INSTRUCTIONS–PARTS LIST 308–248 Rev D Supercedes Rev C This manual contains important warnings and information.
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.
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 Graco Technical Assistance at 1–800–543–0339. Do not alter or modify this equipment. Check equipment daily. Repair or replace worn or damaged parts immediately.
Component Identification and Function N B C H A K E G L F M D J Model 231–208 Shown 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 2750 psi (195 bar) Working Pressure. This is to reduce the risk of serious injury caused by static sparking, fluid injection or over-pressurization and rupture of the hose or gun. 3.
Operation How to use the gun trigger safety Open or drain, position When engaged, the gun safety latch prevents the gun from accidental triggering. See Fig. 3. Closed, or spray position WARNING INJECTION HAZARD If the gun still sprays when the gun trigger safety is locked, repair the gun. See manual 307–614, supplied. Gun safety latch shown engaged Gun safety latch shown disengaged Fig. 4 02825A How to use the pressure control.
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. 1 1 Tip handle shown in spraying position. 2 Turn handle 180 , trigger gun to clear clog Fig. 6 2 04647 How to remove a tip clog. The tip guard alerts you to the risk and helps prevent placing any part of the body close to the spray tip.
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: are instructed to relieve the pressure, stop spraying, check or service any of the system equipment, or install or clean the spray tip.
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 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 INJECTION HAZARD See the warning section INJECTION HAZARD on page 3 for information on the hazard of using damaged hoses. 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 25. 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 30. 3. Check pressure control (64) for smooth operation. 3. Replace pressure control. See page 29. 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 A Remove the drive housing. See page 27. 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. 11.
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.
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 112–766, 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 236–967 2 NOTE: Replacement brushes may last only half as long as the original ones.
Motor Brushes Test the brushes. a. Remove the pump connecting rod pin (17). See Fig. 17, 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 235–703 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).
Displacement Pump Repair Intake valve repair (See Fig. 16) 1. Remove the suction hose. See Step 3, Removing the pump. 2. Unscrew the intake valve (118). Remove the o-ring (119*), 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 needed. Use a new o–ring (119*). If no further service is needed, reassemble the pump. 2.
Displacement Pump Repair 3. Tighten the nut (110) onto the piston valve (108) to 2 in-lb (0.23 N.m). See Fig. 19. Torque to 2 in–lb (0.23 N.m) Apply one drop of sealant to these threads 6. Hand tighten the valve into the piston rod just until the nut (110) contacts the rod. See Fig. 20. 7. Place the flats of the rod (107) in a smooth jaw vise. 107 109* 8. CAREFULLY tighten the nut (110) against the piston rod to 19 ft-lb (25 N.m). See Fig. 20.
Displacement Pump Repair 11. Place a new o-ring (116*) firmly in the cylinder groove. See Fig. 21. 15. Torque the cylinder jam nut (117) to 73 ft-lb (98 N.m). See Fig. 21. 12. Coat the piston rod and packings with oil. Carefully slide the assembly into the top of the cylinder (115). See Fig. 21. 16. Install the pump. See page 21. 13. Put the manifold upside down in a vise. Fully thread the jam nut (117) onto the cylinder (115). Guide the rod/cylinder assembly down through the manifold (101).
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 10 on page 27. 11. Connect the wires in the junction box. Refer to Fig. 26 on page 26. 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. NOTE: See Fig. 26 for this procedure. 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. 26 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. Removal Do not allow the gear (16) to fall; it may stay attached to the drive housing or to the motor. Do not lose the thrust balls (11a or 4a) or let them fall between the gears, which will damage the drive housing if not removed.
Drive Housing, Connecting Rod, Crankshaft 64 REF A 12a Torque to 80 in–lb (9 N.m) Quantity of three Quantity of one Apply a total of 3 fl. oz.(29 cc) of grease to gears. 16 5,6 C 4a 12b 11a 12 A 47 59 56 31 11 6 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. 29 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. 30 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.
Suction Hose Models 231–208 and 231–354 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. CAUTION Misalignment or cross-threading will damage the parts and/or create shavings which can cause the o–ring (27) to leak. Lubricate Note: Filter not shown 1. Remove the drain hose (33) from the clip. Remove the front cover (13). 13 2.
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 42d 42c Apply thread sealant Apply grease to face of base Torque into pump manifold to 185 in–lb (21 N.m) Handle shown in closed position 42 44 45 NOTE: Whenever the gasket (42a) is removed, replace it with a new one. 3. Coat the o-ring (42d) with grease. Press the stem into the valve body.
Displacement Pump Parts Drawing and List Model 235–699, Series A 123 Includes items 101 to 127 Ref. No. Part No. 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 187–611 176–758 176–757* 176–997* 176–755* 176–754* 235–709 218–197 105–444* 176–751 176–750* 176–882* 176–749* 180–073* 235–708 108–526* 187–614 224–966 111–603* 176–760 105–445* 176–759* 180–656 102–969* 105–522* 186–652* 188–663 Description 102 Qty.
Sprayer Parts Drawing Model 231–208, Series B 39 30 74 1 Label 2 See detail on page 35 REF 33 67 24 4e 5 3 REF 32 1 6 64 4 4a 16 85 12b 12 4f 28 63 6 11b 4g 12a 19 15 10 1 1 89 11a 17 13 2 11 35 66 18 OUTSIDE LABEL 50 26 14 56 INSIDE LABEL 29 42a 42b 42d 42c 28 31 34 21 20 23 23 42 46 36 43 32 27 33 38 45 44 37 25 O2833A
Sprayer Parts List Model 231–208, Series B Includes items 3 to 89 as listed below Ref. No. Part No. Description 3 4{ 111–700 237–458 4a.a 4b.b 4c.c 4d.dY 4e.eY 4f.
Sprayer Parts Drawing Model 231–354, Series A 62 3 72 23 39 24 REF 66 REF 30 4e REF 33 4 6 5 64 24 REF 32 11b 85 1 12 12a 16 19 17 4g 1 66 6 15 11a 89 59 18 56 11 35 OUTSIDE LABEL 46 2 10 13 1 12b 4a 28 63 4f 65 29 14 INSIDE LABEL 50 42a 42b 28 25 42d 26 37 42c 31 21 20 34 45 42 36 32 27 38 43 33 44 74 67 1 Label 2 See page 37 for detail O5120
Sprayer Parts List Model 231–354, Series A Includes items 3 to 89 as listed below Ref. No. Part No. Description 3 4{ 280–290 237–458 4a.a 4b.b 4c.c 4d.dY 4e.eY 4f.
Sprayer Parts Drawing Model 231–357, Series A 3 24 23 62 64 72 12b 16 12a 11b 28 4f 4g 6 15 19 11a 17 13 6 4e 12 63 85 10 4 4a 5 89 11 59 56 35 26 50 OUTSIDE LABEL 29 28 20 21 42a 42b 42d 42c 14 INSIDE LABEL 34 46 18 31 66 42 65 36 65 88 32 33 30 39 37 43 44 45 25 74 67 Label See page 39 for detail
Sprayer Parts List Model 231–357, Series A Includes items 3 to 89 as listed below Ref. No. Part No. Description Qty. Ref. No. Part No. Description Qty. 3 4{ 280–290 237–458 4a.a 4b.b 4c.c 4d.dY 4e.eY 4f.
Technical Data DANGER LABELS Power Requirements . . . . . . . . . . . . . . . . . . . . 120 VAC,60Hz, 1 phase, 15 amp minimum Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 Watt minimum Working Pressure Range . . . . . . . . . 0–2750 psi (0 – 195 bar) Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 hp Cycles/Gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . . . . 620 (164) Delivery . . . . . . . . . . . . . . . . . . . . . . .
3X8–248 Rev. G Supersedes Rev. D and PCN F Parts Change Notice Some parts in Rev. D of manual 308–248 have changed but have not yet been changed in the instruction manual. Please note the changes below and mark them in your manual or keep this sheet with your manual. Assembly No. 231–357 231–208 Series Letter Change Part That Changed Ref No.
Other Changes Page 23: Change instruction in step 3.: From: Tighten the nut (110) onto the piston valve (108) to 2 in-lb (0.23 N m). To: Tighten the nut (110) onto the piston valve (108) to 5 in-lb (0.57 N m). Change note 1 of Fig. 19: From: Torque to 2 in-lb (0.23 N m) To: Torque to 5 in-lb (0.57 N m) Change second instruction in step 4.: From: Apply one drop of adhesive, supplied, to the threads. To: Apply one strip of adhesive, supplied, to the threads. Change first instruction in step 8.
490st 02821A Model 231–208 Shown Model 231–208 Standard mount: complete sprayer with hose and gun with RAC IV DripLess Tip Guard and SwitchTip Model 231–257 Upright cart: complete sprayer with hose and gun with RAC IV DripLess Tip Guard and SwitchTip Model 231–354 Low profile cart: complete sprayer with hose and gun with RAC IV DripLess Tip Guard and SwitchTip Technical Data Application Power requirements . . . . . . . . . . . . . . . 120 VAC, 60 Hz, 15A minimum Generator . . . . . . . . . .
3Z8–248 Rev A Supplement to instruction manual 308–248. 490st Airless Paint Sprayer 13a 13f WARNING INJECTION HAZARD This form is only a quick reference to the features and frequently INSTRUCTIONS ordered parts of this sprayer. To reduce the risk of serious injury, including fluid injection, while operating or repairing this sprayer, follow the warnings and instructions in manual 308–248. 25 26 13e Model 231–208, Series B 13c Ref No. Part No.
