Graco 308180D ELECTRIC, 120 VAC 390 st Airless Paint Sprayer Owner's Manual

INSTRUCTIONS–PARTS LIST

This manual contains important warnings and information.

READ AND RETAIN FOR REFERENCE

ELECTRIC, 120 VAC

390

st

Airless Paint Sprayer

2750 psi (195 bar) Maximum Working Pressure

Model 231–201, Series D

Standard mount; complete sprayer with hose, gun,

RAC IV DripLess Tip Guard and SwitchTip

Model 231–328, Series A

Basic sprayer on;y

308–180

Rev. D

Supercedes Rev. C

Model 231–201 Shown

02821A

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

COPYRIGHT 1992, GRACO INC.

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Identification and Function . . . . . . . . . . . .

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutdown and Care . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

11

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

13

6

7

2

5

Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Repair Information . . . . . . . . . . . . . . . . . . . . .

Motor Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pump Repair

Motor

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Start Board

Power Supply Cord

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

18

19

21

25

26

26

Symbols

ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Housing, Connecting Rod, Crankshaft . . . . . .

Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Hose

Drain Valve

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pump Parts Drawing and List

Model 231–201 and 231–328

. . . . . .

Sprayer Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . .

Model 231–201 and 231–328

Sprayer Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data

Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Warranty and Disclaimers . . . . . . . . . . . . . . . .

34

35

36

36

36

26

27

29

30

31

32

33

Warning Symbol

WARNING his symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

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.

INJECTION HAZARD

Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also cause serious injury.

Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious injury. Get immediate medical attention.

Do not point the gun at anyone or at any part of the body.

Do not put your hand or fingers over the spray tip.

Do not stop or deflect leaks with your hand, body, glove or rag.

Do not “blow back” fluid; this is not an air spray system.

Always have the tip guard and the trigger guard on the gun when spraying.

Check the gun diffuser operation weekly. Refer to the gun manual.

Be sure the gun trigger safety operates before spraying.

Lock the gun trigger safety when you stop spraying.

Follow the Pressure Relief Procedure on page 9 if the spray tip clogs and before cleaning, checking or servicing the equipment.

Tighten all fluid connections before operating the equipment.

Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not repair high pressure couplings; you must replace the entire hose.

Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by kinks or bends near the couplings.

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed.

Know the specific hazards of the fluid you are using.

Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.

Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

Keep clear of all moving parts when starting or operating the pump.

Before servicing the equipment, follow the Pressure Relief Procedure on page 9 to prevent the equipment from starting unexpectedly.

INSTRUCTIONS

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

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 Graco Technical Assistance at 1–800–543–0339.

Do not alter or modify this equipment.

Check equipment daily. Repair or replace worn or damaged parts immediately.

Do not exceed the maximum working pressure of the lowest rated system component. Refer to the Technical Data on page 36 for the maximum working pressure of this equipment.

Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-

nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use could result in a chemical reaction, with the possibility of explosion.

Do not use hoses to pull equipment.

Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 82 C (180 F) or below –40 C (–40 F).

Do not lift pressurized equipment.

Comply with all applicable local, state, and national fire, electrical, and safety regulations.

NOTE: This is an example of the DANGER label on your sprayer. This label is available in other languages, free of charge. See page 36 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.

Use outdoors or in extremely well ventilated areas. Ground equipment, hoses, containers and objects being sprayed.

Avoid all ignition sources such as static electricity from plastic drop cloths, open flames such as pilot lights, hot objects such as 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.

Liquids can be injected into the body by high pressure airless spray or leaks – especially hose leaks.

Keep body clear of the nozzle. Never stop leaks with any part of the body. Drain all pressure before removing parts.Avoid accidental triggering of gun by always setting safety latch when not spraying.

Never spray without a tip guard.

In case of accidental skin injection, seek immediate

“Surgical Treatment”.

Failure to follow this warning can result in amputation or serious injury.

READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE

4 308-180

H

K

N

Component Identification and Function

C

B

A

E

G

L

M

D

F

J

Fig. 1

A Motor

B Drive Assembly

C Pressure Adjusting Knob

D ON/OFF Switch

E Fluid Outlet

F Displacement Pump

G 50 ft (15 m) Main Hose

H RAC IV Tip Guard

J Contractor Gun

K RAC IV Switch Tip

L Pressure Drain Valve

M Pressure Control

N Spray Gun Safety Latch


02823A

DC motor, 120 Vac, 15A, 1 phase

Transfers power from DC motor to the displacement pump

Controls fluid outlet pressure

Power switch that controls 120 Vac power to sprayer

Hose and spray gun is connected here

Pressurizes fluid to be sprayed through spray gun

1/4 in. ID, grounded, nylon hose with spring guards on both ends

Reverse-A-Clean (RAC) tip guard reduces the risk of fluid injection injury

High pressure spray gun with gun safety latch

RAC switch tip atomizes fluid and removes clogs from spray tip without removing tip from spray gun

Relieves fluid pressure when open

Controls motor to maintain fluid pressure. Works with pressure adjusting knob.

Inhibits accidental triggering of spray gun

308-180 5

WARNING

If you supply your own hoses and spray gun, be sure the hoses are electrically conductive, that the gun has a tip guard, and that each part is rated for at least 2750 psi (195 bar) Working Pressure. This is to reduce the risk of serious injury caused by static sparking, fluid injection or over-pressurization and rupture of the hose or gun.

Setup

2.

Fill the wet–cup (102). Pry off the wet-cup seal.

Fill the cup 1/3 full with Graco Throat Seal Liquid

(TSL), supplied. Install the wet-cup seal.

3.

Plug in the sprayer. Be sure the ON/OFF switch

(52) is OFF. Plug the cord into a 15A grounded outlet at least 20 feet away from the spray area. A

12 AWG 150 ft (45 m) grounded extension cord may be used.

CAUTION

To avoid damaging the pressure control, which may result in poor equipment performance and component damage, follow these precautions:

1. Always use a nylon spray hose at least 50 ft.

(15 m) long.

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. 2.

WARNING


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.

4.

Flush the pump to remove the lightweight oil which was left in to protect pump parts after factory testing. See page 12.

1.

Connect the hose (74) and gun (67) and screw it onto the outlet nipple (28). Don’t use thread sealant, and don’t install the spray tip yet!

5.

Prepare the paint according to the manufactuers’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.

1

2

3

4

5

1/4 npsm(m) fluid outlet

Do not install any shutoff device here

Rotate clockwise to increase pressure

Shown in closed or spray position

Fill 1/3 full with TSL

3 64

33

32

2 1 28

74

67

52

4

102 5


02823A

Fig. 2

6 308-180

Operation

How to use the gun trigger safety

When engaged, the gun safety latch prevents the gun from accidental triggering. See Fig. 3.

1

2

Open or drain, position

Closed, or spray position

WARNING


If the gun still sprays when the gun trigger safety is locked, repair the gun. See manual 307–614, supplied.

1

1

2

Gun safety latch shown engaged

Gun safety latch shown disengaged

Fig. 4

1

2

2

02825A

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. 5.

+

–

Fig. 3

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 13. See Fig. 4.

Fig. 5

02824A

308-180 7

How to use the RAC IV tip guard.

Operation

WARNING


To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief

Procedure on page 9.

The tip guard alerts you to the risk and helps prevent placing any part of the body close to the spray tip. The tip guard also adjusts the vertical or horizontal spray pattern. See Fig. 8. The tip guard holds a reversing spray tip. The tip is in the spraying position when the tip handle points forward. See Fig. 6.

Clean the front of the tip frequently during the day’s operation. First, follow the Pressure Relief Procedure on page 9.

1 2

1

Tip handle shown in spraying position.

2 Turn handle 180 ,

trigger gun to clear clog

Fig. 6

04647

How to remove a tip clog.

1. Release the gun trigger. Lock the safety latch. Rotate the RAC IV tip handle 180 . See Fig. 6.

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.

WARNING


The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you: are instructed to relieve the pressure, stop spraying, check or service any of the system equipment, or install or clean the spray tip.

Startup

NOTE: Refer to Fig. 2 and the other figures referenced in the text as you start the sprayer.

1.

Open the pressure drain valve (42). See Fig. 7.

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.

Pressure Relief Procedure

1. Engage the gun safety latch.

2. Turn the ON/OFF switch to OFF.

3. Unplug the power supply cord.

4. Disengage the gun safety latch. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure.


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 12.

42 1

1

Fig. 7

Open or drain, position

4.

Turn the pressure knob (64) to the minimum setting.

5.

Disengage the gun trigger safety. See Fig. 3, page 7.

CAUTION

Do not run the sprayer dry for more than 30 seconds to avoid damaging the pump packings.

01021A

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.

308-180 9

WARNING


To reduce the risk of static sparking and splashing when priming or flushing the system, hold a metal part of the gun firmly to the side of a grounded metal pail before triggering the gun.

Startup

b. If more coverage is needed, use a larger tip rather than increasing the pressure.

c. Adjust the direction of the spray pattern. See

Fig. 8. Engage the gun safety latch. Loosen the retaining nut (A). Position the tip guard for a horizontal or vertical pattern. Hold the tip guard in place and tighten the retaining nut.

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.


10.

Install the spray tip and tip guard. Install the spray tip. If you are using the RAC IV tip guard, refer to manual 307–848 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.

NOTE: Spray patterns will change as tips wear.

Change the spray tip if adjusting the pressure will not improve the spray pattern.

1

For a vertical spray pattern

2

Fig. 8

For a horizontal spray pattern

2

1

A

01025

Shutdown and Care

WARNING




WARNING


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.

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. 9.

3.

Periodically clean paint residue from the pres-

sure transducer (29) vent hole area. See Fig. 10.

Replace the transducer when leakage is excessive. See page 30.

4.

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. 10.

5.

Flush the sprayer at the end of each work day and fill it with mineral spirits to help prevent pump corrosion and freezing. See page 12.

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.

1

Turn packing nut clockwise to tighten

Fig. 9

1 Vent hole

1

1 102

29

A

05117

6.

For very short shutoff periods, leave the suction tube in the paint, relieve pressure, and clean the spray tip.

7.

Coil the hose and hang it on a hose rack when storing it, even for overnight, to help protect the hose from kinking, abrasion, coupling damage, etc.

Fig. 10 02827A

Flushing

When to Flush

1.

Before using a new sprayer: flush out the oil which was left in to protect pump parts.

3. Pour one-half gallon (2 liters) of compatible solvent into a grounded metal flushing pail. Put the suction hose in the pail.

Before using water-base paint: flush with mineral spirits followed by soapy water, and then a clean water flush.

4. Open the pressure drain valve. See Fig. 4, page

7.

Before using oil-base paint: flush with mineral spirits only.

2.

Changing colors: flush with a compatible solvent such as mineral spirits or water.

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.

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.

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 flushing.

5.

Storage after using water-base paint: flush with water and then mineral spirits. Leave the system filled with mineral spirits. Relieve pressure. Leave the drain valve open.

Storage after using oil-base paint: flush with mineral spirits. Relieve pressure. Leave the drain valve open.

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.

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.

7. Open the drain valve and circulate the solvent through the drain tube to thoroughly clean it. Close the drain valve.

6.

Startup after storage. Before using water-base paint, flush out the mineral spirits with soapy water and then clean water. When using oil-base paint, flush out the mineral spirits with the paint.

How to Flush

1. Follow the Pressure Relief Procedure on page 9.

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.

9. Remove and clean the inlet strainer. Wipe paint off the suction hose and drain tube.

10. Refer to When To Flush, Step 1 again. Relieve pressure.

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.)

11. Leave the drain valve open until you use the sprayer again.

Troubleshooting

WARNING


To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the

Pressure Relief Procedure on page 9.

Basic Problem Solving

Check everything in the troubleshooting table before disassembling the sprayer.

TYPE OF PROBLEM

Fluid pressure

Mechanical

Electrical

WHAT TO CHECK

If check is OK, go to next check

1. Check pressure control knob setting. The pump won’t develop much pressure if it is at minimum setting (fully counterclockwise).

2. Check for a clogged spray tip or fluid filter, if used. See page 8.

WHAT TO DO

When check is not OK, refer to this column

1. Slowly increase pressure setting to see if motor starts.

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 17.

2. Check pump connecting rod pin (17). It must be completely pushed into connecting rod (15), and retaining spring (18) must be firmly in connecting rod groove. See Fig. 17, page 21.

3. Check for motor damage. Remove drive housing assembly (11). See page 27. Try to rotate motor fan by hand.

1. Check electrical supply with volt meter. Meter should read 105–125 VAC.

2. Check extension cord for visible damage. Use a volt meter or test lamp at extension cord outlet to check.

3. Check sprayer power supply cord (50) for visible damage such as broken insulation or wires.

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.

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. Thaw. Plug in sprayer and turn on. Slowly increase pressure setting to see if motor starts. If it doesn’t, see NOTE, below.

2. Push pin into place and secure with spring retainer.

3. Replace motor (4) if fan won’t turn. See page 25.

1. Reset building circuit breaker; replace building fuse. Try another outlet.

2. Replace extension cord.

3. Replace power supply cord.

See page 26.

4. Refer to page 19.

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 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 21) and/or pressure transducer (page 30) must be replaced.

TYPE OF PROBLEM

Electrical (continued)

TYPE OF PROBLEM

Low output

Basic Problem Solving

WHAT TO CHECK


5. Check motor armature commutator for burn spots, gouges and extreme roughness. Remove motor cover and brush inspection plates to check. See page 19.

6. Check motor armature for shorts using armature tester (growler) or perform motor test.

See page 17.

7. Check leads from pressure control and motor to motor start board (47) to be sure they are securely fastened and properly mated.

8. Check motor start board (47) by substituting with a good board. See page 26.

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 (50). Disconnect black and white power cord terminals; connect volt meter to these leads. Plug in sprayer. Meter should read 105–125VAC. 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 105–125VAC

Turn off and unplug sprayer.

11. Check motor thermal cutout switch. Connect ohmmeter between motor’s red leads. Meter should read 1 ohm maximum.

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.

13. Check pressure transducer (29) for hardened paint or damaged or worn components. See page 30.

WHAT TO DO


5. Remove motor and have motor shop resurface commutator if possible. See page 25.

6. Replace motor. See page 25.

7. Replace loose terminals; crimp to leads.

Be sure male terminal blades are straight and firmly connected to mating part.

8. Replace board. See page 26.

9. Replace power supply cord. See page

26.

10. Replace ON/OFF switch. See page 26.

11. Allow motor to cool. Correct cause of overheating. If switch remains open after motor cools, replace motor.

12. Replace pressure control. See page 29.

13. Replace transducer. See page 30. Thorough system flushing will help extend life of transducer.

Intermediate Problem Solving

WHAT TO CHECK


1. Check for worn spray tip.

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.

WHAT TO DO

When check is not OK refer to this column

1. Follow Pressure Relief Procedure then replace tip. See your separate gun or tip manual.

2. Service pump. See page 21.

14 308-180


TYPE OF PROBLEM

Low output (continued)

Drain valve leaks

Transducer leaks

No output: motor runs and pump strokes

WHAT TO CHECK


3. Release gun trigger. Observe resting position of pump rod (107).

4. Check electrical supply with volt meter. Meter should read 105–125VAC.

WHAT TO DO


3. If pump consistently comes to rest with rod (107) fully extended, the piston packings and/or piston valve may be worn.

Service the pump. See page 21.

4. Reset building circuit breaker; replace building fuse. Repair electrical outlet or try another outlet.

5. Replace with a correct, grounded extension cord.

5. Check extension cord size and length; must be at least 12 gauge wire and less than 150 ft

(45 m) long.

6. Check motor brushes. See Electrical – What To

Check, item 4, on page 13.

7. Check motor start board (47) by substituting with a good board.


8. Check motor armature for shorts by using an armature tester (growler) or perform motor test.

See page 17.

1. Check drain valve for correct torque and/or worn parts. Check for debris trapped on seat.

6. See page 19.



1. Slight leakage from transducer is normal.

1. Check paint supply.

9. Tighten to 185 in–lb (21 N.m). Clean valve and replace with new gasket (42a) and sealant (42d). See page 32.

1. Periodically remove residue from its cylinder port. See page 30.

1. Refill and reprime pump.

No output: motor runs but pump does not stroke

2. Check for clogged intake strainer.

3. Check for loose suction tube or fittings. See page 31.

4. Check to see if intake valve ball and piston ball are seating properly. See page 21.

5. Check for leaking around throat packing nut which may indicate worn or damaged packings.

See page 21.

6. Release gun trigger. Observe resting position of pump rod (107).

1. Check displacement pump connecting rod pin

(17). See Fig. 17, page 21.

7. Check connecting rod assembly (15) for damage. See page 27.

8. Be sure crank in drive housing rotates; plug in sprayer and turn on briefly to check. Turn off and unplug sprayer. See page 27.

2. Remove and clean, then reinstall.

3. Tighten; use thread sealant on npt threads of adapter (38).

4. Remove intake valve and clean. Check ball and seat for nicks; replace as needed. See page 21. Strain paint before using to remove particles that could clog pump.

5. Replace packings. See page 21. Also check piston valve seat for hardened paint or nicks and replace if necessary.

Tighten packing nut/wet-cup.

6. If pump consistently comes to rest with rod (107) fully extended, the piston packings and/or piston valve may be worn.

Service the pump. See page 21.

1. Replace pin if missing. Be sure retainer spring (18) is fully in groove all around connecting rod.

7. Replace connecting rod assembly. See page 27.

8. Check drive housing assembly for damage and replace if necessary. See page 27.

308-180 15


TYPE OF PROBLEM

Spray Pattern Variations

WHAT TO CHECK


1. Spray tip worn beyond sprayer pressure capability.

WHAT TO DO


1. Replace spray tip.

NOTE: A smaller size tip will provide longer life.

2. Replace transducer. See page 30.

3. Replace pressure control. See page 29.

Motor Is Hot and Runs

Intermittently

Building Circuit Breaker

Opens As Soon As Sprayer

Switch Is Turned On.

2. Check transducer (29) for wear or damage.

3. Check pressure control (64) for smooth operation.

4. Check Low output section, page 15.

1. Determine if sprayer was operated at high pressure with small tips, which causes excessive heat build up.

2. Be sure ambient temperature where sprayer is located is no more than 90 F (32 C) and sprayer is not located in direct sun.

3. Check motor.

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 25.

2. Check for missing motor brush inspection plate gasket (see page 17), bent terminal forks or other metal to metal contact points which could cause a short.

3. Check motor armature for shorts. Use an armature tester (growler) or perform motor test. See page 17. Inspect windings for burns.

4. Check motor start board (47) by substituting with a good board.


1. Check ‘Basic Problems – Electrical’ on page

13.

1. Decrease pressure setting or increase tip size.

2. Move sprayer to shaded, cooler area if possible.


1. Repair or replace any damaged wiring or terminals. Securely reconnect all wires.

2. Correct faulty conditions.



Circuit breaker opens after sprayer operates for 5 to 10 minutes.

Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on.

Unit will not run on generator but does run on AC power

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.

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 105–125 VAC.

Check the generator’s peak voltage. This sprayer will not run if the peak voltage is above 190V.

1. Replace ON/OFF switch. See page 26.

2. If voltage is too high, do not operate sprayer until corrected.

Use AC power or a different generator

16 308-180

Motor Test

WARNING




For checking armature, motor winding and brush electrical continuity.

Setup

Remove the drive housing. See page 27. This is to ensure that any resistance you notice in the armature test is due to the motor and not to worn gears in the drive housing.

Remove the motor brush inspection covers (A).

See

Fig. 11.

Remove the junction box screws (56). Lower the junction box. Disconnect the two leads (C) from the motor to the board (47). See Fig. 12.

Armature Short Circuit Test

Remove the fan cover (B). See Fig. 11.

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 25.

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.

When turning the fan on a DC motor, normally you sense an even, pulsing resistance. If there is irregular turning resistance, or no turning resistance, check and repair the following as needed: broken brush springs, brush leads, motor leads; loose brush terminal screws or motor lead terminals; worn brushes. See page 19.

If there is still uneven or no turning resistance, replace the motor. See page 25.

Fig. 11

59

BLACK/

WHITE

BLACK

C

Fig. 12

MOTOR

A

47

RED

56

B

02829A

04720

308-180 17

General Repair Information

WARNING




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


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 13–17, 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).

3 F

G H

2

C

WARNING




1. Remove both inspection covers (A) and their gaskets. See Fig 13.

1 Motor lead; do not disconnect

2 Minimum 0.5” (12.5 mm)

3

Included in Brush Repair

Kit 236–967

1

B

E

Fig. 14

D

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.

F

1

G

A

02831A

Fig. 13

2. Push in the spring clip (F) and release its hook (G) from the brush holder (B). Pull out the spring clip.

See Fig 14.

3. Slide off the brush lead terminal (E) off the blade connector. Remove the old brush (C). See Fig 14.

C

Fig. 15

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. 15. 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.

308-180 19

Motor Brushes

9.

Test the brushes.

a. Remove the pump connecting rod pin (17).

See Fig. 17, page 21.

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


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. 17, page 21.

Displacement Pump Repair

WARNING




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).

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.

NOTE: To minimize down time, and for the best sprayer performance, check the motor brushes (see page 19) and clean the transducer (see page 30) whenever you repack the pump. Replace these parts as needed.

Removing the pump

(See Fig. 16.)

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.

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.

17

2. Remove the filter (85).

3. While pulling upward on the suction hose (32), unscrew the hose from the inlet tube (38). Unscrew the drain hose (33) from the displacement pump nipple (36).

13

1

18

85

107

20

21

*122

120

NOTE: If repairing only the intake valve assembly, go to Intake valve repair, page 22.

4. Use a screwdriver to push the retaining spring (18) up and push out the pin (17).

5. Loosen the screws (21). Remove the pump (20).

Installing the pump

(See Fig. 16 and 17.)

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).

Fig. 16

33

32

27

38

2

36

118

1

2

*121

*119

Torque to

50 ft–lb (68 N.m)

Apply sealant (42d)

02832

17

WARNING


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. 17.

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.

1

15

123

Torque to

50 ft–lb (68 N.m)

Fig. 17

21

1

18

102

04655


Intake valve repair

(See Fig. 16)

1. Remove the suction hose. See Step 3, Removing the pump.

1. Check the outside of the piston rod (107) and the inside of the cylinder (115) for wear. Replace worn parts to ensure a good seal with the new packings.

2. Unscrew the intake valve (118). Remove the o-ring (119*), ball guide (120), stop pin (122*) and ball (121*) from the valve.

2. Stack these parts onto the piston valve (108) one at a time: the female gland (114*), alternately three plastic (112*) with two leather packings (113*), and the male gland (111*). See Fig. 18.

3. Clean and inspect the parts for wear or damage.

Replace parts as needed. Use a new o–ring

(119*). If no further service is needed, reassemble the pump.

1 Throat packings

2 Piston packings

3 Intake valve

Disassembling the pump

(See Fig. 18.)

1. Remove the intake valve (118).

123

102

*103

2. Loosen the packing nut (102) and plug (123).

3. Use a plastic mallet to tap the piston rod (107) down, and then pull the rod out through the bottom of the cylinder.

4. Remove the packing nut (102) and throat packings.

5. Loosen the jam nut (117). Remove the cylinder

(115) and the o-ring (116*).

6. Clamp the flats of the piston rod in a smooth jaw vise. Use an open-end wrench to loosen the nut

(110) and then unscrew the piston valve (108).

7. Remove all parts from the piston valve (108).

Reassembling the pump

NOTE: Alternate plastic and leather packings. See Fig.

18. The lips of the throat V-packings face down. The lips of the piston V-packings face up. Incorrect installation damages the packings and causes pump leakage.

NOTE: Soak the leather packings in oil before reassembling the pump.

1

*104

101

117

*116

115

Fig. 18

105*

106*

*113

122*

107

109*

110

111

2

112*

114*

108

120

121

119

3

118

01069A


3. Tighten the nut (110) onto the piston valve (108) to

2 in-lb (0.23 N.m). See Fig. 19.

6. Hand tighten the valve into the piston rod just until the nut (110) contacts the rod. See Fig. 20.

1

2

Torque to

2 in–lb (0.23 N.m)

Apply one drop of sealant to these threads

110

107

109*

*111

*113

112*

114*

Fig. 19

108

01070

NOTE: Note the alignment of the piston (108) to the nut (110). Maintain this alignment through Step 8.

4. Clean all residue from the piston valve threads.

Apply one drop of adhesive, supplied, to the threads.

5. Place the ball (109*) on the piston valve (108). See

Fig. 19.

7. Place the flats of the rod (107) in a smooth jaw vise.

8.

CAREFULLY tighten the nut (110) against the piston rod to 19 ft-lb (25 N.m). See Fig. 20.

1

2

Use two wrenches to maintain the alignment mentioned in NOTE below Step 3.

Torque nut against rod to 19 ft–lb (25 N.m)

Do not allow nut (110) to move relative to piston (108) when tightening piston against rod.

107

110 1 2

108

CAUTION

Step 6, tightening the piston valve into the rod, is critical. Follow the procedure carefully to avoid damaging the packings by overtightening.

Fig. 20

9. Stack these parts one at a time into the top of the manifold (101): the male gland (106*), alternately three plastic packings (104*) with two leather packings (105*), and then the female gland (103*). See

Fig. 22.

10. Install the packing nut (102) and plug (123), but leave loose for now. See Fig. 22.


11. Place a new o-ring (116*) firmly in the cylinder groove. See Fig. 21.

15. Torque the cylinder jam nut (117) to 73 ft-lb

(98 N.m). See Fig. 21.

12. Coat the piston rod and packings with oil. Carefully slide the assembly into the top of the cylinder

(115). See Fig. 21.

13. Put the manifold upside down in a vise. Fully thread the jam nut (117) onto the cylinder (115).

Guide the rod/cylinder assembly down through the manifold (101). Screw the cylinder (115) into the manifold. See Fig. 21.

16. Install the pump. See page 21.

1

2

3

Leather packings

Poly packings

Lips of V–packings must face down

4

5

Lips of V–packings must face up

Torque to 53 ft–lb

(71 N.m)68 N.m

(50 ft–lb

107

123

102

101

102

1

Torque jam nut (117) to 73 ft–lb (98 N.m)

2

3

Torque cylinder (115) into manifold (101) to

53 ft–lb (71 N.m)

Torque intake valve (116) into cylinder (115) to

53 ft–lb (71 N.m)

4 Piston assembly

4

107

116*

117

115

1

2

*103

*105

1 3

*116

110

111

*113

1 4

115

118 3

Fig. 21 01072A

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 53 ft-lb

(71 N.m). This will also properly torque the cylinder into the manifold. See Fig. 22.

120

*119

5 118

Fig. 22

104*

2 3

106*

101

109*

117

112*

2 4

114*

108*

122*

121*

01073

WARNING




NOTE: See Fig. 25 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. 23.

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 26.

4. Remove the front cover (13).

5. 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.

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 27.

8. Remove the two screws (46) and lift the motor off the base (66).

11

Motor

9. Align the new motor with the base and reinstall the screws (46).

10. Assemble the drive housing to the motor. Follow steps 8 to 10 on page 27.

11. Connect the wires in the junction box. Refer to Fig.

26 on page 26. Install the junction box.

12. Connect the piston rod (107) to the drive housing; see page 21, Installing the Pump, Step 2 and the

WARNING following it.

Fig. 23

Fig. 24

12

16

A

15

107

B

C

1

6

5

4

17

18

19,6

01068

01074

1 Torque to 80 in–lb (9 N.m)

2 Quantity of three

3 Quantity of one

1 19

6

59 46

3

13

31 56

34 2

Fig. 25 05119

Motor Start Board

WARNING




NOTE: See Fig. 26 for this procedure.


2. Remove the junction box screws (56) and lower the junction box (59).

3. Disconnect the motor wires (B) and the 3-wire connector (A) from the motor start board (47). Observe where connections are made.

4. Remove the screws (58) and motor start board

(47). Transfer the white thermal paste from the old board to the new board.

5. Install the new motor start board. Reconnect all wires. Install the junction box. Be sure no leads are pinched against the motor or by the motor start board. Also be sure the gasket (89) is installed.

CAUTION

Be sure the flat blade of the insulated male connector is centered in the wrap–around blade of the female connector when the connections are made.

Route all wires carefully to avoid interference with the motor start board or junction box.

These precautions are essential to reduce the risk of a malfunction.

Power Supply Cord




3. Disconnect the power supply cord leads, including the green wire to the grounding screw (49).

4. Loosen the strain relief bushing (51). Remove the power supply cord (50).

5. Install the new cord (50) in the reverse order of disassembly.

6. Install the junction box. Be sure no leads are pinched against the motor or by the motor start board. Also be sure the gasket (89) is installed.

On/Off Switch




3. Remove the nut and rubber boot (55).

4. Disconnect the black wires from the ON/OFF switch (52) and remove the switch.

5. Place the ring terminal of the ground wire (53) over the barrel of the new switch. Install the 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.

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 (89) is installed.

MOTOR

GREEN

49

53

GREEN/

YELLOW

50

51

89

52

59

BLACK/

WHITE

BLACK

B

54

55

58

A

RED

56

C

47

Fig. 26 04720

Drive Housing, Connecting Rod, Crankshaft

WARNING




CAUTION

Do not allow the gear (16) to fall; it may stay attached to the drive housing or to the motor.

Do not lose the thrust balls (11a or 4a) or 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.

Removal

NOTE: Inspect parts as they are removed. Replace parts that are worn or damaged.

1. Remove the displacement pump. See page 21.

2. Remove the pressure control (64). See page 29.

3. Turn the displacement pump rod (107) so the pin hole aligns with the bottom drive housing screw

(19). See Fig. 27. Remove the three drive housing screws and lockwashers (19,6). Also see Fig. 28 on page 28.

Fig. 27

107

19,6

01074

4. Remove the two motor screws (5) and lock washers (6). See Fig. 28 on page 28.

5. Tap the lower rear of the drive housing (11) with a plastic mallet to loosen the motor. Pull the drive housing straight off the motor.

6. Remove and inspect the crankshaft (12) and the connecting rod (15).

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. (29 cc) of grease.

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 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 21.

12. Install the pressure control (64). See page 29.

Install the front cover (13).

Drive Housing, Connecting Rod, Crankshaft

64

REF A

12a

4 12

11a

1

16

12b

4a

C

5,6

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.(29 cc) of grease to gears.

A

47

59

56

3

31

Note: Filter not shown 13

15 19

1

6

11

34 2

02815

Fig. 28

Pressure Control

WARNING




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: The pressure control (64) cannot be repaired or adjusted. If it has malfunctioned, replace it.

1. Remove the front cover (13). Remove the screws

(56). Lower the junction box (59).

2. Disconnect the harness connector (A) from the motor start board (47).

3. Remove the screws (63). Pull forward on the pressure adjusting knob and tip the pressure control

(64) forward and up to detach it from the drive housing (11).

4. Guide the harness (A) through the motor and drive housing and remove the pressure control.

5. Guide the harness of the new pressure control through the drive housing and motor passages.

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).

A

Fig. 29

56

59

64

63 1

1

11

13

Torque to

21 in–lb (2.4 N.m)

02816A

Pressure Transducer

WARNING





1. Remove the displacement pump. See page 21.

2. Use a pull–twist motion to remove the transducer

(29) from the pump manifold (101).

3. Clean paint residue from the hole in the manifold; do not scratch the surface of the hole.

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.

6. Align the holes in the transducer as shown by the arrows in Fig. 30.

7. Install the displacement pump. See page 21.

Fig. 30

29

101

02817A

Suction Hose

WARNING




CAUTION

Misalignment or cross-threading will damage the parts and/or create shavings which can cause the o–ring (27) to leak.

1. Remove the drain hose (33) from the clip. Remove the front cover (13).

1 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.

4. Lubricate the o–ring (27) and the inlet tube (38) threads with light grease.

33

1

32

27

A

36

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.

Fig. 31

38

02818A

Drain Valve

WARNING




Repair

1. Unscrew the spring retainer from the valve body.

Remove the spring, washers and stem/ball. Clean any debris from the ball or seat area.

2. If replacing the gasket (42a) or seat (42b), pry out the gasket.

NOTE: Whenever the gasket (42a) is removed, replace it with a new one.

42a

42b

3

42

1

42d

42c

1

2

3

4

Apply thread sealant

Apply grease to face of base

Torque into pump manifold to 185 in–lb

(21 N.m)

Handle shown in closed position

2

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.

43

44

Fig. 32

4

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.

NOTE: The gasket will protrude from the end of the valve until the valve is tightened into pump, which correctly seats the gasket.

Replacement

1. Apply a small amount of thread sealant (42e) onto the valve (42) threads. Tighten the valve into the pump manifold to 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).

Displacement Pump Parts Drawing and List


Includes items 101 to 127

123

Ref

No. Part No.

Description

101 187–611 MANIFOLD, pump

102 176–758 PACKING NUT

103 176–757* GLAND, female, throat

104 176–997* V–PACKING, plastic, throat

105 176–755* V–PACKING, leather, throat 2

106 176–754* GLAND, male. throat 1

1

1

3

1

1

107 187–613 DISPLACEMENT ROD

108 224–808 PISTON, valve

109 105–444* BALL, 5/16”, piston

110 176–751 NUT, hex, 1/2–20 unf–2b

111 176–750* GLAND, male, piston

112 176–882* V–PACKING, plastic, piston 3

113 176–749* V–PACKING, leather, piston 2

114 180–073* GLAND, female, piston

1

1

1

1

115 236–786 CYLINDER, pump

116 108–526* PACKING, o–ring, PTFE

117 187–614 NUT, jam,1-3/8 18 unef–2 b

118 224–966 INLET VALVE

119 111–603* PACKING, o–ring,

120 176–760 GUIDE, ball

PTFE

121 105–445* BALL, 1/2”, inlet

122 176–759* PIN, ball stop

123 180–656 PLUG

124 102–969* SEALANT

127 188–663 LABEL, Warning

1

1

1

1

1

1

1

1

1

1

1

1 y t Q

Extra warning labels available free of charge.

*Supplied in Repair Kit 235–703.

Keep a repair kit on hand to reduce down time.

102

*103

*104

127

101

117

*116

105*

106*

*113

*122

107

109*

110

111

112*

114*

108

120

121*

MANUAL CHANGE SUMMARY

This manual has been updated to add manifold filter 85.

115

*119

118

01069A

Sprayer Parts Drawing



39

10

35

OUTSIDE

LABEL

14

INSIDE

LABEL

13

REF 32

31

85

34

30

28

63

19

15

17

6

18

28

21

32

27

REF 33

1

2

Label

See detail on page 35

24

74

67

Included with Model 231–201 only

4e 1

64

3

11b

12a

12

4a

4

6

5

16

12b

4f

4g

1

1

89

11a

26

11

66

2

50

56

29

42a

42b

42d

42c

20

42

36

43

44

33

45

37

25

38

23 46

23

O2833A

34 308-180

Sprayer Parts List

Model 231–201, Series D; Model 231–328, Series A

Includes items 3 to 89 as listed below

Ref.

No.

Part No.

Description

3

4 {

111–700 GRIP, handle

236–965 MOTOR KIT

Includes items 4a to 4g

5

6

10

11

4a.a

100–069 . BALL, sst, 1/4” dia.

4b.b

111–616 . TERMINAL, flat, 1/4” (f), 18 awg

4c.c

107–503 . TERMINAL, 3/16” (m), 16 awg

4d.d

Y 187–784 . LABEL, DANGER, French

4e.e

Y 187–791 . LABEL, DANGER, English

4f.f

Y 187–975 . LABEL, WARNING, electric shock

4g.g

107–504 . TERMINAL, 3/16” (f)

11a

100–643

105–510

100–721

224–965

SCREW, socket head, 1/4–20 x 1”

LOCKWASHER, 1/4”

PLUG, 1/4–18 npt(f)

DRIVE HOUSING KIT

Includes item 11a, 1 1b

100–069 . BALL, stainless steel, 1/4” dia.

42a

42b

42c

42d

42e

34

35

36

37

38

39

29

30

31

32

33

42

20

21

23

24

25

26

27

15

16

17

18

19

11b

12

111–726 . PLUG

224–803 CRANKSHAFT

Includes items 12a, 12b

180–131 . BEARING, thrust 12a

12b

13

107–434 . BEARING

187–789 COVER, front

14 Y 177–762 LABEL, WARNING

218–359

218–364

176–818

176–817

CONNECTING ROD

GEAR REDUCER

PIN, headless, 3/8” dia. x 1”

SPRING, retaining

103–345 SCREW, socket head,

1/4–20 x 1–1/4”

236–787 PUMP KIT see parts on page 29

111–706

111–715

CAPSCREW, 7/16–14 x 1–3/4”

SCREW, 5/16–18 x 1–1/4”

187–631 HANDLE, sprayer

112–759 CAP, tubing

235–036 LEG, with gusset

104–938 O–RING

28 162–453 NIPPLE, hex, 1/4 npsm x

1/4 npt, 1–3/16”

235–009 PRESSURE TRANSDUCER

111–602 CLIP, 3/4”

108–850 SCREW, filh, 8–32 x 1–1/4”

187–624 SUCTION HOSE & TUBE

187–652 DRAIN HOSE

111–705 SCREW, filh, 8–32 x 2–1/2”

187–976 LABEL, identification

111–612 ADAPTER, tube, 9/16–18

187–628 LEG, sprayer

187–627 INLET TUBE

235–004 STRAINER

235–014 DRAIN VALVE KIT

Includes items 42a to 42e

111–699 . GASKET, valve seat

187–615 . SEAT, drain valve

224–968 . STEM, drain valve

168–110 . O–RING, stem

110–110 . SEALANT, pipe (not shown)

Qty.

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

5

1

1

2

1

1

1

1

1

1

5

1

1

1

4

1

1

6

1

1

2

2

1

2

3

1

1

1

1

1

1

1

1

1

Ref.

No.

Part No.

Description

58

59

63

64

66

67

52

53

54

55

56

43

44

45

46

47

187–625 HANDLE, drain valve

110–997 SCREW, washer/hex hd, 5/16”

235–008 MOTOR START BOARD includes items 47a to 47c

48 Y 186–620 LABEL, ground terminal

49

50

110–037

235–010

SCREW, mach, pnhd, 10–24 x 5/8”

POWER CORD SET

51

224–807 BASE, valve

111–600 PIN, grooved, 3/32 x 1”

111–617 STRAIN RELIEF BUSHING,

3/8–18 npt

105–679 SWITCH, ON/OFF

235–035 GROUND HARNESS

105–658 LOCKING RING

105–659 BOOT, switch

111–703 SCREW, filh, 10–24 x 3”

68

74

85

89

100–035

187–795

111–704

224–828

189–932

220–955

SCREW, pan hd, 8–32 x 5/16”

JUNCTION BOX

SCREW, filh, 10–24 x 1–5/8”

PRESSURE CONTROL KIT

BASE, motor

CONTRACTOR GUN

See manual 308–614 for parts

206–994 TSL, 8 oz. (not shown)

223–541 HOSE, grounded, nylon; 1/4” ID; cpld 1/4 npsm(f); 50 ft (15 m);’ spring guards both ends

235–677 FILTER, fluid

See Manual 308–249 for parts

187–963 GASKET

Qty.

1

2

1

1

1

1

1

1

1

1

1

1

1

2

1

2

1

1

1

1

1

1

1

4

Y Extra warning labels available free of charge.

{ Motor Brush and Spring Replacement Kit,

236–967 is available. Purchase separately .

59

BLACK/

WHITE

BLACK

4b

58

48

4g

MOTOR

47

GREEN

49

53

GREEN/

YELLOW

50

51

4c

RED

52

54

55

04720

308-180 35

Technical Data

Power Requirements . . . . . . . . . . . . . . . . . . . . 120 VAC,60Hz,

1 phase, 15 amp minimum

Generator . . . . . . . . . . . . . . . . . . . . . . . . . .

Working Pressure Range

Motor

Cycles/Gallon (liter)

. . . . . . . . .

3000 Watt minimum

0–2750 psi (0 – 195 bar)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

3/4 hp

620 (164)

Delivery

Tip Size

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

0.50 gpm (1.9 lpm) one gun to 0.023 new tip with latex at 2000 psi (138 bar)

Power Cord . . . . . . . . . . . . . . .

Inlet Paint Strainer

Pump Inlet Size

No. 14 AWG, 3 wire, 6’ (1.8 m)

. . . . . . . . . . . . . . . . 12 mesh (1525 micron)

Stainless Steel Screen, reusable

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt(f)

Fluid Outlet Size

Wetted Parts:

PTFE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npsm

Displacement Pump . . . . . . . Stainless steel, Carbon steel,

, Aluminum, Polyethylene, Delrin , Leather

NOTE: PTFE and Delrin are trademarks of the Company.

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: 1–800–328–0211

Apply other language here

French 185–956

Spanish 185–961

German 186–041

Greek 186–045

Korean 186–049

English 185–953

04653

Dimensions

Weight (dry w/o packaging) 37 lb (17 kg)

Height 19 in. (483 mm)

Length 15 in. (381 mm)

Width 14 in. (356 mm)

The Graco Warranty and Disclaimers

WARRANTY

Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defective, with the exception of defects in parts on the drive train/gear box on EM and GM sprayers or power train on EH and GH sprayers, which will be repaired or replaced for twenty-four months from the date of sale for Gas–Hydraulic (GH) and Gas-Mechanical (GM) sprayers and for thirty-six months from the date of sale for Electric-Mechanical

(EM), 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 does not cover, and Graco shall not be liable for, 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 with Graco equipment of structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claim. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the 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.

DISCLAIMERS AND LIMITATIONS

The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or implied), including

warranty of merchantability or warranty of fitness for a particular purpose, and of any non–contractual liabilities, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential damages or loss is expressly excluded and denied. In no case shall Graco’s liability exceed the amount of the purchase price. Any action for breach of warranty must be brought within two (2) years of the date of sale.

EQUIPMENT NOT COVERED BY GRACO WARRANTY

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with respect to 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 to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

Sales Offices: Atlanta, Chicago, Detroit, Los Angeles

Foreign Offices: Belgium; Canada; England; Korea; Switzerland; France; Germany; Hong Kong; Japan


PRINTED IN U.S.A. November, 1992; Revised September, 1995

36 308-180

3X8–180

Rev. E

Supersedes Rev. D

Parts Change Notice

Some parts in Rev. D of manual 308–180 have changed but have not yet been changed in the instruction manual. Please note the changes below and mark them in your manual or keep this sheet with your manual.

Assembly No.

Models 231–201 and 231–328

Series

Letter

Change

Part That

Changed

111–602

Ref

No.

30

Part Description Description of Change

CLIP, 3/4 in.

Replaced by 113–478

187–652 33 DRAIN HOSE Replaced by 238–345

Other Changes

Page 23: Change instruction in step 3.:

From: T

To: ighten the nut (110) onto the piston valve (108) to 2 in-lb (0.23 N

Tighten the nut (110) onto the piston valve (108) to 5 in-lb (0.57 N m).

m).

Change note 1 of Fig. 19:

From: T orque to 2 in-lb (0.23 N m)

To: Torque to 5 in-lb (0.57 N m)

Change second instruction in step 4.:

From: Apply one drop of adhesive, supplied, to the threads.

To: Apply one strip of adhesive, supplied, to the threads.

Change first instruction in step 8.:

From: CAREFULLY tighten the nut (110) against the piston rod to 19 ft-lb (25 N m).

To: Carefully tighten the nut (110) against the piston rod to 30 ft-lb (40 N m).

Change note 1 of Fig. 20:

From: T orque nut against rod to 19 ft-lb (25 N m)

To: Torque nut against rod to 30 ft-lb (40 N m)

29 Jul 96

390 st

02821A

Technical Data

Model 231–201

Standard mount: complete sprayer with hose and gun with RAC IV DripLess Tip Guard and SwitchTip

Power requirements

Motor

. . . . . . . . . . . . . . . 120 VAC, 60 Hz,

Generator . . . . . . . . . . . . . . . . . . . . . . .

Working pressure range . . . . . . . . . . . . . . .

15A minimum

3000W minimum

0 to 2750 psi

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 hp stainless steel screen, reusable

Power cord

Tip size

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

14 AWG, 3 wire, 6 ft one gun to 0.019 (new tip)

Inlet paint strainer

Pump inlet size with latex @ 2000 psi

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

12 mesh

1/2 npt(f)

Fluid outlet size . . . . . . . . . . . . . . . . . . . . . . . . .

Wetted parts, displacement pump . . . .

1/4 npsm stainless steel, carbon steel, aluminum, polyethylene,

Delrin , leather

Delrin

Application

Sprays stains, lacquers, oil base, or emulsion. Do not use with solvents such as methylene chloride or other

HHCs.

Dimensions

Weight (dry, without packaging)

Height

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 lb

19 in.

Length

Width

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 in.

14 in.


COPYRIGHT 1995, GRACO INC. PRINTED IN U.S.A. 3Z8–180 June 1996

3Z8–180

Rev B

Supplement to instruction manual 308–180.

390 st Airless Paint Sprayer

WARNING

INSTRUCTIONS


This form is only a quick reference to the features and frequently ordered parts of this sprayer. To reduce the risk of serious injury, including fluid injection, while operating or repairing this sprayer, follow the warnings and instructions in manual 308–248.

25 26

16

17

18

19

20

21

22

23

24

25

26

13a

13b

13c

13d

13e

13f

14

15


Ref

No.

10

11

12

13

8

9

6

7

3

4

1

2

5

Part No.

Description

111–602 3/4 in. clip

235–004 Strainer

111–700 Handle grip

187–631 Sprayer handle

236–965 Motor kit

187–791 Danger label (English)

235–036 Sprayer Leg with gusset

187–628 Sprayer leg

224–807 Valve base

187–625 Drain valve handle

111–600 Grooved pin

235–014 Drain valve kit

236–787 Pump kit

(includes items 13a to 13f)

176–758 . Packing nut

187–611 . Pump manifold

236–786 . Pump cylinder

224–966 . Inlet valve

224–808 . Piston valve

187–613 . Displacement rod

187–652 Drain hose

104–938 O-ring

187–624 Suction hose and tube

235–009 Pressure transducer

235–677 Fluid filter

218–359 Connecting rod

224–965 Drive housing kit

224–828 Pressure control kit

224–803 Crankshaft

218–364 Gear reducer

235–008 Motor start board

105–679 ON/OFF switch

105–659 Switch boot

Extra danger labels are available for free.

Packing Repair Kit 235–703

Includes all parts marked with a

Motor Brush Repair Kit 236–967

18

1

19

17

16

15

24

2

21

20

3

4

13a

13b

13c

22 23

13 12

14

5

13f

13e

13d

03148A

6

9

10

7

8

11

Graco 308180D ELECTRIC, 120 VAC 390 st Airless Paint Sprayer Owner's Manual

INSTRUCTIONS–PARTS LIST

ELECTRIC, 120 VAC

390

Airless Paint Sprayer

Model 231–201, Series D

Model 231–328, Series A

308–180

Rev. D

Supercedes Rev. C

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

Table of Contents

Symbols

Warning Symbol

Caution Symbol

FIRE AND EXPLOSION HAZARD

INJECTION HAZARD

TOXIC FLUID HAZARD

MOVING PARTS HAZARD

EQUIPMENT MISUSE HAZARD

Component Identification and Function

Setup

Operation

How to use the gun trigger safety

How to use the pressure control.

+

–

How to use the pressure drain valve.

How to use the RAC IV tip guard.

Operation

How to remove a tip clog.

Startup

Pressure Relief Procedure

Startup Procedure

Startup

Shutdown and Care

Shutdown and Care

Flushing

When to Flush

How to Flush

Troubleshooting

Motor Test

Setup

Armature Short Circuit Test

Armature, Brushes, and Motor Wiring

Open Circuit Test (Continuity)

General Repair Information

Tool List

Motor Brushes

Motor Brushes

Displacement Pump Repair

Removing the pump

Installing the pump

Displacement Pump Repair

Intake valve repair

Disassembling the pump

Reassembling the pump

Displacement Pump Repair

Displacement Pump Repair

Motor

Motor Start Board

Power Supply Cord

On/Off Switch

Drive Housing, Connecting Rod, Crankshaft

Drive Housing, Connecting Rod, Crankshaft

Pressure Control

Pressure Transducer

Suction Hose

Drain Valve

Repair

Replacement

Displacement Pump Parts Drawing and List

Model 236–787, Series A

MANUAL CHANGE SUMMARY

Sprayer Parts Drawing

Model 231–201, Series D

Model 231–328, Series A

Included with Model 231–201 only

Sprayer Parts List

Model 231–201, Series D; Model 231–328, Series A