Graco 308745A ELECTRIC, 230 Vac, 50 Hz 290 Easy Airless Paint Sprayer Owner's Manual

Graco 308745A ELECTRIC, 230 Vac, 50 Hz 290 Easy Airless Paint Sprayer Owner's Manual | Manualzz
INSTRUCTIONS-PARTS LIST
308–745
Rev. A
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
ELECTRIC, 230 Vac, 50 Hz
290 Easy Airless Paint Sprayer
190 bar (19 MPa, 2750 psi) Maximum Working Pressure
Model 231–409, Series A
Standard mount; complete sprayer with hose, gun,
RAC IV DripLess Tip Guard and SwitchTip
7150A
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN
COPYRIGHT 1997, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
55440–1441
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Component Identification and Function . . . . . . . . . . . . 5
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Shutdown and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General Repair Information . . . . . . . . . . . . . . . . . . . . . 19
Motor Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Displacement Pump Repair . . . . . . . . . . . . . . . . . . . . . 22
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Motor Start Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power Supply Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing, Connecting Rod, Crankshaft . . . . . .
Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 231–409 Sprayer Parts Drawing . . . . . . . . . .
Model 231–409 Sprayer Parts List . . . . . . . . . . . . . . .
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
24
25
27
28
28
29
29
30
31
32
32
32
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.
Use only with a grounded outlet that matches the grounded plug of this equipment.
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 10 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 10 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
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your distributor.
Do not alter or modify this equipment. Use only genuine Graco parts.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 32 for the maximum working pressure of this equipment.
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.
Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
NOTE: This is an example of the DANGER label on
your sprayer. This label is available in other
languages, free of charge. See page 29 to order.
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
Component Identification and Function
N
C
B
A
H
K
7155A
E
G
L
F
M
D
J
Model 231–409 Shown
7150A
Fig. 1
A
Motor
DC motor, 230 Vac, 50 Hz, 6A, 1 phase
B
Drive Assembly
Transfers power from DC motor to the displacement pump
C
Pressure Adjusting Knob
Controls fluid outlet pressure
D
ON/OFF Switch
Power switch that controls 230 Vac power to sprayer
E
Fluid Outlet
Hose and spray gun is connected here
F
Displacement Pump
Pressurizes fluid to be sprayed through spray gun
G
15 m Main Hose
1/4 in. ID, grounded, nylon hose with spring guards on both ends
H
RAC IV Tip Guard
Reverse-A-Clean (RAC) tip guard reduces the risk of fluid injection injury
J
BLACK MAX Gun
High pressure spray gun with gun safety latch
K
RAC IV Switch Tip
RAC switch tip atomizes fluid and removes clogs from spray tip without
removing tip from spray gun
L
Pressure Drain Valve
Relieves fluid pressure when open
M
Pressure Control
Controls motor to maintain fluid pressure. Works with pressure
adjusting knob.
N
Spray Gun Safety Latch
Inhibits accidental triggering of spray gun
Setup
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 190 bar (19 MPa, 2750 psi) Working Pressure. This is to reduce the risk of serious injury
caused by static sparking, fluid injection or overpressurization and rupture of the hose or gun.
CAUTION
2. Connect the hose (74) and gun (67) and screw it
onto the outlet nipple (28). Don’t use thread
sealant, and don’t install the spray tip yet!
3. Fill the wet–cup (102). Pry off the wet-cup seal.
Fill the cup 1/3 full with Graco Throat Seal Liquid
(TSL), supplied. Install the wet-cup seal.
4. Check the electrical service. It must be 230 Vac,
50 Hz, 6A (minimum) and protected by a fuse or
circuit breaker with a rating of not more than 16A.
You may use a 3-wire, 1.0 mm2 (16 AWG) (minimum) extension cord up to 45 m long.
To avoid damaging the pressure control, which may
result in poor equipment performance and component damage, follow these precautions:
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
1. Always use a nylon spray hose at least 15 m
long.
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. 4.
5. 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. 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. If the
power cord you are using does not have a male
plug attached, have a qualified electrician install an
appropriate plug.
Grounded
Outlet
Fig. 3
6. Flush the pump to remove the lightweight oil
which was left in to protect pump parts after factory testing. See page 13.
65
57
Fig. 2
A
7. Prepare the paint according to the manufacturer’s
recommendations. Remove any paint skin. Strain
the paint through a fine nylon mesh bag (available
at most paint dealers) to remove particles that
could clog the spray tip. This is an important step
toward trouble-free paint spraying.
Setup
1
1/4 npsm(m) fluid outlet
2
Do not install any shutoff device here
3
Rotate clockwise to increase pressure
4
Shown in closed or spray position
5
Fill 1/3 full with TSL
3
2
1
33
64
28
74
32
52
4
102
67
5
Model 231–409 Shown
7150A
Fig. 4
Operation
How to use the gun trigger safety
When engaged, the gun safety latch prevents the gun
from accidental triggering. See Fig. 5.
1
Open or drain, position
2
Closed, or spray position
WARNING
INJECTION HAZARD
If the gun still sprays when the gun
trigger safety is locked, repair the gun.
See manual 307–821, supplied.
1
Gun safety latch
shown engaged
2
Gun safety latch
shown disengaged
1
2
Fig. 6
7105A
How to use the pressure control.
The pressure control controls the motor operation so
the sprayer maintains constant fluid pressure at the
pump outlet. Turn the pressure control knob fully
counterclockwise to obtain the minimum setting. Turn
the knob clockwise to increase pressure. See Fig. 7.
1
2
Fig. 5
05964
How to use the pressure drain valve.
Use the pressure drain valve to relieve fluid pressure
from the pump and to help prime the pump. If the valve
senses an over pressure condition, it opens automatically to relieve fluid pressure. If this happens, stop
spraying immediately, shut off and unplug the sprayer.
Determine the cause of the problem and correct it
before operating the sprayer again. Refer also to the
Troubleshooting, page 14. See Fig. 6.
Fig. 7
7105A
Operation
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 10.
The tip guard alerts you to the risk and helps prevent
placing any part of the body close to the spray tip. The
tip guard also adjusts the vertical or horizontal spray
pattern. See Fig. 10. The tip guard holds a reversing
spray tip. The tip is in the spraying position when the
tip handle points forward. See Fig. 8.
Clean the front of the tip frequently during the day’s
operation. First, follow the Pressure Relief Procedure
on page 10.
1
1
2
2
Tip handle shown in
spraying position.
Turn handle 180,
trigger gun to clear clog
04647
Fig. 8
How to remove a tip clog.
1. Release the gun trigger. Lock the safety latch.
Rotate the RAC IV tip handle 180. See Fig. 8.
2. Unlock the safety latch. Trigger the gun into a pail
or onto the ground to remove the clog.
3. Lock the safety latch. Rotate the tip handle to the
spraying position.
4. If the tip is still clogged, lock the safety latch, shut
off and unplug the sprayer, and open the pressure
drain valve to relieve pressure. Clean the spray tip
as shown in manual 307–848, supplied.
308-745
9
Startup
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:
NOTE: Refer to Fig. 4 and the other figures referenced
in the text as you start the sprayer.
1. Open the pressure drain valve (42). See Fig. 9.
2. Don’t install the spray tip until the pump is
primed!
3. Put the suction hose (32) into the paint. If you
are pumping from a pail, push the drain hose (33)
down below the top of the pail to avoid splashing
paint when the drain valve is opened.
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tip.
Pressure Relief Procedure
1.
2.
3.
4.
Engage the gun safety latch.
Turn the ON/OFF switch to OFF.
Unplug the power supply cord.
Disengage the gun safety latch. Hold a metal part
of the gun firmly to a grounded metal pail. Trigger
the gun to relieve pressure.
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.
Startup Procedure
Use this procedure each time you start the sprayer to
help ensure the sprayer is ready to operate and that
you start it safely.
NOTE: If this is a first-time startup, flush the sprayer.
See page 13.
42 1
1
Open or drain, position
01021A
Fig. 9
4. Turn the pressure knob (64) to the minimum
setting.
5. Disengage the gun trigger safety. See Fig. 5,
page 8.
CAUTION
Do not run the sprayer dry for more than 30 seconds
to avoid damaging the pump packings.
6. To prime the pump, turn the sprayer switch (52)
on. Slowly increase the pressure until the sprayer
starts. When fluid comes from the pressure drain
valve, close the valve.
Startup
b. If more coverage is needed, use a larger tip
rather than increasing the pressure.
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.
7. To prime the hose, lower the pressure to reduce
splashing. Hold a metal part of the gun firmly
against and aimed into a grounded metal pail. See
the preceding WARNING. Hold the gun trigger
open and slowly increase the pressure 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 the connections.
c.
Adjust the direction of the spray pattern. See
Fig. 10. Engage the gun safety latch. Loosen
the retaining nut (A). Position the tip guard for
a horizontal or vertical pattern. Hold the tip
guard in place and tighten the retaining nut.
NOTE: Spray patterns will change as tips wear.
Change the spray tip if adjusting the pressure will not
improve the spray pattern.
A
1
9. Engage the gun safety latch.
10. Install the spray tip and tip guard. Install the
spray tip. If you are using the RAC IV tip guard,
refer to manual 308–644 for installation instructions.
11. Adjust the spray pattern
a. Increase the pressure 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.
2
1
For a vertical
spray pattern
2
For a horizontal
spray pattern
7155A
Fig. 10
Shutdown and Care
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 10.
8. Coil the hose and hang it on a hose rack when
storing it, even for overnight, to help protect the
hose from kinking, abrasion, coupling damage, etc.
WARNING
INJECTION HAZARD
See the warning section INJECTION
HAZARD on page 3 for information on
the hazard of using damaged hoses.
Shutdown and Care
1. Check the packing nut/wet-cup daily (102).
Relieve pressure first. Keep the wet-cup 1/3 full of
TSL at all times to help prevent fluid buildup on the
piston rod and premature wear of packings.
1
Turn packing
nut clockwise to
tighten
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.
3. Clean the gun’s fluid filter often and whenever
the gun is stored. Relieve pressure first. Refer to
manual 307–821.
1
4. Periodically clean paint residue from the pressure transducer (29) vent hole area. See Fig. 12.
Replace the transducer when leakage is excessive. See page 28.
5. Lubricate the bearing housing after every 100
hours of operation. Remove the front cover. Fill the
bearing housing cavity (A) with SAE 10 nondetergent oil. See Fig. 12.
102
05117
Fig. 11
1
Vent hole
1
29
A
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 13.
CAUTION
To prevent pump corrosion, and to reduce the chance
of fluid freezing in the pump in cold weather, never
leave water or any type of paint in the sprayer when it
is not in use. Freezing can seriously damage the
sprayer or result in a loss of pressure or stalling.
7. For very short shutoff periods, leave the suction
tube in the paint, relieve pressure, and clean the
spray tip.
12
308-745
Fig. 12
7106A
Flushing
When to Flush
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. Changing colors: flush with a compatible solvent
such as mineral spirits or water.
3. Changing from water-base to oil-base paint:
flush with warm, soapy water, and then mineral
spirits.
4. 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 clean water. When using oil-base paint,
flush out the mineral spirits with the paint.
How to Flush
3. Pour one-half gallon (2 liters) of compatible solvent
into a grounded metal flushing pail. Put the suction
hose in the pail.
4. Open the pressure drain valve. See Fig. 6, page
8.
5. To save the paint still in the pump and hose,
follow Step 6, except put the drain tube in the paint
pail. When solvent appears, close the drain valve.
Put the drain tube in the flushing pail. Trigger the
gun into the paint pail. When solvent appears,
release the trigger. Continue with Step 6.
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.
6. Lower the pressure setting. Turn on the sprayer.
Maintaining metal-to-metal contact, trigger the gun
into the flushing pail. Slowly increase the sprayer
pressure until the pump starts. Keep the gun
triggered until the solvent flows freely from the
gun. Circulate the solvent to thoroughly clean the
sprayer. Release the gun trigger. Engage the gun
trigger safety.
7. Open the drain valve and circulate the solvent
through the drain tube to thoroughly clean it. Close
the drain valve.
8. Remove the suction hose from the pail. Disengage
the gun trigger safety. Trigger the gun and run the
pump a few seconds to push air into the hose. Do
not run the pump dry for more than 30 seconds to
avoid damaging the pump packings! Relieve
pressure.
1. Follow the Pressure Relief Procedure on
page 10.
9. Remove and clean the inlet strainer. Wipe paint off
the suction hose and drain tube.
2. Remove the spray tip and clean it separately.
Remove the filter screen and then reinstall the
bowl, hand tight, without the screen. Clean the
screen separately. (See instruction manual
308–249.)
10. Refer to When To Flush, Step 1 again. Relieve
pressure.
11. Leave the drain valve open until you use the
sprayer again.
Troubleshooting
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 10.
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 or fluid filter, if
used. See page 9.
2. If tip is still clogged, relieve pressure; refer to separate gun or tip instruction manual for tip cleaning. Clean or replace filter
element. See manual 308–249.
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 18.
1. Thaw. Plug in sprayer and turn on. Slowly
increase pressure setting to see if motor
starts. If it doesn’t, see NOTE, below.
Mechanical
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 Fig. 19, page 22.
Electrical
3. Check for motor damage. Remove drive housing assembly (11). See page 25. Try to rotate
motor fan by hand.
3. Replace motor (4) if fan won’t turn. See
page 23.
1. Check electrical supply with volt meter. Meter
should read 210–250 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 vis3. Replace power supply cord.
ible damage such as broken insulation or wires.
See page 24.
4. Check motor brushes for the following:
a. Loose terminal screws.
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.
4. Refer to page 20.
a. Tighten.
b. Replace broken spring and/or align
spring with brush
c. Clean brush holders. Remove carbon
with small cleaning brush. Align brush
leads with slot in brush holder to assure free vertical brush movement.
d. Replace brushes
e. Replace brushes if less than 12.5 mm
(0.5 in.) long.
NOTE: Thaw sprayer if water or water–based paint has frozen in it, due to exposure to low temperatures, by placing in a warm
area. Do not try to start sprayer until completely thawed or damage to motor and/or start board may occur. If paint hardened
(dried) in sprayer, the pump packings (page 22) and/or pressure transducer (page 28) must be replaced.
Basic 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
Electrical (continued)
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 23.
6. Check motor armature for shorts using armature tester (growler) or perform motor test.
See page 18.
6. Replace motor. See page 23.
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 24.
8. Replace board. See page 24.
CAUTION: Do not perform this check until motor armature is determined to be good. A bad
motor armature can burn out a good board.
9. Check power supply cord (57). Disconnect
9. Replace power supply cord. See page
black and white power cord terminals; connect
24.
volt meter to these leads. Plug in sprayer. Meter
should read 210–250 Vac. Unplug sprayer.
10. Check ON/OFF switch (52). Disconnect the
motor start board (47) and switch and connect
volt meter between exposed terminal on switch
and power cord’s white wire. Plug in sprayer
and turn ON. Meter should read 210–250 Vac
Turn off and unplug sprayer.
10. Replace ON/OFF switch. See page 24.
11. Check motor thermal cutout switch. Connect
ohmmeter between motor’s red leads. Meter
should read 1 ohm maximum.
11. Allow motor to cool. Correct cause of
overheating. If switch remains open after
motor cools, replace motor.
12. Remove pressure control (64) and check microswitch operation with ohmmeter:
(1) With pressure knob at lowest setting and
stem pushed into control, readings should
be: white & black = 1 ohm max.
white & red = open.
(2) With pressure knob at highest setting,readings should be: white & black = open;
white & red = 1 ohm max.
12. Replace pressure control. See page 27.
13. Check pressure transducer (29) for hardened
paint or damaged or worn components. See
page 28.
13. Replace transducer. See page 28. 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 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 lock safety latch.
Relieve pressure, turn off and unplug sprayer.
2. Service pump. See page 22.
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 (continued)
3. Release gun trigger. Observe resting position of 3. If pump consistently comes to rest with
pump rod (107).
rod (107) fully extended, the piston packings and/or piston valve may be worn.
Service the pump. See page 22.
4. Check electrical supply with volt meter. Meter
should read 210–250 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 12 gauge wire and less than 150 ft
(45 m) long.
5. Replace with a correct, grounded extension cord.
6. Check motor brushes. See Electrical – 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 24.
CAUTION: Do not perform this check until motor armature is determined to be good. A bad
motor armature can burn out a good board.
8. Check motor armature for shorts by using an
armature tester (growler) or perform motor test.
See page 18.
8. Replace motor. See page 23.
Drain valve leaks
1. Check drain valve for correct torque and/or
worn parts. Check for debris trapped on seat.
9. Tighten to 185 in–lb (21 N.m). Clean
valve and replace with new gasket (42a)
and sealant (42e). See page 29.
Transducer leaks
1. Slight leakage from transducer is normal.
1. Periodically remove residue from its cylinder port. See page 28.
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 suction tube or fittings. See
page 28.
3. Tighten; use thread sealant on npt
threads of adapter (38).
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 22. 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 22.
No output: motor runs but
pump does not stroke
1. Check displacement pump connecting rod pin
(17). See Fig. 19, page 22.
1. Replace pin if missing. Be sure retainer
spring (18) is fully in groove all around
connecting rod.
7. Check connecting rod assembly (15) for damage. See page 25.
7. Replace connecting rod assembly. See
page 25.
8. Be sure crank in drive housing rotates; plug in
sprayer and turn on briefly to check. Turn off
and unplug sprayer. See page 25.
8. Check drive housing assembly for
damage and replace if necessary. See
page 25.
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 28.
3. Check pressure control (64) for smooth operation.
3. Replace pressure control. See page 27.
4. Check Low output section, page 16.
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 90F (32C) and
sprayer is not located in direct sun.
2. Move sprayer to shaded, cooler area if
possible.
3. Check motor.
3. Replace motor. See page 23.
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 23.
1. Repair or replace any damaged wiring or
terminals. Securely reconnect all wires.
2. Check for missing motor brush inspection plate
gasket (see page 18), 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 18. Inspect windings for burns.
3. Replace motor. See page 23.
4. Check motor start board (47) by substituting
with a good board.
4. Replace board. See page 24.
CAUTION: Do not perform this check until
motor armature is determined to be good. A
bad motor armature can burn out a good board.
Circuit breaker opens
after sprayer operates
for 5 to 10 minutes.
1. Check ‘Basic Problems – Electrical’ on page
14.
Building circuit breaker
opens as soon as sprayer
is plugged into outlet and
sprayer is NOT turned on.
1. 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.
1. Replace ON/OFF switch. See page 24.
CAUTION: A short in motor circuit can damage
switch and or motor start board (47).
2. Check electrical supply with volt meter. Meter
should read 210–250 Vac.
Unit will not run on generator but does run on AC
power
2. If voltage is too high, do not operate
sprayer until corrected.
Check the generator’s peak voltage. This sprayer will Use AC power or a different generator
not run if the peak voltage is above 190V.
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 10.
For checking armature, motor winding and brush
electrical continuity.
B
Setup
Remove the drive housing. See page 25. 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.
A
Remove the motor brush inspection covers (A). See
Fig. 13.
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 Circuit Test
7156A
Fig. 13
Remove the fan cover (B). See Fig. 13.
MOTOR
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 23.
BLACK/
WHITE
Armature, Brushes, and Motor Wiring
Open Circuit Test (Continuity)
Connect the two black motor leads together with a test
lead. Turn the motor fan by hand at about two revolutions per second.
BLACK
59
RED
56
When turning the fan on a DC motor, normally you
sense an even, pulsing resistance. If there is irregular
turning resistance, or no turning resistance, check and
repair the following as needed: broken brush springs,
brush leads, motor leads; loose brush terminal screws
or motor lead terminals; worn brushes. See page 20.
If there is still uneven or no turning resistance, replace
the motor. See page 23.
C
47
Fig. 14
05563
General Repair Information
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 10.
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
Tool List
These are the tools required to service all parts of the
sprayer.
3/16” Allen wrench: gear housing, legs, handle
3/8” Allen wrench: pump manifold
#1 Phillips screwdriver: junction box,
pressure control, front cover
3/8” socket wrench: motor mount
5/8” socket wrench: drain valve, outlet fittings,
on/off switch boot, piston
13/16” socket wrench: drain valve
1-1/4” socket wrench: pump inlet valve
1/2” open end wrench: pump rod
11/16” open end wrench: piston jam nut
15/16” open end wrench: flats of inlet tube
1-3/4” open end wrench: pump jam nut
5/64” drive pin: drain valve pin
3” needle nose pliers: wiring, on/off switch
Hammer & punch: packing nut
Torque wrenches: various fasteners
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.
Shut off the sprayer and unplug it as soon as you
complete the inspection.
Reinstall all covers, gaskets, screws and washers
before operating the sprayer.
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.
1. When disconnecting wires in the junction box
assembly, 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
Improper wire routing can result in poor sprayer
performance or damage to the pressure control.
3. Route wires carefully through the drive housing
and motor. Avoid pinching the wires between the
junction box and the motor or pressure control.
4. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair procedures. These parts are not normally provided with
replacement assemblies.
5. Test your repair before regular operation to be
sure the problem is corrected.
6. If the sprayer does not operate properly, verify
that everything was done correctly. Also refer to
the Troubleshooting Guide, pages 14–17, to help
identify other possible problems and solutions.
Motor Brushes
NOTE: Replace brushes when worn to about 0.5 in.
(12.5 mm). Always check both brushes. Brush Repair
Kit 236–967, which includes spring clip 112–766, is
available for motors manufactured by Pacific Scientific.
NOTE: Replacement brushes may last only half as
long as the original ones. To maximize brush life, break
in new brushes by operating the sprayer for at least
one hour with no load (remove the pump connecting
rod pin).
1
Motor lead; do not disconnect
2
Minimum 0.5” (12.5 mm)
3
Included in Brush Repair
Kit 236–967
2
3
1
H C
G
F
B
WARNING
E
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 10.
1. Remove both inspection covers (A) and their
gaskets. See Fig 15.
D
Fig. 16
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.
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
A
F
G
C
Fig. 15
02831A
Fig. 17
2. Push in the spring clip (F) and release its hook (G)
from the brush holder (B). Pull out the spring clip.
See Fig 16.
3. Slide off the brush lead terminal (E) off the blade
connector. Remove the old brush (C). See Fig 16.
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. 17. 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. 19, page 22.
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. 19, page 22.
308-745
21
Displacement Pump Repair
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 10.
NOTE: Packing Repair Kit 235–703 is available.
Reference numbers of parts included in the kit are
marked with an asterisk, i.e., (121*). For the best
results, use all the new parts in the kit, even if the old
ones still look good.
2. Align the hole in the rod (107) with the connecting
rod assembly (15). Use a screwdriver to push the
retaining spring (18) up and push in the pin (17).
Push the retaining spring (18) into place around
the connecting rod.
3. Replace the o-ring (27) if it is worn or damaged.
Reconnect the suction and drain hoses (32,33).
Install the front cover (13).
4. Tighten the packing nut (102) just enough to stop
leakage, but no tighter. Fill the packing nut/wet-cup
1/3 full with Graco TSL. Push the plug (123) into
the wet-cup.
NOTE: To minimize down time, and for the best sprayer
performance, check the motor brushes (see page 20)
and clean the transducer (see page 28) whenever you
repack the pump. Replace these parts as needed.
Removing the pump (See Fig. 18.)
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. Push downward on the inner face of elbow (78)
and while pushing upward on the elbow, pull the
elbow from the displacement pump stem
adapter (36).
3. Use a screwdriver to push the retaining spring (18)
up and push out the pin (17).
18
17
13
107
20
1
*121
21
36
118
40
4. Loosen the screws (21). Remove the pump (20).
*119
78
33
32
Repairing the pump
See manual 308–190 for pump repair instructions.
27
Installing the pump (See Fig. 18 and 19.)
1. Mount the pump on the drive housing. Tap it into
the alignment pins with a soft hammer. Tighten the
screws (21) to 50 ft-lb (68 N.m).
120
*122
1
Torque to
50 ft–lb (68 N.m)
2
Apply anaerobic
polycrystal pipe
sealant
38
Fig. 18
2
02832C
17
WARNING
15
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. 19.
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 drive housing.
123
18
1
Torque to
50 ft–lb (68 N.m)
21
Fig. 19
1
102
04655
Motor
9. Align the new motor with the base and reinstall the
screws (46).
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 10.
10. Assemble the drive housing to the motor. Follow
steps 8 to 10 on page 25.
11. Connect the wires in the junction box. Refer to Fig.
23 on page 24. Install the junction box.
12. Connect the piston rod (107) to the drive housing;
see page 22, Installing the Pump, Step 2 and the
WARNING following it.
NOTE: See Fig. 22 except where noted.
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. 20.
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. 23 on page 24.
17
15
18
Fig. 20
01068
4. Remove the front cover (13).
107
5. Turn the displacement pump rod (107) so the pin
hole aligns with the bottom drive housing screw
(19). See Fig. 21. Remove the three drive housing
screws and lockwashers (19,6). Also see Fig. 22.
19,6
6. Remove the two motor screws (5) and the lock
washers (6).
7. Tap the lower rear of the drive housing (11) with a
plastic mallet to loosen the motor. Pull the drive
housing straight off the motor while guiding the
harness (A) from the motor. Do not allow the gear
(16) to fall. Read the CAUTION on page 25.
01074
Fig. 21
1
C
B
8. Remove the two screws (46) and lift the motor off
the base (66).
6
5
4
A
12
16
11
1
Torque to 80 in–lb (9 N.m)
2
Quantity of three
3
Quantity of one
6
1
19
3
Fig. 22
46
59
13
56
31
34
7151A
2
Motor Start Board
6. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board. Also be sure the gasket (50) is installed.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 10.
On/Off Switch
NOTE: See Fig. 23 for this procedure.
1. Relieve pressure.
NOTE: See Fig. 23 for this procedure.
2. Remove the junction box screws (56) and lower
the junction box (59).
1. Relieve pressure.
3. Remove the nut and rubber boot (55).
2. Remove the junction box screws (56) and lower
the junction box (59).
4. Disconnect the black wires from the ON/OFF
switch (52) and remove the switch.
3. Disconnect the motor wires (B) and the 3-wire
connector (A) from the motor start board (47).
Observe where connections are made.
5. Place the ring terminal of the ground wire over the
barrel of the new switch. Install the switch so the
internal tab of the anti-rotation ring (54) engages
with the vertical groove in the threads of the
switch, and the external tab engages with the blind
hole (C) of the junction box.
4. Remove the screws (58) and motor start board
(47). Transfer the white thermal paste from the old
board to the new board.
5. Install the new motor start board. Reconnect all
wires. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board. Also be sure the gasket (50) is installed.
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.
6. 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.
7. Reconnect the ON/OFF switch black wires.
8. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board. Also be sure the gasket (50) is installed.
MOTOR
GREEN/
YELLOW
Route all wires carefully to avoid interference with
the motor start board or junction box.
49
These precautions are essential to reduce the risk of
a malfunction.
BLACK/
WHITE
Power Supply Cord
NOTE: See Fig. 23 for this procedure.
52
BLACK
54
B
59
58
50
RED
1. Relieve pressure.
2. Remove the junction box screws (56) and lower
the junction box (59).
A
56
C
55
47
3. Disconnect the power supply cord leads, including
the green wire to the grounding screw (49).
4. Remove the power supply cord (57).
5. Install the new cord (57) in the reverse order of
disassembly.
Fig. 23
05563
Drive Housing, Connecting Rod, Crankshaft
WARNING
CAUTION
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 10.
Removal
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 27.
3. Turn the displacement pump rod (107) so the pin
hole aligns with the bottom drive housing screw
(19). See Fig. 24. Remove the three drive housing
screws and lockwashers (19,6). Also see Fig. 25
on page 26.
Do not lose the thrust balls (11a or 4a) or let them fall
between the gears, which will damage the drive housing if not removed. The balls, which are heavily covered
with grease, usually stay in the gear recesses, but
could be dislodged. If the balls are not in place, the
bearings will wear prematurely.
6. Remove and inspect the crankshaft (12) and the
connecting rod (15).
Installation
7. Install the connecting rod.
8. Lubricate the inside of the drive housing bearing
with SAE non-detergent oil. Pack the roller bearing
and gears with the grease supplied.
NOTE: The gears and bearings between the drive
housing (11) and motor front end bell (C) should contain a total of 3 fl. oz. (89 cc) of grease.
107
9. Place the large washer (12a) and then the small
washer (12b) on the crankshaft (12).
19,6
Fig. 24
Do not allow the gear (16) to fall; it may stay attached to the drive housing or to the motor.
01074
4. Remove the two motor screws (5) and lock washers (6). See Fig. 25 on page 26.
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.
10. Lift the crank to the top of the stroke and insert
crankshaft (12). Align the gears and push the drive
housing (11) straight onto the motor and the locating pins. Install the screws (19, 5) and their lockwashers (6). Torque to 80 in–lb (9 N.m).
11. Install the displacement pump. See page 22.
12. Install the pressure control (64). See page 27.
Install the front cover (13).
Drive Housing, Connecting Rod, Crankshaft
1
64
REF A
12a
1
Torque to 80 in–lb (9 N.m)
2
Quantity of three
3
Quantity of one
4
Apply a total of
3 fl. oz.(89 cc) of
grease
to gears.
4
11a
12
16
5,6
C
4a
12b
A
47
59
56
3
31
6
15
13
34
Fig. 25
2
19
11
1
7152A
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 10.
7. Loosely install the screws (63) and then torque
them to 21 in–lb (2.4 N.m).
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: See Fig. 26 for this procedure.
64
NOTE: The pressure control (64) cannot be repaired
or adjusted. If it has malfunctioned, replace it.
63
1. Remove the front cover (13). Remove the screws
(56). Lower the junction box (59).
1
11
13
2. Disconnect the harness connector (A) from the
motor start board (47).
A
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.
59
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).
56
1
Torque to
21 in–lb (2.4 N.m)
7154A
Fig. 26
Pressure Transducer
6. Align the holes in the transducer as shown by the
arrows in 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 10.
7. Install the displacement pump. See page 22.
NOTE: See Fig. 27 for this procedure.
1. Remove the displacement pump. See page 22.
2. Use a pull–twist motion to remove the transducer
(29) from the pump manifold (101).
29
3. Clean paint residue from the hole in the manifold;
do not scratch the surface of the hole.
101
4. 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.
Fig. 27
02817A
Suction Hose
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 10.
CAUTION
Misalignment or cross-threading will damage the
parts and/or create shavings which can cause the
o–ring (27) to leak.
1
1. Remove the drain hose (33) from the stem adapter
(36). Remove the front cover (13).
Lubricate
Note: Filter
not shown
13
2. Pull upward on the hose (32) while unscrewing it
from the inlet tube (38). The hose coupling (A)
threads will engage and the hose will separate
from the tube.
3. Replace the o–ring (27) if it is worn or damaged.
36
4. Lubricate the o–ring (27) and the inlet tube (38)
threads with light grease.
5. Align the suction hose coupling with the threads of
the inlet tube (38). Tighten the hose onto the tube at
least 4 turns to ensure that the threads have disengaged and can function as a swivel joint.
1
33
32
27
A
Fig. 28
38
06978
Drain Valve
Repair
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 10.
42a
42b
1
Apply grease
to face of base
2
42d
42c
3
Apply thread sealant
1
3
Torque into pump
manifold to 185 in–lb
(21 N.m)
4
Handle shown
in closed position
2
42
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.
43
44
Fig. 29
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.
4
Replacement
45
02819
1. Turn the handle (45) to the closed position. Drive
out the pin (44). Remove the handle.
2. Remove the base (43).
3. Unscrew the drain valve (42). The gasket (42a)
and seat (42b) will stay in the valve.
1. Apply a small amount of thread sealant (42e) onto
the valve (42) threads. Tighten the valve into the
pump manifold to 185 in–lb (21 N.m).
2. Lightly grease the face of the base (43) and install
the base. Turn the stem so the pin hole is vertical.
3. Securely install the handle (45) and drive pin (44).
Accessories
FLUID HOPPER
Must order a hopper installation kit separately.
188–337
2.5 liter hopper & cover
188–338
5 liter hopper & cover
FLUID HOPPER INSTALLATION KIT
235–576
Includes fittings and mounting hardware to replace the
suction hose assembly with a 2 or 5 liter hopper,
purchased separately. Instructions included.
DANGER LABELS
The English language DANGER label shown on page 1
is also on your sprayer. If you have painters who do not
read English, order one of the following labels to apply
to your sprayer. The drawing below shows the best
placement of these labels for good visibility.
Order the labels directly from Graco, free of charge:
Apply other
1–800–328–0211
French
Spanish
German
Greek
Korean
English
185–956
185–961
186–041
186–045
186–049
185–953
language here
04653
Sprayer Parts Drawing
Model 231–409, Series A
39
74
30
67
1
Label
2
See detail
on page 31
24
REF 33
1
79
3
64
REF 32
4
6
1
5
4a
86
12
63
19
88 28 15
28
87
35
11b
6
4e
4d
1
1
50
11a
2
11
18
OUTSIDE
LABEL
12b
12a
17
13
16
66
26
57
14
INSIDE
LABEL
56
29
31
42a
42b
42d
42c
21
40
34
20
36
32
27
78
23
42
43
44
33
38
23
46
45
37
25
7149A
Sprayer Parts List
Model 231–409, Series A
Ref
No.
Part No.
Description
1
3
4
4a
4b
4c
4d
4e
5
6
10
11
187–791
111–700
238–066
100–069
107–262
107–265
187–975
187–791*
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
40
42
42a
42b
42c
42d
42e
43
44
45
46
47
100–069
111–726
224–803
180–131
107–434
187–789
188–360*
218–359
218–364
176–818
176–817
103–345
236–787
111–706
111–715
192–219
112–759
239–522
104–938
162–453
235–009
114–026
108–850
187–624
190–336
111–705
290–443
190–446
192–218
192–167
237–820
190–451
235–014
111–699
187–615
224–968
168–110
110–110
224–807
111–600
187–625
110–997
235–578
47a
47b
47c
49
50
51
51a
52
53
107–260
107–266
107–267
110–037
187–963
235–450
107–260
111–826
111–840
LABEL, DANGER, English
GRIP, handle
MOTOR KIT Includes 4a to 4e
. BALL, SST, 1/4” dia.
. TERMINAL, 1/4” F, 18 AWG
. TERMINAL, 3/16” M, 16 AWG
. LABEL, Warning, Shock
. LABEL, DANGER, English
SCREW, sch, 1/4–20 x 1”
LOCKWASHER, spring, 1/4”
GASKET, inlet filter
DRIVE HOUSING KIT
Includes 11a, 11b
. BALL, stainless steel, 1/4” dia.
. PLUG
CRANKSHAFT Includes 12a, 12b
. BEARING, thrust
. BEARING
COVER, front
LABEL, Warning
ROD, CONNECTING
GEAR REDUCER
PIN, straight, hdls, 3/8” dia. x 1”
SPRING, retaining
SCREW, sch, 1/4–20 x 1–1/4”
PUMP KIT See manual 308–190
CAPSCREW, sch, 7/16–14 x 1–3/4”
SCREW, special, 5/16–18 x 1–1/4”
HANDLE, sprayer
CAP, tubing
LEG, w/gusset
O–RING
NIPPLE, 1/4 npsm x 1/4 npt
PRESSURE TRANSDUCER
CLIP, spring
SCREW, filh, 8–32 x 1–1/4”
SUCTION HOSE & TUBE
DRAIN HOSE
SCREW, filh, 8–32 x 2–1/2”
LABEL, identification
ADAPTER, stem
LEG, sprayer
TUBE, inlet
STRAINER
ADAPTER, union
DRAIN VALVE KIT Includes 42a–42e
. GASKET, valve seat
. SEAT, drain valve
. STEM, drain valve
. O–RING, stem
. SEALANT, pipe (not shown)
BASE, valve
PIN, grooved, 3/32 x 1”
HANDLE, drain valve
SCREW, washer/hex hd, 5/16”
MOTOR START BOARD
Includes 47a,47b
. TERMINAL, 1/4” F, 16 AWG
. TERMINAL, 1/4” M, 16 AWG
. TERMINAL, 3/16” F, 16 AWG
SCREW, mach, pnhd, 10–24 x 5/8”
GASKET, junction box
FILTER, power inlet Includes 51a
. TERMINAL, 1/4” F, 16 AWG
SWITCH, ON/OFF
SCREW, panhead, M3 x 10 mm
Ref
No.
Qty
1
1
1
1
2
2
1
1
2
5
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
2
6
1
4
1
1
2
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
54
55
56
57
Part No.
Description
Qty
105–658
105–659
111–703
LOCKING RING
BOOT, switch
SCREW, filh, 10–24 x 3”
POWER CORD with IEC–320 Connector
239–680
France, Germany, Sweden, (schuko 7/7)
239–681
Italy (CEI 23–16/VII)
Denmark (Asnit 107–2–01)
239–682
239–683
Switzerland (SEV 1011)
Other countries (cord without male plug)
239–684
58
100–035
SCREW, panhd, 8–32 x 5/16”
59
187–958
JUNCTION BOX
63
111–704
SCREW, filh, 10–24 x 1–5/8”
64
224–828
PRESSURE CONTROL KIT
65
111–848
CLAMP, power cord
66
189–932
BASE, motor
BLACK MAX GUN
67
220–730
See manual 307–821 for parts
68
206–994
TSL, 8 oz.
WRENCH, hex, 3/8” (not shown)
71
111–827
(Use for capscrew #21)
73
111–839
SCREW, panhead w/lockwasher,
6–32 x .375”
HOSE, grounded, nylon; 1/4” ID;
74
238–360
cpld 1/4 npsm(f); 7.5 m;
spring guards both ends
78
190–447
ELBOW, union
79
103–473
STRAP, wire tie
86
102–814
GAUGE
87
104–984
TEE
UNION, swivel
88
156–823
*Extra warning labels available free of charge.
Motor Brush and Spring Replacement Kit,
P.N. 235–007 is available. Purchase separately.
1
1
4
1
2
1
2
1
1
1
1
1
2
1
1
2
1
1
1
MOTOR
GREEN/
YELLOW
49
RED
BROWN
BLACK
BLACK/
WHITE
47a
4b
4c
47c
47b
73
59
58
53
4b
51a
54
52
55
BLUE
BROWN
Ref 57
65
47
10
51
1
2
Technical Data
Power Requirements . . . . . . . . . . . . . . . . . . . 230 Vac, 50 Hz,
1 phase, 6A minimum
Working Pressure Range 0–190 bar (0–19 MPa, 0–2750 psi)
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 hp
Cycles/liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 gpm (1.25 lpm)
Power Cord . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm2, 3 wire, 3 m
Inlet Paint Strainer . . . . . . . . . . . . . . . . . . . . . . . . . 1525 micron
Stainless Steel Screen, reusable
Pump Inlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt(f)
Fluid Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npsm
Sound Data:
Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . 79 dB(A)*
Sound Power Level . . . . . . . . . . . . . . . . . . . . . . . . . 88 dB(A)*
*Measured while spraying with a .017 tip
Wetted Parts:
Displacement Pump . . . . . . . Stainless steel, Carbon steel,
PTFE , Aluminum, Polyethylene, Delrin, Leather
NOTE:PTFE and Delrin are trademarks of the
Company.
Dimensions
Weight (dry w/o packaging)
16 kg
Height
483 mm
Length
381 mm
Width
356 mm
Graco Warranty
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.
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment W arranty
Program”.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Atlanta, Detroit, Los Angeles
Foreign Offices: Belgium, Canada, England, Korea, Switzerland, France, Germany, Hong Kong, Japan
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN
PRINTED IN U.S.A. 308–745 March 1997
55440–1441
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