the pin
hole aligns with the bottom drive housing screw
(19). Seethe DETAIL in Fig . Remove the three
drive housing screws and lockwashers (19,6).
8. Lubricate the insideof the drive housing bearing
with SAE non-detergent oil. Pack the roller bearing and gears with the greasesupplied.
4. Remove the two motor screws and lockwashers
(5,6).
CAUTION
Do not allow thegear (16) to fall; it may stay attached to the drive housing or to the motor.
Do not lose the thrust balls (1 1 ora 4a) or allow
them to fall between the gears, which will seriously
damage thedrive housing if not removed. The
balls, which are heavilycovered with grease, usually stayin the gear recesses,but couldbe dislodged. If the balls are not in place, the bearings
will wear prematurely.
9. Place the large washer (12a)and then the small
washer (12b) on the crankshaft (12).
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 drivehousing 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 28.
12. Install thedisplacement pump. See page 20.
13. Install thefront cover (13).
26
308-298
Drive Housing, ConnectingRod, Crankshaft
)€TAIL
1
Fig. 27
“34(x3)
1075
308-298
~
~~
27
Pressure Control
WARNING
To reduce the risk of serious bodily injury, always
follow the Pressure Relief Procedure on page 2
when instructed in this procedure to relieve
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.
NOTE: The pressure control (64)cannot be repaired
or adjusted. If it hasmalfunctioned, replace it.
1. Remove the front cover (13). Remove the screws
(56). Lowerthe junction box (59).
2. Disconnect the harness connector (A) from the
motor startboard (47). Turn the pressure adjustment knob (8) fully counterclockwise.
3. Remove the screws (63). Pull forward on the pressure adjusting knob and tip
the pressure control
(64) forward and up todetach it from the drive
housing (1 1).
4.
Guide the harness(A) through the motor and
drive housing and remove the pressure control.
5.
Guide the harness of the new pressurecontrol
through the drive housing and motor passages.
6.
Install the new pressure control. Tip the pressure
control down and back into the drivehousing
(1 1).Do not pinch or damage the harness (A).
7. Loosely install the screws (63) and then torque
them to 2.4 N.m.
28
308-298
A
Fig. 28
IOBO
Pressure Transducer
To reduce the risk of serious bodily injury, always
follow the Pressure Relief Procedure on
page 2
when instructed in this procedure to relieve
pressure.
FWAR
1. Remove the displacement pump. See page 20.
2. Use apull-twist motion to remove the transducer
(29) from the pump manifold (101).
3. Clean paint residue from thehole in the manifold;
do notscratch the surfaceof the hole.
4.
29
f
Lightly apply oil to the O-ring of the new transducer.
5. Install the transducer in the pump manifold, while
guiding the O-ring and backup ring into place.
101
6. Align the holes in the transducer as shown
by the
arrows in Fig. 29.
7. Install the displacement pump. See page 20.
Fig. 29
308-298
29
Drain Valve
WARNING
To reduce the risk of serious bodily injury, always
follow the Pressure Relief Procedure on page 2
when instructed in this procedure to relieve
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.
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.
d!,l
Apply greaseto face of base
A
Handle shownin closed position
Torque into pump manitoldto 21 N.m
Fig. 30
30
308-298
4. Place the seat (42b)in the valvebody 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 gasketwill protrude from the end of the
valve until the valve istightened into pump, which correctly seatsthe gasket.
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 faceof the base (43) and install
the base. Turnthe stem so the pin hole is vertical.
3. Securely install thehandle (45) and drive the pin
(44).
45
&,
stem into the vaive body. Install the
spring, washers and spring retainer into the valve body.
Replacement
Repair
A
3. Coat the o-ring (42d) with grease. Pressthe
(088
Parts - Displacement Pump
Model 235-699, Series A.
Includes items101 to 126
Ref
No.
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
Pari No.
187-611
176-758
176-757*
176-997*
176-755'
176-754*
235-709
216-197
105-444'
176-751
176-750'
1767682*
176-749*
180-073*
235-708
108-526*
187-614
224-966
1 1 1 -603*
176-760
105-445*
176-759'
180-656
102-969*
105-522*
126 186-652*
Description
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
PACKINGO-r
PTFE
NUT,jam,l-3/8-18unef-Zb
VALVE, inlet
PACKING, O-ring. PTFE
GUIDE, ball
BALL, 1/2, inlet
PIN, ball stop
PLUG
SEALANT (not shown)
PACKING, U-CUP
polyurethane
WASHER, backup, steel
w.
1
1
1
3
'
2
1
1
1
1
1
1
3
2
1
1
1
1
1
1
1
1
1
1
1
1
1
"Supplied in Repair Kit235-703.
Keep a repair kiton hand to reduce
down time.
115
1708
308-298
31
32
308-298
Parts - Sprayer
Model 231 -306, Series A
lncludes items 1 to 85 as listed below
Ref.
No.
1
3
4
4a
4b
4c
4d
4e
4f
5
6
10
11
Part No.
Description
187-791
111-700
235-968t
100-069
107-262
107-504
187-975
187-791'
107-265
100-643
105-510
187-962
224-965
LABEL, DANGER, English
GRIP. handle
MOTOR KIT lncludes 4a to 4f
. BALL, SST, 1 / 4 dia.
. TERMINAL, 1 / 4 F, 18AWG
. TERMINAL, 3/16 F, 18 AWG
. LABEL. Warnina. Shock
:-LABEL; DANGfR, English
TERMINAL. 3/16 M. 16AWG
43
44
45
46
47
100-069
111-726
224-803
180-131
107-434
187-789
186-360*
218-359
218-364
176-818
176-817
103-345
235-699
111-706
111-715
187-631
111-611
235-307
104-938
162-453
235-009
111-602
108-850
187-624
187-652
11 -705
1
188-421
111-612
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
235-979
47a
47b
47c
46
49
50
107-260
107-265
107-267
186-620'
110-037
187-963
lla
llb
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
QtY.
1
1
1
1
1
1
1
1
2
2
5
1
lncludes 1la, Ilb
. BALL. stainless steel, 1/4" dia.
. PLUG
CRANKSHAFT lncludes 124 12b
. BEARING, thrust
. BEARING
COVER, front
LABEL, Warning
ROD, CONNECTING
GEARREDUCER
PIN. straiaht. hdls.
. .3/8"dia. x 1"
SPRING,;^^^^^
1
1
1
1
1
1
1
1
1
1
1
1
3
1
2
6
SCREW. sch. 1/4-20 x 1-1/4"
PUMP KIT seeparts on page 31
CAPSCREW,Sch,7/16-14xl-3/4
SCREW,speciaI,5/16-18~1-1/4"
HANDLE, sprayer
1
4
CAP. tubing
1
LEG, w/gusset
O-RING
1
.
NIPPLE, 1/4 npsm x 1/4 npl
2
1
PRESSURETRANSDUCER
1
CLIP. 3/4"
1
SCREW, filh, 8-32 X 1-114
SUCTION HOSE8 TUBE
1
DRAIN HOSE
1
SCREW, filh, 8-32 x2-1/2"
3
LABEL, identification
1
1
ADAPTER, tube, 9/16-18
LEG, sprayer
1
TUBE, inlet
1
STRAINER
1
DRAIN VALVE KIT lncludes 42a-.42f? 1
. GASKET, valve seat
1
. SEAT, drain valve
1
. STEM, drain valve
1
. O-RING, stem
1
. SEALANT, pipe (not shown)
1
BASE, valve
1
1
PIN, grooved, 3/32x 1"
HANDLE. drain valve
1
SCREW, washerhex hd, 5/16"
2
MOTOR START BOARD
lncludes 47a to 47c
1
1
.TERMINAL, 1/4" F, 16 AWG
.TERMINAL, 3/16 M, 16AWG
1
2
. TERMINAL, 3/16 F, 16 AWG
LABEL, ground terminal
1
SCREW, mach, pnhd, 10-24 x 5/8"
1
GASKET. iunction box
1
51 235-450 FILTER. Dower
inlet lncludes 51a
1
51a
107-260
.TERMINAL, 1/ 4F , 16AWGnotshown
52
111-826
SWITCH. ON/OFF
1
53 111
-840 SCREW,'panhead, M3 x 10 mm
2
55
105-659
BOOT, switch
1
56 11
1-703
SCREW, fiih, 10-24 x 3"
4
57 POWER CORD
with IEC-320 Connector
1
For use in:
6877-194 France, Germany, Sweden, (schuko7 m
6877-195 Denmark
6877-196 Switzerland
6877-197 Italy
6877-198 Other countries (cord without male plug)
58 100-035 SCREW, panhd,
8-32 x5/16"
2
59
187-958
JUNCTION BOX
1
62
186-663* LABEL, Warning
1
63
111-704
SCREW.filh.10-24x1-5/8"
2
64
224-828
PRESS~RE'CONTROLKIT
1
65 11
1-848
1
CLAMe powercord
66 187-770
BASE, motor
1
67 220-955
CONTRACTOR GUN
See manual307-614 for parts
1
8 02.
68 206-994 TSL,
1
71 11
1-627
WRENCH, hex, 3/8" (not shown)
(Use forcatscrew #21)
73 11
1-839
SCREW, panhead w/lockwasher,
6-32 x ,375" 2
74 223-541
HOSE. orounded.
114'ID:
~~.nvlon:
,
cpld li<npsm(f);15 m;
sorina auards both ends
1
84
100-721
PLUG, 714 npt
1
85
235-677
FLUID FILTER
See manual 308-249 for parts
1
*Extra warning labels available free
of charge.
t Motor Brush and Spring ReplacementKit,
PN. 235-980 is available. Purchase separately.
308-298
33
NOTES
.
.
300-290
35
Technical Data
Power Requirements
. . . . . . . . . . . . . .,230VAC, 50Hz,
1 phase, 6 amp minimum
Working Pressure Range...............0 - 195 bar
Cycles/Liter ..................................
164
Power Cord . . . . . . . . . . . . . . . .1.0 mm2, 3 wire, 2.5 m
Inlet Paint Strainer ....................
1525 micron
Stainless Steel Screen, reusable
Pump Inlet Size .........................
112 npt(f)
Fluid Outlet Size ........................
114 npsm
Wetted Parts:
DisplacementPump . . Stainless steel, Carbonsteel,
Aluminum, Polyethylene, DelrinB, Leather
NOTE: DelrinB
Dimensions
Weight (dry w/o packaging)................ 16.6k g
Height ..................................
483mm
381 m m
Length ..................................
Width ...................................
356 mm
Accessories
FLUID HOPPER KIT235-991
Includes hopper and lid and screen. Must order
Installation Kit, below.
HOPPER INSTALLATION KIT 235-576
Includes required hardware for mounting the hopper
sold above.
The Graco Warranty. and Disclaimers
WARRANTY
Graco warrants all equipment manufactured by it and bearing itstoname
be free from defects in material and workmanship
on the
As purchaser's sole remedy for breach
of this wardate of sale byan authorized Graco distributor
to the original purchaser for use.
ranty, Gracowill, for aperiod of twelve months from the date
of sale, repair or replace any part
of the equipment proven defective,
on the drive train/gear box
on EM and GM sprayers or powertrain on EH and GH sprayers,
with the exception of defects in parts
which will be repaired or replaced for twenty-four months from theofdate
sale for Gas-Hydraulic (GH) and Gas-Mechanical (GM)
sprayers and for thirty-six months from the date
of sale for Electric-Mechanical (EM), Electric-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 doesnot cover, and Graco shall
not be liable for, any malfunction, damagewear
or caused by faulty installation, misapplication, abrasion, corrosion, inadequate
or improper maintenance, negligence, accident, tampering, or substitution
of nonGraco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility with Graco
equipment of structures, accessories, equipmentor materialsnot 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
If inspection of the equipment does
not disclose any
equipment willbe returned to the original purchaser transportation prepaid.
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 areofinany
lieuother warranties (express or
implied), including warranty of merchantability or warranty of fitness for a particular purpose,and of any non-contractual
of liability for direct, special
or consequential
liabilities, including productliabilities. basedon negligence or strict liability. Every form
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(2)
two
years of the date of sale,
EQUIPMENT NOT COVEREDBY GRACO WARRANTY
Graco makesno warranty, and disclaims all implied
warranties of merchantability and fitnessfor a particular purpose,with
respect to accessories, 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 tothe warranty, if any, of their manufacturer.
in making any claim for breach
of these warranties.
Graco will provide purchaser with reasonable assistance
Sales Offices: Atlanta, Chicago. Dallas, Detroit, Los Angeles, Mt. Arlington
(N.J.)
Forelgn Offices:Canada; England; Korea; Switzerland; France; Germany: Hong Kong; Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
36
308-298
PRINTED IN U.S.A.
308-298 5/93

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project