Graco 235-699, 231-208 Instructions Manual

INSTRUCTIONS-PARTS

LIST

This

manual contains IMPORTANT

'

READ AND RETAIN

FOR

REFERENCE.

INSTRUCTIONS

and

WARNINGS.

ELECTRIC,

120

VAC

490st

AIRLESS PAINT SPRAYER

NOTE

This

is

an

example

of

the

DANGER

label

on

your sprayer.

This

label

is

available

in

other

languages,

free

of

charge.

See page

32

to order.

I

#

I

EXPLOSIONHAZARD

FIRE

AND

I I

. HAZARD

SKIN INJECTION

I

Spra palntlng, fluahlng

or

cleanlng equlpmnt wlth

flammable

Ilq-

Uquldscan

be

Injected

Into

the

body

by hlgh pnssurs

alrless

Spray

I

uldsrn conflned

areas

an

result

In

are

or

exoloslon.

or

leab

-

esneclak

hose

leak

I

READ

AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE

..

I

GRACO

INC.

P.O.

BOX

1441

MINNEAPOLIS,

MN

55440-1441

@COPYRIGHT

1992,

GRACO INC.

General Safety This equipment generatesvery

high

fluid pressure. Spray from

the gun, leaks or ruptured components can inject fluid through

yourskinandintoyourbodyandcauseextremelyseriousbodily

injury, including the need

for

amputation.

Also,

fluid injected or

spiashedintotheeyesorontheskincancauseseriousdamage.

NEVERpointthespraygunatanyoneoratanypartofthebody.

NEVER

put

hand or fingers over the spray

tip.

NEVER try

to

"blow back" paint:

this

is

NOT an air spray system.

ALWAYS have the tip guard in place on the spray gun when spraying.

ALWAYS follow

the

Pressure Relief Procedure, below. before cleaning or removing the spray tip or servicing any system equipment.

NEVER try to stop or deflect leaks with your hand or body.

Besureequipmentsafetydevicesareoperatingproperlybefore

each use.

Medical Alert- -Airless Sorav Wounds

If

any fluid appears to penetrak ydur skin, get EMERGENCY

MEDICAL CARE AT ONCE.

DO

NOT TREAT AS A SIMPLE

CUT.

Tell the doctor exactly what fluid was injected.

Note to Physlclan: Injection

in

the skin is a traumatic injury It

is important to freaf the

injq

surgically as

soon

as possible.

Do

not delay treatment to research toxIcl$ Toxicity is

a

concern. with some exotic coatings injected rrectly

Into

the

blood stream. Consultation with a plastic surgeon

or

re-

constructive hand surgeon may be advrsable.

Spray Gun Safety Devices

eachuse.Donotremoveormodifyanypartofthegun;thiscan

Be sure all gun safety devices are operating properly before

cause a malfunction and result

in

serious bodily injury.

Safety

Latch

Wheneveryoustopspraying,evenforamoment,alwayssetthe

gunsafetylatchintheclosedor'safe"position,makingthegun

triggering

of

the gun.

inoperative.Failure1osetthesafetylatchcanresultinaccidental

Diffuser

jection when the

tip

is not installed. Check diffuser operation

Thegundiffuserbreaksupsprayandreducestheriskoffluidin-

regularly. Follow the Pressure Rellet Procedure, below, then remove the spray tip. Aim the gun into'a metal pail, holding the

gunfirm1ytothepail.Usingthelowestpossiblepressure.trigger

the gun.

If

the fluid emitted is not diffused into an irregular

stream, replace the diffuser immediately.

ALWAYS have the tip guard in place on the spray gun while

Tip

Guard

spraying.

The

tip guard alerts you to the fluid injection hazard

and helps reduce,

but

does not prevent, the risk

of

accidentally

placing your fingers or any part

of

your body close to the spray

tip.

Trigger

Guard

Alwayshavethetnggerguardinplaceonthegunwhenspraying

to reduce the risk of accidentally triggering the gun

if

it is

dropped or bumped.

Spray

Tip

Safety

spray tip clogs while spraying, engage the gun safety latch im-

Useearemecautionwhencleaningorchangingspraytips.Ifthe

then remove the spray tip to clean it.

mediately. ALWAYSfollowthe Pressure RellelProcedure and

fully relieved and the gun safety latch is engaged.

NEVER wipe off build-up around the spray tip until pressure is

Toreducetheriskofseriousbodilyinjury,includingfluidinjec-

Pressure

Relief

Procedure

tion. splashing fluid orsolvent in the eyesoron theskin, or injury from moving parts or electric shock, always follow this

procedurewheneveryoushutoffthesprayer,whenchecking

or servicing any part

of

the spray system, when installing. cleaning or changing spray tips, and whenever you stop spraying.

1.

Engage the gun safety latch.

2.

Turn the

ON/OFF

switch

to

OFF

3.

Unplug the power supply cord.

4.

Disengagethegunsafetylatch.Ho1dametalpariofthegun

firmly to the side of a grounded

metal

pail, and trigger the

gun to relieve pressure.

5.

Engage the gun safety latch.

6.

ODen the pressuredrainvalve. having acontainerreadvto citch thedrainage. Leave the valvg open until you ire ready to spray again.

lfyoususpectthafthespraytiporhoseiscompletelyclogged,

orthatpressure has not

been

fullyrelievedafterfoliowing

the

sfepsabove,VERYSLOWLYloosenthetipguardretainingnut

or hose

end

coupling to relieve pressure gradually, then

loosen completely. Now clear the

tip

or hose.

'

J

308-248

MOVING PARTS HAZARD

~,~%,~~~-~

Moving parts can pinch or amputate yourfingers or other body parts. KEEP CLEAR of moving parts when starting or operating the sprayer. Follow the Pressure Rellet Procedure

on

page

2

before checking or servicing any part of the sprayer, to prevent it from starting accidentally.

EQUIPMENT MISUSE HAZARD

EE%%

General

Safety

Any misuse of the spray equipment or accessories, such as

calsandfluids,orusingwornordamagedparts,cancausethem

overpressurizing. modifying parts, using incompatible chemi-

toruptureandresultinfluidinjection,splashingintheeyesoron theskin,orotherseriousbodilyinjury,orfire,explosionorprop-

erty damage.

NEVER alter or modify any part

of

this equipment; doing

so

could cause

it

to malfunction.

CHECKallsprayequipmentregularlyandrepairorreplaceworn

or damaged parts immediately.

Alwayswearprotectiveeyewear,gloves,clothingandrespirator

as recommended by the fluid and solvent manufacturer.

Thissprayercandevelop2750psi(195bar)MAXlMUMWORK-

System Pressure

/NGPRESSURE.Besurethatallsprayequipmentandaccesso-

themaximumworkingpressureofanycomponentoraccessory

lies used are rated to withstand this pressure.

DO

NOT exceed

used in the system.

Fluid

and

Solvent Compatibility

BE SURE that all fluids and solvents used are chemically com-

patiblewiththewettedpartsshownintheTECHNICALDATAon

ture before using them in this sprayer.

page32.Alwaysreadthefluidandsolventmanufacturer'sI~era-

Do

not use l,l,l-trichloroethane, methylenechloride. otherha-

vents in this equipment, which contains aluminum andlor zinc

logenated hydrocarbon solvents or fluids containing such

sol-

parts. Such use could result in a serious chemical reaction, with

the possibility of explosion, which could cause death, serious

bodily injury andlor substantial property damage.

HOSE SAFETY

:::~~.r

~~,~,~,,,,,~~~,~~.....;..-..."",r~,~

.~i~,~.~~",~.~l;i",~

.

-"-e

High pressure fluid in the hoses can be very dangerous.

If

the hose develops a leak, split or rupture due to any kind of wear, damage or misuse, the high pressure spray emitted from

it

can cause a fluid injection injuty or other serious bodily injuty or property damage.

ALLFLUIDHOSESMUSTHAVESPRINGGUARDSONBOTH

at or close

to

the coupling which can result in hose rupture.

ENDSlSpringguardshelpprotectthehosefromkinksorbends

TIGHTEN all fluid connections securely before each use. High pressurefluidcan dislodgea loose coupling orallow high pressure spray to be emitted from the coupling.

NNERuseadamagedhose.Beforeeachuse,checktheentire

hose for cuts, leaks, abrasion, bulging cover, or damage or

movementofthehosecouplings.Ifanyoftheseconditionsexist,

sure hose or mend it with tape or any other device. A repaired

replacethehoseimmediately.DON0Ttrytorecouplehighpres-

hose cannot contain the high pressure fluid.

HANDLE AND ROUTE HOSES CAREFULLY

Do

not puli

on

and hot surfaces ofthe pump and

gas engine.

Do

not use fluids

hoses to move equipment. Keep

hoses clear

of moving

parts

or solvents which are not compatible with the inner tube and coverofthe hose. DONOTexposeGraco hosetotemperatures above 180° F

(82"

C) or below

-40"

F

(-40'

C).

Hose

Grounding Continuity

Proper hose grounding continuity is essential to maintaining a

fluidhosesatleastonceaweek.1fyourhosedoesnothaveatag

groundedspraysystem. Checktheelectrical resistanceof your

on

itwhich specifiesthemaximum electrical resistance, contact the hose supplier or manufacturer for the maximum resistance limits. Use a resistance meter in the appropriate range for your

ommended limits. reolace it

immediatelv. An unarounded or

hose to check the resistance.

If

the resistance exceeds the rec-

,,*,

:,,.*...

poorly grounded

hose

can make your syetem haz;?rdous.

Also

read

FIRE

OR

EXPLOSION

HAZARD.

Staticelectricityiscreatedbytheflowoffiuidthroughthepump

and hose.

If

every part of the spray equipment is not properly grounded, sparking may occur, and the system may become hazardous. Sparking may also occur when plugging in or un-

pluggingapowersupplycord.Sparkscanignitefumesfromso1-

vents and the fluid being sprayed, dust particles and otherflammable substances, whether you are spraying indoors

or

outdoors, and can cause afire or explosion and serious bodily injury and property damage. Plug the sprayer into

a

grounded

outlet at least

20

n.

(6

m) from the sprayer.

Ifyouexperienceanystaticsparkingorevenaslightshockwhile

the entire system for proper grounding.

Do

not use the system

usingthisequipment,STOPSPRAYlNGIMMEDIATELY.Check

again until the problem has been identified and corrected.

To reduce the risk of static sparking, ground the sprayer and all

Grounding

other spray equipment used or located in the spray area.

tionsfor your area and

type

of

equipment.

BE

SURE to ground

CHECKyourlocaleiectricalcodefordetailedgroundinginstruc-

ail

of

this spray equipment:

1.

Sprayer:plugintoaproperlygroundedoutlet.Donotusean

for at

least

15

amps.

adapter.Exiensioncordsmusthavethreewiresandberated

2

Fluid

hoses: use only grounded hoses with a maximum of

150mcombinedhoselengthtoensuregroundingcontinu-

ily.

See Hose Groundlng Contlnulty.

3.

Spraygun: obtain grounding through connection to a properly grounded fluid hose and sprayer.

4.

Object being sprayed: according to local code

5.

Fluid

supply container: according

to

local code.

6.

Allsolventpailsusedwhenflushing,

accordingtolocalcode.

Useonlymetalpails,whichareconduciive.Donotplacethe

pail

on

a

non-conductive surface, such as paper or card-

board, which interrupts the grounding continuity.

7.

To

maintain grounding continuity when flushing orrelieving

pressure, always hold a metal part

of

the gun firmly to the

side of

a

grounded metal pail, then trigger the gun.

Flushing Safety

Reducetheriskoffluidinjectioninjuty,staticsparking,orsplash-

ing by following the flushing procedure given

on

page

13

ofthis

manual. Follow the Pressure Relief Procedure

on

page

2,

and

firmly to the side of a grounded metal pail and use the lowest

removethespraytipbeforefiushing.Ho1dametaipartofthegun

possible fluid pressure during flushing.

IMPORTANT

United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards

-

particularly the General Standards, Part

1910,

and the Construction Standards, Part 1926 - should be consulted.

308-248

3

Conslgnes generales de skcurlte

Cet appareil produit

un

fluide tres haute pression. Le

fluide

pulverise par le pistolet ou le fluide sous pression provenant de fuites ou de ruptures peut penetrer sous

la

peau

ou

d

I'interieur du corps et entrainer des blessures tr&s graves, voir meme une amputation. MOme sans &re sous pression, lefluide Qclabous-

santouentrantdanslesyeuxpeutaussientrainerdesblessures

graves.

quelconque du corps. NE JAMAlS mettre

la

main

ou

les doigts

NE JAMAIS pointer le pistoletvers quelqu'un ou vers une partie

surl'ajutagedu pulvbrisateur. NE JAMAlS essayer de"refou1er" la peinture. Cet appareil Nest PAS un compresseur pneumatique.

TOUJOURSgarderlaprotectiondeI'ajutageenplacesurlepis-

tolet pendant la pulvdrisation.

TOUJOURS observer la March

B

Sulvre pour DBtendre la

Presslon donnee plus

loin,

avant de nettoyer

ou

denlever

I'ajutage du pulvhrisateur, ou d'effectuer un travail quelconque sur une partie de I'appareil.

ou le corps.

NEJAMAlSessayerd'arr~terouded~vierlesfuitesaveclamain

Avant chaque utilisation, bien s'assurer que les dispositifs de securite fonctionnent correctemenl.

Solns

medlcaux

En cas de penetration

de

fluide

sous

la

peau: DEMANDER IMMEDIATEMENT DES SOINS MEDICAUX D'URGENCE. Ne pas soigner cette blessure comme une simple coupure.

Avisaumedecin: Lapbnetration desfluides sous iapeau est un

traumatisme.

II

est

Important detralter ChlnIrglCalWnRnt cette blessure Imm6dlatement. Ne pas retarder le traitement pour effectuer des recherches surla toxicite. Certains revetements exotiques sont dangereusement toxiques quand

ils

sont inject& directement dans le sang.

II

est souhaitabie de wnsulter un chirurgien esthetique ou un chirurgien specialise dans la reconstruction des mains.

Avant chaque utilisation, bien s'assure que tous ies dispositifs

Dlsposltlfs de securite du plstolet

de s6curit6 du pistolet fonctionnent correctement. Ne pas en-

lever ni modifier une partie quelconque du pistolet: ceci

risquerait d'entraher

un

mauvais fonctionnement et des bles-

sures graves.

Verrou

de

sdcurit.4

A

chaque fois que l'on s'arrete de pulv6ris6r. meme s'ii s'agit

d'un court instant, toujours mettre

le

verrou de securitb

du

pis-

tolet sur la position "fermbe"

ou

'securitP ("sate") pour

empecherlepistoletdetonctionner.Siieverroudesecuriten'est

pas mis, le pistolet peut se declencher accidentellement.

Diffuser

Lediffuseurdupistoletsertddiviserlejetetareduireiesrisques

d'injectionaccidenteliequandI'ajutagen'estpasenp1ace.VBrif-

verification, detendre la pression en observant

la

Marche

B

ier le fonctionnement du diffuseur regulibrement.

Pour cette

Sulvre

pour

Detendre

la

Presslon donnee plus loin puis en-

lever I'ajutage du pulv6risateur. Pointer

le

pistolet dans un seau en mbtal, en le maintenant fermement contre le seau. Puis, en Utilisant

la

pression

la

plus faible possible, appuyer sur la gachette du pistolet. Si le fluide projete n'est pas diffuse sous forme de jet irregulier, remplacer immediatement le diffuseur.

Protection

de

I'aiutage

TOUJOURS maintenir la orotection de I'aiutaoe en olace sur ie

pistolet du

pulverisateurpendantlapulv6;isacon.

La

protection

de I'ajutage attire I'attention sur les risques d'injection etcontri-

bue

d

reduire, mais n'evite pas le risque, que ies doigts ou une

ximite Immediate de I'ajutage du pulvbrisateur.

partiequelconqueducorpsnepassentaccidentellementapro-

Conslgnes de securite concernant l'ajutage du

E.

alre extremement attention d l'occasion du nettoyage

ou

du

ulverlsateur

rempiacement des ajutages du pulvbrisateur. Si i'ajitage se

bouche pendant

la

pulvbrisation, menre immediatement ie ver-

roudesecurRBdupistolet.TOUJ0URSbienobserverlaMarche

B

Sulvre pour DBtendre

18

Presslon puis enlever I'ajutage du

pulverisateur pour

le

nettoyer.

NE JAMAIS essuyer ce qui s'est accumulb autour de I'ajutage

du pulvbrisateur avant que

la

pression ne soit completement

tombee et que

le

verrou de

skurite

du

pistolet

ne

soit engage.

Marche

6

Sulvre pour Detendre

la

Presslon

blessures par projection de fiuide ou celles causees par

de

Pour reduire les risques

de

blessures graves, y compris les

Bclaboussures dans les yeux ou sur la peau, par des pieces en mouvement, toujours bien ObseNe Cette marche suivre

vbrification, du Bgale ou du nettoyage du systbme ou

lors

du

chaque fois que I'on arrete le pulvbrisateur,

d

I'occasion de la

changement des ajutages.

1.

Engager le verrou de sbcurite du pistolet.

2.

Mettre ie levier d'arret du moteur sur ARRET

(OFF).

3.

Debrancher le cord d'alimentation.

4.

DBsengagerleverroudesBcuritedupistolet.Toutenmaintenantunepartiem6talliquedupistoletfermementappuyB

wntrelecbled'unseauenm6tal,actionnerlepistoletpour

liberer

la

pression.

5.

Engager le verrou de sBcurit6 du pistolet.

6.

Ouvrir

la

soupape de &curite et la laisser ouverte jusqu'a

cequeI'onsoitpretdseservirdenouveaudupuiv6risateur.

bouche

ou

que

la

pression

n

'a

pas et6 completement iiberde

Sil'on

soupconne que le tuyau

ou

I'ajutage estcompldtement

TRESLENTEMENTunraccorddeboutdetuyauouI'~croude

aprbs avoir procede aux operations ci-dessus, desserrer

retenue de ia protection de I'ajutage et liberer progressivement

la

pression.

4

308-248

EL

ROCIADO

a

ALTA PRESIC~N

PUEDE

CAUSAR

GRAVES

LESIONES.

SOLO PARA

US0

PROFESIONAL. RESPETE

LOS

AVISOS

DE

ADVERTENCIA.

Lea y entienda

todo

el

manual de instrucci6nes antes

de

manejar el equipo.

PEL~GRO

DE

~NYECC~~N

DE FLU~DO ~~~~~~~~~~~~~~~~

Seguridad general Este equipo genera un Ruido a una presi6n muyalta. El roclado

delapislola,~sescapesdefluidooroturasdeloscomponentes

pueden inyectar fluido en la piel y el cuerpo y causar lesiones extremadamente graves, incluyendo a veces la newsidad de

amputaci6n.Tambi~n,elfluidoinyectadoosalpicadoenlosojos

puede causar graves datios.

cuerpo.NUNCAcolocarlarnanoolosdedosencimadelabo-

NUNCA apuntar la pistola hacia alguien 0 alguna parte del

quilla. NUNCAtratar de "hacer retornar la pintura"; este NO es

un sisterna de rociado de aire.

SIEMPRE tener colocado el protector de la boquilla en la pistolamientras se est6 pulverizando.

SIEMPRE seguir el procedimiento de descarga de presibn,

vicioa cualiquier equipo del sistema.

dadom~sabjo,antesdelimpiarosacarlaboquillaodedarser-

cuerpo.

NUNCA tratar de parar

o

desviar

10s

escapes con la mano o el

Asegurarquetodosiosaparatosdeseguridaddele~uipoestan

funci6nando bien antes de cada

USO.

Tratamiento medico

Si pareciera que un, poco de fluido penetrb la piel. conseguir

TRATAMIENTO MEDICO DE URGENCIA DE INMEDIATO.

NOTRATARLAHERlDACOMOUNSlMPLEC0RTE.Deciral

medico exactamente cua fiuido fue.

Aviso

a1 m&dico: Si se llega a inyectar este fluido en la iel se

causa una lesi6n traumAtica

Es

Importante

tratar

quhrgb

camente

la

lesibn a ia brevedad oslble. No demorar el

tratamiento para investigar la toxicid)ad.

La

toxicidad es aigo

desumaimportanciaenaigunaspinturasex6ticascuandose

wnsultaraunespecialistaencirugiapiasticaoreconstructiva

inyectandirectamentealtorrentesanguineo.Sira~nveniente

de las manos.

Aparatos de segurldad de la plstola pulverlzadora

Asegurarquetodoslosaparatosprolectoresdeiapistolaestan

funci6nando bien antes de cada uso. No sacar

ni

modificar

ningljna pieza de la pistola pues podriacausar el malfunci6na-

mientodelamismaconlasconsiguienteslesionespersonales.

Pestillo de seguridad

Cadavez que se deje de pulverizar, aunque sea por un breve

ci6n "cerrada"

lo

que deja la pistola inoperante.

El

no

hacerlo

momento, siempre colocar el pestillo de seguridad en la posi-

puede llevar al disparo imprevisto de la pislola.

Difusor

El dfusor de la pistola dispersa el chorro pulverizado y reduce el riesgo de inyecci6n cuando

no

esta instalada la boquilla.

Revisarconregularidadelfunci6namientodeldifusor.Seguirel

procedlmlento de descarga de presl6n. dado

mas

abajo, y

co,soslenibndolabienfirmecontrael.Utilizandolapresi6nm~s

despues sacar la boquilla. Apuntar la pistola a un balde metdli-

baio posibie. disparar la pistola. Si el Ruido emitido

no

sale dis-

persoenunchorroirregular,reemplazardeinmediatoeldifusor.

Protector de la boguilla

SIEMPREtenerelprotectordeiaboquillacolocadoenlapistola

mientrasseesthpulverizando.

Esteprotectorllamalaatenci6n

contra el peligro de inyecci6n y ayuda a reducir, per0

no

evita,

lacolocaci6naccidentaldeiosdedosocualquierotrapartedel

cuerpo cerca de la boquilla.

Segurldad de la boquilla pulverizadora

Tenermuchocuidadoallimpiarocambiarlasboquiilas.SiIlega-

raaobstruirsemientrasesl~pulverizando,enganchareipestillo

de la pistola de inmediato. SIEMPRE seguir

el

procedlmlenlo de descarga de presl6n y despues sacar la boquilla para limpiarla.

NUNCA limpiar la acumulacibn de pintura alrededor de la

bo-

y el pestillo este enganchado.

quillaantesdequesehayadescargadoporcompletolapresi6n

Procedimlento de descarga de preslon

Parareducirelriesgodesufrirgraveslesionescorporaies,in-

ciuyendo inyecci6n o lesiones causadas por pie& en movimiento

o

choque elbctrico, siempre seguir este

procedimiento al apagar la maquinapukrerizadora, al revisar

0

dar sewicio a cualquier parte del sistema de pulverizaci6n,

al instalar, limpiar

o

cambiar las boquillas, y cadavezque se

deja de pukrerizar.

1.

Enganchar el pestillo de la pistola.

2.

Mover el interruptor elbctrico (ON/OFFj a laposicibn OFF

3.

Desenchufar el cord6n electrico.

1

(apagado).

2

6

4.

Desenganchar el pestillo de

la

pistola. Sujetar una parte

metalicadeiapistolabienfirmecontraunbaldedemetal,y

disparar la pistola para descargar la presi6n.

5.

Enganchar el pestillo de la pistola.

6.

Abrir

la

valvula de presibn. Dejar la valvula de alivio de presibn abierta hasta que se este nuevamente list0 para pulverizar.

Si se sospecha que la boquilla

o

la manguera est6 com-

pietamente obstruida,

o

que

no

se ha descargado por com-

pleto la presi6n despubs de haber seguido el procedimiento

anterior,aflojarmuylentamentelatuercaderetenci6ndelpro-

tector de la boquilla o acoplamiento de la punta de la manguera y descargar gradualmente la presion, despues. aflojarlo porcompleto. Luego, despejar la boquiilao la manguera.

308-248

PELlGRO POR MAL US0 DEL EQUIP0

Segurldad general

Preslon del slstema

Cualquier mal us0 del equipo pulverizador

o

10s

accesorios,

tal

estd pulverizadora puede desarrollar

195

barias

(2750

psi) de

como sobre presurizaci6n, modificaci6n de piezas, us0 de

presi6n DE TRABAJO MAXIMA. Asegurar que todo el equipo

mat~rialesyproductosquimicosincompatibles,oufilizaci6nde

pulverizadory sus accesorios tienen la capacidad para aguan-

piezas daiiadas

0

desgastadas, puede hacen que se rompan y

tar la presibn maxima de trabajo de est& pulverizadora. NO ex-

causenlainyecci6ndefluidouotraslesionescorporalesgraves,

ceder la presi6n maxima de trabajo de ningljn cornponente

o

incendio, explosibn o daiion a la propiedad.

accesorio de este sistema.

NUNCA alterar o modiicar ningljna pieza de este equipo; el

Siempreleerlasinstrucci6nesdelfabricantedelfluidoysolvente

Compatlbllldad de fluldo

hacerlo podria causar una averia. antes de usarlos en estA pulverizadora, dadas en la pdgina

32.

REWSAR con regularidad el equipo pulverizador y reparar

o

respiradero, tal

como

recomiendan

10s

fabricantes del fluido y

Siempre usar gafas, guantes, vestirnetas protectora y un

reemplazar de inmediato las piezds datiadas

0

desgastadas. del solvente.

SEGURIDAD EN EL US0 DE

LAS

MANGUERAS

.E:E

~y:<@-i!

Elfluidoqueescapaaaltapresi6nporlasmangueraspuedeser

MANEJARY PASAR CUIDADOSAMENTE

IAS

MANGUERAS.

rotura

o

rajadura debido a cualquier tip0 de desgaste. datio

o o

solventes que Sean incompatibles con el tub0 interno y ia

muypeligroso.Sienlamanguerasedesarrollaunescape,una Notirardelasmanguerasparamovere1equipo.Nousarfluidos

maltrato. el chorro a aka presi6n emitldo por

alii

puede

Causal

cubiertadelamanguera.NOexponerlasmanguerasatempera-

una lesion por inyeccibn u otras lesiones corporales graves

o

turas sobre

82"

C

(180'

n

o

baio

-40°

C

1-40'

n.

.dahos a la propiedad.

ITODAS

LAS

MANGUERAS PARA FLUIDOS TIENEN QUE

manguera

TENER

GUARDAS

DE

RESoRTE

EN

EICTREMoS!

Lacontinuidaddelcircuitodepuestaatierraapropiadoesesen-

Estas~rote~en~asman~uerascontradob~eceso

retorceduras

cialparamantenerconectadoatierraelsistemapu1verizador.Es

traducirse en roturas de la manguera.

en

loS

acoplamientos

CerM

de

ellos.

IDS

que

POdrian

indispensable revisar la resistencia elbctrica maxima de las

mannuerasdeairevdefluidooorlomenosunaveznlasemana.

-

Continuldad del circulto de puesta a tierra de la

~ ~

Antes de usarlas, APRETAR bien fumes todas

las

conexiones. Si la manguera notiene una etiqueta en la cual se especifica la

~"

~~~

-

"r..

~

El fluido a alta presi6n puede desalojar un acoplamiento suelto

o

dejar que por el escape un chorro a aka presi6n.

NUNCA usar una manguera que estd datiada. Siempre, revisarla en busca de cortaduras. escapes, abrasion. cubierta abuilada,

o

acoplamientos sueltos o datiados. Si llegara a en-

cnntrarse cualquiera de est& condici6nes, reemplazar de

in-

mediato la manguera. NO intentar racoplar una manguera de aka presi6n

o

enmendarla con cinta adheslva u otro material

similar. Una manguera que ha sido remendada

no

aguante el

fluido a alta presi6n.

PELIGRO DE INCENDIO 0 EXPLOSION

*?!%ZS

guera crea electricidad estatica. Si todas las partes del equipo

El flujo a aka velocidad del fluido ai pasar por la bomba y man-

convirtiendo al sistema en algo peligroso. Tambih. pueden

pulverizador

no

tienen buena tierra, pueden ocurrir chispas.

co.Est~schispaspuedeninflamarlosvaporesdelossolventes

producirsechispas a enchufaro desenchufarel cord6n electri-

yelchorrodefluidopulverizado,particulasdepolvoyotrassus-

tanciasinflamables, seaalaire libreo bajotecho, loquepodria

causar unaexplosi6n

o

incendio y graves lesionescorporalesy

tomacorrientequeseencuentreaporlomenos6m(ZOpies)de

dahos al a propiedad. Enchufar siempre la pulverizadora a un

la maquina y del area que se va a rociar.

Si ocurre una chispa de electricidad estatica

o

incluso

un

ligero

choque electrico mientras se usa el equipo. DEJAR DE PUL-

VERIZAR

DE INMEDIATO. Revisartodo el sistema en buscade una tierra apropiada. No usar de nuevn el sistema hasta haber identificado y soluci6nado el problema.

Peusta a tierra Para reducir el reisao de ChisDas estdticas. conectara tierra la

pulverisadora y togo el otro equipo de pulverisar que se use

o

se encuentre en el lugar que se va a rociar. CONSULTAR el codigoelectricode lalocalidad

paralasinstrucci6nessobre

las

conexiones a tierra exigidas para la zona y tip0 de equipo.

ASEGURARdeconectaratierratodoesteequipopuivensador:

1.

Pulverizadora: enchufar el cord6n electrico. o cable exten-

sor, cada

uno

un enchuf de tr&s patas en buen estado, a un

tornacorreinte con puesat a tierra aporpiado. No usar un

adaptador.Totosloscablesextensorestienenquetenertr&s

hilos y una capacidad de

15

amperios.

resistenc'k elbctrica. ponerse

en

contact0 con el proveedor

0

fabricante de la manguera para la informaci6n sobre

10s

lirnites de resistencia. Usar un metro de resistencia en la gama apropiade para comprobar la resistencia; si excede

10s

limites

tener una manguera sin puestd a tierra

o

con la puesta a tierra

recomendados,reemplazarladeinmediato.Esmuyarriesgado

en malas condicibnes. Leer tambih la

information

sobre

RIESGO DE INCENDIO 0 EXPLOSION,

mds

arriba.

2.

Mangueras para fluidos: usar solamente mangueras con puestd a tierra de una longitud combinada de

150

m

(500 pies), para asequrar buena continuidad a tierra. Referirse iambibn al pirrafo sobre contlnuldad

a

tlerra de la

manugeura.

3.

Pistola: hace la puesta a tierra conectandola a una

man-

guera de fluido y pulverizadora bien conectadas a tierra.

4.

Suministrar

un

recipiente: de acuerdo al codigo de la

localidad.

5.'

0bjetoqueseestirociando:deconformidadconelcodigo

local.

6.

Todos

10s

baldes de sohrente usados durante el lavado, de

conformidad con el c6digo local. Usarsolarnente baldes de

meta/,queseanconductivos.nocolocarelbaldeenunasu-

perficienoconductiva,comopapeiocart6n,queinterumpe

la continuidad a tierra.

7.

Para mantenar la continuidad a tierra durante el lavado

o

descargadepresion,siempreapoyarunapartemetdlicade

la pistola bien firme contra el costado del balde de metal, despues apretar el gatilio.

Segurldad durante el lavado

piel,

o

que ocurra una descarga de electricidad esatica.

Para reducir el riesgo de que se inyecte

o

salpique fluido

en

la

siempreseguirlasINSTRUCC16NESPARAEClAVAD0,dadas

enlapagina13.Seguirelprocedlmlentodedescargadepres-

1611

en la pagna

6.

y quita la boquilla rociadora antes de lava,:

Apoyarunapartemetalicadelapistolabienfirmecontraelcos-

tadodeunbaldedemetalyusarlepresi6nm~sbajaposibiede

fluido durante el lavado.

308-248

7

WARNING

sure the hoses are electrically conductive, that

If you supply your own hoses and spray gun. be

the gun has a tip guard, and that. each part

Is

rated for at least

2750psi

(195

bar) Workng

Pressure. This

is

to reduce the risk

of

serious bodily Injury caused by static sparking, fluld injection or over-pressurizatlon and rupture

of

the

hose or gun.

CAUTION

To avpld damaging the pressure control, which

component damage, follow these precautions:

may result in poor equipment performance and

1.

Always

use

nylon spray hose at least

50

R.

2. Never use a wire braid hose as

it

is

too rigid

3. Never install any shutoff device between the

(6

m) long.

to act

as

a pulsation dampener.

pump and the hose. See Flg

I.

1.

Connect the hose and gun and screw

it

onto the

outlet nipple. Don't use

thread

sealant,

and don't

install the

spray tip yet!

2. Fill the wet-cup.

Pry

off

the wet-cup seal. Fill

the cup 113

full

with Graco Throat Seal Liquid

(TSL),

supplied. Install the seal.

3.

Check

the

electrical service. Be sure it is 120

V,

60

HAC, 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 (minimum), 15 amp extension cord up to 150

ft.

(45

m) long. Longer lengths af-

fect sprayer performance.

4.

Plug

In

the sprayer.

Be

sure the ON/OFF switch

is

OFF.

Plug the cord into a grounded outlet at

least

20

R.

(6

m) away from the spray area.

WARNING

Proper electrical grounding

is

essential to reduce

the risk

of

fire or explosion which can result in serious bodily Injury and property damage. Also read

FIRE

OR,

EXPLOSION

HAZARD

on page 3.

5. Flush the pump to remove the oil which was

left

in to protect pump parts after factory testing. See page 13.

6.

Prepare the paint according

to

the manufactur- er'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.

OPERATION

How

to

use the

gun

safety latch

from accidental triggering. See Fig

2.

When engaged, the gun safety latch prevents the gun

If

the gun still sprays when the gun safety latch

is

engaged, adjust the gun. See manual

307-614,

supplied.

How

to

use the pressure

drain

valve

from the pump and to help prime the pump. If the

Use

the pressure drain valve to relieve fluid pressure

tomatically to relieve fluid pressure.

If

this happens,

valve senses an over pressure condition,

it

opens au-

stop spraying immediately, shut

off

and unplug the

sprayer. Determine the cause of the problem and cor-

the Troubleshooting Guide, page

14.

See

Fig

3.

rect it before operating the sprayer again. Refer also to

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

4.

TO

INCREASE

PRESSURE

ROTATE

CLOCKWISE

PRESSURE

ADJUSTING

KNOB

Fig

4

How

to

use

the

RAC

IV

tip

guard

WARNING

To reduce the risk of serious bodily injury from from fluid injection:

NEVER operate the spray gun with the tip guard

removed.

of the spray tip when cleaning or checking a

DO NOT hold your hand, body, or

a

rag in front

clogged tip. Always point the gun toward the

tip

is

clear.

ground or into a pail when checking to see

if

the

DO NOT try to 'blow back" paint: this

is

NOT an

air spray sprayer.

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 page

11.

The tip guard holds a

reversing spray tip. The tip

is

in the spraying position

when the tip handle polnts forward.

See

Fig

5.

Clean the front of the tip frequently during the day's operation. First, follow the Pressure Relief Proce-

dure

Warning on page

2.

SPRAYING

POSITION.

HANDLE

SHOWN

IN

How

to

remove a

tip

clog

1.

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

RAC

IVtip handle 180".

See

Fig

5.

2.

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

3.

Engage the safety latch. Rotate the tip handle to

the spraying position.

4.

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.

308-248

9

‘g

STARTUP

WARNING

Pressure Relief Procedure

To

reduce the risk of serious bodily injury, including fluid injection, Splashing fluid or solvent in the eyes or on the skin, or injury from moving parts or

you shut

off

the sprayer, check or service any part

electric shock, always follow this procedure when

spraytips, and whenever you stop spraying.

of

the spray system, install, clean or change

1 Engage the

gun

safety latch. 2 Turn the ON/OFF switch to OFF.

3 Unplug the sprayer.

4

Disengage the

gun

safety latch. Hold a metal

part of the gun firmly to the side of a

grounded metal pail. Trigger the gun to re-

lieve pressure.

5

Engage the gun safety latch.

6

Open the pressure drain valve. Leave

it

open

lf

you suspect that the spray tip

or

hose is

com-

pletely clogged,

or

that pressure has

not

been

fully

relieved after fo/lowing the steps above,

VERY

SLOWLY loosen the tip guard retaining nut or hose.coup1ing to reileve pressure gradually, then loosen completely.

until you are ready to spray again.

Use this procedure each time you start the sprayer to

you start it safely.

help ensure the sprayer is ready to operate and that

NOTE

1:

If this is a first-time startup, flush the

NOTE

2:

‘Refer to Fig 9 and the other figures refer-

enced in the text as you start the sprayer.

1.

Open the pressure drain valve. See Fig

6.

2.

Don’t install the spray

tip

until the pump is

sprayer. See page 13.

primed!

Fig

6

W

1022

3. Put the suction hose into the paint. If you are

down below the

top

of the pail

to

avoid

splashing

pumping from a

1

gallon pail, push the

drain hose

paint when the drain valve is opened.

4. Turn the pressure setting to minimum.

5.

Disengage the gun safety latch. See Fig

2,

page

9.

CAUTION

To

reduce the risk of damage to the displace:

ment pump packings, never

run

the pump with-

out

fluid

in

it

for more than 30 seconds.

6.

To

prime the pump, turn the sprayer on. Slowly

When fluid comes from the pressure drain valve,

increase the pressure until the sprayer starts.

close the valve.

Fig

7

7.

To

prime the hose, lower the pressure to reduce

splashing. Hold a metal part of the gun firmly

against and aimed into the side of a grounded

metal pail. See Fig

7. Hold the trigger open and

slowly increase the pressure until the pump starts. Keep the gun triggered until all air is forced

the gun. Release the trigger and engage the gun

out

of

the system

and

the fluid flows freely from

safety latch.

8.

Check all

fluid

connections for leaks. Relieve

pressure before tightening any connections.

9. Install

the

spray

tip.

Engage the

gun

safety latch

first! See manual 307-848 for how to install the tip.

10

308-248

STARTUP

10.

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. Position the tip guard horizontally for a horizontal pattern or vertically for a vertical pattern.

Hold

the

tip guard in place while tightenlng the retaln-

ing nut. See Fig

8.

NOTE

3:

Spray patterns will change as tips wear. Change the spray tip if adjusting the pressure will not improve the spray pattern.

Fig

9

1022

308-248

11

~ ~~

-

SHUTDOWN AND CARE

WARNING

follow the Pressure Relief Procedure Warning

To

reduce the risk of serious bodily injury, always

on page

2

when instructed in this procedure to

1.

Check the packing nutbetcup daily. Relieve pressure

first.

Keep the wet-cup

1/3

full

of

TSL

at

all times

to

help prevent fluid buildup on the pis-

ton rod and premature wear of packlngs.

2.

lighten the packing nuffwetcup 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.

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

manual

307-614.

4. Periodically clean paint residue

from

the pres

sure transducer vent hole area. See Fig

11.

Re-

place the transducer when leakage

is

excessive.

See page

27.

5.

Lubricate the bearing housing after every

100

the bearing housing cavity with

SAE

10

non-

hours of operation. Remove the front cover.

Fill

detergent oil. See Fig

11

..

6.

Flush the sprayer at the end of each work day and fill

it

with mineral spirits to help prevent pump

corrosion and freezing. See page

13.

CAUTION

To

prevent pump corrosion, and to reduce the

chance.of fluid freezing in the pump in cold

the sprayer when

it

is not

in

use.

Freezing can

weather, never leave water or any type

of

paint

in

seriously damage the sprayer or result in a

loss

of pressure or stalling.

7.

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

the

spray tip.

8.

Coil the

hose

when storing

it,

even for overnight,

to

help protect the hose from kinking, abrasion,

coupling damage, etc.

WARNING

See the waming section,

HOSE

SAFEn,

on

damaged hoses.

page

3,

for information on the hazard of using

WITH

PRESSURE

RELIEVED

TURN

PACKING NUT

CLOCKWISE

TO

TIGHTEN

c

Fig

10

u

PRESSURE

FILL

BEARING HOUSING

TRANSDUCER

CAVITY WITH

SAE

NON-

VENT HOLE

DETERGENT

OIL

AFTER

EVERY

100

HOURS

OF

OPERATION

\

Fig

11

W

Ice7

12

308-248

..

~~

~~~~

FLUSHING GUIDELINES

When

to

flush

1.

2.

3.

4.

5.

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

Before using water-base paint: flush with min-

clean water flush.

era1 spirits followed by soapy water, and then a

spirits only.

Before using oil-base paint: flush with mineral

such

as

mineral spirits or water.

Changing colors: flush with a compatible solvent

flush with warm, soapy water, and then mineral

Changing from water-base

to

oil-base paint:

spirits.

Changing from oil-base to water-base paint:

flush with mineral spirits, then warm, soapy water,

and then a clean water flush.

water and then mineral spirits. Leave the system

Storage after using water-base paint: flush with

the drain valve open.

filled with mineral spirits. Relieve pressure. Leave

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

NEVER

leave water or water-based fluids in the

the water out with mineral spirits. Frozen fluid in

sprayer

If

there is a chance

it

could freeze. Push

the sprayer prevents

it

from being started and

may cause serious damage.

6.

Startup after storage. Before using water-base paint, flush out the mineral spirits with soapy wa-

-

paint, flush out the mineral spirits with the paint.

ter and then clean water. When using oil-base

How

to

flush

1.

Follow Pressure Relief Procedure. See page

2.

Remove the.spray tip and clean It separately.

bowl, hand tight, without the screen. Clean the

Remove the filter screen and then reinstall the

screen separately. See Fig

12.

r

.,

,/

Fig

12

3.

Pour one-half gallon

(2

liters) of compatible sol-

vent into

a

grounded metal flushing pail.

Put

the

suction hose in the pail.

4.'

Open the pressure drain valve. See Fig

IO.

5.

To

save the paint still

In

the pump and hose,

follow Step

6,

except put the drain hose in the

valve.

Put

the drain hose in the flushing pail. Trig-

paint pail. When solvent appears, close the drain

ger the gun into the paint pall. When solvent ap-

pears, release the trigger. Continue with Step

6.

WARNING

To

reduce static sparking and splashing, always remove the spray tip from the gun, and hold a metal part of the gun firmly to the side of a

METALTO METAL

MAINTAIN

FIRM

CONTACT BETWEEN THE

GUNANOAGROUNDEO

METAL CONTAINER

Flg

13

Me3

6.

Lower the pressure setting. Turn on the sprayer. Maintaining metal-to-metal contact, trigger the gun Into the flushing pail. Slowly increase the

the gun

triggered

until the solvent flows freely

sprayer pressure

just

until

the pump starts. Keep

from the gun. Circulate the solvent to thoroughly clean the sprayer. Release the gun trigger. Engage the gun safety latch.

7.

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

it.

Close the drain valve.

8.

Remcive the suction hose from the pail. Disengage the gun safety latch. Trigger the gun and run the pump afew seconds to push air Into the

seconds to avoid damaging the pump packingsl

hose. Do not run the pump dry for more than

30

Relieve pressure.

9.

Reinstall the clean filter screen.

IO.

Remove and clean the inlet strainer. Wipe paint

off

11.

Refer to When

To

Flush, Step 1 again. Relieve

the suction hose and drain hose.

pressure.

12.

Leave the drain valve open until you

use

the

sprayer again.

308-248

13

TROUBLESHOOTING GUIDE

WARNING

Toreducetheriskofseriousbodilyinjury,includingfluidinjec-

Pressure

Relief

Procedure

tion,injuryfromsplashingRuidorsolventintheeyesoronthe

skin,movingpartsorelectricshock,aEwaysfollowthisproce-

dure whenever you shut

off

the sprayer, when checking or

servicinganypartofthespraysystem,wheninstailing,clean-

ingorchangingspraytips,andwheneveryoustopspraying.

1.

Engage the gun safety latch.

2.

Turn the ON/OFF switch to

OFF.

3.

Unplug the power supply cord.

4.

Disengage the gun safety latch. Hold a metal part of

the gun firmly to a grounded metal pail. Trigger the

5.

Engage the gun safety latch.

gun

to

relieve pressure.

6.

Open the pressure drain valve, having a container

valve open until you are ready

to

spray again.

ready

to

catch the drainage. Leave the pressure drain

If

you

suspect that

the

spray tip

or

hose

is

complete&

clogged, orthatpressure has notbeen fu/&re/ievedafferfo/-

/owing the steps above,

VERY

SLOWLY loosen the the tip

guard retaining

nut

or

hose

coupling

to

reliwe pressure

gradually, then loosen completely.

Check

evelything

in

the

guide

before

disassembling

the

sprayer.

@gg&g

BASIC PROBLEM SOLVING

YPE OF PROBLEM

:hid Pressure

Aechanical

Iiectrical

WHAT

TO

CHECK

rf

check

is

OK,

go to next check

1.

Check pressure control k.nob setting. The pumF won't develop much pressure

if

it is at minimum

setting (fully counterclockwise).

2.

Check for a clogged spray tip or fluid filter. See page

9.

1.

Check for frozen or hardenedpaint

in

pump

(20).

Using a screwdriver, carefully

try

to rotate

fan at back

of

motor bv hand. See page

18.

2.

Check pump connecting rod pin

(17).

It

must be

completely pushed into connecting rod

(15),

and retaining spring (la) must be firmly in connecting rod groove. See Fig

20,

page

21.

3.

Check for motor damage. Remove drive

hous-

ing assembly

(1

1).

See

page

26.

Try to rotate

motor fan by hand.

1.

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

2.

Check extension~Gd for visible damaEUse

a

to check.

volt meter or test lamD at extension cord outlet

3.

Check sprayer power supply cord

(50)

for

vis-

4.

Check motor brushes for the following:

a.

Loose

terminal screws.

b.

Broken or misaligned brush springs.

c.

Brushes binding

in

holders.

~~ ~~

ible damage such as broken insulation or wires.

d.

Broken leads.

e.

Worn brushes.

NOTE:

The brushes do not wear at same rate

on

both sides

of

motor. Check both brushes.

WHAT

TO

DO

when

check

is

not

OK,

refer

to

this column

1.

Slowly increase pressure setting

to

see

i

motor

starts.

2.

If

tip is still clogged, relieve pressure: re- fer to separate gun or tip instruction man ual for tip cleaning. Clean or replace fib element. See manual

308-249.

1.

Thaw. Plug in sprayer and turn

on.

Slow!)

increase pressure setting

to

see

if

motor

starts.

If

it

doesn't,

see

NOTE

1,

below.

~~ ~ ~

2.

Push pin into piace and secure with

spring retainer.

3.

Replace motor

(4)

li

fan won't turn..

See

page

24.

I.

Reset building circuit breaker; replace

~~

building

fuse.

Try another outlet.

2.

Replace extension cord.

3.

Replace power supply cord. See page

25.

%.

Refer

to

page

20.

a. lighten. b. Replace broken spring and/or align

spring with brush

c.

Clean brush holders. Remove carbon with small cleaning brush. Align brust leads with

slot

in brush holder to as-

sure free vertical brush movement. d. Replace brushes e. Replace brushes

if

less

than

1/2"

long.

area.Donottrytostartsprayeruntilithasthawedcompietelyordamagetomotorand/orstartboardmayoccur.Ifpainthardened(dried)

NOTE

1

:

Thaw sprayer

if

water or water-based paint has frozen in

it,

due to exposure to low temperatures, by placing it in a warm

in sprayer, the pump packings and/or pressure transducer must be replaced.

See

page

21

(pump) or

27

(pressure transducer),

14

308-248

BASIC PROBLEM SOLVING

YPE

OF

PROBLEM

lectrical (continued)

NHAT TO CHECK

f

checkis

OK,

go

to

i.

Check motor armature commutator for bum spots. aouaes and extreme rouahness. Removc motor cover and brush inspectron plates

to

check. See page

20.

3.

Checkmotorarmatureforshortsusing armaturf

tester (growler) or perform motor test.

See

pagc

18.

~~ ~~~

7.

Check leads from pressure control and motor tc motor start board

(47)

to be sure they are

se-

curely fastened and properly mated.

I.

Check motor start board

(47)

by substituting

with a good board.

See

page

25.

tor armature is determined to be good. A bad

CAUTION: Do

not

perform this check until mo.

motor armature can burn out a good board.

3.

Check power supply cord

(50).

Disconnect

black and white oower cord terminals: connecl

volt

meter to these leads. Plug in sprayer.

Mete

should read 105-125 VAC. Unplug sprayer.

IO.

Check ON/OFF switch

(52).

Disconnect the

"L"

wire between motor stalt board

(47)

and switct and connect volt meter between exposed term1 nal

on

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 motork red leads. Meter should read 1 ohm maximum.

12. Remove pressure control

(64)

and check micro

switch operation with ohmmeter:

(1) With pressure knob at lowest setting and

stem pushed into control, readings should be: white

&

black = 1

ohm max.

white

&

red = open.

(2)

With pressure knob at highest setting,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

27.

NHAT

TO

DO

When check is

not

OK,

refer

to

this column

i.

Remove motor and have motor shop resurface commutator

if

Dossible.

See

page

24.

1.

Replace motor.

See

page

24.

I.

Replace

loose

terminals: crimp

to

leads.

Be

sure male terminal blades are straight

and firmly connected to mating part.

1.

Replace board.

See

page

25.

3.

Replace power supply cord.

See

page

25.

IO.

Replace ON/OFF switch.

See

page

25.

11.

Allow motor to cool. Correct cause of

overheating.

If

switch remains open after

motor cools, replace motor.

12.

Replace pressure control. See page

27.

13.

Replace transducer.

See

page

27.

Thor-

ough system flushing will help extendiife

of

transducer.

INTERMEDIATE PROBLEM SOLVING

TYPE

OF

PROBLEM WHAT TO CHECK

If

check is

OK,

go

to

When

check

is

not

OK

refer

to

this column

WHAT TO

DO

I

Low output

I

1.

Check for worn spray tip.

I

1.

Follow

Pressure

Rellef

Procedure

2.

Be

sure pump does not continue to stroke when

gun trigger

is

released. Plug in and turn

on

tarily, then release and engage safety latch.

Re-

sprayer. Prime with paint. Trigger gun momen-

lieve pressure. turn

off

and undua sDraver.

Warning then replace tip.

See

your sepa-

rate gun or tip manual.

2. Service pump.

See

pages 21.

306-248

I5

INTERMEDIATE PROBLEM SOLVING

YPE

OF

PROBLEM WHAT TO CHECK

If check

is

OK,

go

to

newt check

WHAT TO

DO

When check

is

not

OK,

refer

to

this

column

ow Output (continued)

3.

Release gun trigger. Observe resting position of

3.

If

pump consistently comes

to

rest with

ings and/or piston valve may be worn. Service the pump.

See

page 21.

pump rod (107).

rod

(107)

fully extended. the piston pack

)rain Valve Leaks

ransducer Leaks

lo

Output: Motor Runs

md Pump Strokes

lo

Output: Motor Runs

iUt

Pump

Does

Not Stroke

4.

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

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

R.

6. Check motor brushes. See Electrical - What To Check, item

4,

on

page 14.

with a good board.

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.

7. Check motor start board (47) by substituting

4. Reset building circuit breaker: replace buildina

fuse.

ReDair electrical outlet or

try anoiher outlei.

5.

Replace with a correct, grounded extension cord.

6.

See

page 20.

7.

Replace board. See page 25.

8.

Replace motor. See page 24.

8. Check motor armature for shorts by using an

~~

armature tester (arowler) or Derform motor test.

._

See

page 18.

worn parts. Check for debris trapped

on

seat.

valve and replace with new gasket (42a)

1.

Slight leakage from transducer

is

normal.

1. Periodically remove residue from its cylin.

1. Check paint supply.

2. Remove and clean, then reinstall.

2.

Check for clogged intake strainer.

1.

Refill

and reprime pump.

3.

Check for

loose

suction tube or fittings. See

3.

Tighten: use thread sealant

on

npt

1. Check drain valve for correct torque and/or

9.

Tighten

to

185 in-lb (21 N.m). Clean

and sealant (42d). See page 28.

der port. See page 27.

page 28.

threads of inlet tube

(38).

Check for dam.

aged O-ring (27).

4. Check to see

if

intake valve ball

and

piston ball

4.

Remove intake valve and clean. Check

are seating properly. See page 21.

ed.

See

page 21. Strain paint before us-

ball and seat for nicks: replace as need-

ing

to

remove particles that could clog

pump.

5.

Check for leaking around throat packing

nut

See

page 21.

check piston valve seat for hardened

which may indicate worn ordamaged packings.

5.

Replace packings.

See

page 21,

Also

Tighten packing nuvwet-cup.

paint or nicks and replace

if

necessary.

.

-

6. Release gun trigger. Observe resting position

of

6.

If

pump consistently comes to rest with

ings and/or piston valve may

be

worn.

Service the pump.

See

page 21.

pump rod (107).

rod (107) fully extended, the piston pack.

I

1. Check displacement pump connecting rod pin

1.

Replace pin if missing.

Be

sure retainer

(17). See Fig 20, page 21.

SPrina (18)

is

fullv in aroove all around

I

&nnectin$ rod.

.-

7. Check connecting rod assembly (15) for dam-

7.

Replace connecting rod assembly. See

age.

See

page 26. page 26.

8.

Be

sure crank in drive housing rotates: plug

in

26.

and unplug sprayer. See page 26.

age and replace

if

necessary.

See

page

sprayer and turn

on

briefly

to

check. Turn

off

8.

Check drive housing assembly for dam-

16

308-248

INTERMEDIATE PROBLEM SOLVING

YPE

OF

PROBLEM

;pray Pattern Variations

dotor

Is

Hot and Runs

itermittently

luilding Circuit Breakel )pens

As

Soon

As

Sprayel

;witch

Is

Turned

On.

:ircuit breaker opens anel prayeroperatesfor5tolC rinutes.

3uilding circuit breaker

j

plugged into outlet and

rpens

as

soon

as

sprayer

;prayeris NOTturnedon.

WHAT TO CHECK

M

check

is

OK,

go

to

newt

check

1.

Spray tip worn beyond sprayer pressure capability.

2. Check transducer

(29)

for wear or damage.

3.

Check pressure control

(64)

for smooth opera-

tion.

4.

Check

Low

Output section, page 16.

1.

Determine

if

sprayer was operated~achigh pressure with small tips, which causes excessive heat build

UD.

~~ ~~

2.

Be

sure ambient temperature where sprayer is

located is

no

more than90'F and sprayer is

no1

located in direct

sun.

3.

Check motor.

1.

Check

all

electrical wiring for damaged insula-

tion, and all terminals for

loose

fit or damage. Also check wires between Dressure control and motor.

See

page 24.

2.

Check for missing motor brush inspection plate gasket

(see

page 20), bent terminal forks or

cause a short.

other metal

to

metal contact points which could

3.

Check motor armature for shorts.

Use

an arma.

ture tester (growler) or perform motor test.

See

page 18. Inspect windings for burns.

4.

Check motor start 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.

1.

Check 'Basic Problems - Electrical'

on

page

14.

1.

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

2.

Check tightness of pump packing

nut.

Over-

tightening tightens packings

on

rod, restricts

pump

action,

damages packings.

3.

Check for damaged motor.

4.

Check

ONlOFF

switch (52).

Be

sure

sprayer

is

unplugged1

Disconnect wires from switch.

Check switch with ohmmeter. The reading

zero with switch

ON.

should be infinity with

ON/OFF

switch

OFF,

and

CAUTION

A

short in motor circuit can damage

switch and or motor start board (47).

WHAT

TO

DO

When check

is

not

OK,

refer

to

this column

1. Replace spray tip.

longer life.

NOTE

A

smaller size tip will provide

2.

Replace transducer.

See

page

27.

3.

Replace pressure control.

See

page 27.

1.

Decrease pressure setting or increase

til:

size.

2.

Move sprayer to shaded, cooler area

if

possible.

3.

Replace motor.

See

page 24.

1.

Repair or replace any damaged wiring

01

terminals. Securely reconnect all wires.

2.

Correct faulty conditions.

3.

Replace motor. See page 24.

1.

Replace board.

See

page 25.

I.

If

voltage is too high, do not operate

sprayer

until

corrected.

?.

Loosen

packing nut. Check

for

leaking

around throat. Replace pump packings,

A

necessary.

See

page 21.

3.

Replace motor.

See

page 24.

1.

Replace

ON/OFF

switch.

See

page 25.

MOTOR

TEST

WARNING

Pressure

Relief

Procedure

Warning

on page

14

before doing this procedure. Unplug the sprayer1

For checking armature, motor winding and brush electrical continuity.

Setup

Remove the drive housing. See page

26.

This

Is

to

ensure that any resistance you notice in the armature

test

is due to the motor and not to worn gears in the

drive housing.

Remove the motor brush inspection covers

(A).

See

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

15.

Armature Short Circuit Test

Remove the handle

(24)

and the fan cover

(8).

See

Fig

14.

Spin the motor fan by hand.

If

there are no shorts, the

ing to a complete stop.

If

the motor

does

not spin

motor will mast

two

or three revolutions before com-

freely, the armature

is

shorted and the motor must be

replaced. See page

24.

Armature, Brushes, and Motor Wiring

Open

Circuit Test (Continuity)

Connect the

two

black motor leads together with a

test lead. Turn the motor fan by hand at about

two

revolutions per second.

When turning the fan on a DC motor, normally you

sense an even, pulsing resistance.

If

there

is

irregular turning resistance, or no turning resistance, check and repair the following

as

needed: broken brush springs, brush leads, motor leads: loose brush terminal screws, motor lead terminals; worn brushes. See

page

20.

the motor. See page

24.

If there

is

still uneven

or no turning resistance, replace

14.

M

Fig

14

V

1022

18

308-248

GENERAL REPAIR INFORMATION

To reduce the risk of serious bodily injury, including

Pressure Relief Procedure

4.

Disengage the gun safety latch. Hold a metal

part of the gun firmly to the side of a grounded

fluid injection, splashing fluid or solvent

in

the eyes metal pail, and trigger the gun to relieve pres- or on the skin, or injury from moving parts or elec- sure. tric shock, always follow this procedure whenever

5.

Engage the

gun

safety latch.

you shut

off

the sprayer, check or service any part

of the spray system, install, clean or change spray

tips, and whenever you stop spraying.

6. Open the pressure drain valve, having a con- tainer ready to catch the drainage. Leave the valve open

until

you are ready

to

spray again.

1.

Engage the gun safety latch.

2.

Turn the ON/OFF switch to

OFF.

3. Unplug the power supply cord.

If

you suspect that the spray tip or hose

is

complete/y clogged, or that pressure has not been ful/y relieved after following the steps above, VERY

SLOWLY loosen the tip guard retaining nut or hose coupling to relieve pressure gradually, then loosen completely. Now clear the tip or hose.

Tool List These are the tools required to service all parts of the

sprayer.

3/16" Allen@ wrench: gear housing, legs, handle

3/8"

Allen@ wrench: pump manifold

#1

Phillips@ screwdriver: junction box, pressure

3/8" socket wrench: motor mount

control, front cover

5/8"

socket wrench: drain valve, 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

144"

open end wrench pump jam nut

5/64" drive pin: drain valve

3" needle nose pliers: wiring,

onloff

switch

Hammer

&

punch: packing

nut

Torque wrenches: various fasteners

onloff switch boot, piston

1.

When disconnecting wires in the junction box

assembly, use needle nose pliers to separate mating connectors.

2.

When reconnecting the wires, be sure the flat

blade of the insulated male connector is centered in the wrap-around blade of the female connector.

CAUTION

To reduce the risk of a pressure control malfunction, be sure to properly mate connectors, and

never pull on a wire to disconnect it. Pulling on a

wire could loosen the connector from the wire.

J

3. Route wires carefully through the drive housing and motor. Avoid pinching the wires between the

junction box and the motor.

.

CAUTION

performance or damage to the pressure control.

Improper wire routing can result in poor sprayer

-

4.

Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts are not normally provided with

replacement assemblies.

sure the problem is corrected.

5.

Test your repair before regular operation to

be

6.

If

the sprayer does not operate properly, verify that everything was done correctly. Also refer to theTroubleshooting Guide, pages 14-17, to help

identify other possible problems and solutions.

WARNING

To

reduce the risk of serious bodily injury, includ-

ing electric shock, DO NOT touch any moving

while inspecting the repair.

parts or electrical parts with your fingers

or

a tool

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.

1-

WARNING

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

1

explosion.

-

~~

MOTOR

BRUSH

REPLACEMENT

NOTE

1:

Replacethe brushes when they have worn to

lessthan1/2in(13mm).RefertoFig17.

Note thatthe brushes weardifferentlyon each side ofthe motor,

so

check them both.

Brush Repair

Kit

235-727

is available.

r"wARN'NG

1

To

reduce the risk

of

serious lnjuty, follow

the

Pressure Relief Procedure Warning on page 19 before doing this procedure. Unplug the sprayeri

1.

Remove both inspection covers

(A)

grid

their gas-

kets. See Fig

16.

2.

3.

4.

the brush holder. Pull out the spring clip. See

Fig

Push in the spring clip and release

its

hooks from

17.

Loosen the brush lead terminal screw. Pull the

brush lead away, but leave the motor lead terminal in place. Remove and discard the brush. See Fig 17.

Inspect the cornmutator for excessive pitting,

tator

is

normal. Have the cornmutator resurfaced

burning or gouging.

A

black color on the'commu-

by a qualified motor repair shop

if

the brushes

seem to wear too fast or arc excessively.

5.

Repeat for the other side.

CAUTION

When installing the brushes, follow all steps carefully. Improper installation damages parts

beyond use.

6.

7.

8.

9.

to the fan-end ofthe motor. Slide the terminal under

Place a new brush in the holder

so

the lead is closer

the terminal screw washer. Ensure the motor lead is

still

connected at the screw.

See

Fig 17.

Holding the spring/cllp at'a slight angle, slide the

the end

of

the holder. See Fig 18. Pull on the

spring/clip Into the brush holder

and

hook

it

over

spring/clip to be

sure

it

stays in place. Be sure the

brush lead is tucked under the spring/cllp tab.

Repeat for the other side.

Test the brushes.

a. Wlth the sprayer

OFF,

turn

the pressure control

sure. Plug in the sprayer.

knob

fully

counterclockwise to minimum pres-

b.

Turn the sprayer

ON.

Slowly increase the pres-

sure until the motor is at

full

speed.

c. Inspectthe brush and commutator contact area

for excessive arcing.

Arcs

should not

"trail"

or

circle around the commutator surface.

WARNING

IcAw'oNl

Do

not run the sprayer dry for more than 30 sec- onds while checking the brushes to avoid damaging the displacement pump packings.

IO.

Install the brush inspection covers and gaskets.

HOOK,

TERMINAL

SCREW

BRUSH

LEAD'

/

Fig

17

Fig

18

20

308-248

DISPLACEMENT PUMP

WARNING

To reduce the risk of serious injury, follow the Pressure Relief Procedure Warning on page

19

before doing this procedure. Unplug the sprayer1

NOTE

1:

Packing Repair

Kit

235-703

is available.

kit

are marked with

an

asterisk, Le.,

(121*).

Reference numbers of parts included in the

the

kt,

even

if

the old ones still look good.

For the best results, use all the new parts In

NOTE

2

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

20)

and clean the

trans-

ducer (see page

27)

whenever you repack

the pump. Replace these parts

as

needed.

Intake

valve repalr (See Fig

19)

1.

Unscrew the intake valve

(118).

Remove the

O-ring

(119*),

ball guide

(IZO),

stop pin

(122*)

and bail

(121*)

from the valve.

2.

Clean and inspect the parts for wear or damage.

Replace parts as needed. Use a new O-ring

(1 19*).

If no further service

Is

needed, reassemble

the pump.

NOTE

3:

For additional pump repair, go to page 22.

Removing the pump

(See

Fig

19)

1.

Flush the pump,

If

possible. Relieve pressure.

Stop the pump with the piston rod

(107)

In Its low-

est position,

If

possible.

To

lower the piston rod

manually, rotate the motor fan blades.

2.

Remove the filter

(85).

3.

While pulling upward on the suction hose

(32),

unscrew the hose from the inlet tube

(38).

Un-

screw the drain hose

(33)

from

the displacement

pump nipple

(36).

NOTE 4 If

repairing only the intake valve assembly,

go to Intake valve repair, below.

4. Use a screwdriver to push the retaining spring

(18)

up and push

out

the pin

(17).

5.

Loosen the screws

(21).

Remove the pump (20).

Installing the pump (See Fig

19

and

20)

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).

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).

the connecting rod.

Push the retaining spring

(18) into place around

I

17

15

123

18

Fig

20

WARNING

groove all theway around, to preventthe

(17)

Be

sure the retalnlng spring

(1

8)

Is firmly

In

the

from working loose due to vibration. See Fig

20.

If

the pin works loose,

It

or other parts could break offduetotheforceofthepumpaction. These parts could

be

projected into the air and result

in

serious Injury or property damage, lncludingthe pump connecting rod

or

bearing housing.

3.

Replace the O-ring

(27)

if

it

is

wom or damaged.

Reconnect the suction and drain hoses

(32,33).

Install the front cover

(13).

leakage, but no tighter.

Fill

the packing

nut/wet-

cup

1/3

full with Graco TSL. Push the plug

(123)

Into the wet-cup.

4. Tighten the packing nut

(102)

just

enough to stop

308-248

21

DISPLACE

iMENT

PUMP

Disassembling the pump (See Fig

21)

1.

Remove the intake valve

(1 18).

See page

21.

2.

Unscrew the packing nut

(102)

and plug

(123).

3.

Use a plastic mallet to tap the piston rod

(107)

down, and then pull the rod out through the bottom of the cylinder.

4.

Remove the throat packings.

5.

Loosen the jam nut

(117).

Remove the cylinder

(115)

and the o-ring

(116").

6.

Clamp the flats of the piston rod in a vise. Use

an

then unscrew the piston valve

(108).

open-end wrench to loosen the nut

(1 10)

and

7.

Remove all parts from the piston valve

(108).

Reassembling the pump

NOTE

1:

Alternate plastic and leather packings.

See

'Fig

21.

The lips of the throat V-packings

face down. The lips

of

the piston V-pack-

the packings and causes pump leaking.

lngs face up. lncorreci installation damages

NOTE

2:

Soak the leather packings in oil before reassembling the pump.

1.

Check the outside

of

the piston rod

(1

07)

and the

inside ofthe cylinder

(1 15)

forwear. Replace wom

parts to ensure a good seal with the new packings.

2.

Stackthese parts onto the piston valve

(108)

one

at

a time: the backup washer

(126")

and

u-cup

(125*),thefemalegland(114*),altematelythree

and the male

gland

(1

1

I*).

See

Fig

22.

plastic

(1

12")

with

two

leather packings

(1

13*),

3.

lighten the

nut

(1

10)

onto the piston valve

(1

08)

to

NOTE

3:

Note

the alignment of the piston

(108)

to

2

in-lb

(0.23

N.m). See Fig

22.

through Step

8.

the

nut

(110).

Maintain this alignment

4.

Clean all residue from the piston valve threads.

Ap-

ply one drop

of

adhesive, supplied, to the threads.

5.

Place the ball

(log*)

on the piston valve

(108).

See Fig 22.

CAUTION

Step

6,

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

6.

Hand tighten the valve into the piston rod

just

un-

22

308-248

til the nut

(1

10)

contacts the rod. See Fig

23.

110

0

AGAINST

ROD

TORQUE

NUT

TO

1s

n-lb

(25

N.m)

108

Fig

23

1721

7.

Place the flats

of

the rod

(1

07)

In a vise.

8.

CAREFULLY

tighten the nut

(1 10)

against the pis-

ton rod

to

19

ft-lb

(25

N.m). See Fig

23.

Use

two

wrenches to maintain the alignment

mentioned in NOTE

3,

to the

left.

DISPLACEMENT

PUMP

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

25.

IO.

Install the packing nut

(102)

and plug

(124),

but

leave

loose

for now.

See

Fig

24.

11.

Piace a new O-ring

(1

16")

firmly in the cylinder

groove.

See

Fig

24.

12.

Coat the piston

rod

and packings

with

oil. Care-

fully slide the assembly

INTO

THE TOP

OF

THE

CYLINDER

(115).

See

Fig

24.

13.

Place

the

intake valve

(1 18)

in avise and

assemble its parts.

See

page

21.

Screw the

cylinder

(1

15)

onto

the

valve

(1

18).

Turn

the

jam

nut

(1

17)

all

the

way down.

See

Fig

24.

14.

Put the manifold in a

vise.

Guide the rod/cylinder

assembly up through the manifold

(101).

Screw

the cylinder

(1 15)

Into the manifold and tighten to

53

ft-lb

(71

N.m).

See

Fig

24.

15.

Tighten Intake valve

(118)

to 53ft-lb

(71

N.m).

See

Fig

24.

16.

Tighten

the

cylinder

jam

nut

(117)

to

73

ft-lb

(98

N.m).

See

Fig

24.

17.

Install the pump.

See

page

21.

n

TORQUE

JAM

NUT

(117)

73

R-Lb

(98

N.m)

TORQUECWNDER

(119

63

R-lb

(71

Nm).

INTO

MANIFOLD

(101)

TO

118

TORQUE

INTAKE

VALVE

(1

18)

INTO

CYLINDER

63

R-lb

(71

N.m)

(l19

TO

Fig

24

1717

308-248 23

~

MOTOR

WARNING

To

reduce the risk of serious injury, follow the

before doing this procedure. Unplug the sprayer1

Pressure Relief Procedure Warning on page

19

NOTE

I:

See

Fig

27

except

where

noted.

NOTE

2:

Stop the sprayer at the bottom of

its

stroke

to

get the crank

(12)

in the lowest position.

To manually lower the crank, mtate the

blades

of

the motor fan

with

a screwdriver.

1.

Remove the drive housing

(1 1).

See

Steps

1

to

5,

page

26.

2.

Rotate the blades

of

the motor

fan

to

raise

the

crank

(12).

Turn the displacement pump rod

(107)

which gives

access

to that screw.

See

Fig

26.

so

the pin hole aligns with the bottom screw

(la),

3.

Remove the three drive housing screws

(19)

and

4.

Tap

the lower rear

of

the drive housing

(1 1)

with a

plastic mallet to loosen the motor. Pull the drive

housing straight

off

the motor while guiding the

two motor

screws

(5)

and their lockwashers

(6).

.

harness

(A)

from

the motor.

CAUTION

Do

not allow the gear

(16)

to

fall;

it

may stay

attached to the drive housing or to the mdor.

Do

not

lose

the thrust balls

(1

la or

41)

or al-

seriously damage the ddve housing

if

not

re-

low them to

fall

between the gears, which

will

moved.

The

balls, which are heavily covered

with grease, usually stay in the gear recesses,

place,

the

bearings

will

wear prematurely.

but could be dislodged. If the balls

are

not in

5.

Remove the

two

screws

146)

and

lift

the

NOTE

3

The

gears and bearings between the drive

housing

(1 1)

and motor front end bell

(C)

should contain a total of

3

fl.

02.

of grease.

6.

Grease

the gear cluster

(16)

and pinion gear

(B)

and pack all bearings.

Be

sure the thrust balls

(1

la,

43 are in place.

washer

(12b)

on the crankshaft

(12).

crankshaft

(12).

Align the gears and push the

drive housing

(1

1)

straight

onto

the

motor and

the

locating pins. Install the screws

(19,5)

and their

lochashers

(6).

Torque to

80

In-lb

(9

Nm).

9.

See

page

27,

Steps

5-9,

to

install

the pressure

control

(64)

and junction box

(59).

10.

Reconnect the piston rod

(107)

to the drive hous-

ing;

see

page

21,

Installing the Pump, Step

2

and the Warning following it.

7.

Place the large washer

(12a)

and then the small

6.

Lift

the crank to the top

of

the stroke and insert

10

19,6

MOTOR

START

BOARD

ON/OFF

SWITCH

-1

WARNING

-1

To

reduce the risk

of

serious injury, follow the

Pressure Relief Procedure

Wamlng

on page

19

before doing this procedure. Unplug the sprayer!

To

reduce the risk of serious Injury, follow the

Pressure Relief Procedure Warning on page

19

before doing this procedure. Unplug the sprayerl

1.

Remove the junction box

screws

(56)

and

lower

the junction box

(59).

See

Fig

28.

2.

Disconnect the motor wires (4b) and the %wire connector

(A)

from the motor

start

board (47).

20.

Observe where connections

are

made.

See

Fig

3.

Remove the screws

(58)

and motor

start

board

(47). Transfer the

white

thermal paste from the old

board to the new board.

See

Fig

28.

wires. Mount the junction box.

CAUTION

tor is centered in the wrap-around blade ofthefe

Be

sure the flat blade

ofthe

insulated male connec-

male connector when the connections are made.

Route all wires carefully to avold interference

with

the motor

start

board or junction box

These

precautions are essential to reduce the risk

of a malfunction.

4.

Install

the

new motor

start

board. Reconnect all

rWARNiNG

1

POWER

SUPPLY

CORD

To

reduce the risk of serious injury, follow the

Pressure Relief Procedure Warnlng on page

19..

before doing this procedure. Unplug

the

sprayerl

I.

Remove the junction box screws

(56)

and lower

2.

Disconnect the power supply cord leads, includ-

the junction box

(59).

See

Fig

28.

ing the green wire to the grounding screw

(49).

See

Fig

28.

3.

Loosen the strain relief bushing

(51).

Remove the

power supply cord

(50).

4. Install the new cord

(50)

in the reverse order

of

disassembly.

5.

Install the junction box.

Be

sure

no

leads

are

pinched against the motor or by the motor

start

board.

1.

Remove the junction box

smews

(56)

and lower

the junction box

(59).

See

Fig

28.

2.

Remove the

nut

and rubber

boot

(55).

3.

Disconnect the black wires from the ONOFF switch

(52)

and remove the switch.

See

Fig

28.

4. Place the ring terminal of the ground wire

(53)

switch

so

the internal tab of the anti-rotation ring

over the barrel of the new swltch. Install the

(54)

engages with the vertical groove in the threads of the switch, and the external tabengages with the blind hole

(C)

of

the

junction box.

5.

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.

6.

Reconnect the ONOFF swltch black wires.

7. Install the junction box.

Be

sure no leads are

pinched against the motor or by the motor

start

board.

308-248

25

DRIVE HOUSING, CONNECTING ROD & CRANKSHAFT

WARNING

To

reduce the risk

of

serious

injury, follow the

Pressure Relief

Procedure

Warning

on page 19

before dolng this procedure. Unplug the sprayer1

NOTE

4

Inspect parts

as

they are removed. Replace

parts that are worn or damaged.

1.

Rotate the blades of the motor

fan

with a screw-

driver to get the crank in

its

lowest position.

2. Remove the displacement pump.

See

page 21.

3. Remove the pressure control

(64).

See

page 27.

17

18

Fig 29

4.

Remove the three screws (19) and the two motor screws

(5)

and their lockwashers

(6).

5.

Tap the lower rear

of

the drive housing (1

1)

with a

plastic mallet to loosen the motor.

Pull

the drive

housing straight

off

the motor while guiding the

harness

(A)

from the motor.

CAUTION

attached to the drive housing

or

to the motor.

Do

not allow the gear (16) to fall;

it

may stay

allow them to fall between the gears, which

Do

not

lose

the thrust balls (1 la or

4a)

or

will seriously damage the drive housing

M

not

removed.

The

balls, which are heavily covered with grease, usually stay in the gear recesses,

but

could be dislodged. Ifthe balls

are not In place, the bearings

will

wear pre-

maturely.

6.

Remove and Inspect the crankshaft (12)

and

the

connecting rod

(15).

7.

Install

the

connecting rod.

8. Lubricate the inside of the drive housing bearing with

SAE

nondetergent oil. Pack the roller bear-

ing and gears with the grease supplied.

NOTE

5:

The

gears

and bearings between the drive

housing

(1

1) and motor front end bell

(C)

should congin a total of 3

fl.

oz.

of grease.

9.

Route

the wire harness

(A)

through the motor

passages to

the

junction box

(59).

10. Place

the

large washer (12a) and then the small

washer (12b)

on

the crankshaft (12).

11.

uft

the crank to the top of the stroke and insert crankshaft (12). Align the gears and push the drive housing (1 1) straight onto the motor and the locatlng pins. Install the screws (19,

5)

and their

lockwashers

(6).

Torque to

80

in-lb

(9

Nm).

12. Install the displacement pump.

See

page

21.

13. Install the front cover (1 3) and the pressure control

(64).

See

page 27.

80

In-lb

(e

N.m)

56

TORQUE

TO

26

308-248

PRESSURE CONTROL

8.

Install the front cover

(13).

Connect the harness

(A) to the motor

start

board

(47).

I

Pressure

Relief

Procedure Warning on page

19

before doing this procedure. Unplug the sprayer!

I

9.

Install the junction

box.

Be

sure no leads are

pinched agalnst the motor or by the motor start

NOTE

1:

See Fig

31

for this procedure.

NOTE

2:

The pressure control

(64)

cannot be repaired

or adjusted.

If

it

has malfunctioned, replace it.

1.

Remove the front cover

(13).

Remove the screws

2.

Disconnect the harness connector (A) from the

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

(1

1).

A

drlve housing and remove the pressure control.

through the drive housing and motor passages.

(56).

Lower the junction box

(59).

21

In-lb

(2.4

N.m)

motor start board

(47).

13

4.

Guide the harness (A) through the motor and

5.

Guide the harness of the new pressure control

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).

Note: Fiiter

them to

21

in-lb

(2.4

N.m). Fig

31

7.

Loosely install the screws

(63)

and then torque

not

shown

lo80

PRESSURETRANSDUCER

IWARNING

1

To

reduce the risk of serious injuly, follow the

Pressure

Relief

Procedure Warning on page

19

before doing this procedure. Unplug the sprayer!

NOTE

1

:

See Fig

32

for this procedure.

Remove the displacement pump.

See

page

21.

Use a pull-twist motion to remove the transducer

1.

2.

3.

4.

5.

6.

7.

(29)

from the pump manifold

(101).

Clean paint residue from the hole in the manifold;

29

do not scratch the surface of the hole.

Lightly apply

oil

to the O-ring

of

the new transducer.

Install the transducer in the pump manifold, while

101

guiding the O-ring and backup ring into place.

Align the holes in the transducer as shown by the arrows in Fig

32.

Install the displacement pump. See page

21.

Fig

32

/r

Note:

Filter

not

shown

308-248

27

~~

.

SUCTION HOSE

WARNING

-1

CAUTION

-1

To reduce the risk of serious injury, follow the Pressure Relief Procedure Warning on page

19

Misalignment or cross-threading will damage the parts and/or create shavings which can cause the

before doing this procedure. Unplug the sprayer! O-ring (27) to leak.

1.

Remove the drain hose (33) from the clip.

Re-

move the front cover (13).

2.

Pull

upward on the hose (32) while unscrewing it from the inlet tube (38). The hose coupling (A) threads

will

engage and the hose will separate

from the tube.

3.

Replace the O-ring (27)

if

it

is worn or damaged.

4.

Lubricate the O-ring (27) and the inlet tube (38)

threads with light grease.

5.

Align the suction hose coupling with the threads of the inlet tube (38). Tighten the hose onto the tube at least

4 turns to ensure that the threads have

disenaaaed and can function as a swivel joint.

Note:

Filler

not

shown

DRAIN VALVE

WARNING

Repair

To

reduce the risk of serious injury, follow the

Pressure Rellef Procedure Warning on page

19

1.

Unscrew the spring retainer from the valve body. Remove the spring, washers and stem/ball. Clean

before doing this procedure. Unplug the sprayer! any debris from the ball or seat area.

1.

Turn the handle (45) to the closed position. Drive

the gasket.

2.

If

replacing the gasket (42a) or seat (42b), pry

out

the pin (44). Remove the handle.

NOTE

1:

Whenever the gasket (42a) is removed, re-

2.

Remove the base (43).

place it with a new one.

3.

Unscrew the drain valve (42). The gasket (42a)

3. Coat the O-ring (42e) with grease. Press the

and seat (42b) will stay in the valve. stem into the valve body. Install the spring, wash-

ers

and spring retainer into the valve body.

42a

4.

Place the seat (42b) in the valve body

so

the lapped side is toward the ball. Apply a small amount

of

grease to the new gasket (42a) and

install

it

in the valve body.

APPLY GREASE

NOTE

2:

The gasket

will

protrude from the end of the

valve until the valve

is

tightened into pump,

which correctly seats the gasket.

TORQUE

INTO

Replacement

PUMP MANIFOLD

1.

Apply a small amount of thread sealant (42e) onto

185

In-lb

(21

Nm)

the valve (42) threads. Tighten the valve into the pump manifold to 185 in-lb (21 Nm).

2. tightly grease the face

of

the base (43) and install

the base. Turn the stem

so

the pin hole

is

vertical.

HANDLE

SHOWN

45

Fig 34

IN

CWSED

POSITION

lMul

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

28

308-248

(44).

PARTS DRAWING & LIST - DISPLACEMENT PUMP

Includes items

101

to

126

Model

235-699

Serles

A

Ref

No.

Part

No.

101 187-611 102 176-750 103 176-757* 104 178-997' 105 176-755' 106 176-754'

107 235-709 108 218-197 109 105-444* 110 176-751 1 1

1

176-75O* 112 176-882' 1 13 176-749' 114 160-073* 115 235-708 116 108-526* 117 167-614 118 224-966 119 111-603* 120 176-760 121 105-445. 122 176-759* 123 180-656 124 102-969. 125 105-522*

126 166-652*

Description

MANIFOLD,

pump NUT, packing GLAND, female, throat V-PACKING, plastic, throat V-PACKING, leather, throat GLAND, male. throat

ROD, displacement PISTON, valve

BALL,

5/16",

piston

NUT, hex,

1/2-20

unf-2b

GLAND, male, plston

V-PACKING, leather, piston GLAND, female. piston CYLINDER, pump

PACKING, O-ring, NUT,

jam,l-3/8-18

unef-2b

VALVE,

inlet

GUIDE, ball

PACKING, O-ring,

BALL,

lp,

inlet

PIN,

ball

stop

V-PACKING, plastic, piston

PLUG

SEALANT

PACKING, ucup,

WASHER,

backup, aluminum

polyurethane

*Supplied

In

Repalr Klt

235-703.

Keep a repair

kit

on hand to reduce

down time.

1 1

3

1

2 1 1 1 1 1

3

1

2 1

1

1 1 1 1 1 1 1 1 1

1

308-248

29

PTFE

~~~~

~~

PARTS - COMPLETE SPRAYER

Model

231

-208,

Series

A

@

\

39

IN

PROPORTION

TO

SPRAYER

67

30

306-246

PARTS DRAWING - COMPLETE SPRAYER

Model 231 -208, Series

A

includes items 3 to 85

as

listed below

Ref

No.

Part

No.

.

Description

w

3 4

4a

4b

4c 4e

4i

ICa

5

6

10

11

lla llb 12

128 12b 13 14 15 16 17 18

20

19

21

23

24

25

26 27 28

29

30 31 32

33

34 35 36 37 38 39 42

42a 42b 42c 42d

428

111-700

235-69at

100

-069

111-616 107-503 107-784* 187-791* 107-975* 100-643

100-721

105-510

224-965

100-069

224-803

111-726

181-131 107-434 187-789 188-360" 218-359 218-364 176-818 176-817

224-999

103-345

111-706

111-715

187-631 111-611 235-037 104-938

162-453

235-009

111-602 108-850 187-624 187-652 111-705 188-421 111-612 187-895

235-004

187-627

235-014

111-699

224-968

187-615

168-110 110-110

GRIF:

handle

1

MOTOR KIT

Includes

items

4

to

4f

1

.

BALL,

SST,

114" dia.

.TERMINAL, flat, 114" (9

1

2

.TERMINAL, 3116"

(m)

2

.

LABEL, DANGER, French

1

. LABEL, DANGER, English

1

SCREW,

sch,

1/4-20

X

1"

. LABEL, Warning, Elec. Shock

1

2

LOCKWASHER. spring, 114"

5

PLUG, 114 npt DRIVE HOUSING KIT

1

Includes

item

1

la,

1

lb

1

. BALL, stainless steel, 114" dia.

1

. PLUG

1 CRANKSHAFT Includes Items 12a. 126

1

. BEARING, thrust .

BEARING

1

COVER, front

1

LABEL, Warning ROD, CONNECTING

1

GEAR REDUCER

1

PIN, straight. hdls, 318" dia. x

1'

1

SPRlNG,;&ining

PUMP KIT

see parts

on

page 29

CAPSCREW, sch,

SCREW, special Rh, 5/16-18

HANDLE, sprayer

CAI?

tubina

SCREW, Sch, 114-20~ 1-114"

7/16-14

X

1-314"

X

1-114"

LEG, w/g&set

NIPPLE, hex, 1/4 npsm x

O-RING

114 npt, 1-3116" PRESSURETRANSDUCER CLlF: 314"

SUCTION HOSE &TUBE DRAIN HOSE

LABEL, identification ADAPTER, tube, 9/16-18

TUBE, Inlet

LEG, sprayer

STRAINER DRAIN VALVE KIT Includes Items 42a

to

42e

. GASKET, valve seat . SEAT, drain valve . STEM, drain valve

.O-RING, stem

.

SEALANT, pipe (not shown)

SCREW, filh, 8-32

X

1-114"

SCREW, filh, 8-32 X 2-112"

1

3

1

2

6

4

1

1 1

2

1

3

1

1 1

1

1 1 1

1

Ret

No.

Part

No.

Description

w

43

44 45

46

47

40

49

50

51

52

53

54

55

56

58

59

62

63

64

66

67

68

74

85

224-807

111-600 187-625

235-707

110-997

186-620' 110-037

235-010 111-617

235-035

105-679

105-658 105-659 111-703 100-035 187-795 183-466*

224-828

111-704

220-955

187-770

206-994 223-541

235-677

BASE, valve

1

PIN, grooved, 3/32 x 1' 1 HANDLE, drain valve 1 SCREW, washerhex hd, 5116"

2

MOTOR START BOARD

1

LABEL, ground terminal

1

x 518"

SCREW, mach, pnhd, 10-24

1

POWER CORD

SET

1

BUSHING, strain relief, 3/8-18 npt SWITCH, ONIOFF

1

GROUND HARNESS

1

LOCKING RING

1

BOOT, switch

1 1

SCREW, filh, 10-24 X 3" 4

JUNCTION BOX

SCREW, panhd, 8-32

X

5116" 2

1

LABEL, Warning

1 SCREW, filh, 10-24 X 1-518" 2 PRESSURE CONTROL

KIT

1 BASE, motor 1 CONTRACTOR GUN

See

manual 307-614 forparts 1

TSL,

8

02.

(not shown) 1

cpld 114 npsm(9;50

R

(15 m);'

HOSE, grounded, nylon;

114"

ID

spring guards both ends FLUID FILTER

1

see manual 308-249 forparts

1

*Extra

warning

labels available

free

of

charge.

t

Motor Brush

and

Spdng Replacement

Kit,

PN.

235-727 Is available. Purchase separate&

MOTOR

308-248

31

TECHNICAL DATA

Power Requirements

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

.120

VAC,

60Hr,

Working Pressure Range

. O-2750

psi

(0

-

105

bar)

1

phase,

15

amp

minimum

Motor

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

314

HP

Cycles/Gallon (liter)

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

620

(164)

Tip Size

one

gun

to

0.017

tip

Delivety

0.50

gpm

(1.90

Ipm)

Power

Cord

No.

14AWG,3

wire.

6'

(1.8

m)

with

latex

at

2000

psi

(138

bar)

Inlet Paint

Strainer

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

12

mesh

(15%

micron)

Stainless Steel Screen, reusable

Outlet

Filter

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

60

mesh

(250

micron)

Pump

Inlet

Size

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

1/2

npt(9

wetted

Pam:

Fluid Outlet

Sire

1/4

npsm

Displacement Pump

.......

Stainless

steel,

Carbon

steel,

Alumlnum,

Polyethylene, DelrInaD, Leather

Finer.,

.........

Aluminum,

Steel,

Stainless

steel

.......

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

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

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

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

NOTE

TeRon

and Deirln

me

trademarks

ofthe

Company.

PHONE NUMBERS

T0,PUCE

AN

ORDER,

contact

your

distributor,

or

call

this

number

to

identify

the

distributor

closest

to

you:

1-800-328-0211

Toll

Free

FOR

TECHNICAL ASSISTANCE,

service

repair

infor-

mation

or

assistance

regarding

the

application

of

equipment:

1-800-543-0339

Toll

Free

DIMENSIONS

Weight (dty

wlo

packaging)

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

.36.5

Ib

(17

kg)

Height

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

19

in.

(483

mm)

Wldth

14

In.

(356

mm)

Length

15

in.

(381

mm)

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

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

ACCESSORIES

DANGER

LABELS

The

English language DANGER label shown on page

1

is

alsoonyoursprayer.Ifyouhavepalnterswhodonotread

sprayer.

The

drawing below shows the

best

placament

of

English,

order

one

ofthe

following labels

to

apply

to

your

these

labels

for

gocd

visibilii.

I

Order the

labels

directly from Gram.

free

of

charge:

1-800-328-

French Spanlsh German Greek Korean English

-021 1

Order the

labels

directly from Gram.

free

of

charge:

1-800-328-021 1

French Spanlsh 185-956

German 185-961 Greek Korean

English 187-791

THE

GRACO WARRANTY AND DISCLAIMERS

WARRANTY

.

Gram wanants

all

equlpment manufactured by

It

and beering

Its

me

to

be

from

defects

In

maWal

and

worlonsnshlp on

the

date

of

sale

by an

authorized

Gram

dlstrlbutor

to

the

original purchaser for

use.

As

purcha6$r's

8019

remedy for breach

of

this

warranty,

Gram

will,

for a pe

the

drive

tralrJg~

box

on

EM

and

GM

sprayers

or power

train

on EH

and GH sprayers,

whlch

will

be

repaired

or

replaced for twentyfour

months

rind

of

twelve

months

from

the

date

of

sale.

repair

or

replace any

part

of

the

equipment

proven

defedlve,

with

the

exception

of

del- in

parts

on

from

the

date

of

sale

for Gas-Hydraulic (OH) and

GasMechanlcal

(GM) sprayers

and

for

thlrtyaix

months

from

the

date

of

sale

for

Electric-

Mechanical

(EM),

Electric-Hydraulic

(EH),

39osl

and

49ost

sprayers.This

warranty

applies only when

the

equipment

is

Installed, operated and

maintained In sccurdance

with

Gram's

written

recommendations.

~hl~

warranty

does

not

cover, and

SMI

not

be

Ilabletor, any

Mm;&on,

damage

or

wear

c~u88d

by

taunv

Installation,

misapplication,

abrasion.

mrmsion.

inadequate or Improper

maintenance,

negligence,

ddent. tampering, M subsMutlon.of non-Gram

mmponent

parts. Nor

or

materials

not

supplied

by

Gram. or

the

improper design, manufacture,

instaltallation.

operation

or

maintenance

of

structures, nczssnries. equip

shall Gram

be

ilable

for

malfunction,

damage

or

wear

caused

by

the

Incompatlbliky

with

Qram

equipment

of

structures,

accessories.

equipment

This

warranty

is

conditioned upon

the

prepaid rehrm of

the

equipment

dalmed

to

be

defecthre

to

an

authorized

Gram

distributor for

verlRcaUon

of

mentor materials not supplied by Gram.

the

dalm.

II

the

clalmed

defect

is

vened,

Gram

wlll

repair or replace

free

of

charge

my

dm

parts.

The

equlpment

wlll

be

returned

to

the

orlglnal purchaser transportaton prepaid.

II

Inspedlon

of

the

equipment does

not

disclose any defect

In

materlal

or

workmanship, repalrs

will

be

made

at

a

reasonable

charge,

whldl

charges

may indude

the

Costs

of

parts,

lsbor and trmportatlon.

DISCLAIMERS

AND

LIMITATIONS

The

terms

of

this

warranty

constitute

purchaser's

sole

and

exduslve

remedy

and

are

in

lieu

of

any

other

warmties

(express

01

implied),

lncludlng warranly

of

merchantnblllly

or

wamnly

of

fltnesl

for

a

prtleular

purpose,

and of any non-contractual liabilities, including

product

liabilities,

based

on

negligence

or

strlct

Ilablllty.

Every

form

of

liability

for direct,

special

or

consequential

damages or

loss

is

expressly

excluded

and

denied. In no

case

shall

Graw's

iiabllity

exceed

the

amount

of

tiw

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

sorles,

equipment, materials, or

mmponents

6o!d

but

not

manufactured

tff

graco.

maSa

items

wid,

but

not

manufactured

by

Gram (such

88

Gram

makes

no

warranty,

and disclaims

all

Implied wanantlea

of

merchantmblllty

and

Mnerrs

for

a

particular

purpose.

wivl

respect

to

BCCBS

tanm

in

making

any claim for breach

of

these

wBnBn11es.

electric

motor,

switches.

hose.

etc.)

are

subject

to

the

warmly,

H

any,

of thelr manufacturer. Graco

will

provide purchaser

wiIh

reasonable

assis-

r

Subsldlay

and

Atllllate

Cornpanlea:

Canada; England; Korea, Swikerland; France; Germany; Hong Kong; Japan

GRACO INC.

RO.

BOX

1441 MINNEAPOLIS,

MN

55440-1441

Factory

Branches:

Atlanta,

Dallas,

Detroit,

Los

Angeles,

Mt.

Arlington

(N.J.)

PRINTED

IN

U.SA.

308-248

11

-92

PTFE

Graco 235-699, 231-208 Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual