INSTRUCTIONS-PARTS LIST 308715 Rev. E This manual contains important warnings and information. READ AND KEEP FOR REFERENCE.
Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Component Identification and Function . . . . . . . . . . . 5 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Shutdown and Care . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING INJECTION HAZARD Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also cause serious injury. Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious injury. Get immediate medical attention. Do not point the gun at anyone or at any part of the body. Do not put your hand or fingers over the spray tip.
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. Repair or replace worn or damaged parts immediately.
Component Function and Identification N C B A H K 05963 E G M D L F J Model 231580 shown 06973 Fig.
Setup 2. Fill the wet–cup (102). Pry off the wet-cup seal. Fill the cup 1/3 full with Graco Throat Seal Liquid (TSL), supplied. Install the wet-cup seal. 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 3000 psi (210 bar, 21 MPa) Working Pressure. This is to reduce the risk of serious injury caused by static sparking, fluid injection or overpressurization and rupture of the hose or gun.
Setup Grounding 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. Grounding Prong Fig. 3 2. Do not alter the ground prong or use an adapter. 1. This equipment requires a 120 Vac, 60 Hz, 15A circuit with a grounding receptacle. See Fig. 3. 3. A 12 AWG gauge, 50 ft extension cord may be used with this equipment.
Operation How to use the RAC IV tip guard. WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. The tip guard alerts you to the risk and helps prevent placing any part of the body close to the spray tip. The tip guard also adjusts the vertical or horizontal spray pattern. See Fig. 9. The tip guard holds a reversing spray tip. The tip is in the spraying position when the tip handle points forward.
Startup WARNING INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you: NOTE: Refer to Fig. 2 and the other figures referenced in the text as you start the sprayer. 1. Open the pressure drain valve (42). See Fig. 8. 2.
Startup b. If more coverage is needed, use a larger tip rather than increasing the pressure. WARNING FIRE AND EXPLOSION HAZARD To reduce the risk of static sparking and splashing when priming or flushing the system, hold a metal part of the gun firmly to the side of a grounded metal pail before triggering the gun. 7. To prime the hose, lower the pressure to reduce splashing. Hold a metal part of the gun firmly against and aimed into a grounded metal pail. See the preceding WARNING.
Shutdown and Care WARNING WARNING INJECTION HAZARD See the warning section INJECTION HAZARD on page 3 for information on the hazard of using damaged hoses. INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. Shutdown and Care 1 1. Check the packing nut/wet-cup daily (102). Relieve pressure first.
Flushing When to Flush 1. Before using a new sprayer: flush out the oil which was left in to protect pump parts. Before using water-base paint: flush with mineral spirits followed by soapy water, and then a clean water flush. Before using oil-base paint: flush with mineral spirits only. 2. Changing colors: flush with a compatible solvent such as mineral spirits or water. 3. Changing from water-base to oil-base paint: flush with warm, soapy water, and then mineral spirits. 4.
Troubleshooting WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. Basic Problem Solving Check everything in the troubleshooting table before disassembling the sprayer. TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check WHAT TO DO When check is not OK, refer to this column Fluid pressure 1. Check pressure control knob setting.
Basic Problem Solving TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check WHAT TO DO When check is not OK, refer to this column Electrical (continued) 5. Check motor armature commutator for burn spots, gouges and extreme roughness. Remove motor cover and brush inspection plates to check. See page 19. 5. Remove motor and have motor shop resurface commutator if possible. See page 22. 6. Check motor armature for shorts using armature tester (growler) or perform motor test. See page 17. 6.
Intermediate Problem Solving TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check WHAT TO DO When check is not OK, refer to this column Low output (continued) 3. Release gun trigger. Observe resting position of 3. If pump consistently comes to rest with pump rod (107). rod (107) fully extended, the piston packings and/or piston valve may be worn. Service the pump. See page 21. 4. Check electrical supply with volt meter. Meter should read 105–125VAC. 4.
Intermediate Problem Solving TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check WHAT TO DO When check is not OK, refer to this column Spray Pattern Variations 1. Spray tip worn beyond sprayer pressure capability. 1. Replace spray tip. NOTE: A smaller size tip will provide longer life. 2. Check transducer (29) for wear or damage. 2. Replace transducer. See page 27. 3. Check pressure control (64) for smooth operation. 3. Replace pressure control. See page 26. 4.
Motor Test WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. For checking armature, motor winding and brush electrical continuity. B 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. A Remove the motor brush inspection covers (A). See Fig. 12.
General Repair Information WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. WARNING HOT SURFACE HAZARD During operation, the motor and drive housing become very hot and could burn your skin if touched. Flammable materials spilled on the hot, bare motor could cause a fire or explosion Tool List These are the tools required to service all parts of the sprayer.
Motor Brushes NOTE: Replace brushes when worn to about 0.5 in. (12.5 mm). Always check both brushes. Brush Repair Kit 236967, which includes spring clip 112766, is available for motors manufactured by Pacific Scientific. 1 Motor lead; do not disconnect 2 Minimum 0.5” (12.5 mm) 3 Included in Brush Repair Kit 236967 2 NOTE: Replacement brushes may last only half as long as the original ones.
Motor Brushes 9. Test the brushes. a. Remove the pump connecting rod pin (17). See Fig. 18, page 21. b. With the sprayer OFF, turn the pressure control knob fully counterclockwise to minimum pressure. Plug in the sprayer. c. Turn the sprayer ON. Slowly increase the pressure until the motor is at full speed. d. Inspect the brush and commutator contact area for excessive arcing. Arcs should not trail or circle around the commutator surface.
Displacement Pump Repair WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. NOTE: Packing Repair Kit 235703 is available. 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. 2. Align the hole in the rod (107) with the connecting rod assembly (15).
Motor 9. Align the new motor with the base and reinstall the screws (46). WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. 10. Assemble the drive housing to the motor. Follow steps 8 to 11 on page 24. 11. Connect the wires in the junction box. Refer to Fig. 22 on page 23. Install the junction box. 12.
Motor Start Board WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. 5. Install the new cord (50) in the reverse order of disassembly. 6. Install the junction box. Be sure no leads are pinched against the motor or by the motor start board. Also be sure the gasket (89) is installed. On/Off Switch NOTE: See Fig. 22 for this procedure. NOTE: See Fig. 22 for this procedure. 1. Relieve pressure. 1.
Drive Housing, Connecting Rod, Crankshaft WARNING CAUTION INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. NOTE: Inspect parts as they are removed. Replace parts that are worn or damaged. Do not allow the gear (16) to fall; it may stay attached to the drive housing or to the motor.
Drive Housing, Connecting Rod, Crankshaft 1 64 REF A 4 12a 1 Torque to 80 in–lb (9 N.m) 2 Quantity of three 3 Quantity of one 4 Apply a total of 3 fl. oz.(29 cc) of grease to gears. 16 5 C 4a 12b 11a 12 A 47 59 56 3 31 11 15 Note: Filter not shown 13 34 Fig.
Pressure Control WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. 7. Loosely install the screws (63) and then torque them to 21 in–lb (2.4 N.m). 8. Install the front cover (13). Connect the harness (A) to the motor start board (47). 9. Install the junction box. Be sure no leads are pinched against the motor or by the motor start board. NOTE: See Fig. 25 for this procedure.
Pressure Transducer WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. NOTE: See Fig. 26 for this procedure. 29 1. Remove the displacement pump. See page 21. 2. Use a pull–twist motion to remove the transducer (29) from the pump manifold (101). 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.
Drain Valve Repair WARNING INJECTION HAZARD To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. 42a 42b 1 1 42d 42c 3 Apply thread sealant 2 Apply grease to face of base 3 Torque into pump manifold to 185 in–lb (21 N.m) 4 Handle shown in closed position 2 42 44 4 45 2. Remove the base (43). 3. Unscrew the drain valve (42). The gasket (42a) and seat (42b) will stay in the valve.
Technical Data DANGER LABELS Power Requirements . . . . . . . . . . . . . . . . . . . . 120 VAC, 60Hz, 1 phase, 15A minimum Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000W minimum Working Pressure Range . . 0–3000 psi (0–210 bar, 21 MPa) Motor Model 231580 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 hp Models 232654 & 232655 . . . . . . . . . . . . . . . . . . . . . . . 3/4 hp Cycles/Gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sprayer Parts Drawing Model 231580, Series A Model 232654, Series A HOSE AND GUN NOT SHOWN IN PROPORTION TO SPRAYER 74 1 Label 2 See detail on page 31 39 30 67 REF 33 REF 32 24 4e 1 3 5 64 4 4a 16 85 12b 12 4f 63 10 5 11b 4g 12a 1 1 89 15 28 11a 17 13 18 11 2 66 50 26 56 14 INSIDE LABEL 29 42a 42b 42d 42c 28 31 34 21 23 46 20 42 23 36 32 43 44 33 45 37 27 25 38 06974
Sprayer Parts List Model 231580, Series A, Model 232654, Series A Ref. No. 3 4{ Part No. Description 111700 GRIP. handle MOTOR KIT Includes items 4a to 4g Model 231580 Model 232654 . BALL, sst, 1/4 in. dia. . TERMINAL, flat, 1/4 in. (f), 18 awg . TERMINAL, 3/16 in. (m), 16 awg . TERMINAL, 3/16 in. (f) . LABEL, DANGER, French . LABEL, DANGER, English . LABEL, WARNING, electric shock SCREW, socket head 1/4–20 x 1–1/8 in. PLUG, DRIVE HOUSING KIT Includes item 11a, 11b . BALL, stainless steel, 1/4 in. dia.
Sprayer Parts Drawing Model 232655, Series A 3 24 72 64 12b 16 4a 4 6 5 4e 73 62 1 23 12 63 85 12a 11b 10 15 19 28 4f 4g 6 11a 17 13 89 11 35 OUTSIDE LABEL 21 2 59 56 26 50 20 29 42a 42b 42d 42c 28 14 INSIDE LABEL 34 1 46 18 31 1 66 42 65 36 88 43 33 44 32 30 37 65 45 25 39 74 67 1 Label 2 See page 33 for detail 05121B 32 308715
Sprayer Parts List Model 232655, Series A Ref. No. Part No.
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.