airless paint sprayers. This section will help you be
familiar with the sprayer before operating it.
1000
BASIC COMPONENTS
Pressure Control
The
pressure control includes
sprayer, a pressure adjusting control knob and a freeze
resistant pressure sensing device. The function of the
pressure
sprayer maintains constant fluid pressure at the pump
outlet.
Pressure
The pressure drain valve provides pressure relief of the
sprayer.
and allows normal sprayer operation. In the downward
position, the pressure drain valve relieves the pressure
the system. The pressure drain valve will also open au
in
tomatically in the case of a control overpressure failure.
control is to control the
Drain V
In the forward position, the drain valve is closed
alve
an ON/OFF switch for the
motor speed so that the
Motor
The
DC motor has sealed bearings and replaceable
tor brushes. It drives the displacement pump at the rate
needed
pressure. W orking together , the pressure control and
motor
pressure
sounds like an automobile starter cranking. When the
pump
til
self off. However, there will still be power to the sprayer
and it will stay pressurized and ready to use until you
manually
to supply suf
cause the pump to cycle whenever there
demand.
is not cycling, the motor may hum intermittently un
the fluid pressure stabilizes, then the motor will shut
shut it of
ficient paint volume
When the pump is cycling, the motor
f and relieve pressure.
at the selected
ferently than
mo
is fluid or
it
Because the motor is DC, it is less sensitive to low voltage or voltage fluctuations than an AC motor, and a 12
or larger extension cord of up to 300 ft. (90 m) can
gauge
be
used without performance loss.
Drive Assembly
The
sealed drive assembly
motor
to the displacement pump.
transfers power from the DC
Displacement Pump
The
positive displacement, volume-balanced pump pro
equal fluid delivery on both the up
vides
strokes. The pump has a wet-cup which, when filled with
Graco Throat Seal Liquid, helps prevent damage to the
packings and piston rod.
throat
and down pump
Fluid Filter
The
fluid filter strains the paint to help avoid clogs in
hose
and spray tip. The filter includes a reusable element
and
has a pressure drain valve for manually relieving fluid
-
pressure.
Hoses
The
grounded, nylon spray hoses have spring guards on
both
ends. The 50 ft. (15.2 m) hose has a 1/4 in. ID. The
3 ft.
-
(0.9 m), 3/16
movement. The nylon hose material acts
dampener to absorb pressure fluctuations.
in. ID hose provides more flexible gun
as a pulsation
Spray Gun & RAC IV DripLess Tip Guard
Graco high pressure spray guns have a safety latch
prevents accidental
which
See T in Fig. 1. The gun provided with the sprayer also
-
-
a filter for final paint straining. The Reverse-A-Clean
has
IV SwitchTip uses high pressure fluid to remove clogs
the
from
Reverse-A-Clean IV DripLess tip guard is a safety feature
spray tip without removing it from the gun. The
which helps reduce the risk of fluid injection injury
triggering when it is engaged.
-
the
.
T
A
B
C
D
S
0137
Fig. 1
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
J
K
Motor
Pressure Adjusting Knob
ON/OFF Switch
Drive Assembly
Fluid Filter
Secondary Fluid Outlet
Pail Hanger
Displacement Pump
50 ft (15 m) Main Hose
RAC IV T
ip Guard
Contractor Gun
RAC IV Switch T
ip
3 ft (0.9 m) Hose
Primary Fluid Outlet
Pressure Drain V
alve
Pressure Control
Spray Gun Safety Latch
M
E
F
G
H
R
P
N
L
04239
DC motor
, 120 V
ac, 15A, 1 phase
Controls fluid outlet pressure
Power switch that controls 120 V
T
ransfers power from DC motor to the displacement pump
ac main power to sprayer
Final filter of fluid between source and spray gun
Second spray gun operation is connected here
Container for fluid to be sprayed may be hung here
T
ransfers fluid to be sprayed from source through spray gun
1/4 in. ID, grounded, nylon hose with spring guards on both ends
Reverse-A-Clean (RAC) tip guard reduces the risk of injection injury
High pressure spray gun with gun safety latch
RAC switch tip uses high pressure fluid to remove clogs from spray
tip without removing tip from spray gun
3/16 in. ID, grounded, nylon hose used between 50 ft hose and
spray gun to allow more flexibility when spraying
Single spray gun operation is connected here
Relieves fluid outlet pressure when open
Controls motor speed to maintain fluid outlet pressure at displace
ment pump outlet. W
orks with pressure adjusting knob.
-
Gun safety latch inhibits accidental triggering of spray gun
Symbols
Warning Symbol
WARNING
his
symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNINGWARNING
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 Graco distributor
Do not alter or modify this equipment. Use only genuine Graco parts.
misuse can cause the equipment to rupture or malfunction and result in serious injury
Caution Symbol
CAUTION
This
symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
.
.
.
Check equipment daily
Do not exceed the maximum working pressure of the lowest rated system component. Refer to
the Technical Data
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
T
echnical Data
warnings.
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex
pose Graco hoses to temperatures above 82C (180F) or below –40C (–40
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
section of all equipment manuals. Read the fluid and solvent manufacturer
. Repair or replace worn or damaged parts immediately
on page 39 for the maximum working pressure of this equipment.
.
F).
’s
-
4
308-619
WARNINGWARNING
INJECTION HAZARD
Spray
from the gun, leaks or ruptured components can inject fluid into your body and cause ex
tremely serious injury
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.
, including the need for amputation. Fluid splashed in the eyes or on the skin
.
. The injury may look like just a cut, but it is a serious
.
, glove or rag.
fuser operation weekly
. 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
not repair high pressure couplings; you must replace the entire hose.
Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
Pressure Relief Procedure
on page 13 if the spray tip clogs and before cleaning,
. Replace worn or damaged parts immediately
TOXIC FLUID HAZARD
Hazardous
skin, 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
and solvent manufacturer
fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
. Dispose of hazardous fluid according to all local,
, gloves, clothing and respirator as recommended by the fluid
.
. Do
308-619
5
WARNING
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,
spraying immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or 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.
MOVING PARTS HAZARD
Moving
parts, such as the air motor piston, can pinch or amputate your fingers.
stop
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the
NOTE: This
your sprayer
equipment from starting unexpectedly
is an example of the DANGER label on
. This label is available in other
.
languages, free of charge. See page 39 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,
Avoid
open
connecting
off.
Failure
areas can result in fire or explosion.
containers and objects being sprayed.
all ignition sources such as static electricity from
flames such as pilot lights, hot objects such as cigarettes, arcs
or disconnecting power cords or turning light switches on
to follow this warning can result in death or serious injury
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
plastic drop cloths,
from
and
.
Pressure Relief Procedure
on page 13 to prevent the
.
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
-
Setup
WARNING
To reduce the risk of serious injury from static
sparking, injection, or over pressurization and
rupture
cally conductive, the gun must have a tip guard, and
each
Maximum Working Pressure.
of the hose or gun, all hoses must be electri
part must be rated for at least 3000 psi (210 bar)
CAUTION
T
o avoid damaging the pressure control, which may
result in poor equipment performance and component
damage, follow these precautions:
1. Always use grounded, flexible spray hose at
least
50 ft. (15 m) long.
2. Never
3. Never
4. Always
use a wire braid hose as it is too rigid to act
as
a pulsation dampener
install any shutof
and
the main hose. See Fig. 2.
use the main filter outlet for one gun op
eration.
Never plug this outlet.
.
f device
between the filter
NOTE:
1. Fill the packing nut/wet-cup
-
-
2. Connect the gun, 3 ft. hose and 50 ft. hose.
3. Two gun hookup
4.
See Fig. 2 while doing the setup.
1/3 full with Graco
Throat Seal Liquid (TSL), supplied.
Screw the assembly onto the outlet nipple. Don’t
use thread sealant and don’t install the spray tip
yet!
. Unscrew the cap from the 1/4
npsm(m) secondary hose outlet. Connect a hose
and gun to the outlet. Use a 1/4 in. ID, 50 ft. long
(minimum) main hose. For more flexible gun
movement, install a 3/16. ID, 3 ft. hose between
the main hose and the gun.
Check the Electrical Service.
Two gun hookup. Unscrew the cap from the 1/4
npsm(m) secondary hose outlet. Connect a hose
and gun to the outlet. Use a 1/4 in. ID, 50 ft. long
(minimum) main hose. For more flexible gun movement,
install a 3/16 in. ID, 3 ft. hose between the main
hose
and the gun.
a.
Electrical requirements: 120 V AC, 60 Hz, 15
Amp (minimum).
Proper electrical grounding is essential
to reduce the risk of fire or explosion
which can result in serious injury and
property damage. Read the warning sec
tion
FIRE OR EXPLOSION HAZARD
page 6 for more detailed grounding
instructions.
on
5. Plug
6. Flush the pump
7.
-
in the sprayer. Turn the ON/OFF switch
OFF
. Plug the cord into a grounded electrical
outlet.
to remove the oil left in to protect
pump parts after factory testing. See
on page 12.
Prepare the paint
recommendations. Remove any paint skin. Stir the
paint thoroughly
nylon mesh bag (available at most paint dealers)
to remove particles that could clog the filter or
spray tip. This is an important step for trouble-free
paint spraying.
according to the manufacturer
. Strain the paint through a fine
Flushing
308-619
’s
7
Setup
PRESSURE ADJUSTING KNOB
P
ACKING NUT/ WET–CUP
FILL 1/3 FULL WITH TSL
Fig.
2
PRESSURE
DRAIN
VALV E
1/4 npsm(m) FLUID OUTLET NIPPLE
DO NOT INST
ALL ANY SHUT
DEVICE HERE
OFF
ON/OFF
SWITCH
Startup
Use this procedure each time you start the sprayer to
help
ensure the sprayer
start
it safely
.
is ready to operate and that you
WARNING
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
warning on page 13 when
Pressure Relief
,
-
ever you are instructed to relieve pressure.
NOTE:
Flush the sprayer if this is a first-time startup.
See page 12.
NOTE:
See Fig. 4 except where noted.
1. Put the suction tube into the paint container.
2. Turn the pressure adjusting knob fully coun-
terclockwise to zero pressure.
3.
Plug in the sprayer
.
CAUTION
c. Release
5. Check all fluid connections for leaks
the trigger. Engage the gun safety latch.
. Relieve
the fluid pressure before tightening connections.
6. Install the spray tip and tip guard.
Engage the
gun safety latch. See Fig. 3. Install the spray tip
according to the instructions supplied with it.
7. Adjust the spray pattern.
a. Increase the pressure just until spray from the
gun is completely atomized. Use the lowest
pressure
needed to
get the desired results. This
reduces overspray and fogging, decreases tip
wear
and extends the life of the sprayer
b.
If more coverage is needed, use a larger tip
rather
than increasing the pressure.
c.
Test the spray pattern. T o adjust the pattern,
engage
nut.
the gun safety latch, loosen the
Position the tip guard horizontally for a hori
zontal pattern or vertically for a vertical pattern.
Then
tighten the retaining nut.
GUN
SAFETY
LA
TCH SHOWN
ENGAGED
.
retaining
-
Do not run the pump without fluid in it for more than
30 seconds to avoid damage to the displacement
pump
packings.
WARNING
FIRE AND EXPLOSION HAZARD
T
o reduce the risk of static sparking and
splashing when flushing, 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.
4.
Prime the pump
a.
Open
the pressure drain valve (handle in down
ward position). If you did not install a secondary
hose, be sure the nipple is tightly plugged with
the cap provided. T urn the ON/OFF switch to
ON. Slowly turn the pressure adjusting knob
clockwise until the sprayer starts. When fluid
comes
dle
in forward position).
b. Disengage the gun safety latch. See Fig. 3.
Following the warning, above, trigger the gun
until all air is forced out of the system and the
paint
flows freely from the gun.
.
from the drain hose, close
the valve (han
Fig.
3
ON/OFF
GUN SAFETY LA
SHOWN DISENGAGED
SWITCH
TCH
0137
PRESSURE ADJUSTING KNOB
-
-
OUTLET NIPPLE
Fig.
4
DRAIN HOSE
PRESSURE
DRAIN
VALV E
04243
Startup
Cleaning a Clogged Tip
WARNING
FLUID
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
warning on page 13 when
Pressure Relief
ever you are instructed to relieve pressure.
1. Clean the front of the tip frequently during the day’s
operation. First, relieve pressure.
2. If the spray tip does clog, release the gun trigger
gage the gun safety latch, and rotate the RAC IV
handle
180. See Fig. 5.
3.
Disengage the gun safety latch and trigger the gun
into a waste container. Engage the gun safety latch
again.
,
-
, en
4. Return
the handle to the original position, disengage
the
gun safety latch, and resume spraying.
5. If the tip is still clogged, engage the gun safety latch,
shut
of
f and unplug the sprayer
sure
drain valve to relieve pressure. Clean the spray
, and open the pres-
tip as shown in manual 307–848, supplied with the
RAC
IV
.
TIP GUARD HANDLE
SHOWN IN SPRA
TURN HANDLE 180
DISENGAGE SAFETY
LATCH AND TRIGGER
GUN TO CLEAR CLOG
YING
POSITION
,
GUN
LA
ENGAGED
-
Fig.
5
SAFETY
TCH SHOWN
Shutdown
WARNING
FLUID
INJECTION HAZARD
T
o reduce the risk of serious injury
follow the illustrated
Procedure
ever you are instructed to relieve pressure.
1.
Check
pressure.
to help prevent fluid buildup on the piston rod and
premature
the packing nut/wet-cup daily. First relieve
Keep the wet-cup
wear of packings.
warning on page 13 when
Pressure Relief
1/3 full of TSL at all times
and Care
6.
Coil
the hose and hang it on the
storing
it, even for overnight, to help protect the hose
from
kinking, abrasion, coupling damage, etc.
,
-
PACKING
NUT/
WET–CUP
hose rack
when
Tighten
Over
ing wear. Use a round punch or brass rod and light
hammer
2.
Clean
er
12 or refer to manual 307–273, supplied, for the
cleaning
3.
Lubricate the bearing housing after every 100
hours of operation. First relieve pressure. Remove
the front cover. Fill the bearing housing cavity with
SAE
4. For very short shutoff periods, leave the suction
tube in the paint, relieve pressure, and clean the
spray
5. Flush
fill
sion
the packing nut just enough to stop leakage.
tightening causes binding and excessive pack
to adjust the nut. Refer to Fig. 6.
the fluid filter often
is stored. Follow the Flushing Guidelines on
procedure.
10 non-detergent oil. See Fig. 7.
tip.
the sprayer at the end of each work day
it with mineral spirits to help prevent pump corro
and freezing. See page 12.
and whenever the spray
page
and
CAUTION
-
TIGHTEN
-
Fig.
6
FILL BEARING HOUSING
CA
VITY WITH SAE
NON-DETERGENT OIL
AFTER EVER
HOURS OF OPERATION
FRONT
COVER
-
Y 100
To
prevent pump corrosion,
type
of paint in the sprayer when it is not in use. Pump
water
or paint out with mineral spirits.
never leave water or any
Fig.
7
Flushing
NOTE:
Several flushes are often required to thoroughly clean the system and prepare it for the next fluid to be
sprayed, or to store the sprayer
. Use this chart to determine the required flushing order for the fluid you are
using, and then follow the procedure below for flushing.
*Use this category for flushing a brand new sprayer and flushing after storage.
System has
this fluid in it:
Next fluid to be
sprayed.
Flushing order:
Flush 1Flush 2Flush 3
*Oil-based
solvent or paint
Oil-based
solvent or paint
Oil-based
solvent or paint
Water or waterbased paint
Water or waterbased paint
Water or waterbased paint
Oil-based paint –
new color
W
ater-based paint
Prepare for
storage
W
ater-based paint
– new color
Oil-based paint
Prepare for
storage
Mineral spirits
nonenone
Mineral spiritsWarm soapy
water
Mineral spirits
W
arm soapy
nonenone
Clean water
water
W
arm soapy
Clean water
water
W
arm soapy
Clean water
water
Clean water
none
Mineral spirits
Mineral spirits
Before you spray or store
sprayer:
Prime with oil-based paint
Prime with water-based
paint
Relieve pressure,
Leave drain valve open
Prime with water
Prime with oil
Relieve pressure,
Leave drain valve open
WARNING
FIRE AND EXPLOSION HAZARD
T
o reduce the risk of static sparking and
splashing when flushing, 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.
1.
Follow the illustrated
on page 13. Engage the gun safety latch.
2. T
urn the pressure adjusting knob fully counter
clockwise to zero pressure.
3.
Remove the spray tip from the gun. Remove the
filter bowl and screen; see manual 307–273. Clean
the screen separately and install the bowl without
the screen to flush it. See Fig. 8.
4.
Put the suction tube into a grounded metal pail
with 1/2 gallon of compatible solvent.
Pressure Relief Procedure
6.
Do not run the pump dry for more than 30 seconds
to avoid damaging the pump packings!
7.
Follow the illustrated
Pressure Relief Procedure
on page 13. Engage the gun safety latch.
8.
Unscrew the filter bowl and reinstall the clean
screen. Install the bowl and hand tighten.
9.
Remove the suction tube and screen and clean
them separately
.
-
FILTER
SCREEN
FIL
TER
SUPPORT
BOWL
5.
Start the sprayer
still in the sprayer
. See page 9. T
o save the fluid
, trigger the gun into another
container until the next fluid appears, then trigger
the gun back into the fluid you are pumping. Circu
late the flushing fluid a couple of minutes to thor
oughly clean the system.
PRESSURE
DRAIN
V
ALVE
-
-
Fig.
8
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