Graco 231–581 A Series, 231–583 A Series, 231-581, 231-583 Instructions-parts List Manual

Page 1
INSTRUCTIONS-PARTS
This
manual contains important warnings and information. READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
ELECTRIC, 120 VAC
LIST
First choice when
quality counts.
308–720
Rev.
C
Supercedes Rev. B
455
3000
Model 231–581, Series A
Standard RAC IV DripLess
Model 231–583, Series A
Low
profile cart; complete sprayer with hose, gun,
RAC IV DripLess
st
Airless
psi (210 bar
mount; complete sprayer with hose, gun,
, 21 MPa) Maximum Working Pressure
T
ip Guard and SwitchT
T
ip Guard and SwitchT
Paint Sprayer
ip
ip
Related
Displacement Fluid Filter 308–249. Spray
Gun
Spray Tip 308–644.
Manuals
Pump
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GRACO INC. P.O. BOX 1441
308–190.
308–645.
MINNEAPOLIS, MN
COPYRIGHT
Graco
Inc. is registered to I.S. EN ISO 9001
1997, GRACO INC.
231–581
55440–1441
06973
Page 2
Table
of Contents
Warnings 2. Component Setup 6 Operation Startup Shutdown Flushing 12 Troubleshooting 13 Motor Test 17. General Motor Displacement Motor 22 Motor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Function5. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
and Care
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Information
Brush
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Board
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Repair
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.
18.
19.
21.
23.
Symbols
Warning Symbol
WARNING
his
symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Power
Supply Cord ON/OFF Drive Pressure Pressure Transducer 27. Suction Drain Valve 28. Model Model Model Model Technical Dimensions 34 Graco Warranty and Disclaimers
Switch
Housing, Connecting Rod, Crankshaft
Control
Hose
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
231–581 Sprayer Parts Drawing 231–581 Sprayer Parts List 231–583 Sprayer Parts Drawing 231–583 Sprayer Parts List
Data
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23.
23.
24.
26.
27.
30.
31.
32.
33.
34.
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
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.
Use only with a grounded outlet that matches the grounded plug of this equipment.
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 9 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.
Always wear protective eyewear solvent manufacturer
fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
. Dispose of hazardous fluid according to all local,
, gloves, clothing and respirator as recommended by the fluid and
.
MOVING PARTS HAZARD
. Do not
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 equipment from starting unexpectedly
Pressure Relief Procedure
.
on page 9 to prevent the
 
Page 4
WARNING
EQUIPMENT MISUSE HAZARD
INSTRUCTIONS
Equipment
This equipment is for professional use only
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your distributor
Do not alter or modify this equipment. Use only genuine Graco parts.
Check equipment daily
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
T
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
nical Data
Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
misuse can cause the equipment to rupture or malfunction and result in serious injury
.
echnical Data
. Repair or replace worn or damaged parts immediately
on page 34 for the maximum working pressure of this equipment.
.
section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
.
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 expose Graco hoses to temperatures above 82C (180F) or below –40C (–40
F).
.
Tech-
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 34 to order
FIRE
AND
EXPLOSION HAZARD
Spray
painting, flushing or cleaning equipment with flammable liquids in
confined
Use outdoors or in extremely well ventilated areas. Ground equipment, hoses,
A cloths, arcs switches on and of
Failure to follow this warning can result in death or serious injury
areas can result in fire or explosion.
containers and objects being sprayed.
void all ignition sources such as static electricity from plastic drop
open flames
from connecting or disconnecting power cords or turning light
such as pilot lights, hot objects such as cigarettes,
f.
.
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
.
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.A
ing 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 T
Failure to follow this warning can result in amputation or serious injury
reatment”.
void accidental trigger
-
.
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Page 5
Component
H
Identification and Function
N
B
C
A
05963
Fig.
1
A Motor
B
Drive Assembly
C
Pressure Adjusting Knob
D
ON/OFF Switch
E
Fluid Outlet
F
Displacement Pump
G
50 ft (15 m) Main Hose
H
RAC IV T
J
Contractor FTx Gun
K
RAC IV Switch T
L
Pressure Drain V
M
Pressure Control
N
Spray Gun Safety Latch
K
ip Guard
E
G
D
M
L
s t
he ris
k o
f f
lui
orks with pressure
d i
njectio
n i
06973
njury
ip
alve
F
J
Model 231–581 Shown
DC motor
T
ransfers power from DC motor to the displacement pump
Controls fluid outlet pressure
Power switch that controls 120 V
Hose and spray gun is connected here
Pressurizes fluid to be sprayed through spray gun
1/4 in. ID, grounded, nylon hose with spring guards on both ends
Reverse-A-Clean (RAC) ti
High pressure spray gun with gun safety latch
RAC switch tip atomizes fluid and removes clogs from spray tip without removing tip from spray gun
Relieves fluid pressure when open
Controls motor to maintain fluid pressure. W adjusting knob.
Inhibits accidental triggering of spray gun
, 120 V
ac, 15A, 1 phase
p g
uard reduce
ac power to sprayer
 
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
sure
caused by static sparking, fluid injection or over­pressurization and rupture of the hose or gun.
3000 psi (210 bar
. This is to reduce the risk of serious injury
, 21 MPa) Working Pres
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 Fig. 2.
1. Connect the hose (74) and gun (67) onto the outlet nipple (28). Don’t use thread sealant, and don’t install the spray tip yet!
.
f device between the filter
and screw it
2. Fill the wet–cup (102). 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 outlet at least 20 feet away from the spray area. A 12 A may be used.
. Plug the cord into a 15A grounded
WG 150 ft (45 m) grounded extension cord
Pry of
f the wet-cup seal.
WARNING
FIRE AND EXPLOSION HAZARD
Proper electrical grounding is essential
-
4. Flush the pump which was left in to protect pump parts after fac tory testing. See page 12.
5.
Prepare the paint
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.
to reduce the risk of fire or explosion which can result in serious injury and property damage. Also read
EXPLOSION HAZARD
to remove the lightweight oil
according to the manufacturer
FIRE OR
on page 2
-
’s
1
1/4
npsm(m) fluid outlet
2
Do not install any shutof
3
Rotate clockwise to increase pressure
4
Shown in closed or spray position
5
Fill 1/3 full with TSL
Fig. 2
f device here
74
67
33
3
64
12
28
32
52
4
5
102
231–581 Shown
06973
 
Page 7
Grounding
A
Setup
Grounded Outlets
WARNING
Improper installation or alteration of the grounding plug will result in a risk of electric shock, fire or explosion that could cause serious injury or death.
1.
This equipment requires a 120 V
ac, 60 Hz, 15A
circuit with a grounding receptacle. See Fig. 3.
Operation
How to use the gun trigger safety
When
engaged, the gun safety latch prevents the gun
from accidental triggering. See Fig. 4.
WARNING
INJECTION HAZARD
If the gun still sprays when the gun trigger safety is locked, repair the gun. See manual 308–645, supplied.
Gun
1
2
safety latch
shown engaged
Gun safety latch shown disengaged
Grounding
Fig. 3
2. Do
3.
not alter the ground prong or use an adapter
A 12 A
WG gauge, 50 ft extension cord may be
used with this equipment.
Open or drain, position
1
2
Closed,
or spray position
Fig. 5
Prong
.
1
2
02825
Fig. 4
How to use the pressure drain valve.
Use
the pressure drain valve to relieve fluid pressure from the pump and to help prime the pump. If the valve senses an over pressure condition, it opens automati cally to relieve fluid pressure. If this happens, stop spraying immediately, shut of Determine the cause of the problem and correct it before operating the sprayer again. Refer also to the
Troubleshooting
, page 13. See Fig. 5.
f and unplug the sprayer
How to use the pressure control.
The
pressure control controls the motor operation so
the sprayer maintains constant fluid pressure at the
1
2
05964
counterclockwise to obtain the minimum setting. T the knob clockwise to increase pressure. See Fig. 6.
-
.
Fig. 6
pump outlet. T
urn the pressure control knob fully
urn
02824A
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Page 8
How to use the RAC IV tip guard.
WARNING
Operation
INJECTION
T
o reduce the risk of serious injury
HAZARD
,
whenever you are instructed to relieve
Procedure
pressure, follow the
on page 9.
Pressure Relief
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. 9. The tip guard holds a reversing spray tip. The tip is in the spraying position when the tip handle points forward. See Fig. 7.
Clean the front of the tip frequently during the day’ operation. First, follow the
Pressure Relief Procedure
s
on page 9.
1
Tip
handle shown in
1
spraying position.
T
urn handle 180
2
trigger gun to clear clog
,
Fig. 7
How to remove a tip clog.
1. Release Rotate the RAC IV tip handle 180. See Fig. 7.
2.
Unlock the safety latch. T or onto the ground to remove the clog.
3.
Lock the safety latch. Rotate the tip handle to the spraying position.
4.
If the tip is still clogged, lock the safety latch, shut of drain valve to relieve pressure. Clean the spray tip as shown in manual 308–644, supplied.
the gun trigger
. Lock the safety latch.
f and unplug the sprayer
rigger the gun into a pail
, and open the pressure
2
04647
 
Page 9
Startup
WARNING
INJECTION HAZARD
The system pressure must be manually relieved to prevent the system from
starting or spraying accidentally under high pressure can be injected through the skin and cause serious injury an injury from injection, splashing fluid, or moving parts, follow the 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
. T
o reduce the risk of
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. T 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
en the tip guard retaining nut or hose end coupling to relieve pressure gradually Now clear the tip or hose obstruction.
, VER
Y SLOWL
, then loosen completely
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:
See page 12.
If this is a first-time startup, flush the sprayer
.
. Fluid
rigger
Y loos
-
.
.
NOTE:
in the text as you start the sprayer
1.
2. Don’t install the spray tip until the pump is
3. Put the suction hose (32) into the paint
Fig.
4. T
5. Disengage the gun trigger safety
Refer to Fig. 2 and the other figures referenced
.
Open the pressure drain valve (42).
primed!
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.
Open
1
or drain, position
8
urn the pressure knob (64) to the minimum
setting.
page 7.
See Fig. 8.
. If you
.
See Fig. 4,
42
CAUTION
Do not run the sprayer dry for more than 30 seconds to avoid damaging the pump packings.
6. T
o prime the pump,
on. Slowly increase the pressure until the sprayer starts. When fluid comes from the pressure drain valve, close the valve.
turn the sprayer switch (52)
1
01021A
 
Page 10
WARNING
FIRE AND EXPLOSION HAZARD
T
o 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.
7. T
o prime the hose
splashing. Hold a metal part of the gun firmly against and aimed into a grounded metal pail. See the preceding W 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.
, lower the pressure to reduce
ARNING. Hold the gun trigger
Startup
b.
c.
NOTE:
Change the spray tip if adjusting the pressure will not improve the spray pattern.
If more coverage is needed, use a larger tip rather than increasing the pressure.
Adjust the direction of the spray pattern. See Fig. 9. 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.
Spray patterns will change as tips wear
.
A
8. Check all fluid connections for leaks 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 308–644 for installation instruc tions.
11. Adjust the spray pattern
a.
Increase the pressure until spray from the gun is completely atomized. T
o avoid excessive overspray and fogging, and to extend tip and sprayer life, always use the lowest pressure needed to get the desired results.
. Relieve
1
-
For a vertical
1
spray pattern
For
a horizontal
2
spray pattern
2
05971
Fig. 9
10 308-720
Page 11
Shutdown and Care
WARNING
INJECTION
T
o reduce the risk of serious injury whenever you are instructed to relieve pressure, follow the
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.
binding and excessive packing wear punch or brass rod and a light hammer to adjust the nut. See Fig. 10.
3.
Periodically clean paint residue from the pres sure transducer (29)
Replace the transducer when leakage is exces sive. See page 27.
4. Lubricate the bearing housing hours of operation. Remove the front cover bearing housing cavity (A) with SAE 10 non­detergent oil. See Fig. 1
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.
HAZARD
,
Pressure Relief
Over-tightening causes
. Use a round
vent hole area. See Fig. 1
-
after every 100
. Fill the
1.
1.
WARNING
INJECTION HAZARD
See the warning section
HAZARD
the hazard of using damaged hoses.
Turn nut tighten
Vent
packing
clockwise
1
hole
to
1
-
Fig. 10
1
on page 3 for information on
102
29
1
A
INJECTION
05117
CAUTION
To
prevent pump corrosion, and to reduce the chance of fluid freezing in the pump in cold weather 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, 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.
, never
leave the suction
Fig. 11
02827A
308-720 11
Page 12
Flushing
When to Flush
1. Before which was left in to protect pump parts.
Before using water-base paint:
eral spirits followed by soapy water clean water flush.
Before using oil-base paint:
spirits only
2. Changing colors: such as mineral spirits or water
3. Changing from water-base to oil-base paint: flush with warm, soapy water 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: 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:
mineral spirits. Relieve pressure. Leave the drain valve open.
using a new sprayer:
.
flush with a compatible solvent
CAUTION
flush out the oil
flush with min
, and then a
flush with mineral
.
, and then mineral
flush with
flush with
Pour one-half gallon (2 liters) of compatible solvent
3. into a grounded metal flushing pail. Put the suction hose in the pail.
4.
-
Open the pressure drain valve. See Fig. 5, 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. T gun into the paint pail. When solvent appears, release the trigger
. Continue with Step 6.
rigger the
WARNING
FIRE AND EXPLOSION HAZARD
T
o reduce static sparking and splashing,
,
firmly to the side of a grounded metal pail when flushing.
6.
Lower the pressure setting. T 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 trigger safety
always remove the spray tip from the gun, and hold a metal part of the gun
urn on the sprayer
. Release the gun trigger
.
. Engage the gun
.
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.
paint, flush out the mineral spirits with soapy water and then clean water flush out the mineral spirits with the paint.
Before using water-base
. When using oil-base paint,
How to Flush
1. Follow
2.
the
Pressure Relief Procedure
page 9.
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 308–249.)
. (See instruction manual
on
.
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 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 the suction hose and drain tube.
10.
Refer to pressure.
11.
Leave the drain valve open until you use the sprayer again.
When To Flush,
. T
rigger the gun and run the
. Wipe paint of
Step 1 again. Relieve
f
12 308-720
Page 13
Troubleshooting
WARNING
INJECTION HAZARD
T
o reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the
sure Relief Procedure
Check
everything in the troubleshooting table before disassembling the sprayer
on page 9.
Basic Problem Solving
Pres-
.
TYPE OF PROBLEM WHA
If check is OK, go to next check
Fluid pressure
Mechanical
Electrical 1.
1.
2.
1.
2.
3.
2.
T T
O CHECK
Check pressure control knob setting. The pump won’t develop much pressure if it is at minimum setting (fully counterclockwise).
Check for a clogged spray tip or fluid filter used. See page 8.
Check for frozen or hardened paint in pump (20). Using a screwdriver fan at back of motor by hand. See page 17.
Check pump connecting rod pin (17). It must be completely pushed into connecting rod (15), and retaining spring (18) must be firmly in con necting rod groove. See Fig. 18, page 21.
Check for motor damage. Remove drive hous ing assembly (1 motor fan by hand.
Check electrical supply with volt meter should read 105–125 V
Check extension cord for visible damage. Use a volt meter or test lamp at extension cord out let to check.
1). See page 24. T
, carefully try to rotate
AC.
, if
ry to rotate
. Meter
WHA
T T
O 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; re fer to separate gun or tip instruction ual for tip cleaning. Clean or replace filter element. See manual 308–249.
-
-
-
1. Thaw
2.
3.
1.
2.
. Plug i
n spraye
e p
increas starts
Push pin into place and secure with spring retainer
Replace motor (4) if fan won’t turn. See page 22.
Reset building circuit breaker; replace building fuse. T
Replace extension cord.
ressure settin
. I
f i
t d
oesn’t, se
r and turn on. S
g t
o se
e N
OTE
, b
.
ry another outlet.
e i
f m
elow.
man
lowly
otor
-
-
3. Check sprayer power supply cord (50) for vis-
4. a. b.
c.
d. e. W
NOTE:
on both sides of motor
NOTE:
area. Do not try to start sprayer until completely thawed or damage to motor and/or start board may occur (dried) in sprayer
Thaw sprayer if water or water–based paint has frozen in it, due to exposure to low temperatures, by placing in a warm
, the pump packings (page 21) and/or pressure transducer (page 27) must be replaced.
ible damage such as broken insulation or wires.
Check motor brushes for the following:
Loose terminal screws. Broken or misaligned brush springs.
Brushes binding in holders.
Broken leads.
orn brushes.
The brushes do not wear at same rate
. Check both brushes.
3.
Replace power supply cord. See page 23.
4.
Refer to page 19.
a. Tighten.
Replace broken spring and/or align
b.
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.
. If paint hardened
308-720 13
-
Page 14
Basic Problem Solving
TYPE OF PROBLEM WHA
If check is OK, go to next check
Electrical
(continued)
5. Check
6.
7. Check
8.
9. Check power supply cord (50). Disconnect
10. Check ON/OFF switch (52). Disconnect the
T T
O CHECK
motor armature commutator for burn spots, gouges and extreme roughness. Re move motor cover and brush inspection plates to check. See page 19.
Check motor armature for shorts using arma ture tester (growler) or perform motor test. See page 17.
leads from pressure control and motor to motor
start board (47) to be sure they are se
curely fastened and properly mated.
Check motor start board (47) by substituting with a good board. See page 23.
CAUTION:
tor armature is determined to be good. A bad motor armature can burn out a good board.
black and white power cord terminals; connect volt should
motor start board (47) and switch and connect volt meter between exposed terminal on switch and power cord’ and turn ON. Meter should read 105–125 V
urn of
T
Do not perform this check until mo
meter to these
read 105–125 V
f and unplug sprayer
leads. Plug in sprayer
AC. Unplug sprayer
s white wire. Plug in sprayer
.
-
-
-
. Meter
.
AC
WHA
T T
O DO
When check is not OK, refer to this column
5.
Remove motor and have motor shop resurface commutator if possible. See page 22.
6.
Replace motor
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 23.
-
9.
Replace power supply cord. See page
23.
10.
Replace ON/OFF switch. See page 23.
. See page 22.
11.
12.
(1)
(2)
13.
Intermediate Problem Solving
TYPE OF PROBLEM WHA
If check is OK, go to next check
Low output
1.
2.
Check motor thermal cutout switch. Connect ohmmeter between motor’s red leads. Meter should read 1 ohm maximum.
Remove pressure control (64) and check mi croswitch operation with ohmmeter:
With pressure knob at lowest setting and stem pushed into control, readings should be: white & black = 1 ohm max. white & red = open.
With pressure knob at highest setting,read ings should be: white & black = open; white & red = 1 ohm max.
Check pressure transducer (29) for hardened paint or damaged or worn components. See page 27.
T T
O CHECK
Check for worn spray tip. 1.
Be sure pump does not continue to stroke when gun trigger is released. Plug in and turn on sprayer mentarily Relieve pressure, turn of
. Prime with paint. T
, then release and lock safety latch.
rigger gun mo
f and unplug sprayer
-
-
-
.
11.
Allow motor to cool. Correct cause of overheating. If switch remains open after motor cools, replace motor
12.
Replace pressure control. See page 26.
13.
Replace transducer ough system flushing will help extend life of transducer
WHA
T T
O DO
.
.
. See page 27. Thor
When check is not OK refer to this column
Follow
Pressure Relief Procedure
replace tip. See your separate gun or tip manual.
2.
Service pump. See page 21.
then
-
14 308-720
Page 15
Intermediate Problem Solving
TYPE OF PROBLEM WHA
If check is OK, go to next check
Low output
Drain valve leaks 1.
(continued)
3. Release
4.
5.
6.
7.
8.
T T
O CHECK
pump
Check electrical supply with volt meter should read 105–125 V
Check extension cord size and length; must be at least 12 gauge wire and less than 150 ft (45 m) long.
Check motor brushes. See Electrical – What T Check, item 4, on page 13.
Check motor start board (47) by substituting with a good board.
CAUTION:
tor armature is determined to be good. A bad motor armature can burn out a good board.
Check motor armature for shorts by using an armature tester (growler) or perform motor test. See page 17.
Check drain valve for correct torque and/or worn parts. Check for debris trapped on seat.
gun trigger
rod (107).
Do not perform this check until mo
. Observe resting position of
. Meter
AC.
WHA
T T
O DO
When check is not OK, refer to this column
3.
If pump consistently comes to rest with rod (107) fully extended, the piston pack ings 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 exten sion cord.
o
6.
See page 19.
7.
Replace board. See page 23.
-
8.
Replace motor
9. T
ighten to 185 in–lb (21 N.m). Clean valve and replace with new gasket (42a) and sealant (42d). See page 28.
. See page 22.
-
-
Transducer leaks 1.
No output: motor runs and pump strokes
No output: motor runs but pump does not stroke
Slight leakage from transducer is normal.
1.
Check paint supply
2.
Check for clogged intake strainer
3.
Check for loose suction tube or fittings. See page 27.
4.
Check to see if intake valve ball and piston ball are seating properly
5.
Check for leaking around throat packing nut which may indicate worn or damaged packings. See page 21.
6. Release pump
1.
Check displacement pump connecting rod pin (17). See Fig. 18, page 21.
7.
Check connecting rod assembly (15) for dam age. See page 24.
gun trigger
rod (107).
. 1.
. 2.
. See page 21.
. Observe resting position of
1.
Periodically remove residue from its cyl inder port. See page 27.
Refill and reprime pump.
Remove and clean, then reinstall.
3. T
ighten; use thread sealant on npt
threads of adapter (38).
4.
Remove intake valve and clean. Check ball and seat for nicks; replace as need ed. See page 21. Strain paint before us ing 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 T
ighten packing nut/wet-cup.
6.
If pump consistently comes to rest with rod (107) fully extended, the piston pack ings 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 page 24.
-
-
-
.
-
. See
8.
Be sure crank in drive housing rotates; plug in sprayer and turn on briefly to check. T and unplug sprayer
. See page 24.
urn of
f
8.
Check drive housing assembly for damage and replace if necessary page 24.
308-720 15
. See
Page 16
Intermediate Problem Solving
TYPE OF PROBLEM WHA
If check is OK, go to next check
Spray Pattern V
Motor Is Hot and Runs Intermittently
Building
ariations
Circuit Breaker
1.
2.
3.
4.
1. Determine
2.
3. Check motor. 3.
1. Check
Opens As Soon As Sprayer Switch Is T
urned On.
2.
T T
O CHECK
Spray tip worn beyond sprayer pressure capa bility.
Check transducer (29) for wear or damage.
Check pressure control (64) for smooth opera tion.
Check Low output section, page 15.
sure with small tips, which causes excessive heat build up.
Be sure ambient temperature where sprayer is located is no more than 90F (32C) and sprayer is not located in direct sun.
tion, and all terminals for loose fit or damage. Also check wires between pressure control and motor
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.
if sprayer was operated at high pres
all electrical wiring for damaged insula
. See page 22.
-
WHA
T T
O DO
When check is not OK, refer to this column
-
1.
Replace spray tip.
NOTE:
A smaller size tip will provide
longer life.
2.
Replace transducer
-
3.
Replace pressure control. See page 26.
-
1.
Decrease pressure setting or increase tip size.
2.
Move sprayer to shaded, cooler area if possible.
Replace motor
1.
Repair or replace any damaged wiring or terminals. Securely reconnect all wires.
2.
Correct faulty conditions.
. See page 27.
. See page 22.
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
Unit will not run on gener ator but does run on AC power
is NOT turned on.
3.
Check motor armature for shorts. Use an arma ture 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:
motor armature is determined to be good. A bad motor armature can burn out a good board.
1. Check
13.
1. Check ON/OFF switch (52).
unplugged!
Check switch with ohmmeter should be infinity with ON/OFF switch OFF and zero with switch ON.
CAUTION:
switch and or motor start board (47).
2.
Check electrical supply with volt meter should read 105–125 V
-
Check
the generator’s peak voltage. This sprayer will
not
run if the peak voltage is above 190V
Do not perform this check until
‘Basic Problems – Electrical’ on page
Disconnect wires from switch.
A short in motor circuit can damage
Be sure sprayer is
. The reading
AC.
. Meter
.
-
3.
Replace motor
4.
Replace board. See page 23.
1.
Replace ON/OFF switch. See page 23.
,
2.
If voltage is too high, do not operate sprayer until corrected.
Use AC power or a dif
. See page 22.
ferent generator
16 308-720
Page 17
WARNING
Motor
T
est
INJECTION
T
o reduce the risk of serious injury whenever you are instructed to relieve pressure, follow the
Procedure
For checking armature, motor winding and brush electrical continuity
on page 9.
HAZARD
,
Pressure Relief
.
Setup
Remove the drive housing. See page 24. This is to ensure that any resistance you notice in the armature test is due to the motor and not to worn gears in the drive housing.
Remove the motor brush inspection covers (A). See Fig. 12.
Remove the junction box screws (56). Lower the junction box. Disconnect the two leads (C) from the motor to the board (47). See Fig. 13.
Armature Short Circuit Test
Remove
the fan cover (B). See Fig. 12.
Fig. 12
B
A
02829A
Spin the motor fan by hand. If there are no shorts, the motor will coast two or three revolutions before coming to a complete stop. If the motor does not spin freely the armature is shorted and the motor must be re placed. See page 22.
,
-
Armature, Brushes, and Motor Wiring Open Circuit Test (Continuity)
Connect lead. T tions 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
the two black motor leads together with a test
urn the motor fan by hand at about two revolu
. See page 22.
-
59
Fig. 13
MOTOR
BLACK/ WHITE
BLACK
C
RED
56
47
04720
308-720 17
Page 18
General
Repair Information
WARNING
INJECTION
T
o reduce the risk of serious injury whenever you are instructed to relieve pressure, follow the
Procedure
on page 9.
Tool List
These
are the tools required to service all parts of the
sprayer.
3/16” Allen wrench: 3/8” Allen wrench: #1 Phillips screwdriver:
pressure control, front cover
3/8” socket wrench: 5/8” socket wrench:
on/off switch boot, piston
13/16” socket wrench: 1-1/4” socket wrench: 1/2” open end wrench: 1
1/16” open end wrench: 15/16” open end wrench: 1-3/4” open end wrench: 5/64” drive pin: 3” needle nose pliers: Hammer & punch: T
orque wrenches:
HAZARD
Pressure Relief
gear housing, legs, handle
pump manifold
junction box,
motor mount
drain valve, outlet fittings,
drain valve
pump inlet valve
pump rod
piston jam nut
flats of inlet tube
pump jam nut
drain valve pin
wiring, on/off switch
packing nut
various fasteners
WARNING
,
als spilled on the hot, bare motor could cause a fire or explosion
HOT SURF
During operation, the motor and drive housing become very hot and could burn your skin if touched. Flammable materi
ACE HAZARD
-
CAUTION
T
o 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 assembly mating connectors.
2.
When reconnecting the wires
blade of the insulated male connector is centered in the wrap–around blade of the female connector.
, use needle nose pliers to separate
in the junction box
, be sure the flat
CAUTION
Improper wire routing can result in poor sprayer performance or damage to the pressure control.
WARNING
MOVING P
T
o reduce the risk of serious injury cluding electric shock, DO NOT touch any moving parts or electrical parts with
your fingers or a tool while inspecting the repair
Shut of complete the inspection.
Reinstall all covers, gaskets, screws and washers before operating the sprayer
f the sprayer and unplug it as soon as you
ARTS HAZARD
.
, in
-
.
3.
Route wires carefully through the drive housing and motor junction box and the motor or pressure control.
4.
Keep all screws, nuts, washers, gaskets, and electrical fittings
dures. These parts are not normally provided with replacement assemblies.
5. T
est your repair before regular operation
sure the problem is corrected.
6.
If the sprayer does not operate properly
that everything was done correctly. Also refer to the T identify other possible problems and solutions.
. A
void pinching the wires between the
removed during repair proce
roubleshooting Guide, pages 13–17, to help
-
to be
, verify
18 308-720
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 1
12–766, 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
T
o reduce the risk of serious injury whenever you are instructed to relieve pressure, follow the
Procedure
1.
Remove both inspection covers (A) and their
on page 9.
Pressure Relief
gaskets. See Fig 14.
,
lead; do not disconnect
Motor
1
2
Minimum 0.5” (12.5 mm)
3
Included in Brush Repair Kit 236–967
2
C
G
3
F
H
E
Fig. 15
4. Inspect
the commutator for excessive pitting,
D
burning or gouging. A black color on the commuta tor is normal. Have the commutator resurfaced by a qualified motor repair shop if the brushes seem to wear too fast or arc excessively
. See Step 9.d.,
also.
5.
Repeat for the other side.
1
B
03881
-
A
Fig. 14
2.
Push in the spring clip (F) and release its hook (G) from the brush holder (B). Pull out the spring clip. See Fig 15.
3.
Slide of connector
f the brush lead terminal (E) of
f the blade
. Remove the old brush (C). See Fig 15.
02831A
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. 16
Holding the spring clip (F) at a slight angle, slide
7.
E
the spring clip into the brush holder and hook it over the end of the holder
. See Fig. 16. Pull on the spring clip to be sure it stays in place. Connect the brush lead to the blade connector (E).
8.
Repeat for the other side.
03881
308-720 19
Page 20
9. Test the brushes.
Remove the pump connecting rod pin (17).
a.
See Fig. 18, page 21.
b.
With the sprayer OFF trol knob fully counterclockwise to minimum pressure. Plug in the sprayer
urn the sprayer ON. Slowly increase the
c. T
pressure until the motor is at full speed.
Motor
, turn the pressure con
.
Brushes
-
shock and serious injury
10.
Install the brush inspection covers and gaskets.
WARNING
MOVING P
Do not touch the brushes, leads, springs or brush holders while the sprayer is plugged in to reduce the risk of electric
ARTS HAZARD
.
d. Inspect
for excessive arcing. Arcs should not trail or circle
the brush and commutator contact
around the commutator surface.
area
11.
Break in the brushes.
least one hour with no load. Install the pump connecting rod pin. See Fig. 18, page 21.
Operate the sprayer for at
 
Page 21
Displacement
WARNING
INJECTION
T
o reduce the risk of serious injury whenever you are instructed to relieve pressure, follow the
Procedure
NOTE:
Reference 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: T
performance, check the motor brushes (see page 19) and clean the transducer (see page 27) whenever you repack
on page 9.
Packing Repair Kit 235–703 is available.
o minimize down time, and for the best sprayer
the pump. Replace these parts as needed.
Removing the pump (See Fig. 17.)
1.
Flush the pump, if possible. Relieve pressure. Stop the pump with the piston rod (107) in its lowest position, if possible. T ally
, rotate the motor fan blades.
2.
Remove the filter (85).
3.
While pulling upward on the suction hose (32), unscrew the hose from the inlet tube (38). Un screw the drain hose (33) from the displacement pump nipple (36).
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).
HAZARD
,
Pressure Relief
o lower the piston rod manu
-
Pump Repair
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. T
ighten the packing nut (102) just enough to stop leakage, but no tighter 1/3 full with Graco TSL. Push the plug (123) into the wet-cup.
­13
85
18
107
20
1
21
33 32
. Fill the packing nut/wet-cup
17
120
*122
*121
36
*119
118
Repairing the pump
See
manual 308–190 for pump repair instructions.
Installing the pump (See
1.
Mount the pump on the drive housing. T the alignment pins with a soft hammer screws (21) to 50 ft-lb (68 N.m).
WARNING
MOVING P
Be sure the retaining spring (18) is firmly in the groove all the way around, to pre vent the pin (17) from working loose due
to vibration. See Fig. 18.
If the pin works loose, it or other parts could break of
f 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.
ARTS HAZARD
Fig. 17 and 18.)
ap it into
. T
ighten the
27
38
2
Fig. 17
15
123
-
Torque
1
Fig.
to
50 ft–lb (68 N.m)
18
21
Torque
1
50 ft–lb (68 N.m)
2
Apply anaerobic polyacrylate pipe sealant
17
1
308-720 21
to
02832B
18
102
04655
Page 22
WARNING
Motor
8.
Remove the two screws (46) and lift the motor of the base (66).
f
INJECTION
T
o reduce the risk of serious injury
HAZARD
whenever you are instructed to relieve pressure, follow the
Procedure
NOTE:
1.
Relieve pressure.
2. T
ry to stop the pump with the piston rod (107) in its
lowest position. T
on page 9.
See Fig. 21 except where noted.
o lower the piston rod manually
Pressure Relief
rotate the motor fan blades. Use a screwdriver to push the retaining spring (18) up and push out the pin (17). See Fig. 19.
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. 22 on page 23.
4.
Remove the front cover (13).
5. T
urn the displacement pump rod (107) so the pin hole aligns with the bottom drive housing screw (19). See Fig. 20. Remove the three drive housing screws and lockwashers (19,6). Also see Fig. 21.
9.
Align the new motor with the base and reinstall the
,
screws (46).
10.
Assemble the drive housing to the motor
. Follow
steps 8 to 10 on page 24.
11.
Connect the wires in the junction box. Refer to Fig. 22 on page 23. Install the junction box.
12.
Connect the piston rod (107) to the drive housing; see page 21, W
ARNING following it.
,
Installing the Pump
17
, Step 2 and the
15
18
Fig. 19
01068
107
19,6
6.
Remove the two motor screws (5) and the lock washers (6).
7. T
ap the lower rear of the drive housing (1
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 24.
1
2
3
to 21 in–lb (2.4 N.m)
Torque
Quantity of three
Quantity of one
6
1
19
13
31
3
1) with a
11
Fig. 20
16
12
01074
1
C
4
5
6
B
A
59
46
56
2
Fig. 21
34
 
05119
Page 23
Motor
Procedure
Start Board
WARNING
INJECTION
T
o reduce the risk of serious injury whenever you are instructed to relieve pressure, follow the
on page 9.
HAZARD
,
Pressure Relief
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.
NOTE:
On/Off
See Fig. 22 for this procedure.
Switch
NOTE:
1.
2.
3.
4.
5.
See Fig. 22 for this procedure.
Relieve pressure.
Remove the junction box screws (56) and lower the junction box (59).
Disconnect the motor wires (B) and the 3-wire connector (A) from the motor start board (47). Observe where connections are made.
Remove the screws (58) and motor start board (47). T
ransfer the white thermal paste from the old
board to the new board.
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 connec tor 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
NOTE:
1.
2.
3.
4.
See Fig. 22 for this procedure.
Relieve pressure.
Remove the junction box screws (56) and lower the junction box (59).
Disconnect the power supply cord leads, including the green wire to the grounding screw (49).
Loosen the strain relief bushing (51). Remove the power supply cord (50).
Supply Cord
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) en gages with the vertical groove in the threads of the switch, and the external tab engages with the blind hole (C) of the junction box.
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
RED
58
A
47
Fig. 22
53
56
GREEN/ YELLOW
50
51
52
C
-
89
54
55
04720
 
Page 24
Drive
Housing, Connecting Rod, Crankshaft
WARNING
INJECTION
T
o reduce the risk of serious injury whenever you are instructed to relieve pressure, follow the
Procedure
Removal
NOTE:
parts that are worn or damaged.
1.
Remove the displacement pump. See page 21.
2.
Remove the pressure control (64). See page 26.
3. T
urn the displacement pump rod (107) so the pin hole aligns with the bottom drive housing screw (19). See Fig. 23. Remove the three drive housing screws and lockwashers (19,6). Also see Fig. 24 on page 25.
on page 9.
Inspect parts as they are removed. Replace
107
HAZARD
Pressure Relief
CAUTION
Do not allow the gear (16) to fall; it may stay at
,
tached to the drive housing or to the motor
Do not lose the thrust balls (11a or 4a) or let them fall between ing with grease, usually stay in the gear recesses, but could be dislodged. If the balls are not in place, the bearings
6.
Installation
7.
8.
NOTE:
housing (1 tain a total of 3 fl. oz. (29 cc) of grease.
the gears, which will damage the drive hous
if not removed. The balls, which are heavily covered
will wear prematurely
Remove and inspect the crankshaft (12) and the connecting rod (15).
Install the connecting rod.
Lubricate the inside of the drive housing bearing with SAE non-detergent oil. Pack the roller bearing and gears with the grease supplied.
The gears and bearings between the drive
1) and motor front end bell (C) should con
.
-
.
-
-
Fig. 23
4.
Remove the two motor screws (5) and lock wash ers (6). See Fig. 24 on page 25.
5. T
ap the lower rear of the drive housing (1 plastic mallet to loosen the motor housing straight of
f the motor
. Pull the drive
.
19,6
1) with a
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 (1
-
ing pins. Install the screws (19, 5) and their lock washers (6). T
11.
Install the displacement pump. See page 21.
12.
Install the pressure control (64). See page 26. Install the front cover (13).
1) straight onto the motor and the locat
orque to 80 in–lb (9 N.m).
-
-
 
Page 25
Drive
1
Torque
2
Quantity of three
3
Quantity of one
Apply a total of
4
3 fl. oz.(89 cc) of grease to gears.
Note:
Filter
not shown
Fig.
24
Housing, Connecting Rod, Crankshaft
5,6
1
C
4a
12b
A
47
59
56
02815
to 21 in–lb (2.4 N.m)
31
3
34
64
REF
A
16
11a
4
12a
12
11
6
15
19
1
13
2
 
Page 26
Pressure
WARNING
Control
7.
Loosely install the screws (63) and then torque them to 21 in–lb (2.4 N.m).
INJECTION
T
o reduce the risk of serious injury whenever you are instructed to relieve pressure, follow the
Procedure
NOTE:
NOTE:
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 (1
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. T control down and back into the drive housing (1 Do not pinch or damage the harness (A).
on page 9.
See Fig. 25 for this procedure.
The pressure control (64) cannot be repaired
HAZARD
Pressure Relief
1).
ip the pressure
8.
,
1).
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
11
A
Torque
to
21 in–lb (2.4 N.m)
Fig.
25
56
59
1
13
02816A
 
Page 27
Pressure
WARNING
T
ransducer
INJECTION
T
o reduce the risk of serious injury whenever you are instructed to relieve pressure, follow the
Procedure
NOTE:
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
Install the transducer in the pump manifold, while
5. guiding the o-ring and backup ring into place.
6.
Align the holes in the transducer as shown by the arrows in Fig. 26.
7.
Install the displacement pump. See page 21.
on page 9.
See Fig. 26 for this procedure.
HAZARD
Pressure Relief
Suction
,
29
101
.
Fig. 26
02817A
Hose
WARNING
INJECTION
T
o reduce the risk of serious injury whenever you are instructed to relieve pressure, follow the
Procedure
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 least 4 turns to ensure that the threads have disen­gaged
on page 9.
inlet tube (38). T
and can function as a swivel joint.
HAZARD
Pressure Relief
ighten the hose onto
,
the tube at
CAUTION
Misalignment or cross-threading will damage the parts and/or create shavings which can cause the o–ring (27) to leak.
Lubricate
1
Filter
Note:
not shown
13
33
32 27
1
A
38
Fig. 27
36
06978
 
Page 28
Procedure
42a
42b
3
Drain
WARNING
INJECTION
T
o reduce the risk of serious injury whenever you are instructed to relieve pressure, follow the
on page 9.
1
42
42d
HAZARD
Pressure Relief
42c
Apply
1
2
3
4
thread sealant
Apply grease to face of base
T
orque into pump manifold to 185 in–lb (21 N.m)
Handle shown in closed position
V
alve
Repair
1.
Unscrew the spring retainer from the valve body Remove the spring, washers and stem/ball. Clean
,
2
any debris from the ball or seat area.
2.
If replacing the gasket (42a) or seat (42b), pry out the gasket.
NOTE:
place it with a new one.
3.
4.
Whenever the gasket (42a) is removed, re
Coat the o-ring (42d) with grease. Press the stem into the valve body spring retainer into the valve body
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
. Install the spring, washers and
.
.
.
-
43
44
45
Fig.
28
1. T
urn 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.
4
02819
NOTE:
valve until the valve is tightened into pump, which correctly seats the gasket.
The gasket will protrude from the end of the
Replacement
1.
Apply a small amount of thread sealant (42e) onto the valve (42) threads. T pump manifold to 185 in–lb (21 N.m).
2.
Lightly grease the face of the base (43) and install the base. T
3.
Securely install the handle (45) and drive pin (44).
urn the stem so the pin hole is vertical.
ighten the valve into the
 
Page 29
Notes
 
Page 30
Sprayer Parts Drawing
Model 231–581, Series A
39
30
REF
10
28
35
OUTSIDE LABEL
14
INSIDE LABEL
85
32
13
63
15
17
REF 33
6
19
18
64
3
Label
1
See detail
2
on page 31
11b
29
12a
12
26
11
74
16
24
11a
12b
66
67
4a
4e
1
5
6
4
1
4f
4g
1
89
2
50
56
28
31
34
21
32
27
 
20
36
33
38
42a
42
42b
42d
43
44
42c
23
45
37
25
23
46
06974C
Page 31
Sprayer
Model 231–581, Series A
Includes
Ref. No.
3 111–700 GRIP, 4{ 238–344 MOTOR KIT
4a 100–069 . 4b 111–616 . 4c 107–504 . 4dY 187–784 . LABEL, DANGER, French 1 4eY 187–791 . LABEL, DANGER, English 1 4fY 187–975 . 4g 107–503 . 5 100–643 SCREW 6 105–510 LOCKWASHER, 1/4” 5 10 100–721 11 224–965 DRIVE HOUSING KIT 1
11a 100–069 . 11b 111–726 . PLUG 1 12 224–803 CRANKSHAFT 1
12a 180–131 . BEARING, thrust 1 12b 107–434 . BEARING 1 13 187–789 COVER, front 1 14Y 177–762 15 218–359 CONNECTING ROD 1 16 218–364 GEAR REDUCER 1 17 176–818 18 176–817 19 103–345 SCREW
20 235–699 PUMP KIT
21 111–706 CAPSCREW 23 111–715 SCREW 24 192–166 HANDLE, sprayer 1 25 112–759 CAP 26 239–276 LEG, with gusset 1 27H 104–938 O–RING 1 28 162–453
29 235–009 PRESSURE TRANSDUCER 1 30 114–026 CLIP 31 108–850 SCREW 32 187–624 SUCTION HOSE & TUBE 1 33 187–652 DRAIN HOSE 1 34 111–705 SCREW 35 290–377 36 111–612 37 187–628 LEG, sprayer 2 38 192–167 INLET TUBE 1 39 235–004 STRAINER 1 42 235–014 DRAIN VALVE KIT 1
42a 111–699 . GASKET, valve seat 1 42b 187–615 . SEAT 42c 224–968 . 42dH 168–110 . O–RING, stem 1 42e 110–110 . SEALANT
items 3 to 89 as listed below
Part No.
Description Qty.
handle
Includes items 4a to 4g
BALL, sst, 1/4” dia. TERMINAL, flat, 1/4” (f), 18 awg TERMINAL, 3/16” (m), 16 awg
LABEL, W TERMINAL, 3/16” (f)
PLUG, 1/4–18 npt(f)
Includes item 1
BALL, stainless steel, 1/4” dia.
Includes items 12a, 12b
LABEL, W
PIN, headless, 3/8” dia. x 1” SPRING, retaining
1/4–20 x 1–1/4”
See manual 308–190 for parts
NIPPLE, hex, 1/4 npsm x 1/4 npt, 1–3/16”
LABEL, identification ADAPTER, tube, 9/16–18
Includes items 42a to 42e
STEM, drain valve
ARNING, electric shock 1
, socket head, 1/4–20 x 1”
1a, 1
ARNING 1
, socket head,
, 7/16–14 x 1–3/4”
, 5/16–18 x 1–1/4”
, tubing
, 3/4”
, filh, 8–32 x 1–1/4”
, filh, 8–32 x 2–1/2”
, drain valve
, pipe (not shown)
1b
Parts List
Ref. No.
43 224–807 BASE, valve 1
1
44 111–600
1
45 187–625 HANDLE, drain valve 1
1
46 110–997 SCREW
2
47 235–008 MOTOR START BOARD 1
1
48Y 186–620 49 110–037 SCREW 50 235–010 POWER CORD SET 1
51 111–617 STRAIN RELIEF BUSHING, 1 1 2
52 105–679 SWITCH, ON/OFF 1
53 235–035 GROUND HARNESS 1 1
54 105–658 LOCKING RING 1
55 105–659 BOOT, switch 1
56 111–703 SCREW 1
58 100–035 SCREW
59 187–795 JUNCTION BOX 1
63 111–704 SCREW
64 239–515 PRESSURE CONTROL KIT 1
66 189–932
67 238–350 CONTRACTOR FTx GUN 1
68 206–994
74 238–361
1 1
85 239–447 FIL 3
89 187–963 GASKET 1
Y
1
{
2
236–967 is available. Purchase separately
6
H
4
2
1 1
3 1 1
1 1
1
Part No.
Extra warning labels available free of charge.
Motor Brush and Spring Replacement Kit,
Replace Ref. No. 27 with 1
1
12–319 if using severe solvents such as lacquer thinner
and acetone.
48
4g
BLACK/ WHITE
BLACK
Description Qty.
PIN, grooved, 3/32 x 1”
, washer/hex hd, 5/16”
LABEL, ground terminal
, mach, pnhd, 10–24 x 5/8”
3/8–18 npt
, filh, 10–24 x 3” , pan hd, 8–32 x 5/16”
, filh, 10–24 x 1–5/8”
BASE, motor
See manual 308–645 for parts
TSL, 8 oz. (not shown) HOSE, grounded, nylon; 1/4” ID; cpld 1/4 npsm(f); 50 ft (15 m);’ spring guards both ends
TER, fluid
See Manual 308–249 for parts
.
14–048 and Ref. No. 42d with
MOTOR
GREEN
49
GREEN/
53
YELLOW
50
52
4b
59
RED
58
4c
47
1
2
1 1
4 2
2
1
1 1
1
51
54
55
04720
308-720 31
Page 32
Sprayer Parts Drawing
Model 231–583, Series A
10
28
30
REF
85
32
17
63
15
39
REF 33
19
62
23
72
3
24 REF
66
REF
4e
1
5
6
64
11b
24
12a
12
16
12b
4
4a
4f
4g
1
1
66
6
11a
89
2
46
OUT­SIDE LABEL
14
INSIDE LABEL
31
35
34
13
18
59
11
56
65
29
50
42a
26
37
28
42b
42d
25
42c
21
20
42
45
36
32
27
33
43
44
38
74
67
Label
1
2
page 33 for detail
See
 
O5120A
Page 33
Sprayer
Model 231–583, Series A
Includes
Ref. No.
3 280–290 SLEEVE, cart 2 4{ 238–344 MOTOR KIT
4a 100–069 . 4b 111–616 . 4c 107–503 . 4dY 187–784 . LABEL, DANGER, French 1 4eY 187–791 . LABEL, DANGER, English 1 4fY 187–975 . 4g 107–503 . 5 100–643 SCREW 6 105–510 LOCKWASHER, 1/4” 3 10 100–721 11 224–965 DRIVE HOUSING KIT 1
11a 100–069 . 11b 111–726 . PLUG 1 12 224–803 CRANKSHAFT 1
12a 180–131 . BEARING, thrust 1 12b 107–434 . BEARING 1 13 187–789 COVER, front 1 14Y 177–762 15 218–359 CONNECTING ROD 1 16 218–364 GEAR REDUCER 1 17 176–818 18 176–817 19 103–345 SCREW
20 235–699 PUMP KIT 1
21 111–706 CAPSCREW 23 112–620 SCREW 24 189–934 HANDLE, sprayer 1 25 112–759 CAP 26 110–849 WHEEL, sprayer 2 27H 104–938 O-RING 1 28 162–453
29 235–009 PRESSURE TRANSDUCER 1 30 114–026 CLIP 31 108–850 SCREW 32 187–624 SUCTION HOSE & TUBE 1 33 187–652 DRAIN HOSE 1 34 111–705 SCREW 35 290–377 36 111–612 37 112–612 HUBCAP 38 192–167 INLET TUBE 1 39 235–004 STRAINER 1 42 235–014 DRAIN VALVE KIT 1
42a 111–699 . GASKET, valve seat 1 42b 187–615 . SEAT 42c 224–968 . 42dH 168–110 . O–RING, stem 1 42e 110–110 . SEALANT 43 224–807 BASE, valve 1
items 3 to 89 as listed below
Part No.
Description Qty.
Includes items 4a to 4f
BALL, sst, 1/4” dia. TERMINAL, flat, 1/4” (f), 18 awg TERMINAL, 3/16” (m), 16 awg
LABEL, W TERMINAL, 3/16” (f)
PLUG, 1/4–18 npt(f)
Includes item 1
BALL, stainless steel, 1/4” dia.
Includes items 12a, 12b
LABEL, W
PIN, headless, 3/8” dia. x 1” SPRING, retaining
1/4–20 x 1–1/4”
See manual 308–190 for parts
NIPPLE, hex, 1/4 npsm x 1/4 npt, 1–3/16”
LABEL, identification ADAPTER, tube, 9/16–18
Includes items 42a to 42e
STEM, drain valve
ARNING, electric shock 1
, socket head, 1/4–20 x 1”
1a, 1
ARNING 1
, socket head,
, 7/16–14 x 1–3/4”
, 6–32 x 0.187”
, tubing
, 3/4”
, filh, 8–32 x 1–1/4”
, filh, 8–32 x 2–1/2”
, wheel
, drain valve
, pipe (not shown)
1b
Parts List
Ref.
No.
44 111–600
45 187–625 HANDLE, drain valve 1 1
46 110–997 SCREW 1
47 235–008 MOTOR START BOARD 1 2
48Y 186–620 1
49 110–037 SCREW
50 235–010 POWER CORD SET 1
51 111–617 STRAIN RELIEF BUSHING, 1
1
52 105–679 SWITCH, ON/OFF 1 3
53 235–035 GROUND HARNESS 1
54 105–658 LOCKING RING 1 1
55 105–659 BOOT, switch 1
56 111–703 SCREW
58 100–035 SCREW 1
59 187–795 JUNCTION BOX 1
62 109–567
63 111–704 SCREW
64 239–515 PRESSURE CONTROL KIT 1
65 109–570 WASHER, cart 2
66 235–735 FRAME, cart 1
67 238–350 CONTRACTOR FTx GUN 1
68 206–994
72 178–565 BUTTON, spring 2 1
74 238–361 1 5
85 237–447 FIL
89 187–963 GASKET 1 2
Y
4
{
236–967 is available. Purchase separately
2
H
2
1 1
3 1 1 2
1 1
1
Part No.
Extra warning labels available free of charge.
Motor Brush and Spring Replacement Kit,
Replace Ref. No. 27 with 1
1
12–319 if using severe solvents such as lacquer thinner
and acetone.
48
4g
BLACK/ WHITE
BLACK
Description Qty.
PIN, grooved, 3/32 x 1”
, washer/hex hd, 5/16”
LABEL, ground terminal
, mach, pnhd, 10–24 x 5/8”
3/8–18 npt
, filh, 10–24 x 3” , pan hd, 8–32 x 5/16”
PIN, handle
, filh, 10–24 x 1–5/8”
See manual 308–645 for parts
TSL, 8 oz. (not shown)
HOSE, grounded, nylon; 1/4” ID; cpld 1/4 npsm(f); 50 ft (15 m);’ spring guards both ends
TER, fluid
See Manual 308–249 for parts
.
14–048 and Ref. No. 42d with
MOTOR
GREEN
49
GREEN/
53
YELLOW
50
52
4b
59
RED
58
4c
47
1
2
1 1
4 2
2 2
1
1
1
51
54
55
04720
 
Page 34
Technical
PTFEPTFEPTFE
Power
Requirements
Generator Working Motor Cycles/Gallon Delivery 0.44 Tip Size
Power Cord Inlet
Pump Inlet Size Fluid Sound
Sound Pressure at 3.1 ft (1 m) 80.1 dB(A) Sound *Measured
W
etted Parts:
Displacement Pump
NOTE:
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Range
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(liter)
.
. . . . . . . . . . . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . . . .
Paint Strainer
Outlet Size
Data:
Power
while spraying with a .017 tip, per ISO 3744
TFE,
P
and Delrin
. . . . . . . . . . . . . . . . . .
0–3000 psi (0–210 bar
.
. . . . . . . . . . . . . . . . . . . . . . . . . .
with
latex at
.
. . . . . . . . . . . . . . .
Stainless
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
. . . . . .
Aluminum, Polyethylene, Delrin, Leather
are
trademarks of the DuPont Company
Data
120 V
AC, 60 Hz,.
1
phase, 15A minimum
3000W minimum
, 0–21
MPa)
5/8 hp
620 (164)
gpm (1.66 lpm)
one gun to 0.021 new tip
2000 psi (138 bar
14 A
WG, 3 wire, 6 ft (1.8 m) 12 mesh (1525 micron)
Steel Screen, reusable
.
. . . . . . . . . . . . . .
Stainless steel, Carbon steel,
, 13.8
MPa)
1/2 npt(f)
1/4 npsm
95.2 dB(A)*
DANGER
The 4 is also on your sprayer not read English, order one of the following labels to apply to your sprayer best placement of these labels for good visibility
Order the labels directly from Graco, free of charge: 1–800–328–0211
French 185–956
LABELS
English language DANGER label shown on page
. If you have painters who do
. The drawing below shows the
.
Apply
other
language here
Spanish 185–961 German 186–041 Greek 186–045 Korean 186–049 English 185–953
04653
Dimensions
Model
231–581
W
eight
(dry w/o packaging)
.
Height
37 lb (17 kg)
19 in. (483 mm) 21 in. (533 mm)
Model 231–583
50 lb (22.7 kg)
Length
Width
15 in. (381 mm) 22 in. (559 mm)
14 in. (356 mm) 15 in. (381 mm)
 
Page 35
Notes
 
Page 36
Graco
Graco
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
In hereunder, breach
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.
no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
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
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.
, 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
FOR
GRACO CANADA CUST
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 judiciaires
avoir convenu que la rédaction du présente document sera en Anglais,
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
OMERS
ainsi que tous documents, avis et procédures
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment W arranty Program”.
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:
Sales Offices:
Belgium, Canada, England, Korea, France, Germany
GRACO INC. P.O. BOX 1441
PRINTED
 
IN U.S.A. 308–720 February 1997, Revised May 1998
Minneapolis, Detroit, Los Angeles
MINNEAPOLIS, MN
http://www.graco.com
, Hong Kong, Japan
55440–1441
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