Graco Inc. 308-646 manual

 INSTRUCTIONS–P ARTS LIST 308–646 Rev . B Supercedes Rev . A ELECTRIC, 120 V AC Performance 390  Airless Paint Sprayer 2750 psi (195 bar) Maximum Working Pressure Model 231–553, Series A Complete sprayer with hoses, gun, RAC IV  DripLess  T ip Guard and SwitchT ip  GRACO INC. P .O. BOX 1441 MINNEAPOLIS, MN 55440–1[...]

  T able of Contents W arnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Identification and Function 5 . . . . . . . . . . . Setup 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation 7 . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  TOXIC FLUID HAZARD Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed.  Know the specific hazards of the fluid you are using.  Store hazardous fluid in an approved container . Dispose of hazardous fluid according to all local, state and na[...]

  EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury .  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 no[...]

308-646 5 05993 Component Function and Identification C Fig. 1 G E F D A K M B H N J L 05963 A Motor DC motor , 120 V ac, 15A, 1 phase B Drive Assembly T ransfers power from DC motor to the displacement pump C Pressure Adjusting Knob Controls fluid outlet pressure D ON/OFF Switch Power switch that controls 120 V ac power to sprayer E Fluid Outlet H[...]

  Setup W ARNING 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 2750 psi (195 bar) Working Pressure . This is to reduce the risk of serious injury caused by static sparking, fluid injection or over-pressuriza[...]

308-646 7 Operation How to use the gun trigger safety When engaged, the gun safety latch prevents the gun from accidental triggering. See Fig. 3. W ARNING INJECTION HAZARD If the gun still sprays when the gun trig - ger safety is locked, repair the gun. See manual 308–235, supplied. Fig. 3 1 2 Gun safety latch shown engaged 2 Gun safety latch sho[...]

  Operation How to use the RAC IV tip guard. W ARNING INJECTION HAZARD T o 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[...]

308-646 9 Startup 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 . T o reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure [...]

10 308-646 Startup W ARNING 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. 6. T o prime the hose , lower the pressure to reduce splashing. Hold a metal part of the gun firmly agains[...]

308-646 11 Startup 05993 Fig. 9 1 3 4 2 32 33 64 28 74 102 52 1/4 npsm(m) fluid outlet Rotate clockwise to increase pressure Do not install any shutof f device here Fill 1/3 full with TSL Shown in closed or spray position 5 1 2 3 4 5 67[...]

12 308-646 Shutdown and Care W ARNING INJECTION HAZARD T o 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. Check the packing nut/wet-cup daily (102). Re - lieve pressure first. Keep the wet-cup 1/3 full of TSL at all times to help prevent fluid[...]

308-646 13 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 min - eral 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 so[...]

14 308-646 T roubleshooting W ARNING INJECTION HAZARD T o 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 WHA T T O CHECK If check is OK, go to ne[...]

  Basic Problem Solving TYPE OF PROBLEM WHA T T O CHECK If check is OK, go to next check WHA T T O DO When check is not OK, refer to this column Electrical (continued) 5. Check motor armature commutator for burn spots, gouges and extreme roughness. Re - move motor cover and brush inspection plates to check. See page 20[...]

16 308-646 Intermediate Problem Solving TYPE OF PROBLEM WHA T T O CHECK If check is OK, go to next check WHA T T O DO When check is not OK, refer to this column Low output (continued) 3. Release gun trigger . Observe resting position of pump rod (107). 3. If pump consistently comes to rest with rod (107) fully extended, the piston pack - ings and/o[...]

  Intermediate Problem Solving TYPE OF PROBLEM WHA T T O CHECK If check is OK, go to next check WHA T T O DO When check is not OK, refer to this column Spray Pattern V ariations 1. Spray tip worn beyond sprayer pressure capa - bility . 1. Replace spray tip. NOTE: A smaller size tip will provide longer life. 2. Check tr[...]

18 308-646 Motor T est W ARNING INJECTION HAZARD T o 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 elec - trical continuity . Setup Remove the drive housing. See page 28. This is to ensure that any resistance you not[...]

  General Repair Information W ARNING INJECTION HAZARD T o reduce the risk of serious injury , whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. T ool List These are the tools required to service all parts of the sprayer . 3/16” Allen  wrench: gear housing, legs, hand[...]

  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. T o maximize br[...]

308-646 21 Motor Brushes 9. T est the brushes. a. Remove the pump connecting rod pin (17). See Fig. 18, page 22. b. With the sprayer OFF , turn the pressure con - trol knob fully counterclockwise to minimum pressure. Plug in the sprayer . c. T urn the sprayer ON. Slowly increase the pressure until the motor is at full speed. d. Inspect the brush an[...]

  Displacement Pump Repair W ARNING INJECTION HAZARD T o 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 235–703 is available. Refer - ence numbers of parts included in the kit are marked with an asterisk, i.[...]

  Displacement Pump Repair Intake valve repair (See Fig. 17) 1. Remove the suction hose. See Step 2, Removing the pump. 2. Unscrew the intake valve (1 18). Remove the o-ring (1 19*), ball guide (120), stop pin (122*) and ball (121*) from the valve. 3. Clean and inspect the parts for wear or damage. Replace parts as nee[...]

  Displacement Pump Repair 3. T ighten the nut (1 10) onto the piston valve (108) to 5 in-lb (0.57 N.m). See Fig. 20. NOTE: Note the alignment of the piston (108) to the nut (1 10). Maintain this alignment through Step 8. 4. Clean all residue from the piston valve threads. Apply one drop of adhesive, supplied, to the t[...]

  Displacement Pump Repair 1 1. Place a new o-ring (1 16*) firmly in the cylinder groove. See Fig. 22. 12. Coat the piston rod and packings with oil. Carefully slide the assembly into the top of the cylinder (1 15) . See Fig. 22. 13. Put the manifold upside down in a vise. Fully thread the jam nut (1 17) onto the cylin[...]

  Motor W ARNING INJECTION HAZARD T o 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 except where noted. 1. Relieve pressure. 2. T ry to stop the pump with the piston rod (107) in its lowest position. T o lower the p[...]

  Motor Start Board W ARNING INJECTION HAZARD T o reduce the risk of serious injury , whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. NOTE: See Fig. 27 for this procedure. 1. Relieve pressure. 2. Remove the junction box screws (56) and lower the junction box (59). 3. Dis[...]

  Drive Housing, Connecting Rod, Crankshaft W ARNING INJECTION HAZARD T o 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. 1. Remove the displacement pump.[...]

  Drive Housing, Connecting Rod, Crankshaft 6 19 15 13 64 11 19 12a 12 12b 59 11 a 4a A 34 31 REF A 16 47 Fig. 29 1 T orque to 80 in–lb (9 N.m) 3 2 Quantity of three Quantity of one 1 1 2 3 Apply a total of 3 fl. oz.(29 cc) of grease to gears. 4 4 C 04657 24 56[...]

  Pressure Control W ARNING INJECTION HAZARD T o reduce the risk of serious injury , whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. NOTE: See Fig. 30 for this procedure. NOTE: The pressure control (64) cannot be repaired or adjusted. If it has malfunctioned, replace it.[...]

308-646 31 Pressure T ransducer W ARNING INJECTION HAZARD T o reduce the risk of serious injury , whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. NOTE: See Fig. 31 for this procedure. 1. Remove the displacement pump. See page 22. 2. Use a pull–twist motion to remove the transducer (29) from the pum[...]

  Drain V alve W ARNING INJECTION HAZARD T o reduce the risk of serious injury , whenever you are instructed to relieve pressure, follow the Pressure Relief Procedure on page 9. 44 42a 42b 43 45 Apply thread sealant Handle shown in closed position Apply grease to face of base 42 T orque into pump manifold to 185 in–l[...]

  Displacement Pump Parts Drawing and List Model 236–787, Series A Includes items 101 to 127 Ref No. Part No. Description Qty 101 187–61 1 MANIFOLD, pump 1 102 176–758 P ACKING NUT 1 103* 176–757 GLAND, female, throat 1 104* 176–997 V–P ACKING, plastic, throat 3 105* 176–755 V–P ACKING, leather , throat[...]

  Sprayer Parts Drawing Model 231–553, Series A O4658 33 20 4a 12 18 15 16 45 37 29 32 25 12b 12a 64 30 19 19 6 17 31 34 21 38 36 46 4 39 28 56 43 42 42a 42b 4e 44 REF 32 REF 33 11 23 63 HOSE AND GUN NOT SHOWN IN PROPOR TION T O SPRA YER 67 74 42c 42d 11 b 14 4g INSIDE LABEL 35 OUT- SIDE LABEL 4f See detail on page 3[...]

308-646 35 Sprayer Parts List Model 231–553, Series A Includes items 3 to 89 as listed below Ref. No. Part No. Description Qty . Ref. No. Part No. Description Qty . 4 { 236–965 MOT OR KIT Includes items 4a to 4g 1 4a. 100–069 . BALL, sst, 1/4” dia. 1 4b. 1 1 1–616 . TERMINAL, flat, 1/4” (f), 18 awg 2 4c. 107–503 . TERMINAL, 3/16” (m[...]

  T echnical Data Power Requirements 120 V AC,60Hz, . . . . . . . . . . . . . . . . . . . . 1 phase, 15 amp minimum Generator 3000 W att minimum . . . . . . . . . . . . . . . . . . . . . . . . . . Working Pressure Range 0–2750 psi (0 – 195 bar) . . . . . . . . . Motor 1/2 hp . . . . . . . . . . . . . . . . . . . . [...]