INSTRUCTIONS-PARTS LIST This manual contains important warnings and information. READ AND KEEP FOR REFERENCE. 307–830 Rev. F Supersedes Rev. E First choice when quality counts. INSTRUCTIONS EM590 Airless Paint Sprayer 2750 psi (190 bar, 19 MPa) Maximum Working Pressure Model 220–856, Series D Basic sprayer on Upright cart without hose or gun Model 231–590, Series A Same as 220–856 and includes 50 ft (15.1 m) hose, 3 ft (0.
Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Application Methods . . . . . . . . . . . . . . . . . . . .
WARNING INJECTION HAZARD Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also cause serious injury. Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious injury. Get immediate medical attention. Do not point the gun at anyone or at any part of the body.
WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury. INSTRUCTIONS 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.
Setup WARNING To reduce the risk of serious bodily injury caused by static sparking, fluid injection or over–pressurization and rupture of the hose or gun, all hoses must be electrically conductive, the gun must have a tip guard, and each part must be rated for at least 2750 psi (190 bar, 19 MPa) Working Pressure. CAUTION To avoid damaging the pressure control, which may result in poor equipment performance and component damage: 1. Always use grounded, flexible spray hose (85) at least 50 ft (15 m) long.
Setup 114 Keep 1/3 full with TSL at all times Never install any shutoff device here 15b 221 85 Fig.
Startup Use this procedure to help you start and operate the sprayer properly and safely. WARNING INJECTION HAZARD To reduce the risk of serious bodily injury, follow the Pressure Relief Procedure Warning on page 11 before checking or repairing any part of the spray system. 5. Check all fluid connections for leaks. Follow the Pressure Relief Procedure on page 11 before tightening connections. 6. Install the spray tip and tip guard. Engage the trigger safety latch.
Maintenance WARNING INJECTION HAZARD To reduce the risk of serious bodily injury, follow the Pressure Relief Procedure Warning on page 11 before checking or repairing any part of the spray system. 5. For very short shutoff periods, leave the suction tube in the paint, relieve pressure, and clean the spray tip. 6. Flush the sprayer at the end of each work day and fill it with mineral spirits to help prevent pump corrosion and freezing. See page 9.
Flushing NOTE: Several flushes may be required to clean the system and prepare it for the next fluid or storage. Use this chart to determine the required flushes and use the procedure below for flushing. *Use this category for flushing a brand new sprayer and flushing after storage.
Application Methods Hold the gun perpendicular to the surface. Keep the gun at an even 12 to 14 in. (300 to 356 mm) from the surface you are spraying. See Fig. 7. Begin moving the gun horizontally at a steady rate. Start the spray stroke off the target surface and pull the trigger as the gun is moving. Then, while the gun is still moving, and as you approach the other edge of the surface, release the trigger. This method avoids excess paint buildup at the end of each stroke.
Troubleshooting WARNING Pressure Relief Procedure 5. Engage the gun safety latch. To reduce the risk of serious bodily injury always follow this procedure before checking or repairing the sprayer. 1. Engage the gun safety latch. 6. Open the pressure drain valve. Leave the valve open until you are ready to spray again. 2. Turn the ON/OFF switch to OFF. 3. Unplug the power supply cord. 4. Disengage the gun safety latch.
Troubleshooting PROBLEM CAUSE SOLUTION Paint leaks into wet-cup Packing nut is loose Tighten. See page 8. Throat packings are worn or damaged Replace packings. See page 14. Spray tip or fluid filter is plugged Disassemble and clean. Spray tip too big or worn Change spray tip. Paint too viscous Thin the paint. Wrong type hose Use minimum 50 ft (15 m), grounded, flexible hose (wire braid hose is unacceptable). Pressure setting too low Increase the pressure.
Motor Brush Replacement NOTE: Replace the brushes when they have worn to less than 10 mm. See Fig. 12. Always replace both brushes at the same time. A Brush Repair Kit, 220–853, and spring clip, 110–816, are available. NOTE: Replacement brushes may last only half as long as the original ones. To maximum brush life, break in new brushes by operating the sprayer with no load (remove the pump connecting rod pin) for at least one hour. 9. Test the brushes. Remove the connecting rod pin (50). See 15, page 14.
Displacement Pump Repairing the pump 52 See manual 307–806 for pump repair instructions. A Reinstalling the pump See Fig. 14 and 15. 1. Rotate the crankshaft (A) so the connecting rod is in its lowest position. 2. The pump piston rod (223) should protrude about 1 in. (25 mm) above the pump cylinder. 49 223 51 50 30 32 3. Screw the pump into the bearing housing (51) until its pin hole is aligned with the connecting rod (52) pin hole. Insert the pin (50).
Connecting Rod and Bearing Housing WARNING INJECTION HAZARD To reduce the risk of serious bodily injury, follow the Pressure Relief Procedure Warning on page 11 before checking or repairing any part of the spray system. 10. Align the connecting rod (52) with the crank (C) and push the bearing housing (51) onto the drive housing (14). 11. Assemble the remaining parts. Refer to page 14 to reinstall the pump. NOTE: Refer to Fig. 16. Detail A 1. Remove the pail hanger (7). 2. Remove the front cover (12). 3.
Drive Housing 5. Lightly tap the lower rear of the drive housing (14) with a plastic mallet to loosen it from the motor (16). Pull the drive housing (14) off the motor. WARNING INJECTION HAZARD To reduce the risk of serious bodily injury, follow the Pressure Relief Procedure Warning on page 11 before checking or repairing any part of the spray system. CAUTION DO NOT drop the gear cluster (56) when removing the drive housing (14). The gear may stay engaged in the motor or drive housing.
Motor WARNING INJECTION HAZARD To reduce the risk of serious bodily injury, follow the Pressure Relief Procedure Warning on page 11 before checking or repairing any part of the spray system. NOTE: Refer to Fig. 18. 1. Remove the four screws (13) and front cover (12). Disconnect the hose (30) and drain hose (80). 2. Remove the pressure control cover (21). Disconnect the four motor leads. 3. Unscrew the connector nut (103) at the pressure control. Swing the conduit (27) away from the connector. 4.
Motor ÇÇÇ ÉÉ ÉÉÉ ÉÉ Partial Wiring Diagram C Conduit Seal Detail 1 D 18 3 103 2 2 103 53 1 All wires to the over-pressure switch (C) and the pressure switch (D) must be insulated with shrink tubing or electrical tape. 2 Motor leads 3 Conduit seal (18) shown installed in conduit connector (103) 4 See Detail above 16 54 35 14a 16b 25 56 14b 21 14c 14 70 10 9 103 12 13 34 33 27 30 4 Fig.
Pressure Control WARNING INJECTION HAZARD To reduce the risk of serious bodily injury, follow the Pressure Relief Procedure Warning on page 11 before checking or repairing any part of the spray system. CAUTION Do not remove the nipple (105e) or elbow (105d) from the pressure control unless they are damaged. Twisting or jarring the these fittings could alter the factory setting of the control or permanently damage it. If they must be removed, use extreme care.
Pressure Control ÇÇÇÇ ÇÇÇÇ ÉÉ ÉÉ C D ÉÉÉÉ ÉÉÉÉ RED WHITE 1 2 Motor leads 3 Power supply leads All wires to the over-pressure switch (C) and the pressure switch (D) must be insulated with shrink tubing or electrical tape. ÉÉ ÉÉ ÎÎ ÎÎ ÎÎ ÎÎ 102 101 1 3 68 18 2 130 Fig.
Pressure Control Adjustment WARNING USE EXTREME CAUTION WHEN PERFORMING THIS ADJUSTMENT PROCEDURE to reduce the risk of a fluid injection injury or other serious bodily injury, which can result from component rupture, electric shock, fire, explosion or moving parts. This procedure sets the sprayer to 2750 psi (190 bar) MAXIMUM WORKING PRESSURE. NEVER attempt to increase the sprayer’s maximum working pressure by performing these adjustments in any other way.
Pressure Control Adjustment E 6. If the pressure is lower than 2750 psi (190 bar): Unplug the sprayer and relieve pressure. Insert the wrench through the hole (C) and tighten the adjustment nut (B) 1/8 turn or less. Repeat steps 5 and 6. A + If the pressure is higher than 2750 psi (190 bar): Unplug the sprayer and relieve pressure. Insert the wrench through the hole (C) and loosen the pressure adjustment nut (B) 1/8 turn or less. Repeat steps 5 and 6.
Parts – Pressure Control Part No. 220–858 Pressure Control Assembly Includes replaceable items listed below ÇÇÇÇ ÇÇÇÇ ÉÉ ÉÉ 105c 104 105b 114 121 105a 105 ÉÉÉÉ ÉÉÉÉ 115 105f 105d 113,110,112 118 RED WHITE 105f 106,107 16d ÉÉ ÉÉ ÎÎ ÎÎ ÎÎ ÎÎ 101 68 18 102 111 103 16c 120,107,119 103 See parts list on page 25 Ref No. Part No.
Parts – Upright Sprayer Model 220–856, Series D Includes items 1 to 81 Detail A 20 14 Model 231–590, Series A Includes items 1 to 87 52 11 23 35 15a 51 10 21 70 22,24 27 15 9 12,41 15b 13 5 7 43 Ref 30 49 81 Ref 75 44 30 Detail B 32 50 6 1g 4 76 1e 1d 16a 75 53 16 54 35 1f 25 74 14a 16b 56 3 2 53 14b 54 14c See Detail A 1b 33 34 33 45 1a 48 86 85 87 1c 62
Parts – Upright Sprayer Model 220–856, Series D Includes items 1 to 81 Model 231–590, Series A Includes items 1 to 87 Ref No. Part No. Description 1 220–365 CART ASSEMBLY Includes items 1a – 1g .RETAINING RING .WASHER, plain, 5/8” .PLUG, plastic .SPRING .SNAP BUTTON .SLEEVE .
Notes
Technical Data Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 HP, DC Electric Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 AWG, 3 wire Power Requirements . . . . . . . . . . . . . . . 120 VAC, 60 Hz, 15A Maximum Working Pressure . . . . . . . . . . . 2750 psi (190 bar) Maximum Delivery . . . . . . . . . . . . . . . . . . . . 0.75 gpm (2.8 lpm) Cycles/Gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 (70) Tip Size . . . . . . . . .
Graco Warranty Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special extended or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
