Page 1
INSTRUCTIONS-PARTS LIST
308–180
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
First choice when
quality counts.
ELECTRIC, 120 VAC
390st Airless Paint Sprayer
2750 psi (19.5 MPa, 195 bar) Maximum Working Pressure
Model 231–201, Series D
Standard mount; complete sprayer with hose, gun,
RAC IV DripLess Tip Guard and SwitchTip
Model 231–328, Series A
Basic sprayer only
Rev. E
Supersedes Rev D
and PCN E
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
02821A
Model 231–201 Shown
COPYRIGHT 1992, GRACO INC.
Page 2
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 5. . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown and Care 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Test 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information 18. . . . . . . . . . . . . . . . . . . . .
Motor Brush 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 21. . . . . . . . . . . . . . . . . . . . .
Motor 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Start Board 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Cord 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
ON/OFF Switch 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing, Connecting Rod, Crankshaft 27. . . . . .
Pressure Control 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer 30. . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Hose 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Valve 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Parts Drawing and List 33. . . . . . .
Model 231–201 and 231–328
Sprayer Parts Drawing 34. . . . . . . . . . . . . . . . . . . . . . . . .
Model 231–201 and 231–328
Sprayer Parts List 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty and Disclaimers 36. . . . . . . . . . . . . . . .
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
If there is any static sparking or you feel an electric shock while using this equipment, stop
spraying immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not operate a gasoline engine in the spray area.
2 308-180
Page 3
WARNING
WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause serious injury.
Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious
injury. Get immediate medical attention.
Do not point the gun at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip.
Do not stop or deflect leaks with your hand, body, glove or rag.
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the gun when spraying.
Check the gun diffuser operation weekly. Refer to the gun manual.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 9 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do
not repair high pressure couplings; you must replace the entire hose.
Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the Pressure Relief Procedure on page 9 to prevent the
equipment from starting unexpectedly.
308–180 3
Page 4
INSTRUCTIONS
WARNING
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call Graco Technical Assis-
tance at 1–800–543–0339.
Do not alter or modify this equipment.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. Refer to
the Technical Data on page 36 for the maximum working pressure of this equipment.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warn-
ings.
Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-
pose Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
NOTE: This is an example of the DANGER label on
your sprayer. This label is available in other
languages, free of charge. See page 36 to order.
FIRE AND
EXPLOSION HAZARD
Spray painting, flushing or cleaning equipment with flammable liquids in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equipment, hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic drop
cloths, open flames such as pilot lights, hot objects such as cigarettes, arcs from connecting or disconnecting power cords or turning light switches on and off.
Failure to follow this warning can result in death or serious injury.
SKIN INJECTION
HAZARD
Liquids can be injected into the body by high pressure airless spray
or leaks – especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts.Avoid accidental triggering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical Treatment”.
Failure to follow this warning can result in amputation or serious
injury.
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
4 308-180
Page 5
Component Identification and Function
N
B
H
K
E
G
C
A
D
M
F
L
J
Model 231–201 Shown
Fig. 1
02823A
A Motor DC motor, 120 Vac, 15A, 1 phase
B Drive Assembly Transfers power from DC motor to the displacement pump
C Pressure Adjusting Knob Controls fluid outlet pressure
D ON/OFF Switch Power switch that controls 120 Vac power to sprayer
E Fluid Outlet Hose and spray gun is connected here
F Displacement Pump Pressurizes fluid to be sprayed through spray gun
G 50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
H RAC IV Tip Guard Reverse-A-Clean (RAC) tip guard reduces the risk of fluid injection inju-
ry
J Contractor Gun High pressure spray gun with gun safety latch
K RAC IV Switch Tip RAC switch tip atomizes fluid and removes clogs from spray tip without
removing tip from spray gun
L Pressure Drain Valve Relieves fluid pressure when open
M Pressure Control Controls motor to maintain fluid pressure. Works with pressure
adjusting knob.
N Spray Gun Safety Latch Inhibits accidental triggering of spray gun
308–180 5
Page 6
Setup
WARNING
If you supply your own hoses and spray gun, be
sure the hoses are electrically conductive, that the
gun has a tip guard, and that each part is rated for
at least 2750 psi (19.5 MPa, 195 bar) Working
Pressure. This is to reduce the risk of serious injury caused by static sparking, fluid injection or overpressurization and rupture of the hose or gun.
2. Fill the wet–cup (102). Pry off the wet-cup seal.
Fill the cup 1/3 full with Graco Throat Seal Liquid
(TSL), supplied. Install the wet-cup seal.
3. Plug in the sprayer. Be sure the ON/OFF switch
(52) is OFF. Plug the cord into a 15A grounded
outlet at least 20 feet away from the spray area. A
12 AWG 150 ft (45 m) grounded extension cord
may be used.
WARNING
CAUTION
To avoid damaging the pressure control, which
may result in poor equipment performance and
component damage, follow these precautions:
1. Always use a nylon spray hose at least 50 ft.
(15 m) long.
2. Never use a wire braid hose as it is too rigid to
act as a pulsation dampener.
3. Never install any shutoff device between the
filter and the hose. See Fig. 2.
1. Connect the hose (74) and gun (67) and screw it
onto the outlet nipple (28). Don’t use thread
sealant, and don’t install the spray tip yet!
1
1/4 npsm(m) fluid outlet
2
Do not install any shutoff device here
3
Rotate clockwise to increase pressure
4
Shown in closed or spray position
5
Fill 1/3 full with TSL
FIRE AND EXPLOSION HAZARD
Proper electrical grounding is essential
to reduce the risk of fire or explosion
which can result in serious injury and
property damage. Also read FIRE OR
EXPLOSION HAZARD on page 2.
4. Flush the pump to remove the lightweight oil
which was left in to protect pump parts after factory testing. See page 12.
5. Prepare the paint according to the manufactuers’s recommendations. Remove any paint skin.
Strain the paint through a fine nylon mesh bag
(available at most paint dealers) to remove particles that could clog the spray tip. This is an important step toward trouble-free paint spraying.
32
33
3
64
74
67
Fig. 2
6 308-180
12
28
52
4
5
102
Model 231–201 Shown
02823A
Page 7
Operation
A
How to use the gun trigger safety
When engaged, the gun safety latch prevents the gun
from accidental triggering. See Fig. 3.
WARNING
INJECTION HAZARD
If the gun still sprays when the gun trigger safety is locked, repair the gun. See
manual 307–614, supplied.
Gun safety latch
1
shown engaged
Gun safety latch
2
shown disengaged
1
2
Open or drain, position
1
2
Closed, or spray position
1
2
Fig. 4
02825
How to use the pressure control.
The pressure control controls the motor operation so
the sprayer maintains constant fluid pressure at the
pump outlet. Turn the pressure control knob fully counterclockwise to obtain the minimum setting. Turn the
knob clockwise to increase pressure. See Fig. 5.
Fig. 3
How to use the pressure drain valve.
Use the pressure drain valve to relieve fluid pressure
from the pump and to help prime the pump. If the valve
senses an over pressure condition, it opens automatically to relieve fluid pressure. If this happens, stop
spraying immediately, shut off and unplug the sprayer.
Determine the cause of the problem and correct it before operating the sprayer again. Refer also to the
Troubleshooting, page 13. See Fig. 4.
Fig. 5
+
–
02824A
308–180 7
Page 8
Operation
How to use the RAC IV tip guard.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
The tip guard alerts you to the risk and helps prevent
placing any part of the body close to the spray tip. The
tip guard also adjusts the vertical or horizontal spray
pattern. See Fig. 8. The tip guard holds a reversing
spray tip. The tip is in the spraying position when the
tip handle points forward. See Fig. 6.
2
04647
Tip handle shown in
spraying position.
1
Turn handle 180,
2
trigger gun to clear clog
Fig. 6
1
How to remove a tip clog.
1. Release the gun trigger. Lock the safety latch. Rotate the RAC IV tip handle 180. See Fig. 6.
2. Unlock the safety latch. Trigger the gun into a pail
or onto the ground to remove the clog.
3. Lock the safety latch. Rotate the tip handle to the
spraying position.
Clean the front of the tip frequently during the day’s
operation. First, follow the Pressure Relief Procedure
on page 9.
4. If the tip is still clogged, lock the safety latch, shut
off and unplug the sprayer, and open the pressure
drain valve to relieve pressure. Clean the spray tip
as shown in manual 307–848, supplied.
8 308-180
Page 9
WARNING
Startup
NOTE: Refer to Fig. 2 and the other figures referenced
in the text as you start the sprayer.
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tip.
Pressure Relief Procedure
1. Engage the gun safety latch.
2. Turn the ON/OFF switch to OFF.
3. Unplug the power supply cord.
4. Disengage the gun safety latch. Hold a metal part
of the gun firmly to a grounded metal pail. Trigger
the gun to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve. Leave the pressure
drain valve open until you are ready to spray
again.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, VERY SLOWLY loos-
en the tip guard retaining nut or hose end coupling to
relieve pressure gradually, then loosen completely.
Now clear the tip or hose obstruction.
Startup Procedure
Use this procedure each time you start the sprayer to
help ensure the sprayer is ready to operate and that
you start it safely.
NOTE: If this is a first-time startup, flush the sprayer.
See page 12.
1. Open the pressure drain valve (42). See Fig. 7.
2. Don’t install the spray tip until the pump is
primed!
3. Put the suction hose (32) into the paint. If you
are pumping from a pail, push the drain hose (33)
down below the top of the pail to avoid splashing
paint when the drain valve is opened.
1
42
Open or drain, position
1
Fig. 7
4. Turn the pressure knob (64) to the minimum
setting.
5. Disengage the gun trigger safety. See Fig. 3,
page 7.
01021A
CAUTION
Do not run the sprayer dry for more than 30 seconds to avoid damaging the pump packings.
6. To prime the pump, turn the sprayer switch (52)
on. Slowly increase the pressure until the sprayer
starts. When fluid comes from the pressure drain
valve, close the valve.
308–180 9
Page 10
WARNING
FIRE AND EXPLOSION HAZARD
To reduce the risk of static sparking and
splashing when priming or flushing the
system, hold a metal part of the gun
firmly to the side of a grounded metal pail before
triggering the gun.
Startup
b. If more coverage is needed, use a larger tip
rather than increasing the pressure.
c. Adjust the direction of the spray pattern. See
Fig. 8. Engage the gun safety latch. Loosen
the retaining nut (A). Position the tip guard for
a horizontal or vertical pattern. Hold the tip
guard in place and tighten the retaining nut.
7. To prime the hose, lower the pressure to reduce
splashing. Hold a metal part of the gun firmly
against and aimed into a grounded metal pail. See
the preceding WARNING. Hold the gun trigger
open and slowly increase the pressure until the
pump starts. Keep the gun triggered until all air is
forced out of the system and the fluid flows freely
from the gun. Release the trigger and engage the
gun safety latch.
8. Check all fluid connections for leaks. Relieve
pressure before tightening the connections.
9. Engage the gun safety latch.
10. Install the spray tip and tip guard. Install the
spray tip. If you are using the RAC IV tip guard,
refer to manual 307–848 for installation instructions.
11. Adjust the spray pattern
a. Increase the pressure until spray from the gun
is completely atomized. To avoid excessive
overspray and fogging, and to extend tip and
sprayer life, always use the lowest pressure
needed to get the desired results.
NOTE: Spray patterns will change as tips wear.
Change the spray tip if adjusting the pressure will not
improve the spray pattern.
1
A
2
01025
1
2
Fig. 8
For a vertical
spray pattern
For a horizontal
spray pattern
10 308-180
Page 11
Shutdown and Care
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
Shutdown and Care
1. Check the packing nut/wet-cup daily (102). Relieve pressure first. Keep the wet-cup 1/3 full of
TSL at all times to help prevent fluid buildup on the
piston rod and premature wear of packings.
2. Tighten the packing nut/wet-cup (102) just
enough to stop leakage. Over-tightening causes
binding and excessive packing wear. Use a round
punch or brass rod and a light hammer to adjust
the nut. See Fig. 9.
3. Periodically clean paint residue from the pres-
sure transducer (29) vent hole area. See Fig. 10.
Replace the transducer when leakage is excessive. See page 30.
4. Lubricate the bearing housing after every 100
hours of operation. Remove the front cover. Fill the
bearing housing cavity (A) with SAE 10 nondetergent oil. See Fig. 10.
5. Flush the sprayer at the end of each work day
and fill it with mineral spirits to help prevent pump
corrosion and freezing. See page 12.
Turn packing
1
nut clockwise to
tighten
Fig. 9
1
Vent hole
1
WARNING
INJECTION HAZARD
See the warning section INJECTION
HAZARD on page 3 for information on
the hazard of using damaged hoses.
1
102
29
A
05117
CAUTION
To prevent pump corrosion, and to reduce the
chance of fluid freezing in the pump in cold weather,
never leave water or any type of paint in the sprayer
when it is not in use. Freezing can seriously damage the sprayer or result in a loss of pressure or
stalling.
6. For very short shutoff periods, leave the suction
tube in the paint, relieve pressure, and clean the
spray tip.
7. Coil the hose and hang it on a hose rack when
storing it, even for overnight, to help protect the
hose from kinking, abrasion, coupling damage, etc.
Fig. 10
02827A
308–180 11
Page 12
Flushing
When to Flush
1. Before using a new sprayer: flush out the oil
which was left in to protect pump parts.
Before using water-base paint: flush with mineral spirits followed by soapy water, and then a
clean water flush.
Before using oil-base paint: flush with mineral
spirits only.
2. Changing colors: flush with a compatible solvent
such as mineral spirits or water.
3. Changing from water-base to oil-base paint:
flush with warm, soapy water, and then mineral
spirits.
4. Changing from oil-base to water-base paint:
flush with mineral spirits, then warm, soapy water,
and then a clean water flush.
5. Storage after using water-base paint: flush with
water and then mineral spirits. Leave the system
filled with mineral spirits. Relieve pressure. Leave
the drain valve open.
Storage after using oil-base paint: flush with
mineral spirits. Relieve pressure. Leave the drain
valve open.
CAUTION
3. Pour one-half gallon (2 liters) of compatible solvent
into a grounded metal flushing pail. Put the suction
hose in the pail.
4. Open the pressure drain valve. See Fig. 4, page
7.
5. To save the paint still in the pump and hose,
follow Step 6, except put the drain tube in the paint
pail. When solvent appears, close the drain valve.
Put the drain tube in the flushing pail. Trigger the
gun into the paint pail. When solvent appears, release the trigger. Continue with Step 6.
WARNING
FIRE AND EXPLOSION HAZARD
To reduce static sparking and splashing,
always remove the spray tip from the
gun, and hold a metal part of the gun
firmly to the side of a grounded metal pail when
flushing.
6. Lower the pressure setting. Turn on the sprayer.
Maintaining metal-to-metal contact, trigger the gun
into the flushing pail. Slowly increase the sprayer
pressure until the pump starts. Keep the gun triggered until the solvent flows freely from the gun.
Circulate the solvent to thoroughly clean the sprayer. Release the gun trigger. Engage the gun trigger
safety.
Never allow water to freeze in the pressure control.
Doing so prevents the sprayer from being started
and may cause serious damage. Push the water out
with mineral spirits.
6. Startup after storage. Before using water-base
paint, flush out the mineral spirits with soapy water
and then clean water. When using oil-base paint,
flush out the mineral spirits with the paint.
How to Flush
1. Follow the Pressure Relief Procedure on
page 9.
2. Remove the spray tip and clean it separately. Remove the filter screen and then reinstall the bowl,
hand tight, without the screen. Clean the screen
separately. (See instruction manual 308–249.)
7. Open the drain valve and circulate the solvent
through the drain tube to thoroughly clean it. Close
the drain valve.
8. Remove the suction hose from the pail. Disengage
the gun trigger safety. Trigger the gun and run the
pump a few seconds to push air into the hose. Do
not run the pump dry for more than 30 seconds to
avoid damaging the pump packings! Relieve pressure.
9. Remove and clean the inlet strainer. Wipe paint off
the suction hose and drain tube.
10. Refer to When To Flush, Step 1 again. Relieve
pressure.
11. Leave the drain valve open until you use the
sprayer again.
12 308-180
Page 13
Troubleshooting
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the
Pressure Relief Procedure on page 9.
Basic Problem Solving
Check everything in the troubleshooting table before disassembling the sprayer.
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
Fluid pressure 1. Check pressure control knob setting. The pump
won’t develop much pressure if it is at minimum
setting (fully counterclockwise).
2. Check for a clogged spray tip or fluid filter, if
used. See page 8.
Mechanical 1. Check for frozen or hardened paint in pump
(20). Using a screwdriver, carefully try to rotate
fan at back of motor by hand. See page 17.
2. Check pump connecting rod pin (17). It must be
completely pushed into connecting rod (15),
and retaining spring (18) must be firmly in connecting rod groove. See Fig. 17, page 21.
3. Check for motor damage. Remove drive housing assembly (11). See page 27. Try to rotate
motor fan by hand.
Electrical 1. Check electrical supply with volt meter. Meter
should read 105–125 VAC.
2. Check extension cord for visible damage. Use
a volt meter or test lamp at extension cord outlet to check.
WHAT TO DO
When check is not OK, refer to this column
1. Slowly increase pressure setting to see if
motor starts.
2. If tip is still clogged, relieve pressure; refer to separate gun or tip instruction manual for tip cleaning. Clean or replace filter
element. See manual 308–249.
1. Thaw. Plug in sprayer and turn on. Slowly
increase pressure setting to see if motor
starts. If it doesn’t, see NOTE, below.
2. Push pin into place and secure with
spring retainer.
3. Replace motor (4) if fan won’t turn. See
page 25.
1. Reset building circuit breaker; replace
building fuse. Try another outlet.
2. Replace extension cord.
3. 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.
d. Broken leads.
e. Worn brushes.
NOTE: The brushes do not wear at same rate
on both sides of motor. Check both brushes.
NOTE: Thaw sprayer if water or water–based paint has frozen in it, due to exposure to low temperatures, by placing in a warm
area. Do not try to start sprayer until completely thawed or damage to motor and/or start board may occur. If paint hardened
(dried) in sprayer, the pump packings (page 21) and/or pressure transducer (page 30) must be replaced.
ible damage such as broken insulation or wires.
3. Replace power supply cord.
See page 26.
4. Refer to page 19.
a. Tighten.
b. Replace broken spring and/or align
spring with brush
c. Clean brush holders. Remove carbon
with small cleaning brush. Align brush
leads with slot in brush holder to as-
sure free vertical brush movement.
d. Replace brushes
e. Replace brushes if less than 0.5 in.
long.
308–180 13
Page 14
Basic Problem Solving
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
Electrical (continued) 5. Check motor armature commutator for burn
spots, gouges and extreme roughness. Remove motor cover and brush inspection plates
to check. See page 19.
6. Check motor armature for shorts using armature tester (growler) or perform motor test.
See page 17.
7. Check leads from pressure control and motor to
motor start board (47) to be sure they are securely fastened and properly mated.
8. Check motor start board (47) by substituting
with a good board. See page 26.
CAUTION: Do not perform this check until motor armature is determined to be good. A bad
motor armature can burn out a good board.
9. Check power supply cord (50). Disconnect
black and white power cord terminals; connect
volt meter to these leads. Plug in sprayer. Meter
should read 105–125VAC. Unplug sprayer.
10. Check ON/OFF switch (52). Disconnect the
motor start board (47) and switch and connect
volt meter between exposed terminal on switch
and power cord’s white wire. Plug in sprayer
and turn ON. Meter should read 105–125VAC
Turn off and unplug sprayer.
WHAT TO DO
When check is not OK, refer to this column
5. Remove motor and have motor shop
resurface commutator if possible. See
page 25.
6. Replace motor. See page 25.
7. Replace loose terminals; crimp to leads.
Be sure male terminal blades are straight
and firmly connected to mating part.
8. Replace board. See page 26.
9. Replace power supply cord. See page
26.
10. Replace ON/OFF switch. See page 26.
11. Check motor thermal cutout switch. Connect
ohmmeter between motor’s red leads. Meter
should read 1 ohm maximum.
12. Remove pressure control (64) and check microswitch operation with ohmmeter:
(1) With pressure knob at lowest setting and
stem pushed into control, readings should
be: white & black = 1 ohm max.
white & red = open.
(2) With pressure knob at highest setting,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 30.
11. Allow motor to cool. Correct cause of
overheating. If switch remains open after
motor cools, replace motor.
12. Replace pressure control. See page 29.
13. Replace transducer. See page 30. Thorough system flushing will help extend life
of transducer.
Intermediate Problem Solving
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
Low output 1. Check for worn spray tip. 1. Follow Pressure Relief Procedure then
2. Be sure pump does not continue to stroke
when gun trigger is released. Plug in and turn
on sprayer. Prime with paint. Trigger gun momentarily, then release and lock safety latch.
Relieve pressure, turn off and unplug sprayer.
WHAT TO DO
When check is not OK refer to this column
replace tip. See your separate gun or tip
manual.
2. Service pump. See page 21.
14 308-180
Page 15
Intermediate Problem Solving
TYPE OF PROBLEM WHAT TO CHECK
If check is OK, go to next check
Low output (continued) 3. Release gun trigger. Observe resting position of
pump rod (107).
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 ft
(45 m) long.
6. Check motor brushes. See Electrical – What To
Check, item 4, on page 13.
7. Check motor start board (47) by substituting
with a good board.
CAUTION: Do not perform this check until motor armature is determined to be good. A bad
motor armature can burn out a good board.
8. Check motor armature for shorts by using an
armature tester (growler) or perform motor test.
See page 17.
Drain valve leaks 1. Check drain valve for correct torque and/or
worn parts. Check for debris trapped on seat.
WHAT TO DO
When check is not OK, refer to this column
3. If pump consistently comes to rest with
rod (107) fully extended, the piston packings and/or piston valve may be worn.
Service the pump. See page 21.
4. Reset building circuit breaker; replace
building fuse. Repair electrical outlet or
try another outlet.
5. Replace with a correct, grounded extension cord.
6. See page 19.
7. Replace board. See page 26.
8. Replace motor. See page 25.
9. Tighten to 185 in–lb (21 N.m). Clean
valve and replace with new gasket (42a)
and sealant (42d). See page 32.
Transducer leaks 1. Slight leakage from transducer is normal. 1. Periodically remove residue from its cyl-
No output: motor runs and
pump strokes
No output: motor runs but
pump does not stroke
1. Check paint supply. 1. Refill and reprime pump.
2. Check for clogged intake strainer. 2. Remove and clean, then reinstall.
3. Check for loose suction tube or fittings. See
page 31.
4. Check to see if intake valve ball and piston ball
are seating properly. See page 21.
5. Check for leaking around throat packing nut
which may indicate worn or damaged packings.
See page 21.
6. Release gun trigger. Observe resting position of
pump rod (107).
1. Check displacement pump connecting rod pin
(17). See Fig. 17, page 21.
7. Check connecting rod assembly (15) for damage. See page 27.
inder port. See page 30.
3. Tighten; use thread sealant on npt
threads of adapter (38).
4. Remove intake valve and clean. Check
ball and seat for nicks; replace as needed. See page 21. Strain paint before using to remove particles that could clog
pump.
5. Replace packings. See page 21. Also
check piston valve seat for hardened
paint or nicks and replace if necessary.
Tighten packing nut/wet-cup.
6. If pump consistently comes to rest with
rod (107) fully extended, the piston packings and/or piston valve may be worn.
Service the pump. See page 21.
1. Replace pin if missing. Be sure retainer
spring (18) is fully in groove all around
connecting rod.
7. Replace connecting rod assembly. See
page 27.
8. Be sure crank in drive housing rotates; plug in
sprayer and turn on briefly to check. Turn off
and unplug sprayer. See page 27.
8. Check drive housing assembly for
damage and replace if necessary. See
page 27.
308–180 15
Page 16
Intermediate Problem Solving
TYPE OF PROBLEM WHAT TO CHECK
Spray Pattern Variations
Motor Is Hot and Runs
Intermittently
Building Circuit Breaker
Opens As Soon As Sprayer
Switch Is Turned On.
If check is OK, go to next check
1. Spray tip worn beyond sprayer pressure capability.
2. Check transducer (29) for wear or damage. 2. Replace transducer. See page 30.
3. Check pressure control (64) for smooth operation.
4. Check Low output section, page 15.
1. Determine if sprayer was operated at high pressure with small tips, which causes excessive
heat build up.
2. Be sure ambient temperature where sprayer is
located is no more than 90
sprayer is not located in direct sun.
3. Check motor. 3. Replace motor. See page 25.
1. Check all electrical wiring for damaged insulation, and all terminals for loose fit or damage.
Also check wires between pressure control and
motor. See page 25.
2. Check for missing motor brush inspection plate
gasket (see page 17), bent terminal forks or
other metal to metal contact points which could
cause a short.
F (32C) and
WHAT TO DO
When check is not OK, refer to this column
1. Replace spray tip.
NOTE: A smaller size tip will provide
longer life.
3. Replace pressure control. See page 29.
1. Decrease pressure setting or increase tip
size.
2. Move sprayer to shaded, cooler area if
possible.
1. Repair or replace any damaged wiring or
terminals. Securely reconnect all wires.
2. Correct faulty conditions.
Circuit breaker opens after
sprayer operates for 5 to 10
minutes.
Building circuit breaker
opens as soon as sprayer
is plugged into outlet and
sprayer is NOT turned on.
Unit will not run on generator but does run on AC
power
3. Check motor armature for shorts. Use an armature tester (growler) or perform motor test. See
page 17. Inspect windings for burns.
4. Check motor start board (47) by substituting
with a good board.
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
13.
1. Check ON/OFF switch (52). Be sure sprayer is
unplugged! Disconnect wires from switch.
Check switch with ohmmeter. The reading
should be infinity with ON/OFF switch OFF,
and zero with switch ON.
CAUTION: A short in motor circuit can damage
switch and or motor start board (47).
2. Check electrical supply with volt meter. Meter
should read 105–125 VAC.
Check the generator’s peak voltage. This sprayer will
not run if the peak voltage is above 190V.
3. Replace motor. See page 25.
4. Replace board. See page 26.
1. Replace ON/OFF switch. See page 26.
2. If voltage is too high, do not operate
sprayer until corrected.
Use AC power or a different generator
16 308-180
Page 17
Motor Test
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
For checking armature, motor winding and brush electrical continuity.
Setup
Remove the drive housing. See page 27. This is to
ensure that any resistance you notice in the armature
test is due to the motor and not to worn gears in the
drive housing.
Remove the motor brush inspection covers (A). See
Fig. 11.
Remove the junction box screws (56). Lower the junction box. Disconnect the two leads (C) from the motor
to the board (47). See Fig. 12.
B
A
Armature Short Circuit Test
Remove the fan cover (B). See Fig. 11.
Spin the motor fan by hand. If there are no shorts, the
motor will coast two or three revolutions before coming
to a complete stop. If the motor does not spin freely,
the armature is shorted and the motor must be replaced. See page 25.
Armature, Brushes, and Motor Wiring
Open Circuit Test (Continuity)
Connect the two black motor leads together with a test
lead. Turn the motor fan by hand at about two revolutions per second.
When turning the fan on a DC motor, normally you
sense an even, pulsing resistance. If there is irregular
turning resistance, or no turning resistance, check and
repair the following as needed: broken brush springs,
brush leads, motor leads; loose brush terminal screws
or motor lead terminals; worn brushes. See page 19.
If there is still uneven or no turning resistance, replace
the motor. See page 25.
Fig. 11
BLACK
59
Fig. 12
02829A
MOTOR
BLACK/
WHITE
C
RED
56
47
04720
308–180 17
Page 18
General Repair Information
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
Tool List
These are the tools required to service all parts of the
sprayer.
3/16” Allen wrench: gear housing, legs, handle
3/8” Allen wrench: pump manifold
#1 Phillips screwdriver: junction box,
pressure control, front cover
3/8” socket wrench: motor mount
5/8” socket wrench: drain valve, outlet fittings,
on/off switch boot, piston
13/16” socket wrench: drain valve
1-1/4” socket wrench: pump inlet valve
1/2” open end wrench: pump rod
11/16” open end wrench: piston jam nut
15/16” open end wrench: flats of inlet tube
1-3/4” open end wrench: pump jam nut
5/64” drive pin: drain valve pin
3” needle nose pliers: wiring, on/off switch
Hammer & punch: packing nut
Torque wrenches: various fasteners
WARNING
HOT SURFACE HAZARD
During operation, the motor and drive
housing become very hot and could burn
your skin if touched. Flammable materials spilled on the hot, bare motor could cause a fire
or explosion
CAUTION
To reduce the risk of a pressure control malfunction, be sure to properly mate connectors, and
never pull on a wire to disconnect it. Pulling on a
wire could loosen the connector from the wire.
1. When disconnecting wires in the junction box
assembly, use needle nose pliers to separate mating connectors.
2. When reconnecting the wires, be sure the flat
blade of the insulated male connector is centered
in the wrap–around blade of the female
connector.
CAUTION
Improper wire routing can result in poor sprayer
performance or damage to the pressure control.
WARNING
MOVING PARTS HAZARD
To reduce the risk of serious injury, including electric shock, DO NOT touch
any moving parts or electrical parts with
your fingers or a tool while inspecting the repair.
Shut off the sprayer and unplug it as soon as you
complete the inspection.
Reinstall all covers, gaskets, screws and washers
before operating the sprayer.
3. Route wires carefully through the drive housing
and motor. Avoid pinching the wires between the
junction box and the motor or pressure control.
4. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair procedures. These parts are not normally provided with
replacement assemblies.
5. Test your repair before regular operation to be
sure the problem is corrected.
6. If the sprayer does not operate properly, verify
that everything was done correctly. Also refer to
the Troubleshooting Guide, pages 13–17, to help
identify other possible problems and solutions.
18 308-180
Page 19
Motor Brushes
NOTE: Replace brushes when worn to about 0.5 in.
(12.5 mm). Always check both brushes. Brush Repair
Kit 236–967, which includes spring clip 112–766, is
available for motors manufactured by Pacific Scientific.
NOTE: Replacement brushes may last only half as
long as the original ones. To maximize brush life, break
in new brushes by operating the sprayer for at least
one hour with no load (remove the pump connecting
rod pin).
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
Motor lead; do not disconnect
1
2 Minimum 0.5” (12.5 mm)
Included in Brush Repair
3
Kit 236–967
2
C
G
3
F
H
1
B
E
Fig. 14
D
03881
4. Inspect the commutator for excessive pitting, burning or gouging. A black color on the commutator is
normal. Have the commutator resurfaced by a
qualified motor repair shop if the brushes seem to
wear too fast or arc excessively. See Step 9.d.,
also.
1. Remove both inspection covers (A) and their gaskets. See Fig 13.
A
02831A
Fig. 13
2. Push in the spring clip (F) and release its hook (G)
from the brush holder (B). Pull out the spring clip.
See Fig 14.
3. Slide off the brush lead terminal (E) off the blade
connector. Remove the old brush (C). See Fig 14.
5. Repeat for the other side.
NOTE: The motor brushes on the other side are
upside down.
6. Place a new brush (C) in the holder (B) so the
ramp (H) faces the spring. See Fig. 16.
1
F
G
C
Fig. 15
E
03881
7. Holding the spring clip (F) at a slight angle, slide
the spring clip into the brush holder and hook it
over the end of the holder. See Fig. 15. Pull on the
spring clip to be sure it stays in place. Connect the
brush lead to the blade connector (E).
8. Repeat for the other side.
308–180 19
Page 20
Motor Brushes
9. Test the brushes.
a. Remove the pump connecting rod pin (17).
See Fig. 17, page 21.
b. With the sprayer OFF, turn the pressure con-
trol knob fully counterclockwise to minimum
pressure. Plug in the sprayer.
c. Turn the sprayer ON. Slowly increase the
pressure until the motor is at full speed.
WARNING
MOVING PARTS HAZARD
Do not touch the brushes, leads, springs
or brush holders while the sprayer is
plugged in to reduce the risk of electric
shock and serious injury.
10. Install the brush inspection covers and gaskets.
d. Inspect the brush and commutator contact area
for excessive arcing. Arcs should not trail or
circle around the commutator surface.
11. Break in the brushes. Operate the sprayer for at
least one hour with no load. Install the pump
connecting rod pin. See Fig. 17, page 21.
20 308-180
Page 21
Displacement Pump Repair
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
NOTE: Packing Repair Kit 235–703 is available. Refer-
ence numbers of parts included in the kit are marked
with an asterisk, i.e., (121*). For the best results, use
all the new parts in the kit, even if the old ones still look
good.
NOTE: To minimize down time, and for the best sprayer
performance, check the motor brushes (see page 19)
and clean the transducer (see page 30) whenever you repack the pump. Replace these parts as needed.
Removing the pump (See Fig. 16.)
1. Flush the pump, if possible. Relieve pressure. Stop
the pump with the piston rod (107) in its lowest
position, if possible. To lower the piston rod manually, rotate the motor fan blades.
2. Remove the filter (85).
3. While pulling upward on the suction hose (32), unscrew the hose from the inlet tube (38). Unscrew
the drain hose (33) from the displacement pump
nipple (36).
NOTE: If repairing only the intake valve assembly, go
to Intake valve repair, page 22.
4. Use a screwdriver to push the retaining spring (18)
up and push out the pin (17).
5. Loosen the screws (21). Remove the pump (20).
Installing the pump (See Fig. 16 and 17.)
1. Mount the pump on the drive housing. Tap it into
the alignment pins with a soft hammer. Tighten the
screws (21) to 50 ft-lb (68 N.m).
2. Align the hole in the rod (107) with the connecting
rod assembly (15). Use a screwdriver to push the
retaining spring (18) up and push in the pin (17).
Push the retaining spring (18) into place around
the connecting rod.
3. Replace the o-ring (27) if it is worn or damaged.
Reconnect the suction and drain hoses (32,33).
Install the front cover (13).
4. Tighten the packing nut (102) just enough to stop
leakage, but no tighter. Fill the packing nut/wet-cup
1/3 full with Graco TSL. Push the plug (123) into
the wet-cup.
13
Fig. 16
1
85
18
107
20
21
33
32
27
38
2
17
*122
*121
36
*119
118
Torque to
1
50 ft–lb (68 N.m)
2
Apply sealant (42d)
120
02832
WARNING
MOVING PARTS HAZARD
Be sure the retaining spring (18) is firmly
in the groove all the way around, to prevent the pin (17) from working loose due
to vibration. See Fig. 17.
If the pin works loose, it or other parts could break
off due to the force of the pump action. These parts
could be projected into the air and result in serious
injury or property damage, including the pump connecting rod or drive housing.
Torque to
1
50 ft–lb (68 N.m)
Fig. 17
15
123
21
17
1
308–180 21
18
102
04655
Page 22
Displacement Pump Repair
Intake valve repair (See Fig. 16)
1. Remove the suction hose. See Step 3, Removing
the pump.
2. Unscrew the intake valve (118). Remove the
o-ring (119*), ball guide (120), stop pin (122*) and
ball (121*) from the valve.
3. Clean and inspect the parts for wear or damage.
Replace parts as needed. Use a new o–ring
(119*). If no further service is needed, reassemble
the pump.
Disassembling the pump (See Fig. 18.)
1. Remove the intake valve (118).
2. Loosen the packing nut (102) and plug (123).
3. Use a plastic mallet to tap the piston rod (107)
down, and then pull the rod out through the bottom
of the cylinder.
4. Remove the packing nut (102) and throat packings.
5. Loosen the jam nut (117). Remove the cylinder
(115) and the o-ring (116*).
6. Clamp the flats of the piston rod in a smooth jaw
vise. Use an open-end wrench to loosen the nut
(110) and then unscrew the piston valve (108).
1. Check the outside of the piston rod (107) and the
inside of the cylinder (115) for wear. Replace worn
parts to ensure a good seal with the new packings.
2. Stack these parts onto the piston valve (108) one
at a time: the female gland (114*), alternately three
plastic (112*) with two leather packings (113*), and
the male gland (111*). See Fig. 18.
1
Throat packings
2
Piston packings
Intake valve
3
123
102
*103
1
107
105*
*104
106*
109*
110
111
*113
112*
101
114*
117
108
2
7. Remove all parts from the piston valve (108).
Reassembling the pump
NOTE: Alternate plastic and leather packings. See Fig.
18. The lips of the throat V-packings face down. The
lips of the piston V-packings face up. Incorrect installation damages the packings and causes pump leakage.
NOTE: Soak the leather packings in oil before reassembling the pump.
*116
115
Fig. 18
122*
120
121
3
119
118
01069A
22 308-180
Page 23
Displacement Pump Repair
3. Tighten the nut (110) onto the piston valve (108) to
5 in-lb (0.57 N.m). See Fig. 19.
Torque to
1
5 in–lb (0.57 N.m)
Apply one drop of
2
sealant to these
threads
107
109*
110
*111
*113
112*
114*
108
Fig. 19
01070
NOTE: Note the alignment of the piston (108) to the
nut (110). Maintain this alignment through Step 8.
4. Clean all residue from the piston valve threads.
Apply one strip of adhesive, supplied, to the
threads.
5. Place the ball (109*) on the piston valve (108). See
Fig. 19.
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 until
the nut (110) contacts the rod. See Fig. 20.
7. Place the flats of the rod (107) in a smooth jaw
vise.
8. Carefully tighten the nut (110) against the piston
rod to 30 ft-lb (40 N.m). See Fig. 20.
Use two wrenches to maintain the alignment mentioned in NOTE below Step 3.
Torque nut against rod
1
to 30 ft–lb (40 N.m)
Do not allow nut (110)
2
to move relative to
piston (108) when
tightening piston
against rod.
2
1
110
107
108
Fig. 20
9. Stack these parts one at a time into the top of the
manifold (101): the male gland (106*), alternately
three plastic packings (104*) with two leather packings (105*), and then the female gland (103*). See
Fig. 22.
10. Install the packing nut (102) and plug (123), but
leave loose for now. See Fig. 22.
308–180 23
Page 24
Displacement Pump Repair
11. Place a new o-ring (116*) firmly in the cylinder
groove. See Fig. 21.
12. Coat the piston rod and packings with oil. Carefully
slide the assembly into the top of the cylinder
(115). See Fig. 21.
13. Put the manifold upside down in a vise. Fully
thread the jam nut (117) onto the cylinder (115).
Guide the rod/cylinder assembly down through the
manifold (101). Screw the cylinder (115) into the
manifold. See Fig. 21.
102
101
15. Torque the cylinder jam nut (117) to 73 ft-lb
(98 N.m). See Fig. 21.
16. Install the pump. See page 21.
1
Leather packings
2
Poly packings
Lips of V–packings
3
must face down
Lips of V–packings
4
must face up
Torque to 53 ft–lb
5
(71 N.m)68 N.m
(50 ft–lb
107
123
102
Torque jam nut (117)
1
to 73 ft–lb (98 N.m)
Torque cylinder (115)
2
into manifold (101) to
53 ft–lb (71 N.m)
Torque intake valve (116)
3
into cylinder (115) to
53 ft–lb (71 N.m)
4 Piston assembly
Fig. 21
4
107
116*
117
115
118
1
2
3
01072A
14. Place the ball guide (120), stop pin (122) and ball
(121*) in the cylinder (115). Screw the intake valve
into the cylinder and torque to 53 ft-lb
(71 N.m). This will also properly torque the cylinder
into the manifold. See Fig. 22.
*103
*105
1
3
*116
110
111
*113
1 4
115
120
*119
5
118
Fig. 22
104*
2 3
106*
101
109*
117
112*
2 4
114*
108*
122*
121*
01073
24 308-180
Page 25
WARNING
Motor
9. Align the new motor with the base and reinstall the
screws (46).
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
NOTE: See Fig. 25 except where noted.
1. Relieve pressure.
2. Try to stop the pump with the piston rod (107) in its
lowest position. To lower the piston rod manually,
rotate the motor fan blades. Use a screwdriver to
push the retaining spring (18) up and push out the
pin (17). See Fig. 23.
3. Remove the screws (56) and lower the junction
box (59). Disconnect the motor wires and the pressure control wire (A) from the motor start board.
Refer to Fig. 26 on page 26.
4. Remove the front cover (13).
5. Turn the displacement pump rod (107) so the pin
hole aligns with the bottom drive housing screw
(19). See Fig. 24. Remove the three drive housing
screws and lockwashers (19,6). Also see Fig. 25.
10. Assemble the drive housing to the motor. Follow
steps 8 to 10 on page 27.
11. Connect the wires in the junction box. Refer to Fig.
26 on page 26. Install the junction box.
12. Connect the piston rod (107) to the drive housing;
see page 21, Installing the Pump, Step 2 and the
WARNING following it.
17
15
18
Fig. 23
01068
107
19,6
6. Remove the two motor screws (5) and the lock
washers (6).
7. Tap the lower rear of the drive housing (11) with a
plastic mallet to loosen the motor. Pull the drive
housing straight off the motor while guiding the
harness (A) from the motor. Do not allow the gear
(16) to fall. Read the CAUTION on page 27.
8. Remove the two screws (46) and lift the motor off
the base (66).
11
1
Torque to 80 in–lb (9 N.m)
2 Quantity of three
3
Quantity of one
6
1
19
13
31
3
Fig. 24
16
12
01074
1
C
4
5
6
B
A
59
46
56
Fig. 25
34
2
05119
308–180 25
Page 26
Motor Start Board
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
5. Install the new cord (50) in the reverse order of
disassembly.
6. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board. Also be sure the gasket (89) is installed.
On/Off Switch
NOTE: See Fig. 26 for this procedure.
NOTE: See Fig. 26 for this procedure.
1. Relieve pressure.
2. Remove the junction box screws (56) and lower
the junction box (59).
3. Disconnect the motor wires (B) and the 3-wire connector (A) from the motor start board (47). Observe where connections are made.
4. Remove the screws (58) and motor start board
(47). Transfer the white thermal paste from the old
board to the new board.
5. Install the new motor start board. Reconnect all
wires. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board. Also be sure the gasket (89) is installed.
CAUTION
Be sure the flat blade of the insulated male connector is centered in the wrap–around blade of the
female connector when the connections are made.
Route all wires carefully to avoid interference with
the motor start board or junction box.
These precautions are essential to reduce the risk
of a malfunction.
Power Supply Cord
NOTE: See Fig. 26 for this procedure.
1. Relieve pressure.
2. Remove the junction box screws (56) and lower
the junction box (59).
3. Disconnect the power supply cord leads, including
the green wire to the grounding screw (49).
4. Loosen the strain relief bushing (51). Remove the
power supply cord (50).
1. Relieve pressure.
2. Remove the junction box screws (56) and lower
the junction box (59).
3. Remove the nut and rubber boot (55).
4. Disconnect the black wires from the ON/OFF
switch (52) and remove the switch.
5. Place the ring terminal of the ground wire (53) over
the barrel of the new switch. Install the switch so
the internal tab of the anti-rotation ring (54) engages with the vertical groove in the threads of the
switch, and the external tab engages with the blind
hole (C) of the junction box.
6. Powder the inside of the rubber boot (55) with talcum, then shake the excess out of the boot. Install
the nut and rubber boot and tighten.
7. Reconnect the ON/OFF switch black wires.
8. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board. Also be sure the gasket (89) is installed.
MOTOR
GREEN
49
BLACK/
WHITE
BLACK
B
59
58
A
47
Fig. 26
RED
53
56
GREEN/
YELLOW
50
51
52
C
89
54
55
04720
26 308-180
Page 27
Drive Housing, Connecting Rod, Crankshaft
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
Removal
NOTE: Inspect parts as they are removed. Replace
parts that are worn or damaged.
1. Remove the displacement pump. See page 21.
2. Remove the pressure control (64). See page 29.
3. Turn the displacement pump rod (107) so the pin
hole aligns with the bottom drive housing screw
(19). See Fig. 27. Remove the three drive housing
screws and lockwashers (19,6). Also see Fig. 28
on page 28.
107
CAUTION
Do not allow the gear (16) to fall; it may stay
attached to the drive housing or to the motor.
Do not lose the thrust balls (11a or 4a) or let them
fall between the gears, which will damage the drive
housing if not removed. The balls, which are heavily covered with grease, usually stay in the gear recesses, but could be dislodged. If the balls are not
in place, the bearings will wear prematurely.
6. Remove and inspect the crankshaft (12) and the
connecting rod (15).
Installation
7. Install the connecting rod.
8. Lubricate the inside of the drive housing bearing
with SAE non-detergent oil. Pack the roller bearing
and gears with the grease supplied.
NOTE: The gears and bearings between the drive
housing (11) and motor front end bell (C) should contain a total of 3 fl. oz. (29 cc) of grease.
19,6
Fig. 27
4. Remove the two motor screws (5) and lock washers (6). See Fig. 28 on page 28.
5. Tap the lower rear of the drive housing (11) with a
plastic mallet to loosen the motor. Pull the drive
housing straight off the motor.
01074
9. Place the large washer (12a) and then the small
washer (12b) on the crankshaft (12).
10. Lift the crank to the top of the stroke and insert
crankshaft (12). Align the gears and push the drive
housing (11) straight onto the motor and the locating pins. Install the screws (19, 5) and their lockwashers (6). Torque to 80 in–lb (9 N.m).
11. Install the displacement pump. See page 21.
12. Install the pressure control (64). See page 29.
Install the front cover (13).
308–180 27
Page 28
Drive Housing, Connecting Rod, Crankshaft
5,6
1
C
4a
12b
A
47
59
56
02815
1
Torque to 80 in–lb (9 N.m)
2 Quantity of three
3
Quantity of one
Apply a total of
4
3 fl. oz.(29 cc) of
grease
to gears.
Note: Filter
not shown
Fig. 28
64
REF A
16
11a
4
12a
31
3
12
11
6
15
19
1
13
34
2
28 308-180
Page 29
Pressure Control
WARNING
7. Loosely install the screws (63) and then torque
them to 21 in–lb (2.4 N.m).
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
NOTE: See Fig. 29 for this procedure.
NOTE: The pressure control (64) cannot be repaired
or adjusted. If it has malfunctioned, replace it.
1. Remove the front cover (13). Remove the screws
(56). Lower the junction box (59).
2. Disconnect the harness connector (A) from the
motor start board (47).
3. Remove the screws (63). Pull forward on the pressure adjusting knob and tip the pressure control
(64) forward and up to detach it from the drive
housing (11).
4. Guide the harness (A) through the motor and drive
housing and remove the pressure control.
5. Guide the harness of the new pressure control
through the drive housing and motor passages.
6. Install the new pressure control. Tip the pressure
control down and back into the drive housing (11).
Do not pinch or damage the harness (A).
8. Install the front cover (13). Connect the harness
(A) to the motor start board (47).
9. Install the junction box. Be sure no leads are
pinched against the motor or by the motor start
board.
64
1
63
A
Fig. 29
56
59
11
Torque to
1
21 in–lb (2.4 N.m)
13
02816A
308–180 29
Page 30
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
Pressure Transducer
NOTE: See Fig. 30 for this procedure.
1. Remove the displacement pump. See page 21.
2. Use a pull–twist motion to remove the transducer
(29) from the pump manifold (101).
3. Clean paint residue from the hole in the manifold;
do not scratch the surface of the hole.
4. Lightly apply oil to the o-ring of the new transducer.
5. Install the transducer in the pump manifold, while
guiding the o-ring and backup ring into place.
6. Align the holes in the transducer as shown by the
arrows in Fig. 30.
7. Install the displacement pump. See page 21.
Fig. 30
29
101
02817A
30 308-180
Page 31
Suction Hose
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
1. Remove the drain hose (33) from the clip. Remove
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 disengaged and can function as a swivel joint.
CAUTION
Misalignment or cross-threading will damage the
parts and/or create shavings which can cause the
o–ring (27) to leak.
Lubricate
1
Note: Filter
not shown
13
33
32
27
1
A
38
Fig. 31
36
02818A
308–180 31
Page 32
Drain Valve
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 9.
42a
42b
1
42d
42c
42
3
43
44
Fig. 32
1. Turn the handle (45) to the closed position. Drive
out the pin (44). Remove the handle.
2. Remove the base (43).
3. Unscrew the drain valve (42). The gasket (42a)
and seat (42b) will stay in the valve.
Apply thread sealant
1
Apply grease
to face of base
2
Torque into pump
3
manifold to 185 in–lb
(21 N.m)
Handle shown
4
in closed position
45
4
2
02819
Repair
1. Unscrew the spring retainer from the valve body.
Remove the spring, washers and stem/ball. Clean
any debris from the ball or seat area.
2. If replacing the gasket (42a) or seat (42b), pry out
the gasket.
NOTE: Whenever the gasket (42a) is removed, replace it with a new one.
3. Coat the o-ring (42d) with grease. Press the stem
into the valve body. Install the spring, washers and
spring retainer into the valve body.
4. Place the seat (42b) in the valve body so the
lapped side is toward the ball. Apply a small
amount of grease to the new gasket (42a) and install it in the valve body.
NOTE: The gasket will protrude from the end of the
valve until the valve is tightened into pump, which correctly seats the gasket.
Replacement
1. Apply a small amount of thread sealant (42e) onto
the valve (42) threads. Tighten the valve into the
pump manifold to 185 in–lb (21 N.m).
2. Lightly grease the face of the base (43) and install
the base. Turn the stem so the pin hole is vertical.
3. Securely install the handle (45) and drive pin (44).
32 308-180
Page 33
Displacement Pump Parts Drawing and List
PTFE
PTFE
PTFE
PTFE
PTFE
PTFE
Model 236–787, Series A
Includes items 101 to 127
Ref
No. Part No. Description Qty
101 187–611 MANIFOLD, pump 1
102 176–758 PACKING NUT 1
103 176–757* GLAND, female, throat 1
104 176–997* V–PACKING, plastic, throat 3
105 176–755* V–PACKING, leather, throat 2
106 176–754* GLAND, male. throat 1
107 187–613 DISPLACEMENT ROD 1
108 224–808 PISTON, valve 1
109 105–444* BALL, 5/16”, piston 1
110 176–751 NUT, hex, 1/2–20 unf–2b 1
111 176–750* GLAND, male, piston 1
112 176–882* V–PACKING, plastic, piston 3
113 176–749* V–PACKING, leather, piston 2
114 180–073* GLAND, female, piston 1
115 236–786 CYLINDER, pump 1
116 108–526* PACKING, o–ring, 1
117 187–614 NUT, jam,1-3/8 18 unef–2b1
118 224–966 INLET VALVE 1
119 111–603* PACKING, o–ring, 1
120 176–760 GUIDE, ball 1
121 105–445* BALL, 1/2”, inlet 1
122 176–759* PIN, ball stop 1
123 180–656 PLUG 1
124 102–969* SEALANT 1
127 188–663 LABEL, Warning 1
123
102
*103
105*
*104
106*
*113
127
101
107
109*
110
111
112*
114*
Extra warning labels available free of charge.
*Supplied in Repair Kit 235–703.
Keep a repair kit on hand to reduce
down time.
MANUAL CHANGE SUMMARY
This manual has been updated to add manifold filter 85.
117
*116
115
*122
*119
108
120
121*
118
01069A
308–180 33
Page 34
Sprayer Parts Drawing
Model 231–201, Series D
Model 231–328, Series A
30a
39
1
See detail
2
on page 35
74
67
Label
Included with Model 231–201 only
REF 32
10
35
OUTSIDE
LABEL
14
INSIDE
LABEL
85
13
28
63
15
17
REF 30b
6
19
18
64
11b
29
24
3
5
6
4e
1
4
4a
12b
16
12
1
4f
12a
4g
1
89
11a
2
11
66
50
26
56
31
28
34
21
32
27
34 308-180
20
30b
36
38
42a
42
42b
43
42d
44
42c
23
45
37
25
23
46
O2833A
Page 35
Sprayer Parts List
Model 231–201, Series D; Model 231–328, Series A
Includes items 3 to 89 as listed below
Ref.
No. Part No. Description Qty.
3 111–700 GRIP, handle 1
4 236–965 MOTOR KIT
Includes items 4a to 4g 1
4a 100–069 . BALL, sst, 1/4” dia. 1
4b 111–616 . TERMINAL, flat, 1/4” (f), 18 awg 2
4c 107–503 . TERMINAL, 3/16” (m), 16 awg 1
4d 187–784 . LABEL, DANGER, French 1
4e 187–791 . LABEL, DANGER, English 1
4f 187–975 . LABEL, WARNING, electric shock 1
4g 107–504 . TERMINAL, 3/16” (f) 1
5 100–643 SCREW, socket head, 1/4–20 x 1” 2
6 105–510 LOCKWASHER, 1/4” 5
10 100–721 PLUG, 1/4–18 npt(f) 1
11 224–965 DRIVE HOUSING KIT 1
Includes item 11a, 11b
11a 100–069 . BALL, stainless steel, 1/4” dia. 1
11b 111–726 .PLUG 1
12 224–803 CRANKSHAFT 1
Includes items 12a, 12b
12a 180–131 . BEARING, thrust 1
12b 107–434 . BEARING 1
13 187–789 COVER, front 1
14 177–762 LABEL, WARNING 1
15 218–359 CONNECTING ROD 1
16 218–364 GEAR REDUCER 1
17 176–818 PIN, headless, 3/8” dia. x 1” 1
18 176–817 SPRING, retaining 1
19 103–345 SCREW, socket head, 5
1/4–20 x 1–1/4”
20 236–787 PUMP KIT see parts on page 29 1
21 111–706 CAPSCREW, 7/16–14 x 1–3/4” 2
23 111–715 SCREW, 5/16–18 x 1–1/4” 6
24 187–631 HANDLE, sprayer 1
25 112–759 CAP, tubing 4
26 235–036 LEG, with gusset 1
27 104–938 O–RING 1
28 162–453 NIPPLE, hex, 1/4 npsm x 2
1/4 npt, 1–3/16”
29 235–009 PRESSURE TRANSDUCER 1
30 238–345 DRAIN HOSE KIT 1
Includes items 30a and 30b
30a 113–478 CLIP, 1” 1
30b 187–652 DRAIN HOSE 1
31 108–850 SCREW, filh, 8–32 x 1–1/4” 1
32 187–624 SUCTION HOSE & TUBE 1
34 111–705 SCREW, filh, 8–32 x 2–1/2” 3
35 187–976 LABEL, identification 1
36 111–612 ADAPTER, tube, 9/16–18 1
37 187–628 LEG, sprayer 2
38 187–627 INLET TUBE 1
39 235–004 STRAINER 1
42 235–014 DRAIN VALVE KIT 1
Includes items 42a to 42e
42a 111–699 . GASKET, valve seat 1
42b 187–615 . SEAT, drain valve 1
42c 224–968 . STEM, drain valve 1
42d 168–110 . O–RING, stem 1
Ref.
No. Part No. Description Qty.
42e 110–110 . SEALANT, pipe (not shown) 1
43 224–807 BASE, valve 1
44 111–600 PIN, grooved, 3/32 x 1” 1
45 187–625 HANDLE, drain valve 1
46 110–997 SCREW, washer/hex hd, 5/16” 2
47 235–008 MOTOR START BOARD 1
includes items 47a to 47c
48 186–620 LABEL, ground terminal 1
49 110–037 SCREW, mach, pnhd, 10–24 x 5/8” 1
50 235–010 POWER CORD SET 1
51 111–617 STRAIN RELIEF BUSHING, 1
3/8–18 npt
52 105–679 SWITCH, ON/OFF 1
53 235–035 GROUND HARNESS 1
54 105–658 LOCKING RING 1
55 105–659 BOOT, switch 1
56 111–703 SCREW, filh, 10–24 x 3” 4
58 100–035 SCREW, pan hd, 8–32 x 5/16” 2
59 187–795 JUNCTION BOX 1
63 111–704 SCREW, filh, 10–24 x 1–5/8” 2
64 224–828 PRESSURE CONTROL KIT 1
66 189–932 BASE, motor 1
67 220–955 CONTRACTOR GUN 1
See manual 308–614 for parts
68 206–994 TSL, 8 oz. (not shown) 1
74 223–541 HOSE, grounded, nylon; 1/4” ID; 1
cpld 1/4 npsm(f); 50 ft (15 m);’
spring guards both ends
85 235–677 FILTER, fluid 1
See Manual 308–249 for parts
89 187–963 GASKET 1
Extra warning labels available free of charge.
Motor Brush and Spring Replacement Kit,
236–967 is available. Purchase separately.
MOTOR
48
4g
GREEN
49
53
50
GREEN/
YELLOW
51
BLACK/
WHITE
BLACK
52
54
4b
55
59
RED
58
47
4c
04720
308–180 35
Page 36
Technical Data
PTFE
PTFE
PTFE
PTFE
PTFE
PTFE
Power Requirements 120 VAC,60Hz,. . . . . . . . . . . . . . . . . . . . .
1 phase, 15 amp minimum
Generator 3000 Watt minimum. . . . . . . . . . . . . . . . . . . . . . . . . .
Working Pressure Range 0–2750 psi . . . . . . . . . . . . . . . . . . . .
(0–19.5 MPa, 0–195 bar). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor 3/4 hp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cycles/Gallon (liter) 620 (164). . . . . . . . . . . . . . . . . . . . . . . . . . .
Delivery 0.50 gpm (1.9 lpm). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip Size one gun to 0.023 new tip. . . . . . . . . . . . . . . . . . . . . . . .
with latex at 2000 psi (138 bar)
Power Cord No. 14 AWG, 3 wire, 6’ (1.8 m). . . . . . . . . . . . . . . .
Inlet Paint Strainer 12 mesh (1525 micron). . . . . . . . . . . . . . . .
Stainless Steel Screen, reusable
Pump Inlet Size 1/2 npt(f). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Outlet Size 1/4 npsm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight 37 lb (17 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height 19 in. (483 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length 15 in. (381 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Width 14 in. (356 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wetted Parts:
Displacement Pump Stainless steel, Carbon steel,. . . . . . .
, Aluminum, Polyethylene, Delrin, Leather
NOTE: and Delrin are trademarks of the DuPont Company.
The Graco Warranty and Disclaimers
DANGER LABELS
The English language DANGER label shown on
page 1 is also on your sprayer. If you have painters who do not read English, order one of the following labels to apply to your sprayer. The drawing below shows the best placement of these labels for good visibility.
Order the labels directly from Graco, free of
charge: 1–800–328–0211
French 185–956
Apply other
language here
Spanish 185–961
German 186–041
Greek 186–045
Korean 186–049
English 185–953
04653
Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of
any special extended or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or
replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed,
operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or
substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance or structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT
NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, gas engines,
switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance
in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties
reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures
judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Foreign Offices: Belgium, Canada, England, Korea, France, Germany, Hong Kong, Japan
Sales Offices: Minneapolis, Detroit, Los Angeles
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN U.S.A. 308–180 January 1995, Revised June 1997
36 308-180
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