INSTRUCTIONS–PARTS LIST
308–646
Rev. B
This manual contains important
warnings and information.
Supercedes Rev. A
READ AND RETAIN FOR REFERENCE
ELECTRIC, 120 VAC
Performance 390t
Airless Paint Sprayer
2750 psi (195 bar) Maximum Working Pressure
Model 231–553, Series A
Complete sprayer with hoses, gun, RAC IVr DripLesst
Tip Guard and SwitchTipt
05994
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1996, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
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WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause ex
tremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause serious injury
-
.
D
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.
D
D
D
D
D
D
D
D
D
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.
D Tighten all fluid connections before operating the equipment.
D
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.
D
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.
D
D
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.
D
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.
D
D
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
.
308-646
3
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WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury
.
INSTRUCTIONS
D
D
D
D
D
D
This equipment is for professional use only
.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your distributor
.
Do not alter or modify this equipment.
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 echnical Data on page 36 for the maximum working pressure of this equipment.
T
D
D
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 warn-
ings.
Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
D
D
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex
pose Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).
-
D
D
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 liq
uids in confined areas can result in fire or explosion.
-
-
Liquids can be injected into the body by high pressure airless spray
or leaks – especially hose leaks.
Use outdoors or in extremely well ventilated areas. Ground equip
ment, hoses, containers and objects being sprayed.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts.Avoid accidental trig
-
gering of gun by always setting safety latch when not spraying.
Avoid all ignition sources such as static electricity from plastic drop
cloths, open flames such as pilot lights, hot objects such as ciga
rettes, arcs from connecting or disconnecting power cords or turn
ing light switches on and off.
-
Never spray without a tip guard.
-
In case of accidental skin injection, seek immediate
“Surgical reatment”.
T
Failure to follow this warning can result in death or serious injury
.
Failure to follow this warning can result in amputation or serious
injury.
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
4
308-646
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Component Function and Identification
B
N
C
A
H
E
K
05963
G
D
M
L
F
J
05993
Fig.
1
A
B
C
D
E
F
Motor
DC motor, 120 Vac, 15A, 1 phase
Drive Assembly
Pressure Adjusting Knob
ON/OFF Switch
Fluid Outlet
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
Displacement Pump
50 ft (15 m) Main Hose
RAC IV Tip Guard
Pressurizes fluid to be sprayed through spray gun
1/4 in. ID, grounded, nylon hose with spring guards on both ends
G
H
Reverse-A-Clean (RAC) tip guard reduces the risk of fluid injection inju
ry
-
J
FTx Gun
High pressure spray gun with gun safety latch
K
RAC IV Switch Tip
RAC switch tip atomizes fluid and removes clogs from spray tip without
removing tip from spray gun
L
Pressure Drain Valve
Pressure Control
Relieves fluid pressure when open
M
Controls motor to maintain fluid pressure. Works with pressure
adjusting knob.
N
Spray Gun Safety Latch
Inhibits accidental triggering of spray gun
308-646
5
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Setup
2. Fill the wet–cup (102). Pry off the wet-cup seal.
WARNING
Fill the cup 1/3 full with Graco Throat Seal Liquid
(TSL), supplied. Install the wet-cup seal.
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.
3. Plug in the sprayer Be sure the ON/OFF switch
.
(52) is OFF. Plug the cord into a grounded outlet at
least 20 feet away from the spray area.
WARNING
FIRE AND EXPLOSION HAZARD
Proper electrical grounding is essential
to reduce the risk of fire or explosion
which can result in serious injury and
property damage. Also read FIRE OR
EXPLOSION HAZARD on page 2.
CAUTION
T
o 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.
4. Flush the pump to remove the lightweight oil
2. Never use a wire braid hose as it is too rigid to
which was left in to protect pump parts after fac
tory testing. See page 13.
-
act as a pulsation dampener
.
3. Never install any shutoff device between the
filter and the hose. See Fig. 2.
5. Prepare the paint according to the manufactu
-
ers’s recommendations. Remove any paint skin.
Strain the paint through a fine nylon mesh bag
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!
(available at most paint dealers) to remove par-
ticles that could clog the spray tip. This is an im
portant step toward trouble-free paint spraying.
-
1
2
3
4
1/4 npsm(m) fluid outlet
32
33
Do not install any shutoff device here
Rotate clockwise to increase pressure
Shown in closed or spray position
3
64
5
Fill 1/3 full with TSL
2
1
28
74
52
4
67
102
5
05993
Fig. 2
6
308-646
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Operation
How to use the gun trigger safety
Open or drain, position
1
When engaged, the gun safety latch prevents the gun
from accidental triggering. See Fig. 3.
2
Closed, or spray position
WARNING
INJECTION HAZARD
If the gun still sprays when the gun trig
-
1
ger safety is locked, repair the gun. See
manual 308–235, supplied.
2
Gun safety latch
shown engaged
1
2
04646
Gun safety latch
shown disengaged
Fig.
4
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 coun
terclockwise to obtain the minimum setting. Turn the
knob clockwise to increase pressure. See Fig. 5.
-
1
2
05964
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 automati
-
cally 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 be
fore operating the sprayer again. Refer also to the
Troubleshooting, page 14. See Fig. 4.
-
01022A
Fig. 5
308-646
7
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Operation
How to use the RAC IV tip guard.
WARNING
INJECTION HAZARD
1
2
T
o reduce the risk of serious injury,
Tip handle shown in
spraying position.
whenever you are instructed to relieve
pressure, follow the Pressure Relief
1
2
T
urn handle 180_,
Procedure on page 9.
trigger gun to clear clog
04647
Fig. 6
How to remove a tip clog.
1. Release the gun trigger. Lock the safety latch. Ro
-
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.
tate 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.
Clean the front of the tip frequently during the day’
operation. First, follow the Pressure Relief Procedure
on page 9.
s
8
308-646
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Startup
NOTE: If this is a first-time startup, flush the sprayer
.
WARNING
See page 13.
INJECTION HAZARD
NOTE: Refer to Fig. 9 and the other figures referenced
in the text as you start the sprayer
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:
1. Open the pressure drain valve (42). See Fig. 7.
2. Don’t install the spray tip until the pump is
primed!
D
D
D
D
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tip.
Pressure Relief Procedure
1. Engage the gun safety latch.
1
42
2.
T
urn the ON/OFF switch to OFF
.
3. Unplug the power supply cord.
Open or drain, position
1
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.
04648
Fig.
7
5. Engage the gun safety latch.
3. Turn the pressure knob (64) to the minimum
6. Open the pressure drain valve. Leave the pressure
drain valve open until you are ready to spray
again.
setting.
4. Disengage the gun trigger safety
.
See Fig. 3,
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
page 7.
after following the steps above, VERY SLOWLY loos
en the tip guard retaining nut or hose end coupling to
relieve pressure gradually, then loosen completely
-
CAUTION
Do not run the sprayer dry for more than 30 sec
-
.
onds to avoid damaging the pump packings.
Now clear the tip or hose obstruction.
Startup Procedure
5. 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.
Use this procedure each time you start the sprayer to
help ensure the sprayer is ready to operate and that
you start it safely
.
308-646
9
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Startup
b. If more coverage is needed, use a larger tip
WARNING
FIRE AND EXPLOSION HAZARD
rather than increasing the pressure.
T
o reduce the risk of static sparking and
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.
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.
6. 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.
NOTE: Spray patterns will change as tips wear
Change the spray tip if adjusting the pressure will not
improve the spray pattern.
.
A
7. Check all fluid connections for leaks. Relieve
pressure before tightening the connections.
1
8. Engage the gun safety latch.
9. 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 instruc
tions.
-
2
For a vertical
spray pattern
10. Adjust the spray pattern
1
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.
For a horizontal
spray pattern
2
05971
Fig. 8
10 308-646
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Startup
32
1
2
3
4
1/4 npsm(m) fluid outlet
33
Do not install any shutoff device here
Rotate clockwise to increase pressure
Shown in closed or spray position
3
64
5
Fill 1/3 full with TSL
2
1
28
74
52
4
102
5
67
05993
Fig.
9
308-646
11
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Shutdown and Care
WARNING
INJECTION HAZARD
WARNING
INJECTION HAZARD
See the warning section INJECTION
HAZARD on page 3 for information on
the hazard of using damaged hoses.
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the Pressure Relief
,
Procedure on page 9.
Turn packing
nut clockwise to
tighten
Shutdown and Care
1
1. Check the packing nut/wet-cup daily (102). Re
-
lieve pressure first. Keep the wet-cup 1/3 full of
TSL at all times to help prevent fluid buildup on the
piston rod and premature wear of packings.
1
102
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.10.
3. Periodically clean paint residue from the pres
-
sure transducer (29) vent hole area. See Fig. 11.
Replace the transducer when leakage is exces
-
sive. See page 31.
04650
Fig. 10
4. Lubricate the bearing housing after every 100
hours of operation. Remove the front cover. Fill the
bearing housing cavity (A) with SAE 10 non-
detergent oil. See Fig. 11.
1
Vent hole
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 13.
29
1
A
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 dam
age the sprayer or result in a loss of pressure or
stalling.
-
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.
04651
Fig.
11
12 308-646
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Flushing
3. Pour one-half gallon (2 liters) of compatible solvent
When to Flush
into a grounded metal flushing pail. Put the suction
hose in the pail.
1. Before using a new sprayer: flush out the oil
which was left in to protect pump parts.
4. Open the pressure drain valve. See Fig. 4, page
7.
Before using water-base paint: flush with min
eral spirits followed by soapy water, and then a
clean water flush.
-
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
Before using oil-base paint: flush with mineral
spirits only
.
gun into the paint pail. When solvent appears, re
lease the trigger. Continue with Step 6.
-
2. Changing colors: flush with a compatible solvent
such as mineral spirits or water
.
WARNING
3. Changing from water-base to oil-base paint:
flush with warm, soapy water, and then mineral
spirits.
FIRE AND EXPLOSION HAZARD
T
o 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.
4. Changing from oil-base to water-base paint:
flush with mineral spirits, then warm, soapy water
and then a clean water flush.
,
5. Storage after using water-base paint: flush with
water and then mineral spirits. Leave the system
filled with mineral spirits. Relieve pressure. Leave
the drain valve open.
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 trig
gered until the solvent flows freely from the gun.
Circulate the solvent to thoroughly clean the spray
er. Release the gun trigger. Engage the gun trigger
safety.
-
Storage after using oil-base paint: flush with
mineral spirits. Relieve pressure. Leave the drain
valve open.
-
7. Open the drain valve and circulate the solvent
through the drain tube to thoroughly clean it. Close
the drain valve.
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.
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
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.
avoid damaging the pump packings! Relieve pres
sure.
-
9. Remove and clean the inlet strainer. Wipe paint of
f
the suction hose and drain tube.
How to Flush
10. Refer to When To Flush, Step 1 again. Relieve
1. Follow the Pressure Relief Procedure on
pressure.
page 9.
11. Leave the drain valve open until you use the
sprayer again.
2. Remove the spray tip and clean it separately
.
308-646
13
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Troubleshooting
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the
Pressure Relief Procedure on page 9.
Basic Problem Solving
Check everything in the troubleshooting table before disassembling the sprayer
.
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
Fluid pressure
1. Check pressure control knob setting. The pump 1. Slowly increase pressure setting to see if
won’t develop much pressure if it is at minimum
setting (fully counterclockwise).
motor starts.
2. Check for a clogged spray tip or fluid filter, if
used. See page 8.
2. If tip is still clogged, relieve pressure; re-
fer to separate gun or tip instruction man
ual for tip cleaning. Clean the filter, if
used.
-
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 18.
1. Thaw. Plug in sprayer and turn on.
Slowly increase pressure setting to see if
motor starts. If it doesn’t, see NOTE, be
low.
-
2. Check pump connecting rod pin (17). It must be 2. Push pin into place and secure with
completely pushed into connecting rod (15),
and retaining spring (18) must be firmly in con
necting rod groove. See Fig. 18, page 22.
spring retainer.
-
3. Check for motor damage. Remove drive hous
ing assembly (11). See page 28. Try to rotate
motor fan by hand.
-
3. Replace motor (4) if fan won’t turn. See
page 26.
Electrical
1. Check electrical supply with volt meter. Meter
should read 105–125 VAC.
1. Reset building circuit breaker; replace
building fuse. Try another outlet.
2. Check extension cord for visible damage. Use
2. Replace extension cord.
a volt meter or test lamp at extension cord out
let to check.
-
3. Check sprayer power supply cord (50) for vis-
ible damage such as broken insulation or wires.
3. Replace power supply cord.
See page 27.
4. Check motor brushes for the following:
a. Loose terminal screws.
4. Refer to page 20.
a. Tighten.
b. Broken or misaligned brush springs.
b. Replace broken spring and/or align
spring with brush
c. Brushes binding in holders.
c. Clean brush holders. Remove carbon
with small cleaning brush. Align brush
leads with slot in brush holder to as
-
sure free vertical brush movement.
d. Broken leads.
e. Worn brushes.
d. Replace brushes
e. Replace brushes if less than 0.5 in.
long.
NOTE: The brushes do not wear at same rate
on both sides of motor. Check both brushes.
NOTE: Thaw sprayer if water or water–based paint has frozen in it, due to exposure to low temperatures, by placing in a warm
area. Do not try to start sprayer until completely thawed or damage to motor and/or start board may occur. If paint hardened
(dried) in sprayer, the pump packings (page 22) and/or pressure transducer (page 31) must be replaced.
14 308-646
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Basic Problem Solving
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
Electrical (continued)
5. Check motor armature commutator for burn
5. Remove motor and have motor shop
resurface commutator if possible. See
page 26.
spots, gouges and extreme roughness. Re
-
move motor cover and brush inspection plates
to check. See page 20.
6. Check motor armature for shorts using arma
ture tester (growler) or perform motor test.
See page 18.
-
6. Replace motor. See page 26.
7. Check leads from pressure control and motor to 7. Replace loose terminals; crimp to leads.
motor start board (47) to be sure they are se
curely fastened and properly mated.
-
Be sure male terminal blades are straight
and firmly connected to mating part.
8. Check motor start board (47) by substituting
with a good board. See page 27.
8. Replace board. See page 27.
CAUTION: Do not perform this check until mo
tor armature is determined to be good. A bad
motor armature can burn out a good board.
-
9. Check power supply cord (50). Disconnect
9. Replace power supply cord. See page
27.
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
10. Replace ON/OFF switch. See page 27.
T
urn off and unplug sprayer
.
11. Check motor thermal cutout switch. Connect
11. Allow motor to cool. Correct cause of
overheating. If switch remains open after
ohmmeter between motor’s red leads. Meter
should read 1 ohm maximum.
motor cools, replace motor
.
12. Remove pressure control (64) and check mi
croswitch operation with ohmmeter:
-
12. Replace pressure control. See page 30.
(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,read
ings 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 31.
13. Replace transducer. See page 31. Thor
-
ough system flushing will help extend life
of transducer
.
Intermediate Problem Solving
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Low output
1. Check for worn spray tip.
1. Follow Pressure Relief Procedure then
replace tip. See your separate gun or tip
manual.
2. Be sure pump does not continue to stroke
when gun trigger is released. Plug in and turn
2. Service pump. See page 22.
on sprayer. Prime with paint. Trigger gun mo
-
mentarily, then release and lock safety latch.
Relieve pressure, turn off and unplug sprayer
.
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15
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Intermediate Problem Solving
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
Low output (continued)
3. Release gun trigger. Observe resting position of 3. If pump consistently comes to rest with
pump rod (107).
rod (107) fully extended, the piston pack
ings and/or piston valve may be worn.
Service the pump. See page 22.
-
4. Check electrical supply with volt meter. Meter
should read 105–125VAC.
4. Reset building circuit breaker; replace
building fuse. Repair electrical outlet or
try another outlet.
5. Check extension cord size and length; must be 5. Replace with a correct, grounded exten
-
at least 12 gauge wire and less than 150 ft
(45 m) long.
sion cord.
6. Check motor brushes. See Electrical – What T
o
6. See page 20.
Check, item 4, on page 14.
7. Check motor start board (47) by substituting
with a good board.
7. Replace board. See page 27.
CAUTION: Do not perform this check until mo
tor armature is determined to be good. A bad
motor armature can burn out a good board.
-
8. Check motor armature for shorts by using an
armature tester (growler) or perform motor test.
See page 18.
8. Replace motor. See page 26.
Drain valve leaks
Transducer leaks
1. Check drain valve for correct torque and/or
worn parts. Check for debris trapped on seat.
9. Tighten to 185 in–lb (21 N.m). Clean
valve and replace with new gasket (42a)
and sealant (42d). See page 32.
1. Slight leakage from transducer is normal.
1. Periodically remove residue from its cyl
-
inder port. See page 31.
No output: motor runs and 1. Check paint supply
.
1. Refill and reprime pump.
pump strokes
2. Check for clogged intake strainer
.
2. Remove and clean, then reinstall.
3. Check for loose suction tube or fittings. See
page 34.
3. Tighten; use thread sealant on npt
threads of adapter (38).
4. Check to see if intake valve ball and piston ball 4. Remove intake valve and clean. Check
are seating properly. See page 22.
ball and seat for nicks; replace as need-
ed. See page 22. Strain paint before us
ing to remove particles that could clog
pump.
-
5. Check for leaking around throat packing nut
which may indicate worn or damaged packings.
See page 22.
5. Replace packings. See page 22. Also
check piston valve seat for hardened
paint or nicks and replace if necessary
.
Tighten packing nut/wet-cup.
6. Release gun trigger. Observe resting position of 6. If pump consistently comes to rest with
pump rod (107).
rod (107) fully extended, the piston pack
ings and/or piston valve may be worn.
Service the pump. See page 22.
-
No output: motor runs but 1. Check displacement pump connecting rod pin
pump does not stroke
1. Replace pin if missing. Be sure retainer
spring (18) is fully in groove all around
connecting rod.
(17). See Fig. 18, page 22.
7. Check connecting rod assembly (15) for dam
-
7. Replace connecting rod assembly. See
page 28.
age. See page 28.
8. Be sure crank in drive housing rotates; plug in
sprayer and turn on briefly to check. Turn of
and unplug sprayer. See page 28.
8. Check drive housing assembly for
damage and replace if necessary. See
page 28.
f
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Intermediate Problem Solving
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
1. Spray tip worn beyond sprayer pressure capa
-
-
1. Replace spray tip.
Spray Pattern Variations
bility.
NOTE: A smaller size tip will provide
longer life.
2. Check transducer (29) for wear or damage.
2. Replace transducer. See page 31.
3. Check pressure control (64) for smooth opera
tion.
3. Replace pressure control. See page 30.
4. Check Low output section, page 16.
Motor Is Hot and Runs
Intermittently
1. Determine if sprayer was operated at high pres
sure with small tips, which causes excessive
heat build up.
-
1. Decrease pressure setting or increase tip
size.
2. Be sure ambient temperature where sprayer is 2. Move sprayer to shaded, cooler area if
possible.
located is no more than 90_F (32_C) and
sprayer is not located in direct sun.
3. Check motor.
3. Replace motor. See page 26.
Building Circuit Breaker 1. Check all electrical wiring for damaged insula
-
1. Repair or replace any damaged wiring or
terminals. Securely reconnect all wires.
tion, and all terminals for loose fit or damage.
Opens As Soon As Sprayer
Switch Is Turned On.
Also check wires between pressure control and
motor. See page 26.
2. Check for missing motor brush inspection plate 2. Correct faulty conditions.
gasket (see page 18), bent terminal forks or
other metal to metal contact points which could
cause a short.
3. Check motor armature for shorts. Use an arma
ture tester (growler) or perform motor test. See
page 18. Inspect windings for burns.
-
3. Replace motor. See page 26.
4. Check motor start board (47) by substituting
with a good board.
4. Replace board. See page 27.
CAUTION: Do not perform this check until
motor armature is determined to be good. A
bad motor armature can burn out a good board.
Circuit breaker opens after 1. Check ‘Basic Problems – Electrical’ on page
14.
sprayer operates for 5 to 10
minutes.
Building circuit breaker
1. Check ON/OFF switch (52). Be sure sprayer is 1. Replace ON/OFF switch. See page 27.
unplugged! Disconnect wires from switch.
opens as soon as sprayer
is plugged into outlet and
sprayer is NOT turned on.
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.
2. If voltage is too high, do not operate
sprayer until corrected.
Unit will not run on gener
ator but does run on AC
power
-
Check the generator
not run if the peak voltage is above 190V
’s peak voltage. This sprayer will Use AC power or a different generator
.
308-646
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Motor Test
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
B
For checking armature, motor winding and brush elec
trical continuity
-
.
Setup
A
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.
Remove the motor brush inspection covers (A). See
Fig. 12.
04652
Fig. 12
Remove the junction box screws (56). Lower the junc
tion box. Disconnect the two leads (C) from the motor
to the board (47). See Fig. 13.
-
Armature Short Circuit Test
Remove the fan cover (B). See Fig. 12.
MOTOR
Spin the motor fan by hand. If there are no shorts, the
motor will coast two or three revolutions before coming
to a complete stop. If the motor does not spin freely
,
the armature is shorted and the motor must be re
-
placed. See page 26.
89
Armature, Brushes, and Motor Wiring
Open Circuit Test (Continuity)
BLACK/
WHITE
Connect the two black motor leads together with a test
lead. Turn the motor fan by hand at about two revolu
BLACK
-
tions per second.
C
59
When turning the fan on a DC motor, normally you
RED
sense an even, pulsing resistance. If there is irregular
turning resistance, or no turning resistance, check and
repair the following as needed: broken brush springs,
brush leads, motor leads; loose brush terminal screws
or motor lead terminals; worn brushes. See page 20.
58
56
47
04720
Fig. 13
If there is still uneven or no turning resistance, replace
the motor. See page 26.
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General Repair Information
WARNING
INJECTION HAZARD
WARNING
HOT SURFACE HAZARD
During operation, the motor and drive
housing become very hot and could burn
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the Pressure Relief
,
your skin if touched. Flammable materi
-
als spilled on the hot, bare motor could cause a fire
or explosion
Procedure on page 9.
Tool List
CAUTION
These are the tools required to service all parts of the
sprayer.
T
o reduce the risk of a pressure control malfunc
-
tion, 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.
3/16” Allenr wrench: gear housing, legs, handle
3/8” Allenr wrench: pump manifold
#1 Phillipsr 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
1. When disconnecting wires in the junction box
assembly, use needle nose pliers to separate mat
ing connectors.
-
13/16” socket wrench: drain valve
1-1/4” socket wrench: pump inlet valve
1/2” open end wrench: pump rod
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.
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
CAUTION
Improper wire routing can result in poor sprayer
performance or damage to the pressure control.
Torque wrenches: various fasteners
3. Route wires carefully through the drive housing
and motor. Avoid pinching the wires between the
junction box and the motor or pressure control.
WARNING
MOVING PARTS HAZARD
4. Keep all screws, nuts, washers, gaskets, and
o reduce the risk of serious injury, includ
ing electric shock, DO NOT touch any
moving parts or electrical parts with your
fingers or a tool while inspecting the repair
-
electrical fittings removed during repair proce
-
dures. These parts are not normally provided with
replacement assemblies.
.
5. Test your repair before regular operation to be
Shut off the sprayer and unplug it as soon as you
complete the inspection.
sure the problem is corrected.
6. If the sprayer does not operate properly, verify
that everything was done correctly. Also refer to
the Troubleshooting Guide, pages 14–18, to help
identify other possible problems and solutions.
Reinstall all covers, gaskets, screws and washers
before operating the sprayer
.
308-646
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Motor Brushes
NOTE: Replace brushes when worn to about 0.5 in.
Motor lead; do not disconnect
Minimum 0.5” (12.5 mm)
1
2
(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.
3
Included in Brush Repair
Kit 236–967
2
NOTE: Replacement brushes may last only half as
long as the original ones. To maximize brush life, break
in new brushes by operating the sprayer for at least
one hour with no load (remove the pump connecting
rod pin).
1
C
H
G
3
F
B
E
WARNING
INJECTION HAZARD
03881
D
Fig. 15
To reduce the risk of serious injury,
4. Inspect the commutator for excessive pitting, burn
-
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
ing or gouging. A black color on the commutator is
normal. Have the commutator resurfaced by a
qualified motor repair shop if the brushes seem to
wear too fast or arc excessively. See Step 9.d.,
also.
5. Repeat for the other side.
1. Remove both inspection covers (A) and their gas
-
kets. See Fig 14.
NOTE: The motor brushes on the other side are
upside down.
6. Place a new brush (C) in the holder (B) so the
ramp (H) faces the spring. See Fig. 16.
1
F
G
A
C
04653
Fig. 14
E
03881
Fig. 16
2. Push in the spring clip (F) and release its hook (G)
from the brush holder (B). Pull out the spring clip.
See Fig 15.
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. 16. Pull on the
spring clip to be sure it stays in place. Connect the
brush lead to the blade connector (E).
3. Slide off the brush lead terminal (E) off the blade
connector. Remove the old brush (C). See Fig 15.
8. Repeat for the other side.
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Motor Brushes
9. Test the brushes.
WARNING
a. Remove the pump connecting rod pin (17).
See Fig. 18, page 22.
MOVING PARTS HAZARD
Do not touch the brushes, leads, springs
or brush holders while the sprayer is
plugged in to reduce the risk of electric
b. With the sprayer OFF, turn the pressure con
-
trol knob fully counterclockwise to minimum
shock and serious injury
.
pressure. Plug in the sprayer
.
c.
T
urn the sprayer ON. Slowly increase the
10. Install the brush inspection covers and gaskets.
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.
11. Break in the brushes. Operate the sprayer for at
least one hour with no load. Install the pump
connecting rod pin. See Fig. 18, page 22.
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Displacement Pump Repair
2. Align the hole in the rod (107) with the connecting
WARNING
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.
INJECTION HAZARD
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the Pressure Relief
,
3. Reconnect the suction and drain hoses (32,33).
Install the front cover (13).
Procedure on page 9.
4. Tighten the packing nut (102) just enough to stop
leakage, but no tighter. Fill the packing nut/wet-cup
1/3 full with Graco TSL. Push the plug (123) into
the wet-cup.
NOTE: Packing Repair Kit 235–703 is available. Refer
ence 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 20)
and clean the transducer (see page 31) whenever you re
-
pack the pump. Replace these parts as needed.
Removing the pump (See Fig. 17.)
1. Flush the pump, if possible. Relieve pressure. Stop
the pump with the piston rod (107) in its lowest
13
17
position, if possible. To lower the piston rod manu
ally, rotate the motor fan blades.
-
18
107
120
2. Loosen the swivel nut on adapter (38) and remove
suction hose (32). While pushing in on the collar of
elbow (36), pull out and remove drain tube (33).
*122
20
21
1
*121
*119
NOTE: If repairing only the intake valve assembly, go
to Intake valve repair page 23.
,
36
118
33
32
3. Use a screwdriver to push the retaining spring (18)
up and push out the pin (17).
4. Loosen the screws (21). Remove the pump (20).
Torque to
1
2
50 ft–lb (68 N.m)
38
Installing the pump (See Fig. 18 and 19.)
Apply sealant (42d)
2
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).
04654
Fig. 17
17
WARNING
15
123
MOVING PARTS HAZARD
Be sure the retaining spring (18) is firmly
in the groove all the way around, to pre
vent the pin (17) from working loose due
to vibration. See Fig. 18.
-
18
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
Torque to
50 ft–lb (68 N.m)
1
21
102
injury or property damage, including the pump con
-
1
necting rod or drive housing.
04655
Fig. 18
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Displacement Pump Repair
1. Check the outside of the piston rod (107) and the
Intake valve repair (See Fig. 17)
1. Remove the suction hose. See Step 2, Removing
inside of the cylinder (115) for wear. Replace worn
parts to ensure a good seal with the new packings.
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.
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 (1
11*). See Fig. 19.
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
2
3
Throat packings
Piston packings
Intake valve
Disassembling the pump (See Fig. 19.)
1. Remove the intake valve (118). See page
123
2. Loosen the packing nut (102) and plug (123).
102
3. Use a plastic mallet to tap the piston rod (107)
down, and then pull the rod out through the bottom
*103
107
1
of the cylinder
.
105*
106*
*104
109*
110
4. Remove the packing nut (102) and throat pack
-
ings.
111
2
5. Loosen the jam nut (117). Remove the cylinder
(115) and the o-ring (116*).
*113
112*
101
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).
114*
108
117
7. Remove all parts from the piston valve (108).
*116
Reassembling the pump
3
NOTE: Alternate plastic and leather packings. See Fig.
19. The lips of the throat V-packings face down. The
lips of the piston V-packings face up. Incorrect installa
115
-
118
tion damages the packings and causes pump leakage.
NOTE: Soak the leather packings in oil before reas
sembling the pump.
-
01069A
Fig. 19
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Displacement Pump Repair
3. Tighten the nut (110) onto the piston valve (108) to
Torque to
5 in–lb (0.57 N.m)
1
5 in-lb (0.57 N.m). See Fig. 20.
107
Apply one drop of
sealant to these
threads
NOTE: Note the alignment of the piston (108) to the
nut (110). Maintain this alignment through Step 8.
2
*109
110
2
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. 20.
108
01070
Fig. 20
CAUTION
Step 6, tightening the piston valve into the rod, is
critical. Follow the procedure carefully to avoid
damaging the packings by overtightening.
107
110
Torque nut against rod
to 30 ft–lb (40 N.m)
1
2
2
1
Do not allow nut (110)
to move relative to
piston (108) when
tightening piston
against rod.
108
6. Hand tighten the valve into the piston rod just until
the nut (110) contacts the rod. See Fig. 21.
01071
Fig. 21
7. Place the flats of the rod (107) in a smooth jaw
vise.
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 pack
-
8. CAREFULLY tighten the nut (110) against the pis
-
-
ings (105*), and then the female gland (103*). See
Fig. 23.
ton rod to 30 ft-lb (40 N.m). See Fig. 21.
Use two wrenches to maintain the alignment men
tioned in NOTE below Step 3.
10. Install the packing nut (102) and plug (124), but
leave loose for now. See Fig. 23.
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Displacement Pump Repair
11. Place a new o-ring (116*) firmly in the cylinder
15. Torque the cylinder jam nut (117) to 73 ft-lb
groove. See Fig. 22.
(98 N.m). See Fig. 22.
12. Coat the piston rod and packings with oil. Carefully
slide the assembly into the top of the cylinder
(115). See Fig. 22.
16. Install the pump. See page 22.
Lips of V–packings
must face up
1
2
3
4
5
Leather packings
Poly packings
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. 22.
T
orque to 53 ft–lb
(71 N.m)
Lips of V–packings
must face down
107
123
102
101
102
Torque jam nut (117)
to 73 ft–lb (98 N.m)
1
104*
*103
*105
T
orque cylinder (115)
2
2
3
into manifold (101) to
53 ft–lb (71 N.m)
106*
1
3
Torque intake valve (116)
into cylinder (115) to
53 ft–lb (71 N.m)
3
4
107
101
*116
Piston assembly
109*
117
116*
110
111
112*
117
115
1
2
2
4
4
*113
1
4
114*
115
108*
120
122*
121*
3
118
*119
01072A
Fig. 22
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
5
118
01073
Fig. 23
(71 N.m). This will also properly torque the cylinder
into the manifold. See Fig. 23.
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Motor
8. Remove the two screws (46) and lift the motor of
f
WARNING
the base (66).
INJECTION HAZARD
9. Align the new motor with the base and reinstall the
screws (46).
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the Pressure Relief
,
10. Assemble the drive housing to the motor. Follow
steps 8 to 11 on page 28.
Procedure on page 9.
11. Connect the wires in the junction box. Refer to Fig.
27 on page 27. Install the junction box.
NOTE: See Fig. 26 except where noted.
1. Relieve pressure.
12. Connect the piston rod (107) to the drive housing;
see page 22, Installing the Pump, Step 2 and the
WARNING following it.
2. Try to stop the pump with the piston rod (107) in its
17
lowest position. To lower the piston rod manually
,
15
rotate the motor fan blades. Use a screwdriver to
push the retaining spring (18) up and push out the
pin (17). See Fig. 24.
18
3. Remove the screws (56) and lower the junction
box (59). Disconnect the motor wires and the pres
sure control wire (A) from the motor start board.
Refer to Fig. 27 on page 27.
-
01068
Fig. 24
4. Remove the front cover (13).
107
5. Turn the displacement pump rod (107) so the pin
hole aligns with the bottom drive housing screw
(19). See Fig. 25. Remove the three drive housing
screws and lockwashers (19,6). Also see Fig. 26.
19,6
6. Remove the two motor screws (19) and and re
move the sprayer handle (24).
-
01074
Fig. 25
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 28.
24
1
19
C
B
A
16
12
11
4
1
Torque to 80 in–lb (9 N.m)
6
1
19
2
3
Quantity of three
Quantity of one
13
31
46
59
56
3
34
2
04656
Fig. 26
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5. Install the new cord (50) in the reverse order of
disassembly.
Motor Start Board
6. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board. Also be sure the gasket (89) is installed.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
On/Off Switch
NOTE: See Fig. 27 for this procedure.
1. Relieve pressure.
NOTE: See Fig. 27 for this procedure.
2. Remove the junction box screws (56) and lower
the junction box (59).
1. Relieve pressure.
2. Remove the junction box screws (56) and lower
the junction box (59).
3. Remove the nut and rubber boot (55).
4. Disconnect the black wires from the ON/OFF
switch (52) and remove the switch.
3. Disconnect the motor wires (B) and the 3-wire con
-
nector (A) from the motor start board (47). Ob
-
serve where connections are made.
5. Place the ring terminal of the ground wire (53) over
the barrel of the new switch. Install the switch so
4. Remove the screws (58) and motor start board
the internal tab of the anti-rotation ring (54) en
-
(47). Transfer the white thermal paste from the old
board to the new board.
gages with the vertical groove in the threads of the
switch, and the external tab engages with the blind
hole (C) of the junction box.
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.
6. Powder the inside of the rubber boot (55) with tal
-
cum, then shake the excess out of the boot. Install
the nut and rubber boot and tighten.
7. Reconnect the ON/OFF switch black wires.
CAUTION
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.
Be sure the flat blade of the insulated male con
-
nector is centered in the wrap–around blade of the
female connector when the connections are made.
MOTOR
GREEN
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.
49
GREEN/
YELLOW
53
50
51
52
89
BLACK/
WHITE
Power Supply Cord
BLACK
54
B
55
NOTE: See Fig. 27 for this procedure.
59
58
1. Relieve pressure.
RED
2. Remove the junction box screws (56) and lower
the junction box (59).
C
A
56
3. Disconnect the power supply cord leads, including
the green wire to the grounding screw (49).
47
04720
Fig. 27
4. Loosen the strain relief bushing (51). Remove the
power supply cord (50).
308-646
27
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Drive Housing, Connecting Rod, Crankshaft
WARNING
INJECTION HAZARD
CAUTION
Do not allow the gear (16) to fall; it may stay
attached to the drive housing or to the motor
.
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the Pressure Relief
,
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 heav
Procedure on page 9.
-
-
ily covered with grease, usually stay in the gear re
cesses, 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. Remove the displacement pump. See page 22.
2. Remove the pressure control (64). See page 30.
6. Remove and inspect the crankshaft (12) and the
connecting rod (15).
7. Install the connecting rod.
3. Turn the displacement pump rod (107) so the pin
hole aligns with the bottom drive housing screw
(19). See Fig. 28. Remove the three drive housing
screws and lockwashers (19,6). Also see Fig. 29
on page 29.
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 con
tain a total of 3 fl. oz. (29 cc) of grease.
-
107
9. Route the wire harness (A) through the motor pas
-
sages to the junction box (59).
19,6
10. Place the large washer (12a) and then the small
washer (12b) on the crankshaft (12).
11. Lift the crank to the top of the stroke and insert
01074
Fig. 28
crankshaft (12). Align the gears and push the drive
housing (11) straight onto the motor and the locat
-
ing pins. Install the screws (19, 5) and their lock
washers (6). Torque to 80 in–lb (9 N.m).
-
4. Remove the two motor screws (19) and handle
(24). See Fig. 29 on page 29.
12. Install the displacement pump. See page 22.
5. Tap the lower rear of the drive housing (11) with a
plastic mallet to loosen the motor. Pull the drive
13. Install the pressure control (64). See page 30.
Install the front cover (13).
housing straight off the motor
.
28 308-646
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Drive Housing, Connecting Rod, Crankshaft
24
19
1
64
C
4a
REF
A
12b
16
4
12
12a
1
Torque to 80 in–lb (9 N.m)
Quantity of three
11a
2
3
A
47
59
56
Quantity of one
Apply a total of
3 fl. oz.(29 cc) of
grease
4
31
3
to gears.
11
6
13
15
19
1
34 2
04657
Fig. 29
308-646
29
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Pressure Control
7. Loosely install the screws (63) and then torque
WARNING
them to 21 in–lb (2.4 N.m).
INJECTION HAZARD
8. Install the front cover (13). Connect the harness
(A) to the motor start board (47).
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the Pressure Relief
,
9. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board.
Procedure on page 9.
NOTE: See Fig. 30 for this procedure.
NOTE: The pressure control (64) cannot be repaired
or adjusted. If it has malfunctioned, replace it.
64
1
63
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).
11
13
3. Remove the screws (63). Pull forward on the pres
sure adjusting knob and tip the pressure control
(64) forward and up to detach it from the drive
housing (11).
-
A
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.
Torque to
21 in–lb (2.4 N.m)
59
1
6. Install the new pressure control. Tip the pressure
control down and back into the drive housing (11).
Do not pinch or damage the harness (A).
56
02816A
Fig. 30
30 308-646
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Pressure Transducer
WARNING
INJECTION HAZARD
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the Pressure Relief
,
Procedure on page 9.
NOTE: See Fig. 31 for this procedure.
29
1. Remove the displacement pump. See page 22.
2. Use a pull–twist motion to remove the transducer
(29) from the pump manifold (101).
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.
02817A
Fig. 31
6. Align the holes in the transducer as shown by the
arrows in Fig. 31.
7. Install the displacement pump. See page 22.
308-646
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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.
.
INJECTION HAZARD
T
o reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
2. If replacing the gasket (42a) or seat (42b), pry out
the gasket.
NOTE: Whenever the gasket (42a) is removed, re
-
place it with a new one.
Apply thread sealant
42a
1
2
42b
Apply grease
to face of base
1
3. Coat the o-ring (42d) with grease. Press the stem
into the valve body. Install the spring, washers and
42d
Torque into pump
3
4
manifold to 185 in–lb
(21 N.m)
spring retainer into the valve body
.
42c
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 in
Handle shown
in closed position
-
2
42
3
stall it in the valve body
.
NOTE: The gasket will protrude from the end of the
valve until the valve is tightened into pump, which cor
rectly seats the gasket.
-
43
44
Replacement
45
4
02819
Fig. 32
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. Turn the handle (45) to the closed position. Drive
out the pin (44). Remove the handle.
2. Lightly grease the face of the base (43) and install
the base. Turn the stem so the pin hole is vertical.
2. Remove the base (43).
3. Unscrew the drain valve (42). The gasket (42a)
and seat (42b) will stay in the valve.
3. Securely install the handle (45) and drive pin (44).
Inlet Strainer Installation/Removal
Installation (Fig. 33)
32
1. Align the keyway in the strainer (39) with the small
nub near the end of the suction tube (32).
2. Push the strainer over the nub and up to the suc
-
tion tube’s raised band. While holding the strainer
against the band, rotate it about 1/2 turn in either
direction (a wrench may be necessary).
39
Removal
1. With a wrench or the hand, turn the strainer (39) in
either direction until the keyway aligns with the
raised nub in the suction tube (32). A sudden re
lease in turning resistance will be felt when the
parts align.
-
04717
Fig. 33
2. Pull, or tap, the strainer straight off the suction
tube.
32 308-646
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Displacement Pump Parts Drawing and List
Model 236–787, Series A
Includes items 101 to 127
123
Ref
No. Part No.
Description
Qty
102
101
102
187–611 MANIFOLD, pump
1
1
1
3
2
1
1
1
1
1
1
3
2
1
1
1
1
1
1
1
1
1
1
1
1
176–758 ACKING NUT
P
103* 176–757 GLAND, female, throat
104* 176–997 V–PACKING, plastic, throat
105* 176–755 V–PACKING, leather, throat
106* 176–754 GLAND, male, throat
107
108
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
113* 176–749 V–PACKING, leather, piston
114* 180–073 GLAND, female, piston
*103
107
105*
106*
187–613 DISPLACEMENT ROD
224–808 PISTON VALVE
*104
109*
110
111
115
236–786 CYLINDER, pump
*113
112*
116* 108–526
117
118
119* 111–603 PACKING, o–ring, PTFE
120 176–760 GUIDE, ball
121* 105–445 BALL, 1/2”, inlet
122* 176–759 PIN, ball stop
P
ACKING, o–ring,PTFE r
Y127
187–614 NUT, jam,1-3/8 18 unef–2
b
224–966 INLET ALVE
V
101
r
114*
108
117
123
180–656 PLUG
124* 102–969 SEALANT (not shown)
127Y 188–663 LABEL, Warning
*122
120
*116
115
*Supplied in Repair Kit 235–703.
Keep a repair kit on hand to reduce
down time.
121*
*119
118
01069A
Accessoriese.
Fluid Filter Kit 235–677
Low Profile Cart Kit 235–710
Filters particles from fluid stream. Includes manifold
filter, fittings and installation instructions.
Converts sprayer to low profile wheeled cart.
Upright Cart Kit 236–328
Converts sprayer to tall wheeled cart.
308-646
33
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Sprayer Parts Drawing
Model 231–553, Series A
HOSE AND GUN NOT SHOWN
IN PROPORTION TO SPRAYER
74
Label
1
See detail
on page 31
2
67
39
30
REF 33
REF 32
4e 1
24
19
4
64
4a
12b
29
16
12
12a
1
4f
79
4g
1
11b
63
6
19
89
15
11a
2
13
35
18
OUT-
SIDE
17
11 66
50
56
LABEL
14
INSIDE
LABEL
42a
42b
42d
42c
28
31
23
46
21
20
42
34
36
43
44
32
33
45
37
38
25
O4658
34 308-646
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Sprayer Parts List
Includes items 3 to 89 as listed below
Model 231–553, Series A
Ref.
No. Part No.
Ref.
No. Part No.
Description
Qty.
Description
Qty.
4{
236–965 MOTOR KIT
Includes items 4a to 4g
100–069 .BALL, sst, 1/4” dia.
111–616 .TERMINAL, flat, 1/4” (f), 18 awg
107–503 .TERMINAL, 3/16” (m), 16 awg
107–267 .TERMINAL, 3/16” (f)
44
45
46
47
111–600 PIN, grooved, 3/32 x 1”
187–625 HANDLE, drain valve
110–997 SCREW, washer/hex hd, 5/16”
235–008 MOTOR START BOARD
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
4a.
4b.
4c.
4d.
48Y 186–620 LABEL, ground terminal
49
50
51
110–037 SCREW, mach, pnhd, 10–24 x 5/8”
235–010 POWER CORD SET
111–617 STRAIN RELIEF BUSHING,
3/8–18 npt
105–679 SWITCH, ON/OFF
235–035 GROUND HARNESS
105–658 LOCKING RING
4e.Y 187–784 .LABEL, DANGER, French
4f.Y 187–791
4g.Y 187–975
.
.
LABEL, DANGER, English
LABEL, WARNING, electric shock 1
6
11
105–510 LOCKWASHER, 1/4”
224–965 DRIVE HOUSING KIT
Includes item 11a, 11b
100–069 .BALL, stainless steel, 1/4” dia.
111–726 .PLUG
224–803 CRANKSHAFT
Includes items 12a, 12b
180–131 .BEARING, thrust
107–434 .BEARING
3
1
52
53
54
55
56
58
59
63
64
66
67
1
1
1
1
4
2
1
2
1
1
1
11a
11b
12
1
1
1
105–659 BOOT, switch
111–703 SCREW, filh, 10–24 x 3”
100–035 SCREW, pan hd, 8–32 x 5/16”
187–795 JUNCTION BOX
111–704 SCREW, filh, 10–24 x 1–5/8”
224–828 PRESSURE CONTROL KIT
189–932 BASE, motor
12a
12b
13
1
1
1
1
1
1
1
1
5
188–366 COVER, front
14Y 177–762 LABEL,
WARNING
238–350 FTx GUN
15
16
17
18
19
218–359 CONNECTING ROD
218–364 GEAR REDUCER
176–818 PIN, headless, 3/8” dia. x 1”
176–817 SPRING, retaining
103–345 SCREW, socket head,
1/4–20 x 1–1/4”
See manual 308–645 for parts
68
74
206–994 TSL, 8 oz. (not shown
)
1
1
223–541 HOSE, grounded, nylon; 1/4” ID;
cpld 1/4 npsm(f); 50 ft (15 m);’
spring guards both ends
79
89
Y
103–473 STRAP, tie
2
1
20
236–787 PUMP KIT
1
187–963 GASKET
see parts on page 29
21
23
24
25
28
111–706 CAPSCREW, 7/16–14 x 1–3/4”
111–715 SCREW, 5/16–18 x 1–1/4”
190–337 HANDLE, sprayer
112–759 CAP, tubing
162–453 NIPPLE, hex, 1/4 npsm x
1/4 npt, 1–3/16”
2
4
1
4
2
Extra warning labels available free of charge.
{
Motor Brush and Spring Replacement Kit,
P.N.236–967 is available. Purchase separately
.
MOTOR
29
30
31
32
33
34
35
36
37
38
39
42
235–009 PRESSURE TRANSDUCER
190–464 CLIP, 5/8”
108–850 SCREW, filh, 8–32 x 1–1/4”
237–684 SUCTION HOSE & TUBE
190–336 DRAIN TUBE
1
1
1
1
1
3
1
1
2
1
1
1
GREEN
48
49
GREEN/
YELLOW
53
4c
111–705 SCREW filh, 8–32 x 2–1/2”
,
50
51
290–237 LABEL, identification
237–696 ELBOW, drain
190–334 LEG, sprayer
190–451 ADAPTER, union
237–820 STRAINER
BLACK/
WHITE
52
BLACK
54
4b
235–014 DRAIN VALVE KIT
Includes items 42a to 42e
55
59
58
RED
42a
42b
42c
42d
42e
43
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)
224–807 BASE, valve
1
1
1
1
1
1
4d
47
04720
308-646
35
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DANGER LABELS
Technical Data
The English language DANGER label shown on
page 1 is also on your sprayer. If you have paint
ers who do not read English, order one of the fol
lowing labels to apply to your sprayer. The draw
ing below shows the best placement of these la
bels for good visibility
Power Requirements
.
. . . . . . . . . . . . . . . . . . . 120 VAC,60Hz,
phase, 15 amp minimum
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 Watt minimum
Working Pressure Range . . . . . . . . 0–2750 psi (0 – 195 bar)
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 hp
Cycles/Gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . . . 620 (164)
-
-
-
-
1
.
.
.
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 gpm (1.25 lpm)
Tip Size . . . . . . . . . . . . . . . . . . . . . . . . one gun to 0.019 new tip
with latex at 2000 psi (138 bar)
Order the labels directly from Graco, free of
charge: 1–800–328–021
1
Apply other
language here
Power Cord . . . . . . . . . . . . . . . No. 14 AWG, 3 wire, 6’ (1.8 m)
French
Spanish
German
Greek
185–956
185–961
186–041
186–045
186–049
185–953
Inlet Paint Strainer
.
. . . . . . . . . . . . . . . 12 mesh (1525 micron)
Stainless Steel Screen, reusable
Pump Inlet Size
Fluid Outlet Size
Wetted Parts:
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt(f)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npsm
.
Korean
English
Displacement Pump
.
. . . . . . Stainless steel, Carbon steel,
04653
PTFE,R Aluminum, Polyethylene, DelrinR, Leather
Delrin® is a registered trademark of the DuPont Company.
Graco Phone
Number
Dimensions
Weight (dry w/o packaging)
.
. . . . . . . . . . . . . . . . 35 lb (16 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 in. (457 mm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 in. (381 mm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5 in. (318 mm)
TO PLACE AN ORDER, contact your Graco distrib
utor, or call this number to identify the distributor
closest to you: 1–800–367–4023 Toll Free
-
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
accordance with Graco’s written recommendations.
.
This warranty applies only when the equipment is installed, operated and maintained in
This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by faulty installation, misapplication, abra
sion, 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 mate
rials 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 origi
-
nal purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at
reasonable charge, which charges may include the costs of parts, labor and transportation.
a
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 accesso
-
ries, 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
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN U.S.A. 308–646 February 1996, Revised September 1996
36 308-646
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