Graco 308498A ELECTRIC, 120 VAC ULTRA Plus+ 600 Airless Paint Sprayer Owner's Manual

INSTRUCTIONS–PARTS LIST

This manual contains important warnings and information.

READ AND RETAIN FOR REFERENCE

ELECTRIC, 120 VAC

ULTRA

Plus

+ 600

Airless Paint Sprayer

3000 psi (210 bar) Maximum Working Pressure

Models 231–356 and 231–358, Series A

Complete sprayer with hoses, gun, RAC IV DripLess

Tip Guard and SwitchTip

Model 231–346 and 231–348, Series A

Basic sprayer only

Model 231–356

308–498

Rev A

Model 231–358

04401

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

COPYRIGHT 1994, GRACO INC.

Table of Contents

Warnings

Setup

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

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

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

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

9

11

2

6

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

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

General Repair Information

Motor Test

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

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

12

14

19

20

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

Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Supply Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

22

26

27

27

Symbols

On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Pressure Transducer Seal . . . . . . . . . . . . . . . . . . . . . .

Suction Hose

Drain Valve

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

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

Complete Sprayer Parts . . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pump Parts . . . . . . . . . . . . . . . . . . . . . .

Technical Data

Dimensions

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

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

Accessories

Graco Ultra

)

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

Warranty and Disclaimers

Phone Numbers

. . . . . . . . . .

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

32

33

34

38

27

28

30

31

39

39

39

40

40

Warning Symbol

WARNING

Caution Symbol

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.

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 39 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 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.

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 8 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.

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.

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 8 to prevent the equipment from starting unexpectedly.

NOTE: This is an example of the DANGER label on your sprayer. This label is available in other languages, free of charge. See page 39 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

B

S

D

C

A

0137

H

G

E

F

J

P

R

N

P

R

S

K

Fig. 1

F

G

D

E

H

A

B

C

L

M

J

K

Motor (Undershield shown)

Pressure Adjusting Knob

ON/OFF Switch

Drive Assembly

Fluid Filter

Fluid Outlet

Pail Hanger

Displacement Pump

50 ft (15 m) Main Hose

RAC IV Tip Guard

Contractor Gun

RAC IV Switch Tip

3 ft (0.9 m) Hose

Pressure Drain Valve

Pressure Control

Spray Gun Safety Latch

N

M

L

04939

DC motor, 120 Vac, 15A, 1 phase

Controls fluid outlet pressure

Power switch that controls 120 Vac main power to sprayer

Transfers power from DC motor to the displacement pump

Filter of fluid between source and spray gun

Spray gun operation is connected here

Container for fluid to be sprayed may be hung here

Transfers fluid to be sprayed from source 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 uses high pressure fluid to remove clogs from spray tip without removing tip from spray gun

3/16 in. ID, grounded, nylon hose used between 50 ft hose and spray gun to allow more flexibility when spraying

Relieves fluid outlet pressure when open

Controls motor speed to maintain fluid outlet pressure at displacement pump oulet. Works with pressure adjusting knob.

Inhibits accidental triggering of spray gun

308-498 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 3000 psi (210 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

5.

Fill the wet–cup (D). Pry off the wet–cup seal. Fill the cup 1/3 full with Graco Throat Seal Liquid

(TSL) (68) supplied. Install the seal.

6.

Check the electrical service. Be sure it is 120 V,

60 HzAC, 15 Amp (minimum). Use a properly grounded outlet. Do not remove the third (grounding) prong of the power supply cord, and do not use an adapter.

Use a 3-wire (12 ga recommended), 15 amp extension cord.

CAUTION

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

NOTE: Long extension cord lengths affect sprayer performance.

7.

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

(E) is OFF. Plug the cord into a grounded outlet at least 20 ft. (6 m) away from the spray area.

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 pump and the hose.

See Fig. 2.

4.

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

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 4.

continued on the next page

1

2

3

Do not install any shutoff device here.

Fill 1/3 full with TSL

Shown in closed, or spray position.

1 A

E

3

D

2

Model 231–356 Shown

04382 Fig.2

B

C

6 308-498

Setup

8.

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

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.

9.

Prepare the paint according to the manufacturer’s recommendations. Remove any paint skin. Stir the paint to mix pigments. Strain the paint through a fine nylon mesh bag (available at most paint dealers) to remove particles that could clog the gun filter or spray tip. This is an important step toward trouble-free paint spraying.

1

How to use the gun safety latch

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

1 Engaged

2 Disengaged

Fig. 3

2

01020

WARNING

If the gun still sprays when the gun safety latch is engaged, adjust the gun. See manual 307–614, supplied.

1

1

2

Closed, or spray position

Open, or drain position

2

Fig. 4

02985

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 Guide, page 14. See Fig. 4.

1

Rotate to increase (+) or decrease (–) pressure 1

Fig. 5

–

+

02986

308-498 7

Setup

Pressure Relief Procedure

WARNING

PRESSURIZED EQUIPMENT HAZARD

The equipment stays pressurized until pressure is manually relieved. To reduce the risk of serious injury from pressurized fluid, accidental spray from the gun or splashing fluid, follow this procedure whenever you:

Are instructed to relieve pressure

Stop spraying

Check, clean or service any system equipment

Install or clean fluid nozzles

The tip guard alerts you to the risk of injection and helps prevent placing any part of the body close to the spray tip. The tip guard also adjusts the vertical or horizontal spray pattern. See page 10. The tip guard holds a reversing spray tip. The tip is in the spraying position when the tip handle points forward. See Fig. 6.

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

1 2

1. Engage the gun safety latch.

2. Turn the ON/OFF switch of OFF.

3. Unplug the power cord.

4. Disenge the gun safety latch. Hold a metal part of the gun against a grounded metal pail and trigger the gun into the pail to relieve pressure.

5. Engage the gun safety latch.

6. Open any fluid drain valves in the system. Leave the drain valve open until you are ready to dispense again.

How to use the RAC IV tip guard

WARNING


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. See also page 3.

1

2

Tip handle shown in spraying position.

Turn handle 180 ,

trigger gun to clear clog

Fig. 6

01023

How to remove a tip clog

7. Release the gun trigger. Engage the safety latch.

Rotate the RAC IV tip handle 180 . See Fig. 6.

8. Disengage the safety latch. Trigger the gun into a pail or onto the ground to remove the clog.

9. Engage the safety latch. Rotate the tip handle to the spraying position.

10. If the tip is still clogged, engage 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.

1 Shown in closed, or spray position.

2 Open, or drain position

–

E

+

D

C

Startup

1

F

A

2

B

Fig. 7

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.

11.

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

12.

Don’t install the spray tip until the pump is primed!

13.

Put the suction hose or tube (C) into the paint.

If you are pumping from a 1 gallon (5 liter) pail, push the drain hose (D) down below the top of the pail to avoid splashing paint when the drain valve is opened.

Model 231–356 Shown

14.

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

15.

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

CAUTION

To reduce the risk of damage to the displacement pump packings, never run the pump without fluid in it for more than 30 seconds.

04383

16.

To prime the pump, turn the sprayer ON/FF switch (F) ON.

Slowly increase the pressure until the sprayer starts. When fluid comes from the pressure drain valve, close the valve.

WARNING


To reduce static sparking and splashing when priming, be sure the spray tip is not installed on the gun, and hold a metal part of the gun firmly to the side of a grounded metal pail.

Startup

NOTE: Spray patterns will change as tips wear.

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

1

B

17.

To prime the hose, lower the pressure to reduce splashing. Holding the gun against the pail, trigger the gun 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.

18.

Check all fluid connections for leaks. Relieve pressure before tightening any connections.

19.

Install the spray tip. Engage the gun safety latch first! See manual 307–848 for how to install the tip.

20.

Adjust the spray pattern a. Increase the pressure just until spray from the gun is completely atomized. To avoid excessive overspray and fogging, and to extend tip and sprayer life, always use the lowest pressure needed to get the desired results.

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

c. Test the spray pattern. To adjust the direction of the spray pattern, engage the gun safety latch and loosen the retaining nut (B). Position the tip guard horizontally for a horizontal pattern or vertically for a vertical pattern. Hold the tip guard in place while tightening the retaining nut. See Fig. 8.

1

2

Fig. 8

For a vertical spray pattern

For a horizontal spray pattern

2

01025

10 308-498

Shutdown and Care

WARNING


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

Procedure on page 8.

28.

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

WARNING


See the warning section INJECTION

HAZARD on page 3 for information on the hazard of using damaged hoses.

21.

Relieve pressure.

22.

Check the packing nut/wet-cup daily. 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

1

23.

Tighten the packing nut/wet-cup 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.

24.

Clean the gun’s fluid filter often and whenever the gun is stored. Relieve pressure first. Refer to manual 307–614.

25.

Lubricate the bearing housing after every 100 hours of operation. Remove the front cover. Apply several drops of SAE 10 non-detergent oil in the bearing housing cavity (B). See Fig. 10.

26.

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.

Fig. 9

B

02988

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.

27.

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

Fig. 10 02989

308-498 11

Flushing

When to flush

Determine the material you are going to pump from

Column 1, then flush with the material indicated in

Column 2. Depending on what you plan to do next, follow the recommendations in one of the next three columns.

CAUTION

NEVER leave water or water-based fluids in the sprayer if there is a chance it could freeze. Push the water out with mineral spirits. Frozen fluid in the sprayer prevents it from starting and may cause serious damage.

Column 1

If you are going to:

Column 2

Flush with:

Column 3

Prime with:

Column 4

Clean with:

Column 5

Store unit with:

Spray latex paint

Spray oil paint

Change latex to oil paint

Change oil to latex paint

Warm, soapy water, then clean water

Mineral spirits

Warm, soapy water, then clean water

Mineral spirits, soapy water, and clean water.

Change colors, same base Compatible solvent such as water or mineral spirits

Latex-base paint Warm soapy water, then clean water

Oil–base paint

Mineral spirits

Mineral spirits

Mineral spirits

Latex Warm, soapy water, then clean water

Mineral spirits

Mineral spirits

Mineral spirits

Mineral spirits

How to flush

WARNING




BOWL

29.


30. Remove the spray tip and clean it separately. If you are changing from water-based to oil-based paints or solvents, be sure that the tip is cleaned thoroughly.

31. Remove the filter screen and then reinstall the bowl, hand tight, without the screen. Clean the screen separately. See Fig. 11.

Fig. 11

SCREEN

02990

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

33. Open the pressure drain valve. See Fig.12.

34.

To save the paint still in the pump and hose, follow Step NO TAG, except put the drain hose in the paint pail. When solvent appears, close the drain valve. Put the drain hose in the flushing pail.

Trigger the gun into the paint pail. When solvent appears, release the trigger. Continue with Step

NO TAG.

12 308-498

Flushing

38. Reinstall the clean filter screen.

WARNING

FIRE AND EXPLOSION HAZARD gun, and hold a metal part of the gun firmly to the side of a grounded metal pail when flushing.

To reduce static sparking and splashing, always remove the spray tip from the

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

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

35. 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 just 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 safety latch.

36. Open the drain valve and circulate the solvent through the drain hose to thoroughly clean it.

Close the drain valve.

37. Remove the suction hose from the pail. Disengage the gun safety latch. 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

Open or drain position

Fig. 12

1

02987

308-498 13

Troubleshooting

WARNING

PRESSURIZED EQUIPMENT HAZARD

To reduce the risk of serious injury, always follow the Pressure Relief

Procedure on page 8 before checking or repairing any part of the sprayer.

CAUTION

Thaw sprayer if water or water-based paint has frozen in it, due to exposure to low temperatures, by placing it in a warm area. Do not try to start sprayer until it has thawed completely or damage to motor and/or control board may occur. If paint hardened (dried) in sprayer, the pump packings and/or pressure transducer must be replaced. See page 22 (pump) or 30 (pressure transducer).

Check everything in the troubleshooting tables before disassembling the sprayer.

Basic Problem Solving

TYPE OF

PROBLEM

Fluid Pressure

WHAT TO CHECK

If check is OK, go to next check

1. Check pressure transducer 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.

Mechanical 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 26.

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. After thawing, plug in sprayer and turn it on. Slowly increase pressure setting to see if motor starts. If it doesn’t start, see CAUTION above.

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

Electrical

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. 19, page 23.

3. Check for motor damage. Remove drive housing assembly (11). See page 28. 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 voltmeter 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.

3. Replace motor (4) if fan won’t turn. See page 26.

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

2. Replace extension cord.

3. Replace power supply cord. See page

27.

14 308-498

TYPE OF

PROBLEM

Electrical

(continued)

Basic Problem Solving

WHAT TO CHECK


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.

f. Brush leads snagged on spring clip.

NOTE: The brushes do not wear at same rate on both sides of motor. Check both brushes.

5. Check motor armature commutator for burn spots, gouges and extreme roughness. Remove motor cover and brush inspection plates to check. See page 21.

6. Check motor armature for shorts using armature

tester (growler) or perform motor test. See page

20.

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

8. Check motor control board (47) by substituting with a good board.

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 105–125 VAC. Unplug sprayer.

10. Check ON/OFF switch (52). Disconnect the “L” wire between motor control board (47) and switch and connect volt meter between exposed terminal switch and power cord’s white wire. Plug in sprayer and turn ON. Meter should read 105–125

VAC. 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. Check the transducer (29) by replacing it with a new one.

13. Check pressure adjustment potentiometer (64) by replacing it with a new one.

WHAT TO DO


4. Refer to page 21.

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 0.4”

(10 mm) long.

f. Correctly route the wires. See page

21.

5. Remove motor and have motor shop resurface commutator if possible. See page 26.

6. Replace motor. See page 26.

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 27.

9. Replace power supply cord. See page

27.

10. Replace ON/OFF switch. See page 27.

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

12. Replace pressure transducer. See page

30.

TYPE OF

PROBLEM

Low Output

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 engage safety latch.

Relieve pressure, turn off and unplug sprayer.

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

WHAT TO DO

When check is not OK refer to this column

1. Follow Pressure Relief Procedure

Warning on page 8, then replace tip.

See your separate gun or tip manual.

2. Service pump. See page 23.

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

5. Check extension cord size and length.

6. Check motor brushes. See Electrical – What To

Check, item 4, on page 15.

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 23.

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

5. Replace with a correct, grounded extension cord. Note that long lengths and/or smaller gauges reduce performance.

6. See page 21.


TYPE OF

PROBLEM

Low Output

(continued)


8. Check motor armature for shorts by using an armature tester (growler) or perform motor test. See page 20.

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

No Output: Motor

Runs And Pump

Strokes

WHAT TO CHECK



1. Check paint supply.

WHAT TO DO



8. Replace motor. See page 26

.

1. Tighten to 185 in–lb (21 N.m). Clean valve and replace with new gasket (42a) and sealant (42e). See page 33.

1. Refill and reprime pump.

No Output: Motor

Runs But Pump

Does Not Stroke

Spray Pattern

Variations

2. Check for clogged intake strainer.

3. Check for loose suction tube or fittings. See page 32.

4. Check to see if intake valve ball and piston ball are seating properly. See page 23.

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

See page 23.

2. Remove and clean, then reinstall.

3. Tighten; use thread sealant on npt threads of inlet tube (38). Check for damaged o–ring (27).

4. Remove intake valve and clean. Check ball and seat for nicks; replace as needed. See page 23. Strain paint before using to remove particles that could clog pump.

5. Replace packings. See page 23. Also check piston valve seat for hardened paint or nicks and replace if necessary.

Tighten packing nut/wet-cup.

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

1. Check displacement pump connecting rod pin (17).

See Fig. 19, page 23.

2. Check connecting rod assembly (15) for damage.

See page 28.

3. Be sure crank in drive housing rotates; plug in sprayer and turn on briefly to check. Turn off and unplug sprayer. See page 28.

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 23.

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

2. Replace connecting rod assembly. See page 28.

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

28.

1. Spray tip worn beyond sprayer pressure capability.

1. Replace spray tip.

NOTE: A smaller size tip will provide

longer life.


2. Check motor control board by replacing it with a new one.


3. Replace pressure transducer. See page

30.


TYPE OF

PROBLEM

Spray Pattern

Variations

Motor Is Hot and

Runs Intermittently

Building Circuit

Breaker Opens As

Soon As Sprayer

Switch Is Turned

On.

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

WHAT TO CHECK



5. Check Low Output section, page 16.

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 transducer and motor. See page 26.

2. Check for missing motor brush inspection plate gasket (see page 21), 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 19. Inspect windings for burns.



1. Check ‘Basic Problems – Electrical’ on page 14.

WHAT TO DO


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.



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 control board (47).

2. Check for damaged or pinched wires in junction box (59).

1. Check the generator’s “peak” voltage. This sprayer will not run if the peak voltage is above 190V or below 100V.

1. Replace ON/OFF switch. See page 27.

2. Replace damaged parts.

1. Use AC power or a different generator.

18 308-498

General Repair Information

WARNING




3.

Route wires carefully and avoid pinching any wires between covers.

CAUTION

Improper wire routing can result in poor sprayer performance or damage to the pressure transducer.

Tool List

These service tools are required.

4.

Keep all screws, nuts, washers, gaskets, and

electrical fittings removed during repair procedures.

1/4” Allen wrench: filter plug

3/8” Allen wrench: pump manifold

3/16” Allen wrench: gear housing, legs, handle

5/64” Allen wrench: pressure adjustment knob

#1 Phillips screwdriver: junction box, front cover , motor shield

3/8” socket wrench: motor mount

5/8” socket wrench: drain valve, on/off switch boot, piston

5/8” open end wrench: outlet fittings

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

Pipe wrench: suction tube

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, page 14, to help identify other possible problems and solutions.

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 sprayer.

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 transducer malfunction, properly mate connectors and never pull on a wire to disconnect it.

1.

When disconnecting wires, use needle nose pliers to separate mating connectors.

2.

When reconnecting wires, center the flat blade of the male connector in the blade of the female connector.

WARNING

FIRE 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.

308-498 19

Motor Test

WARNING


To reduce the risk of serious injury, always follow the Pressure Relief

Procedure on page 8 before doing this procedure. Unplug the sprayer!

Armature Short Circuit Test

Remove the fan cover (B). See Fig.13.

Spin the motor fan by hand. If there are no shorts, the motor will coast two or three revolutions before coming to a complete stop. If the motor does not spin freely, the armature is shorted and the motor must be replaced. See page 26.

For checking armature, motor winding and brush electrical continuity.

Setup

Remove the drive housing. See page 28. This is to ensure that any resistance you notice in the armature test is due to the motor and not to worn gears in the drive housing.

Armature, Brushes, and Motor Wiring

Open Circuit Test (Continuity)

Connect the two black motor leads (C) together with a test lead. Turn the motor fan by hand at about two revolutions per second. See Fig. 14.

MOTOR (4)

Remove the motor brush inspection covers (A).

See

Fig. 13.

50 49

Remove the screws (56,75). Lower the control board

(47). Disconnect the two leads (C) from the motor to the board. See Fig.14.

C

D

P 9 G

Fig. 13

A

52

B

02991

47 64 29

Fig. 14

03000

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 21.

If there is still uneven or no turning resistance, replace the motor. See page 26.

Motor Brush

NOTE: Replace brushes when worn to about 0.4 in.

(10 mm). Always check both brushes. Brush Repair Kit

235–727 is available.

A

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 with no load (remove the pump connecting rod pin) for at least

1 hour.

B

WARNING




1.


2. Remove the motor shield (2).

3. Remove both inspection covers (A) and their gaskets. See Fig. 15.

E

1

2

0.4 in. (10 mm)

Minimum

Spring/Clip

111–610

1

F 2

C

D

Fig. 16 01065

5. Loosen the brush lead terminal screw (E). Pull the brush lead (D) away, but leave the motor lead terminal (B) in place. Remove the old brush. See Fig.

16.

6. Inspect the commutator surface on which the brushes ride 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 11.d., also.

7. Repeat for the other side.

8. Place a new brush (C) in the holder (A). Slide the terminal under the terminal screw washer (E). Ensure the motor lead (B) is still connected at the screw. Tighten the screw. See Fig. 16.

9. 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 (G). See Fig. 17. Pull on the spring/clip to be sure it stays in place. Be sure the brush lead is tucked under the spring/clip tab.

G

F

A

C

Fig. 15

02992

4. Push in the spring/clip (F) and release its hooks from the brush holder (A). Pull out the spring/clip.

See Fig. 16.

Fig. 17

10. Repeat for the other side.

Continued on next page

01066

308-498 21

Motor Brush

11.

Test the brushes.

a. Remove the pump connecting rod pin.

b. With the sprayer OFF, turn the pressure transducer knob fully counterclockwise to minimum pressure. Plug in the sprayer.

WARNING

ELECTRIC SHOCK 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 bodily injury.

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.

12. Install the brush inspection covers and gaskets.

13.

Break in the brushes. Operate the sprayer for at least one hour with no load. Install the pump connecting rod pin.

Displacement Pump

NOTE: Packing Repair Kit 235–703 is available. Reference numbers of parts included in the kit are marked with an asterisk, i.e., (121*).

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

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

NOTE: To minimize down time, and for the best sprayer performance, check the motor brushes (see page

21) and clean the transducer (see page 30) whenever you repack the pump. Replace these parts as needed.

Installing the pump (See Fig. 18 and 19)

Removing the pump (See Fig.18)

1. Lightly grease or oil the transducer (29). See Fig.

30. Guide the pump over the alignment pins and pressure transducer. Tap it into position with a soft hammer. Tighten the screws (21) to 50 ft-lb (68

N.m).

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.

1.


2. 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.

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. 19.

3. Remove the filter (85).

If the pin works loose, parts could be projected into the air and cause serious injury or property damage, including the pump connecting rod or bearing housing.

4.

Models 231–346 and 231–356. 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).

5.

Models 231–348 and 231–358. Remove the suction tube (32). Unscrew the drain tube (33) from the displacement pump nipple (36).

3. Replace the o-ring (27) if it is worn or damaged.

See page 32. Reconnect the suction and drain hoses (32,33). Install the front cover (13).

NOTE: If repairing only the intake valve assembly, go to Intake valve repair, on page 23.

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.

85

1

21

32

27

38

Fig. 18

13

17

15

123

1

Torque to

50 ft–lb (68 N.m)

Fig. 19

2

18

107


Disassembling the pump (See Fig. 20)

1

2

Torque to

50 ft–lb (68 N.m)

Apply pipe sealant (42e)

1. Remove the intake valve (118).

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

120

*122

*121

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.

36

20

118

33

*119

231–346, 231–356 shown

02993

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

CAUTION

Incorrect installation of the packings damages the packings and causes pump leaks.

17

21 1

Intake valve repair (See Fig. 18)

18

102

01068

1. Remove the suction hose or tube. See Step 4 and

5, Removing the pump.

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

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

Replace parts as needed. Use a new o–ring

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

NOTE: Alternate the plastic and leather packings. See

Fig. 20. The lips of the throat V-packings face down.

The lips of the piston V-packings face up. The lips of seal (125*) face down.

NOTE: Soak the leather packings in oil before reassembling 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. Stack these parts onto the piston valve (108) one at a time: the backup washer (126*) and u–cup

(125*), the female gland (114*), alternately three plastic (112*) with two leather packings (113*), and the male gland (111*). See Fig. 21.

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

2 in-lb (0.23 N.m). See Fig. 22.

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. 21.


CAUTION

Step 8, tightening the piston valve into the rod, is critical. Follow the procedure carefully to avoid damaging the packings by overtightening.

6. Hand tighten the valve into the piston rod just until the nut (110) contacts the rod. See Fig. 22.

1

Do not allow nut (110) to move relative to piston

(108) when tight– ening piston against rod.

2

Torque nut against rod to 19 ft–lb (25

N.m)

1

110

2

Fig. 22

123

102

*103

1

2

Lips down.

107

Lips up.

1

*104

127

101

117

*116

115

Fig. 20

1

2

Torque to

2 in-lb (0.23 N.m)

Apply one drop of sealant to threads

110

Fig. 21

1

*111

*113

*125

*126

105*

2

*106

1

*113

*122

107

109*

2

108

109*

110

111

112*

2

114*

125*

126*

108

1

120

121*

119*

118

04392

112*

114*

03149

03178

107

108

03179

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. 22.

Use two wrenches to maintain the alignment mentioned in Fig. 22.

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

Fig. 24.

10. Install the packing nut (102) and plug (124), but leave loose for now. See Fig. 24.

11. Place a new o–ring (116*) firmly in the cylinder groove. See Fig. 23.

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

(115). See Fig. 23.

13. Put the manifold in a vise. Fully thread the jam nut

(117) onto the cylinder (115). Guide the rod/ cylinder assembly down through the manifold

(101). Screw the cylinder (115) into the manifold.

See Fig. 23.

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. 23.

15. Torque the cylinder jam nut (117) to 73 ft–lb (98

N.m). See Fig. 23.

16. Install the pump. See page 22.

3

1

2

Torque jam nut (117)

73 ft-lb (98 N.m)

Torque cylinder (115) into manifold (101) to

53 ft-lb (71 N.m)

Torque intake valve (118) into cylinder (115) to 53 ft-lb (71 N.m)

Fig. 23


102

101

107

116*

117

115

1

2

*103

1 *105

LEATHER

*116

110

*111

2 *113

LEATHER

3

108

115

120

*119

118

118 3

01072A

1 Lips face down.

2 Lips face up.

3 Torque to 53 ft-lb (71 N.m)

Fig. 24

107

123

102

104*

PLASTIC

1

106*

101

117

112*

PLASTIC

2

114*

125*

126*

1

122*

121*

03147

WARNING




Motor

9. Remove the two screws (46) and lift the motor off the cart (1).

10. Align the new motor with the cart and reinstall the screws (46).

11. Assemble the drive housing to the motor. Follow steps 9 to 15 on page 28. Install the junction box.

NOTE: See Fig. 27 except where noted.

1. Try to stop the pump with the piston rod (107) in its lowest position. To lower the piston rod manually, remove the shroud (4) and rotate the motor fan blades. Use a screwdriver to push the retaining spring (18) up and push out the pin (17). See Fig.

25.

2.


3. Remove the motor shield (4).

4. Lift the connecting rod. Remove the screws

(56,75) and lower the control card (47). Disconnect the motor wires and the pressure transducer wire

(A) from the motor control board. Remove the control card (47), screws (71), and junction box (59).

Refer to Fig. 27.

5. Remove the drive housing cover (13).

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

(19). See Fig. 26. Remove the three drive housing screws and lockwashers (19,6). See Fig. 26 and

27 .

7. Remove the two motor screws and lockwashers

(5,6).

8. Tap the lower rear of the drive housing (11) with a plastic mallet to loosen the motor. Pull the drive housing straight off the motor while guiding the harness (A) from the motor. Do not allow the gear

(16) to fall. Read the CAUTION on page 28.

12. Connect the wires to the control card. Refer to Fig.

14. Install the control card.

13. Connect the piston rod (107) to the drive housing; see page 22, Installing the Pump, Step 2 and the

WARNING following it.

14. Install the shroud (4) and drive housing cover (13).

17

15

Fig. 25

Fig. 26

16

5

107

1 6

4

18

19,6

01068

01074

11

12

1

6

19

46

1 Torque to 80 in–lb (9 N.m)

Fig. 27

34

13

59 71

A

47

56

75

02994

Motor Control Board

WARNING




4. Remove the screw (9) from the ground wire (G) and remove the board.

5. Install the new motor control board. Reconnect all wires and secure it to the junction box (59).

CAUTION

To reduce the risk of a malfunction:

1.


2. Remove the screws (56,75) and lower the control card (47). See Fig. 27.

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.

3. Disconnect the motor wires (C) and the two connectors (D) from the motor control board (47).

Observe where connections are made. See Fig. 14 on page 20.

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

Power Supply Cord

WARNING




3. Disconnect the power supply cord leads (P), including the green wire to the grounding screw (9).

See Fig. 14 on page 20.

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.

1.


2. Remove the screws (56, 75) and lower the control card (47). See Fig. 27.

6. Install the control card. Be sure no leads are pinched between the card and other components.

On/Off Switch

WARNING




4. Disconnect the black wires from the ON/OFF switch (52) and remove the switch. See Fig. 14 on page 20.

5. 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 slot of the junction box. See page

34.

1.


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.

2. Remove the screws (56,75) and lower the control card (47). See Fig. 29.

3. Remove the rubber boot (55). See page 34.

7. Reconnect the ON/OFF switch black wires.

8. Install the control card. Be sure no leads are pinched between the motor control board or other components.

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.

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

1.


2. Remove the displacement pump. See page 22.

3. Remove the shroud (4).

4. Lower the control card (47) and remove the pressure transducer (29). See page 30.

Fig. 28

107

19,6

01074

5. Remove the three drive housing screws and lockwashers (19,6). Also see Fig. 29.

8. Remove and inspect the crankshaft (12) and the connecting rod (15). Replace all damaged or worn parts.

9. Install the connecting rod.

10. Lubricate the inside of the connecting rod 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.

11. Place the large washer (12a) and then the small washer (12b) on the crankshaft (12).

12. Rotate 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).

13. Plug in the pressure transducer. See page 30.

14. Install the displacement pump. See page 22.

15. Install the front cover (13).

16. Replace the shroud (4).

17. Replace the control card (47).

6. Remove the two motor screws and lockwashers

(5,6). See Fig. 29.

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.

Drive Housing, Connecting Rod, Crankshaft

19

6

12a

12 1 6,5

12b

16

B

Note: Filter not shown

15

11

11a

A

1

56

C

29

75

47

1 Torque to 80 in–lb (9 N.m)

Fig. 29 02995

Pressure Transducer

NOTE: See Fig. 29 and 30 for this procedure.

NOTE: The pressure transducer (29) cannot be repaired or adjusted. If it malfunctions, replace it.

2. Pass a spacer (76) over the harness connector (A) and down into position at the bottom of the transducer (29).

Removal

3. Guide the harness up through the leg and notch of the drive housing (11). Secure the guide wire over the connector.

WARNING




4. While pulling the guide wire out through the bottom of the motor, guide the harness through the drive housing and motor castings.

5. Place the grommet (77) over the harness and push into position in the drive housing hole.

1.


2. Remove the displacement pump (20). See page

22.

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

(56,75). Lower the motor control card.

6. Feed the excess harness cable through the grommet and fully seat the transducer body into the hole in the drive housing leg. Secure it with the retaining ring (72).

7. Attach the connector to the control board.

Replace the cover (13) and board (47) taking care not to pinch any wires between the components.

4. Disconnect the harness connector from the motor control board (47). Remove grommet (77).

5. Remove the retaining ring (72). Pull the pressure transducer down and out past the drive housing

(11).

6. Guide the harness (A) through the motor and drive housing and remove the pressure transducer.

7. Inspect the spacer (76) and seal (7) for damage.

Replace the seal (7) only if it is cut, nicked, or if leakage occurred. See page 31.

Installation

1. Using a small piece of solid copper or mild steel wire (approx. 12”), form a small hook and place it in the passage of the bottom of the motor. Guide it up and out the hole in the drive housing.

Fig. 30

77

A

72

29

76

7

02996

Pressure Transducer Seal

NOTE: The PTFE seal is unaffected by most solvents and materials. Replacement of the seal is recommended only when leakage has occurred.

Installation

1. Lightly coat the cleaned packing recess in the manifold with a light grease or oil.

Removal 2. Heat the packing (7) in hot water for several minutes.

WARNING




CAUTION

Excess pressure from the probes or fingernails will damage the packing and cause subsequent leakage.

1.


2. Remove the displacement pump (20). See page

22.

3. Using a wooden or plastic probe (such as a toothpick), dislodge the packing (7) from its recess in the manifold (101).

3. Using fingertips or a blunt wooden or plastic probe, install the packing into the recess. Be careful not to cause kinks or bends in the packing during installation.

4. Lightly grease or oil the transducer (29) and install the pump (20). See page 22.

7

101

4. Remove the packing and clean the manifold recess with solvent and cloth or cotton swabs.

Inspect for nicks or scratches in the o–ring area.

Fig. 31

02997

308-498 31

Suction Hose

(Models 231–346 and 231–356)

WARNING




CAUTION

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

1.


2. Remove the drain hose (33) from the clip.

3. Pull upward on the suction 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.

4. Replace the o-ring (27) if it is worn or damaged.

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

6. Align the suction hose coupling (A) 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.

33

32

Fig. 32

1

1

27

A

38

1 Lubricate with light grease.

02998

Drain Valve

Repair

WARNING




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.

1.


2. Turn the handle (45) to the closed position. Drive out the pin (44). Remove the handle.

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

3. Remove the base (43).

4. Unscrew the drain valve (42). The gasket (42a) and seat (42b) will stay in the valve.

1. Coat the o–ring (42d) with grease. Press the stem

(42c) into the valve body. Install the spring, washers and spring retainer into the valve body.

42a

42b

2

42d

2. 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.

42c

43 3

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

1

42

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).

1 Torque into pump manifold to

185 in–lb (21 N.m)

2 Apply thread sealant

3 Apply grease to face of base

4 Handle shown in closed position

Fig. 33

44

45

4

02819

2. Lightly grease the face of the base (43) and install the base. Turn the stem so the pin hole is vertical.

3. Securely install the handle (45) and drive the pin

(44).

Complete Sprayer Parts


3 Ref

58

1 Ref

63

3 Ref

62

53

30

39

12b

4

6

4a

5

2c

9

2b

2d

2e

3

33

8

9

12

34

35

13

32

15

77

19

6

11

85

17

18

72

20a

10

28

27

38

76

29

7

11a 16

12a

59 71

42

21

65

20

36

43

44

73

47

56

45

74

75

69

70

25

46

64

Pressure Control Box

(Bottom View)

67

2a

2

86

60

1

22

48

52

54

50

51

49 55

40

57

66

04390

03020


Model 231–346 & 231–356, Series A

Ref.

No.

Part No.

Description Qty.

1

2

2a

2b

2c

2d

2e

3

4

4a

4b

236–367 FRAME,cart, U–600

237–658 KIT, shield, motor, U–600

190–101 LABEL, ID, Ultra 600


187–784 LABEL, DANGER, French 1

187–791 LABEL, DANGER, English 1

187–975 LABEL, WARNING, elec shock 1

1

1

1

1

189–934 HANDLE, cart

236–360 KIT, motor, electric, DC

100–069 BALL, thrust

107–265 TERMINAL, 3/16” (M) QC,

1

1

1

4c

16 AWG

107–504 TERMINAL, 3/16”, (F), QC,

18 AWG

187–784 LABEL, DANGER, French

1

1

4e

4f

4g

5



101–682 SCREW, sch, 1/4–20 x .625

2

5 6

7

8

9

105–510 LOCKWASHER, 1/4 hi–collar

104–319 PACKING, o–ring, PTFE )

189–270 BRACKET, shield

10

108–865 SCREW, panh

100–721 PLUG, pipe, 1/4 npt, headless

11 236–362 KIT, housing, drive, U–600

11a 100–069 BALL, thrust

1

1

1

1

5

1

15

16

17

18

12 218–242 CRANKSHAFT, U–600

12a 107–434 BEARING, thrust, front

12b 180–131 BEARING, thrust, rear

13 236–366 KIT, cover, front, U–600

218–359 CONNECTING, rod assy

218–364 GEAR, assy, 2nd stage

176–818 PIN, straight

176–817 SPRING, retaining

22

25

27

28

29

30

32

33

34

19

20

103–345 SCREW, sch, 1/4–20 x 1.25

237–662 KIT, pump, displacement

20a 188–663* LABEL, WARNING

21 111–706 SCREW, mach, sch, 7/16 x 1.75

1

2

3

1

109–570 WASHER, plain 1/2”

112–759 CAP, tubing

104–938 PACKING, o–ring

1

4

1

1

2

2

1

162–453 NIPPLE, 1/4 npt x 1/4 npsm 2

236–364 KIT, transducer, pressure control 1

111–602 CLIP, spring

187–624 HOSE, suction, swivel

187–652 HOSE, assy drain

107–209 SCREW, filh, 8–32 x 1.0

1

1

1

1

1

1

1

1

*Not supplied with sprayers, Models 231–346 and

231–348

Extra Warning Labels available free

Ref.

No.

Part No.


35

36

38

39

190–099 LABEL, cover, front

111–612 ADAPTER, tube

187–627 TUBE, inlet, swivel

235–004 STRAINER, 3/4 unf

40

42

112–607 WHEEL, semi–pneumatic

235–014 VALVE, drain

42a 111–699 GASKET, seat valve

42b 187–615 SEAT, valve, lapped

42c 224–968 STEM, drain valve

53

54

55

56

57

58

49

50

51

52

45

46

47

48

42d 168–110 O–RING, stem

42e 110–110 SEALANT, pipe (not shown)

43

44

224–807 VALVE, base

111–600 PIN, grooved

187–625 HANDLE, drain valve

110–997 SCREWS, 1/4–20 x .625

237–659 KIT, motor control board

186–620 LABEL, ground terminal

110–037

236–354 CORD, power set

108–295 BUSHING, strain relief

105–679 SWITCH, toggle

112–620

112–381

112–612

SCREW, mach, pnh, 10–24 x .500 1

SCREW, 6–32 x 0.187

105–658 RING, locking

105–659 BOOT, toggle

SCREW, panh, 10–24 x 3.5

CAP, hub

280–290 BUSHING, cart

1

1

2

2

2

4

1

1

1

1

1

1

2

1

1

1

1

1

1

1

2

1

1

1

1

1

59

60

61

62

189–105 HOUSING, junction box

112–400 NUT, self–retaining

112–373 KNOB, pressure adjustment

178–565 BUTTON, spring

63

64

109–567 PIN, dowel 2

236–352 POTENTIOMETER, pressure adj 1

65 185–565 LABEL, knob

66* 214–701 HOSE, whip, 3/16” x 3’

1

1

1

1

1

2

67* 220–955 SPRAY GUN, contractor

68 206–994 LIQUID, throat seal (not shown)

1

1

69

70

112–382

112–158

NUT, shaft sealing

GASKET, motor

1

1

71

72

112–379 SCREW, filh, 10–24 x 0.75

112–396 RING, external retaining

73 112–159 GASKET, heatsink

74* 223–541 HOSE, 1/4” x 50’

75

76

112–380 SCREW, panh, 8–32 x 0.5

189–269 SPACER, transducer

77

85

86

189–483 GROMMET, cable

235–677 FILTER, fluid

(see manual 308–249)

112–598 SCREW, trusshead, 8–32

1

1

1

1

2

1

2

1

2

308-498 35



4

6

12b

5

2a

2b

2c

9

2d

2e

86

3

34 15

6

77

19

11

8

9 12

35

13 85

17

18

10

72

80

81

79

21

20

28

4a

70

76

29

7

11a 16

12a

59 71

73

47

56

42

20a

36

45

75

25

46

33

30

43

44

40

32

39

74

60

1

67

65 69

64

Pressure Control Box

(Bottom View)

48

52

54

50

36 308-498

51 49 55

58

62

78

63

53

22

57

66

04391

03020



Ref.

No.

Part No.


2c

2d

2e

3

1

2

2a

2b

4

4a

4b

236–961 FRAME,cart, U–600

237–658 KIT, shield, motor, U–600




187–791 LABEL, DANGER, English


222–554 HANDLE, cart 1

1

1

236–360 KIT, motor, electric, DC

100–069 BALL, thrust

107–265 TERMINAL, 3/16” (M) QC,

16 AWG

1

1

1

1

1

1

1

4c

4e

4f

4g

5

6

7

8

9

10

107–504 TERMINAL, 3/16”, (F), QC,

18 AWG 1




101–682 SCREW, sch, 1/4–20 x .625

105–510 LOCKWASHER, 1/4 hi–collar

104–319 PACKING, o–ring,

189–270 BRACKET, shield

PTFE )

108–865 SCREW, panh

100–721 PLUG, pipe, 1/4 npt, headless

11 236–362 KIT, housing, drive, U–600

11a 100–069 BALL, thrust

5

1

1

1

1

1

2

5

30

32

33

34

35

36

15

16

17

18

12 218–242 CRANKSHAFT, U–600

12a 107–434 BEARING, thrust, front

12b 180–131 BEARING, thrust, rear

13 236–366 KIT, cover, front, U–600

218–359 CONNECTING, rod assy

218–364 GEAR, assy, 2nd stage

176–818 PIN, straight

176–817 SPRING, retaining

22

25

28

29

19

20

103–345 SCREW, sch, 1/4–20 x 1.25

237–662 KIT, pump, displacement

20a

21

188–663 LABEL, WARNING 1

111–706 SCREW, mach, sch, 7/16 x 1.75

2

3

1

101–242 RING, retaining, wheel

108–691 PLUG, tube

162–453 NIPPLE, 1/4 npt x 1/4 npsm

2

2

2

236–364 KIT, transducer, pressure control 1

1

1

1

1

1

1

1

1

178–342 CLIP, spring

189–928 TUBE, suction

189–087 TUBE, drain

107–209 SCREW, filh, 8–32 x 1.0

190–099 LABEL, cover, front

111–612 ADAPTER, tube

1

4

1

1

1

1

*Not supplied with sprayers, Models 231–346 and

231–356

Extra Warning Labels available free

Ref.

No.

Part No.


47

48

49

50

43

44

45

46

51

52

53

39

40

237–675 STRAINER, 1/2 npsm

106–062 WHEEL, semi–pneumatic

42 235–014 VALVE, drain

42a 111–699 GASKET, seat valve

42b 187–615 SEAT, valve, lapped

42c 224–968 STEM, drain valve

42d 168–110 O–RING, stem

42e 110–110 SEALANT, pipe (not shown)

224–807 VALVE, base

111–600

110–997

PIN, grooved

187–625 HANDLE, drain valve

SCREWS, 1/4–20 x .625

237–659 KIT, motor control board

186–620 LABEL, ground terminal

108–295 BUSHING, strain relief

105–679 SWITCH, toggle

109–032 SCREW, 10–24 x 0.250

1

1

4

1

2

1

1

1

1

110–037 SCREW, mach, pnh, 10–24 x .500 1

236–354 CORD, power set 1

1

1

1

1

1

1

1

2

58

59

60

61

54

55

56

57

105–658 RING, locking

105–659 BOOT, toggle

112–381 SCREW, panh, 10–24 x 3.5

104–811 CAP, hub

187–603 BUSHING, cart

189–105 HOUSING, junction box

112–400 NUT, self–retaining

112–373 KNOB, pressure adjustment

62

63

64

65

111–590 BUTTON, spring

110–243 RING, retaining, handle

236–352 POTENTIOMETER, pressure adj 1

185–565 LABEL, knob 1

2

2

66* 214–701 HOSE, whip, 3/16” x 3’

67* 220–955 SPRAY GUN, contractor

68

69

70

71

206–994 LIQUID, throat seal (not shown)

112–382

112–158

112–379

NUT, shaft sealing

GASKET, motor

SCREW, filh, 10–24 x 0.75

1

1

1

2

1

1

2

1

2

1

2

2

1

1

76

77

78

79

72

73

112–396 RING, external retaining

112–159 GASKET, heatsink

74* 223–541 HOSE, 1/4” x 50’

75 112–380 SCREW, panh, 8–32 x 0.5

189–269 SPACER, transducer

189–483 GROMMET, cable

183–350 WASHER, flat

190–321 HANGER, pail

80

81

85

86

112–777 SCREW, 8–32 x 38

290–061 LABEL, warning

235–677 FILTER, fluid

(see manual 308–249)

112–598 SCREW, trusshead, 8–32

2

1

1

1

1

2

1

1

2

1

1

2

308-498 37

Displacement Pump Parts

Model 237–662 Series A

123

Ref

No. Part No.

Description

101 237–661 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

107 235–709 DISPLACEMENT ROD

108 218–197 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

115 235–708 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

PTFE 119 111–603* PACKING, o-ring,

120 176–760 GUIDE, ball

121 105–445* BALL, 1/2”, inlet

122 176–759* PIN, ball stop

123 180–656 PLUG

124 102–969*

125 105–522* PACKING, u-cup, polyurethane 1

126 186–652*

SEALANT

WASHER, backup, steel

127 104–319 PACKING, o-ring, manifold

1

1

1

1

1

1

1

1

1

1

1

1

1 y t Q

*105

127

101

117

102

103*

104*

106*

*113

*Supplied in Repair Kit 235–703

Keep a repair kit on hand to reduce down time.

*116

115

*122

107

109*

110

111*

112*

114*

125*

126*

108

120

121*

119*

118

04392

Technical Data

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

1 phase, 15 amp minimum

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

Working Pressure Range . . . .

3000 Watt minimum

0–3000 psi (0 – 210 bar)

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cycles/Gallon (liter)

Delivery

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

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

530 (140)

0.55 gpm (2.1 lpm)

Tip Size . . . . . . . . . . . . . . . . . . .

3/4 HP one gun to 0.025 new tip

Power Cord . . . . . . . . . with latex at 2000 psi (138 bar)

No. 14 AWG, 3 wire, 6’ (1.8 m)

Inlet Paint Strainer . . . . . . . . . . . 12 mesh (1525 micron)

Stainless Steel Screen, reusable

Outlet Filter . . . . . . . . . . . . . . . . . .

Pump Inlet Size

60 mesh (250 micron)

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

Fluid Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npsm

Wetted Parts:

Displacement Pump . . Stainless steel, Carbon steel,

Filter

Aluminum, Polyethylene, Delrin , Leather

. . . . . Aluminum, Steel, PTFE ) , Stainless steel

NOTE: PTFE

)

and Delrin

) are trademarks of the Company.

Dimensions

Models 231–346 and 231–356

Weight (dry w/o packaging)

Length

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

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

50 lb (23 kg)

22 in (559 mm)

Width

Height

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

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

15 in (381 mm)

21 in (533 mm)

Models 231–348 and 231–358

Weight (dry w/o packaging)

Length

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

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

70 lb 32 kg)

21 in (533 mm)

Width

Height:

. . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5 in (521 mm)

Handle Down

Handle Up

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

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

29.5 in (749 mm)

39.5 in (1003 mm)

Accessories

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

French

Spanish

German

Greek

Korean

English

187–784

185–956

185–961

186–041

186–045

187–791

Apply other language here

The Graco Ultra ® 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 Ultra equipment proven defective, with the exception of defects in parts on the drive train/gear box, which will be repaired or replaced for forty-eight months from the date of sale and the electric motor (excluding brush replacement, which is routine maintenance) or pressure control assembly which will be repaired or replaced for twenty-four months from the date of sale . 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.

Phone Numbers

TO PLACE AN ORDER, contact your Gracodistributor, or call this number to identify the distributor closest to you: 1–800–367–4023 Toll Free

FOR TECHNICAL ASSIST ANCE, service repair information or assistance regarding the application of equipment: 1–800–543–0339 Toll Free

40 308-498

Sales Offices: Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.)

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

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

PRINTED IN U.S.A. 308–498 11/94

Graco 308498A ELECTRIC, 120 VAC ULTRA Plus+ 600 Airless Paint Sprayer Owner's Manual

INSTRUCTIONS–PARTS LIST

ELECTRIC, 120 VAC

ULTRA

+ 600

Airless Paint Sprayer

Models 231–356 and 231–358, Series A

Model 231–346 and 231–348, Series A

308–498

Rev A

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

Table of Contents

Symbols

Warning Symbol

Caution Symbol

EQUIPMENT MISUSE HAZARD

INJECTION HAZARD

TOXIC FLUID HAZARD

FIRE AND EXPLOSION HAZARD

MOVING PARTS HAZARD

Setup

Setup

How to use the pressure control

How to use the gun safety latch

How to use the pressure drain valve

–

+

Setup

Pressure Relief Procedure

How to use the RAC IV tip guard

How to remove a tip clog

–

+

Startup

Startup

Shutdown and Care

Flushing

When to flush

How to flush

Flushing

Troubleshooting

General Repair Information

Tool List

Motor Test

Armature Short Circuit Test

Setup

Armature, Brushes, and Motor Wiring

Open Circuit Test (Continuity)

Motor Brush

Motor Brush

Displacement Pump

Displacement Pump

Displacement Pump

Displacement Pump

Motor

Motor Control Board

Power Supply Cord

On/Off Switch

Drive Housing, Connecting Rod, Crankshaft

Drive Housing, Connecting Rod, Crankshaft

Pressure Transducer

Pressure Transducer Seal

Suction Hose

Drain Valve

Repair

Replacement

Complete Sprayer Parts

Complete Sprayer Parts

Complete Sprayer Parts

Complete Sprayer Parts

Displacement Pump Parts

Model 237–662 Series A

Technical Data

Dimensions

Models 231–346 and 231–356

Models 231–348 and 231–358

Accessories

The Graco Ultra ® Warranty and Disclaimers

Phone Numbers

Related manuals