symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
FIRE AND EXPLOSION HAZARD
Improper
result in a fire or explosion and serious injury
grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
.
If there is any static sparking or you feel an electric shock while using this equipment,
ing 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 of
Do not operate a gasoline engine in the spray area.
f any light switch in the spray area while operating or if fumes are present.
stop spray-
Page 3
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
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
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 dif
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
.
fuser operation weekly
. The injury may look like just a cut, but it is a serious
.
, glove or rag.
. Refer to the gun manual.
Follow the
checking or servicing the equipment.
 T
ighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily
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.
Pressure Relief Procedure
on page 8 if the spray tip clogs and before cleaning,
. Replace worn or damaged parts immediately
TOXIC FLUID HAZARD
Hazardous
inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container
state and national guidelines.
RAC switch tip atomizes fluid and removes clogs from spray tip without
removing tip from spray gun
1//4 in. ID, grounded, nylon hose used between 50 ft hose and spray
gun to allow more flexibility when spraying
Relieves fluid pressure when open
Controls motor speed to maintain fluid pressure. W
adjusting knob.
Inhibits accidental triggering of spray gun
Allows sprayer to operate on 15A service with reduced performance
System pressure indicator
, 120 V
ac, 60 Hz, 18A, 1 phase
T
N
04426A
ac power to sprayer
-
orks with pressure
, 3000 psi (21.0 MPa, 210 bar)
Page 6
WARNING
FIRE AND EXPLOSION HAZARD
Proper electrical grounding is essential
to reduce the risk of fire or explosion
which can result in serious injury and
property damage. Also read
EXPLOSION HAZARD
FIRE OR
on page 2.
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
Pressure
caused by static sparking, fluid injection or overpressurization and rupture of the hose or gun.
3000 psi (21.0 MPa, 210 bar) Working
. This is to reduce the risk of serious injury
Setup
3.
4.
5.
Check electrical service. Be sure electrical service
is 120 V
outlet. Do not remove grounding prong of power
supply cord or of any extension cords used. Do not
use an adapter
wires of minimum 12 gauge size. Long extension
cords reduce sprayer performance. If 20 amp
service is not available, set 15/20 amp switch (C)
to 15 amp to avoid nuisance tripping of circuit
breakers.
With switch (E) to OFF
into grounded electrical outlet
away from spray area.
Flush pump before using it. See page 10.
ac, 60 Hz, 20 A. Use properly grounded
. Extension cords must have 3
, plug power supply cord
located at least 20 ft
CAUTION
T
o avoid damaging the pressure control, which may
result in poor equipment performance and compo
nent 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 shutof
and the hose. See A, Fig. 2.
1.
Connect gun (B) and 50 ft hose (C). Don’t install
the spray tip yet. See Fig. 2.
2.
Fill wet-cup (D) 1/3 full with Graco Throat Seal
Liquid, supplied.
.
f device between the filter
7148A
E
D
C
B
Fig 2
A
04426A
6 308-785
Page 7
Airless
Operation
WARNING
INJECTION
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the
Procedure
on page 8.
Startup
Always use this procedure to help ensure the sprayer
is ready to operate and that you start it safely
Fig. 3
1.
For first time startup, flush sprayer
2.
Close pressure drain valve (A).
3.
Don’t install spray tip until pump is primed!
4.
Put pump (B) into supply pail
5. T
urn pressure adjusting knob (C) counterclockwise
to lowest setting.
6.
Disengage gun safety latch.
HAZARD
,
Pressure Relief
. See
. See page 10.
.
WARNING
FIRE AND EXPLOSION HAZARD
T
o reduce static sparking and splashing,
always remove the spray tip from the
gun, and hold a metal part of the gun
firmly to the side of a grounded metal pail when
flushing.
WARNING
FIRE AND EXPLOSION HAZARD
T
o reduce the risk of fluids entering
control box, check weep hole (Fig.16, C)
regularly
leakage is seen. Also read
EXPLOSION HAZARD
9.
Check weep hole (Fig. 16, B) of pressure control
for leakage at start up and during operation. If
leakage, replace o–ring as instructed in Pressure
Control T
page 20.
10.
Engage gun safety latch. Install spray tip and tip
guard (E) according to instructions supplied with
tip guard.
11.
Adjust pressure.
a. T
a.
a. T
ransducer and O–Ring Replacement on
urn pressure adjusting knob (C) clockwise
until spray from gun is just completely atom
ized. T
wear and to extend life of sprayer
possible pressure needed to get good atom
ization.
If more coverage is needed, use larger tip
rather than increasing pressure.
est spray pattern. T
pattern, engage gun safety latch, loosen
retaining nut, position tip guard horizontally for
horizontal pattern or vertically for vertical
pattern and tighten retaining nut.
. Replace o–ring when any
o reduce overspray
o adjust direction of spray
FIRE OR
on page 2.
, fogging, and tip
, use lowest
-
-
7. T
o prime pump, squeeze gun trigger and hold it
open, turn ON/OFF switch (D) to ON, and slowly
increase pressure setting (C) until sprayer starts.
Keep gun triggered until all air is forced out of
system and material flows freely from gun. Re
lease gun trigger and engage gun safety latch.
CAUTION
Do not run the sprayer dry for more than 30 seconds
to avoid damaging the pump packings.
8.
Check all fluid connections for leaks. If any leaks
are found, relieve pressure before tightening
connections.
7148A
C
-
E
Fig 3
D
B
04426A
A
Page 8
Operation
Pressure Relief Procedure
WARNING
PRESSURIZED
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally
reduce the risk of an injury from accidental spray
from the gun, splashing fluid, or moving parts,
follow the
you:
D
are instructed to relieve the pressure,
D
stop spraying,
D
check or service any of the system equipment,
D
or install or clean the spray nozzle.
1.
Engage gun safety latch.
2. T
3.
Unplug power cord.
Pressure Relief Procedure
urn ON/OFF switch to OFF
EQUIPMENT HAZARD
. To
whenever
.
Cleaning a Clogged Tip
WARNING
INJECTION
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the
Procedure.
1.
If spray tip clogs, release gun trigger,
engage gun safety latch (B), and rotate RAC IV
handle (A) 180_. See Fig 4.
2.
Disengage gun safety latch (C) and trigger gun
into waste container
again.
3.
Return tip handle to original position,
disengage gun safety latch, and resume spraying.
4.
If tip is still clogged, engage gun safety latch, shut
of
f and unplug sprayer
valve to relieve pressure. Remove tip and soak it
in solvent. Do not scrape or chip of
could damage tip.
The
tip handle (A) is shown in spraying position.
Rotate the tip handle 180_ in direction
of the arrow for clearing a clog.
Engaged.
Disengaged.
HAZARD
Pressure Relief
. Engage gun safety latch
, and open pressure drain
f debris which
,
4.
Disengage gun safety latch. Hold metal part of gun
against grounded metal pail and trigger gun into
pail to relieve pressure.
5.
Engage gun safety latch.
6.
Open any fluid drain valves in system. Leave drain
valve open until ready to dispense again.
Fig 4
A
B
C
03966
Page 9
Operation
Shutdown and Care
1. Check
2.
3.
4.
wet-cup (A) daily
pressure and remove wet-cup plug. Keep wet-cup
1/3 full with Graco Throat Seal Liquid at all times
to help prevent material from building up on piston
rod which causes packings to wear prematurely
T
ighten wet-cup, which is also packing nut, just
enough to stop leakage. Overtightening wet-cup
may cause packings to bind and wear out quickly
Use screwdriver and light hammer to adjust wetcup.
Clean fluid filter (B) often and whenever sprayer is
stored. First relieve pressure. See manual
307–273 for cleaning procedure.
Fill connecting rod cavity (C) with motor oil every
100 hours of operation. First relieve pressure and
then remove front cover
For short shutof
rial, relieve pressure, and clean spray tip.
f periods, leave pump in the mate
. See Fig 5. First relieve
.
B
C
A
.
.
04347A
Fig 5
5.
Before storing sprayer
coating of mineral spirits, then relieve pressure.
-
6.
Coil hose and hang on cart handle for protection.
, flush thoroughly
, leaving a
308-7859
Page 10
Flushing
1
Use this category for flushing a brand new sprayer
and flushing after storage.
System has
this fluid in it:
1
Oil-based
solvent or fluid
Oil-based
solvent or fluid
Water or waterbased fluid
Water or waterbased fluid
The following sections are for preparing a sprayer for storage.
Oil-based
solvent or fluid
Water or waterbased fluid
Next fluid to be
sprayed:
Oil-based fluid –
new color
W
ater-based fluid
W
ater-based fluid
– new color
Oil-based fluid
Prepare for
storage
Prepare for
storage
Flushing order:
Flush 1Flush 2Flush 3
Mineral spirits
Mineral spiritsWarm soapy
W
arm soapy
water
W
arm soapy
water
Mineral spirits
W
arm soapy
water
nonenone
water
Clean water
Clean water
nonenone
Clean water
CAUTION
Before you spray:
Prime with oil-based fluid
Clean water
none
Mineral spirits
Mineral spirits
4.
Pour 2 quarts of compatible solvent into grounded
metal pail. Put pump in pail.
Prime with water-based
fluid
Prime with water
Prime with oil
Relieve pressure,
Leave drain valve open
Relieve pressure,
Leave drain valve open
Never allow water to freeze in the pressure control.
Doing so prevents the sprayer from being started
and causes serious damage to the pressure control.
Push the water out with mineral spirits.
1.
Relieve pressure.
2.
Remove filter bowl (A) and screen (B). Install bowl
(A) and filter support (C) without screen (B). See
Fig 6.
3.
Close pressure drain valve (D).
5.
Remove spray tip from gun.
6. T
urn pressure adjusting knob (E) counterclockwise
to lowest pressure setting.
WARNING
FIRE AND EXPLOSION HAZARD
T
o reduce static sparking and splashing,
always remove the spray tip from the
gun, and hold a metal part of the gun
firmly to the side of a grounded metal pail when
flushing.
10 308-785
Page 11
7.
Hold a metal part of gun firmly against metal waste
container. See preceding W
turn sprayer switch (F) on, and slowly increase
pressure until sprayer just starts. Keep gun trig
gered until all air is forced out of system and
solvent flows freely from the. Release trigger and
engage gun safety latch.
NOTE:
valve. When fluid comes from the valve, close it.
Proceed as in Step 7.
If the pump is hard to prime, open the drain
ARNING! T
rigger gun,
Flushing
11.
If you flushed with mineral spirits and are going to
use a water-base material, flush with soapy water
and then clean water. Relieve pressure.
-
E
7148A
F
A
CAUTION
Do not run the sprayer dry for more than 30 seconds
to avoid damaging the pump packings.
8.
Remove pump from pail. Disengage gun safety
latch and trigger gun to force solvent from hose.
Do not run pump dry for more than 30 seconds to
avoid damaging pump packings! Shut of
9.
Leave pressure drain valve (D) open until ready to
use sprayer again.
10.
Clean filter screen (B) and reinstall it. Reinstall
bowl (A), hand tighten only
.
f sprayer
B
C
.
D
Fig 6
7147A
308-78511
Page 12
Troubleshooting
WARNING
INJECTION HAZARD
T
o reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the
Pressure Relief Procedure
on page 8.
Check everything in the guide before disassembling the sprayer
TYPE OF PROBLEMWHA
Building circuit breaker opens
Sprayer will not run
T T
O CHECK
If check is OK, go to next check
Check all electrical wiring for damaged
insulation.
Check for other electrical appliances on
circuit.
Check position of 15–20 (Lo–High) amp
switch.
Check pressure control knob setting. Motor
will not run if it is at minimum setting (fully
counterclockwise).
Check for a clogged spray tip. Refer to
separate gun or tip instruction manual.
Check extension cord for visible damage.
Use a volt meter or test lamp at extension
cord outlet to check.
Check sprayer power supply cord for visible
damage such as broken insulation or wires.
Check electrical supply with volt meter
Meter should read 105–125 V
AC.
.
WHA
T T
O DO
When check is not OK refer to this column
Replace any damaged wiring.
Shutdown other electrical appliances on
circuit.
Put switch in 15 (LO) position.
Slowly increase pressure setting to see if
motor starts.
Relieve
instruction manual for tip cleaning.
Replace extension cord.
Replace power supply cord.
.
Reset building circuit breaker; replace build
ing fuse. T
pressure. Refer to separate gun or tip
-
ry another outlet.
Poor spray pattern
NOTE: T
roubleshooting is continued on the next page.
Check for motor damage. Remove drive
housing assembly
19. T
ry to rotate fan by hand.
Check for locked motor rotor
and try to turn fan blades with a screwdriver
Check for shorted motor
check for shorts between motor leads or
between motor leads and motor frame.
Defective pressure control transducer.
Check for worn spray tip.
. See motor test on page
. Unplug cord
. Use ohmmeter to
Replace motor (1) if fan won’t turn.
Repair gear train or pump, if damaged. Thaw
.
the
sprayer
13. Replace the pressure control,
Inspect for damage to motor brush leads.
Replace motor
Replace pressure control transducer
page 20.
Relieve pressure and then replace the tip.
See the separate gun or tip manual.
, if frozen; See the NOTE on page
if damaged.
, if necessary.
. See
12 308-785
Page 13
Troubleshooting
TYPE OF PROBLEMWHA
If check is OK, go to next check
(Continued)
Motor runs and pump strokes,
but output is low or there is no
output.
Check for worn spray tip.
Check motor brushes; check for loose leads
and terminals, minimum 10 mm brush
length, broken or misaligned springs, or
brushes binding in holders. See page 14.
Check motor armature for shorts by using
armature tester (growler).
Check to see if pump continues to stroke
when gun trigger is released. With pump on
and primed, trigger gun momentarily
release and engage safety latch. Relieve
pressure, turn of
Check to see if intake valve ball and piston
ball are seating properly
Check for leaking around throat packing nut
which may indicated worn or damaged
packings.
Defective pressure control transducer.
T T
O CHECK
f and unplug sprayer
.
, then
.
WHA
T T
O DO
When check is not OK refer to this column
Follow
Pressure Relief Procedure
Warning
separate gun or tip manual.
Replace parts as needed. See page 14.
an
Replace motor
Repair pump. See manual 307–806 for
repair.
Repair pump. See manual 307–806 for
repair.
T
ighten the packing nut/wetcup.
Repair pump. See manual 307–806 for
repair.
Replace pressure control transducer
page 20.
, then replace tip. See your
. See page 17 .
. See
Motor runs but pump does not
stroke.
Motor is hot and runs
intermittently.
NOTE:
Thaw the sprayer if water or water-based material has frozen in it, by placing it in a warm area. Do not try to
Check displacement pump connecting rod
pin (20). See page 16.
Check for frozen or hardened material in the
pump (39).
Be sure crank in drive housing rotates; plug
in sprayer and turn on briefly to check. T
f and unplug sprayer
of
Determine if sprayer was operated at high
pressure with small tips, which causes low
motor RPM and excessive heat build up.
Be sure ambient temperature where sprayer
is located is no more than 90F and sprayer
is not located in direct sun.
Determine in sprayer was turned on,
pressurized, but not operating for long
periods of time.
start the sprayer until it has thawed completely
ings. See pump manual 307–806.
Replace pin, if missing. Be sure retainer
spring (35) is fully in groove all around
connecting rod. See page 16.
Thaw
. See the NOTE below. Plug in sprayer
and turn on. Slowly increase pressure
setting to see if motor starts.
Check drive housing assembly for damage
urn
.
and replace if necessary
Decrease pressure setting or increase tip
size.
Move sprayer to shaded, cooler area, if
possible.
T
urn of
f sprayer whenever you stop
spraying for a while and relieve fluid
pressure.
. If material hardened (dried) in the sprayer
. See page 24.
, replace the pump pack
-
308-78513
Page 14
Motor
Brush Replacement
WARNING
ELECTRIC
T
o reduce the risk of Electric Shock: wait
5 minutes after turning sprayer of
servicing to allow stored current to dis
charge.
NOTE:
less than 0.4 in. Check both brushes. Brush Repair Kit
220–853 is available. A new spring clip, 1
be purchased separately
Replace brushes when they have worn to
SHOCK HAZARD
f before
-
10–816, may
.
5.
Inspect motor commutator for excessive pitting,
burning or gouging. A black color on commutator is
normal. Have commutator resurfaced by qualified
motor repair shop if brushes seem to wear too
fast.
6.
Install new brush (C) so lead is in long slot (J) of
the brush holder (H). Slide brush lead (E) terminal
under terminal screw (F) washer
lead (G) is still connected at screw
screw (F). See Fig 10.
7.
Place spring (B) on brush (C). See Fig 10.
. Make sure motor
. Tighten
NOTE:
long as the original ones. T
break in new brushes by operating the sprayer for at
least one hour with no load (remove the pump
connecting rod pin).
Replacement brushes may last only half as
o maximize brush life,
WARNING
INJECTION HAZARD
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the
Procedure
1.
Relieve pressure.
2.
Remove motor cover (14) and both brush inspec
tion covers (A). See Fig 7.
3.
Push in spring clip (D) to unhook, and then pull
out. See Fig 8.
4.
Loosen terminal screw (F). Pull brush lead (E)
away
brush (C) and spring (B). See Fig 9.
on page 8.
, leaving motor lead (G) in place. Remove
Pressure Relief
,
8.
Push in spring clip (D) and hook. See Fig 10.
9.
Repeat for other side.
CAUTION
Do not run the sprayer dry for more than 30 seconds
to avoid damaging the pump packings.
10.
Reinstall remaining parts.
14
-
A
Fig 7
 
Page 15
Motor
Brush Replacement
Fig
Fig 9
8
Spring
B
C
must coil
in this direction
Minimum brush
length: 0.4 in.
H
J
C
B
D
E
D
01227
B
D
Fig 10
G
F
01227
C
E
F
G
01227
308-78515
Page 16
Displacement
Removing the pump See
1.
Flush pump, if possible, and relieve pressure
again. Stop pump with piston rod in its lowest
position, if possible.
2.
Remove hose (132).
3.
Push retaining spring (35) up and push out
pin (20).
4.
Loosen locknut (38) and unscrew pump one half
turn from bearing housing (27).
5.
Remove spring clip (75) and drain tube (79) from
pump.
Remove pump.
6.
Fig 1
1 and parts list.
Pump
3.
Install spring clip (75) and drain tube (79) to pump.
4. T
ighten packing nut/wet-cup just enough to stop
leakage, but no tighter
full with Graco TSL.
27
. Fill wet-cup/packing nut 1/3
Repairing the pump
1. See
Installing the pump
list.
1.
2.
manual 307–806 for parts and repair
See Figs. 1
Screw displacement pump into bearing housing
(27) until pin hole in connecting rod assembly (29)
and displacement rod (A) align. Install pin (20).
Continue to screw pump into bearing housing until
top threads of pump cylinder are flush with face of
bearing housing, and outlet nipple (75) is straight
back. Unscrew pump 1/2 turn so pump outlet is at
rear
. Push retaining spring (35) into groove around
connecting rod to prevent it from vibrating loose.
T
ighten locknut (38) to 70 ft-lb (95 N.m).
1, 12, and parts
.
WARNING
MOVING P
If the pin works loose, it or other parts
could break of
pumping action. These parts could be
projected through the air and result in serious
bodily injury or property damage, including damage
to the pump, connecting rod or bearing housing.
ARTS HAZARD
f due to the force of the
Fig 11
1
2
35
A
20
38
39
Torque
to 70 ft–lb
Face
of bearing housing
29
2
27
132
04348A
20
35
CAUTION
If the locknut (38) loosens during operation, the
threads of the bearing housing (29) will be damaged.
Be sure to tighten the locknut firmly
 
.
Fig 12
38
1
02083
Page 17
Procedure
WARNING
INJECTION
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the
on page 8.
HAZARD
,
Pressure Relief
Motor
6. T
NOTE:
stay engaged in the motor bell or in the drive housing.
Do not lose the thrust balls (10) or drop them between
the gears. The balls usually stay in the shaft recesses,
but they can be dislodged. If the balls are not in place,
the bearings will wear prematurely
ap rear of pump (39) with plastic mallet to loosen
drive housing (18) from motor (1). Pull of
housing.
Do not drop the gear cluster (9), which may
.
f drive
WARNING
ELECTRIC SHOCK HAZARD
T
o reduce the risk of Electric Shock: wait
5 minutes after turning sprayer of
servicing to allow stored current to dis
charge.
NOTE:
noted.
1.
2.
3.
4.
5.
Refer to Fig 13 and parts list except where
Relieve pressure.
Remove motor shield (14) and front cover (31).
Disconnect hose (132).
Remove outlet cover on pressure control wiring
box. Disconnect four motor leads. See Fig. 14.
Unscrew conduit fitting (125) from motor and pull
four motor leads from conduit (22).
Remove screws (51) from drive housing. Remove
screws (21 and 30) from motor (1).
f before
-
7. Lower pressure control (130) by unscrewing motor
mounting
8.
Lift of
9.
Mount and center new motor on frame and attach
pressure control (130) with motor mounting
screws (37).
10.
Insert motor leads through conduit fitting (125) and
conduit (22) to pressure control. Screw connector
(125) two or three threads into motor
locknut up to motor. Connect four motor leads.
See Fig. 14.
11.
Liberally grease gear cluster (9) and pinion gear
(G). Pack all bearings in motor bell. Be sure thrust
balls (10) are in place.
12.
Place bronze–colored washer (18b) and then
silver–colored washer (18a) on shaft protruding
from big gear in drive housing (18).
13.
Align gears and push drive housing (18) straight
onto motor bell (F) and locating pins.
14.
Continue to reassemble sprayer
screws (37).
f motor (1).
. Tighten
.
308-78517
Page 18
Seals
1
2
3
4
(93) located inside conduit (22)
Bronze
colored washer
Apply 6 oz. bearing grease
Silver
colored
washer
31
49
33
18
Motor
1
14
21
G
18a
4
9
3
18b
2
63
F
125
22
1
37
Fig 13
39
132
51
27
130
10
30
63
03803B
18 308-785
Page 19
Pressure
CAUTION
Do
not install the pressure control until motor is
checked. A defective motor may damage the pres
sure control. Make sure to test the motor prior to
pressure control installation.
WARNING
ELECTRIC SHOCK HAZARD
T
o reduce the risk of Electric Shock: wait
5 minutes after turning sprayer of
servicing to allow stored current to dis
charge.
Motor Test
With
motor shield off and four motor leads discon
nected:
1.
Check continuity with multimeter from each black
motor lead to ground (one at a time). Any reading
less than infinite resistance – even very high re
sistance – means motor is shorted to ground. Re
place motor
.
f before
Control
8.
Install pump pin and fan cover
WARNING
-
INJECTION HAZARD
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the
Procedure
1.
Relieve pressure.
2.
-
-
-
-
Remove ten screws (64) and motor shield (14).
See Fig. 15 and parts list.
3.
Loosen outlet cover on pressure control wiring box
and disconnect wires. See Fig 14.
4.
Loosen black conduit (22) from pressure control
fitting and pull out wires
5.
Remove hose (132), 45 swivel union (131), check
valve (42), and nipple (59) from rear of pressure
control (130).
6.
Remove hose (134) and 45 swivel union (131)
from front of pressure control (130).
on page 8.
.
,
Pressure Relief
CAUTION
A motor that is shorted to ground will damage the
pressure control.
2.
Remove fan cover from motor
3.
Remove pump pin ( See page 16 for instructions to
remove pin).
4.
With black motor leads not
fan to spin motor quickly
in both directions. If not, replace motor
5.
Connect black motor leads together
6.
Use motor fan to turn motor
harder to turn than in step 4. If there is uneven or
no resistance to turning, check brushes and re
place if necessary
7.
If there is still uneven or no resistance to turning,
replace motor
.
.
.
connected, use motor
. Motor should spin freely
.
.
. It should be much
7.
Support pressure control from falling(130) and
carefully remove motor mount screws (37). Re
move pressure control.
8.
Install new pressure control (130) with screws (37).
9.
Continue to reassemble sprayer
Black/white
-
Red
Fig 14
.
Black
7145A
Yellow
-
Black/
white
Page 20
Pressure
Control
Fig
15
134
14
64
132
131
7093A
37
130
59
131
1Seals
22
1
42
132
(93) located inside conduit (22)
06964
Pressure
General Repair and Replacement
WARNING
INJECTION
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the
Procedure
1.
Relieve pressure.
2.
Remove power cord (23) and plug retainer (23a)
by removing screws (230) and washers (229).
3.
Remove screws (213) and lockwashers (214).
Carefully remove control housing (202) from
control motor board (201) so internal wiring is not
damaged. Lay housing on side next to control
motor board. See Fig. 16 and parts list.
4.
Remove and replace only those components and
wires necessary for repair
ing wire hook–ups for items removed to insure
correct wiring when reinstalling. See Fig. 17 for
wiring information.
 
on page 8.
HAZARD
Pressure Relief
. Make a diagram show
Control Repair
5.
Install control housing (202) to motor control
board (201) using screws (213) and
lockwashers (214).
Pressure Control Transducer and O–Ring
,
-
Replacement
WARNING
FIRE
AND EXPLOSION HAZARD
Proper O–ring replacement is essential
to reduce the risk of fire or explosion
which can result in serious injury and
property damage. Also read
EXPLOSION HAZARD
NOTE:
leakage is seen around weep hole, o–ring or
transducer.
1.
Do not replace o–ring unless damaged or if
See Fig. 16 and pressure control part list. Disas
semble pressure control as in steps 1 through 4 on
page 20 and remove old transducer (219) and, if
necessary
, old o–ring (220).
FIRE OR
on page 2.
-
Page 21
Pressure
PTFE
Control Repair
227
214
216
217
229
202
213
1
215
218
219
A
220
230
23
23a
B
214
213
to 150 in. lbs (17 N–m)
Torque
1
Fig
16
2. Insert
NOTE:
dif
ficult to work with.
new o–ring (220) into bore (A) of motor
control (201) at an angle so that forward facing
part of o–ring is below weep hole (C). Then slide
o–ring down bore into o–ring groove (B). Make
sure o–ring is in groove around its entire circumfer
ence.
O–ring (220) is made of which is more
201
C
7135B
5.
Carefully remove transducer and verify that o–ring
is seated correctly and not pushed out of groove. If
not seated correctly use new o–ring and repeat
steps 2 through 5.
-
6.
When o–ring is correctly installed, reinstall trans
ducer and tighten screws to 150 in. lbs (17 N–m).
Install spacer (216) and C–clip (215). Re–connect
electrical lead and re–assemble sprayer
.
-
3.
Carefully slide new transducer and plastic
spacer (217) down bore. Loosely attach
bracket (218), screws (213), and washers (214).
4.
Seat transducer into o–ring by drawing down
screws and washers until bracket is flush with
motor control surface.
7.
Follow Airless Operation start–up procedures for
sprayer on page 7 using compatible fluid.
8.
Inspect weep hole (C) for any leakage.
9.
If any leakage is present, replace o–ring repeating
steps 1 through 9.
308-78521
Page 22
Pressure
Control W
iring
GRN/YEL wire, E to housing ground
On/of
f sw
WHITE
wire on/of
SW–5 to
to L2 on
board
BLACK
wire on/of
SW–2 to
to L1 on
board
T
wisted pair
T
wisted pair
1253
f
f
L
E
N
BLACK wire, L to on/of
WHITE wire, N to on/of
f sw–1
f sw–4
Housing ground
64
Red wires to I1
and I2 on board
T
wisted pair
7369A
T
o J3
From control housing,
one red wire to I1
From control housing,
one red wire to I2
Connector from
potentiometer to J3
T
wisted pair
Wires J4/J5 to
15/20 switch
I1
I2
J3
J5 J4
J6
Connector from pressure
transducer to J6
L2
J7
GND
L1
7169A
From control
housing, WHITE
wire to L2
From control
housing, BLACK
wire to L1
Ground wire to
housing ground
Fig
17
 
Page 23
Bearing
WARNING
Housing and Connecting Rod
INJECTION
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the
Procedure
NOTE:
get the crank (H) in its lowest position.T
crank manually
a screwdriver
1.
Remove pump. See page 16.
2.
Remove front cover (31). Remove bearing housing
screws (33). See Fig. 18 and part list.
3. T
ap lower rear of bearing housing (27) with plastic
mallet to loosen it from drive housing (18). Pull
bearing housing and connecting rod (29) straight
of
f drive housing.
4.
Inspect crank (H) for excessive wear and replace
parts as needed.
5.
Evenly lubricate inside of bronze bearing (K) with
motor oil. Liberally pack roller bearing (J) with
bearing grease.
6.
Assemble connecting rod (29) and bearing housing
(27).
on page 8.
Stop the sprayer at the bottom of its stroke to
, rotate the blades of the motor fan with
.
HAZARD
Pressure Relief
o lower the
,
Torque
1
2
1
31
33
to 300 in-lb (34 n.m)
Lubricate
2
J
29
27
49
20
38
18
H
K
2
35
132
7.
Clean mating surfaces of bearing and drive hous
ings.
8.
Align connecting rod with crank (H) and align
locating pins in drive housing with holes in bearing
housing (27). Push bearing housing onto drive
housing or tap into place with plastic mallet.
9.
Install bearing housing screws (33). T
to 300 in–lb (34 N.m).
10.
Reinstall all parts. See page 16 to install pump.
orque evenly
-
Fig 18
39
04351A
Page 24
Drive
WARNING
INJECTION
T
o reduce the risk of serious injury
whenever you are instructed to relieve
pressure, follow the
Procedure
NOTE:
NOTE:
get the crank (H) in its lowest position. T
manually
screwdriver.
Remove front cover (31). Remove motor
1.
shield (14).
2.
Disconnect pump outlet hose (132).
3.
Remove screws (33) from bearing housing (27).
4. T
ap rear of pump (39) with plastic mallet to loosen
from drive housing (18). Pull bearing housing
assembly (27) straight of
on page 8.
See Fig 19 and parts list
Stop the sprayer at the bottom of its stroke to
, carefully rotate the blades of the fan with a
HAZARD
Pressure Relief
.
o lower it
f drive housing (18).
Housing
5.
6.
,
7. T
NOTE:
stay engaged in the motor bell or in the drive housing.
Do not lose the thrust balls (10) or drop them between
gears. The balls usually stay in the shaft recesses, but
could be dislodged. If the balls are not in place, the
bearings will wear prematurely
8.
9.
10.
11.
Remove screws (51) from drive housing.
Remove screws (30, 21) from motor (1).
ap drive housing (18) with plastic mallet to loosen
from motor and pull straight of
Do not drop the gear cluster (9), which may
Use approximately 6 oz. of bearing grease
supplied with drive housing replacement kit to
grease gear cluster (9). Check that thrust balls
(10) are in place.
Place bronze-colored washer (18b) and silver-col
ored washer (18a) on shaft protruding from big
gear in drive housing (18).
Align gears and push new drive housing straight
onto motor and locating pins.
Continue to reassemble sprayer
screws (33) to 34 N.m (300 in–lb).
The English language DANGER label shown on
page 4 is also on your sprayer
painters who do not read English, order one of the
following labels to apply to your sprayer
drawing below shows the best placement of these
labels for good visibility
Order the labels directly from your Graco
distributor.
warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in
material
any
replace
operated
This
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or
substitution
Graco
installation,
This
verification
equipment
in
transportation.
Graco’s
remedy (including, but not limited to, incidental or consequential damages for lost
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two
date
GRACO
A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES, EQUIPMENT
NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, gas engines,
switches,
in
and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With the exception
special extended or limited warranty published by Graco, Graco will,
any part of the equipment determined by Graco to be defective. This warranty applies only when the
and maintained in accordance with Graco’
warranty does not cover
of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
equipment with structures, accessories, equipment or materials not supplied by Graco, or the
operation or maintenance or structures, accessories, equipment or materials not supplied by Graco.
warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
material or
of sale.
making any claim for breach of these warranties.
workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor
sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above.
MAKES NO W
hose, etc.), are subject to the warranty
, and Graco shall not be liable
ARRANTY
, AND DISCLAIMS ALL
s written recommendations.
, if any
W
arranty
for a period of twelve months from the date of sale, repair or
for general wear and tear
IMPLIED W
, of their manufacturer
ARRANTIES OF MERCHANT
equipment is installed,
, or any malfunction, damage or wear caused by
improper design, manufacture,
, and
The buyer agrees that no other
profits,
lost sales, injury to person or property
(2)
ABILITY AND FITNESS FOR
, MA
TERIALS OR COMPONENTS SOLD BUT
. Graco will provide purchaser with reasonable assistance
, or any
years of the
of
LIMITATION
In
no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder,
breach
OF LIABILITY
or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
of warranty
, the negligence of Graco, or otherwise.
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment W arranty
Program”.
TO
PLACE AN ORDER
1–800–367–4023 T
Graco
, contact your Graco distributor
oll Free
Phone Number
, or call this number to identify the distributor closest to you:
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, Switzerland, France, Germany
Sales Offices:
GRACO INC.P.O. BOX 1441
 
Atlanta, Chicago, Detroit, Los Angeles
MINNEAPOLIS, MN
PRINTED
IN U.S.A. 308–785 May 1997
, Hong Kong, Japan
55440–1441
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