Graco 231-041 manual

INSTRUCTIONS-P ARTS LIST 307–758 Re v . R Supersede s Re v . P ELECTRIC, 120 V AC UL TRA  500 AIRLESS P AINT SPRA YER 2750 psi (195 bar) MAXIMUM WORKING PRESSURE Model 231–032, Series C Basic sprayer on Upright cart Model 231–041, Series B Complete sprayer on Upright cart, hoses, gun, RAC IV  DripLess  T ip Guard and SwitchT ip  M[...]

2 307–758 T ABLE OF CONTENTS INTRODUCTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W ARNINGS English 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . French 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spanish 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

307–758 3 DISPLACEMENT PUMP Fig 3–1 PRESSURE DRAIN V AL VE 3 ft. (0.9 m) HOSE DRIVE ASSEMBL Y FLUID FIL TER PRESSURE ADJUSTING KNOB MOTOR ON/OFF SWITCH TRIGGER SAFETY SHOWN ENGAGED PRESSURE CONTROL P AIL HANGER (on upright sprayer only) RESET BUTT ON 50 FT (15 M) MAIN HOSE CONTRACTOR GUN FLUID OUTLET 0137 RAC IV TIP GUARD SWITCH TIP 01556[...]

4 307–758 SAFETY W ARNINGS HIGH PRESSURE SPRA Y CAN CAUSE SERIOUS INJUR Y. FOR PROFESSIONAL USE ONL Y . OBSER VE ALL W ARNINGS Read and understand all instruction manuals before operating equipment. FLUID INJECTION HAZARD General Safety This equipment generates very high fluid pressure. Spray from the gun, leaks or ruptured components can inject [...]

307–758 5 MOVING P ARTS HAZARD Moving parts can pinch or amputate your fingers or other body parts. KEEP CLEAR of moving parts when starting or operating the sprayer . Follow the Pressure Relief Procedure on page 2 before checking or servicing any part of the sprayer , to prevent it from starting accidentally . EQUIPMENT MISUSE HAZARD General Saf[...]

6 307–758 A VERTISSEMENT La pulvérisation à haute pression peut causer des blessures très graves. Réservé exclusivement à l’usage professionnel. Observer toutes les consignes de sécurité. Bien lire et bien comprendre tous les manuels d’instructions avant d’utiliser le matériel. RISQUES D’INJECTION Consignes generales de sécurit?[...]

307–758 7 RISQUES EN CAS DE MAUV AISE UTILISA TION DU MA TERIEL Consignes générales de sécurité T oute utilisation anormale de l’appareil de pulvérisation ou des accessoires comme, par exemple, la mise sous une pression excessive, les modifications de pièces, l’utilisation de produits chimiques et de matières incompatibles et l’utili[...]

8 307–758 ADVERTENCIA EL ROCIADO a AL T A PRESIÓN PUEDE CAUSAR GRA VES LESIONES. SOLO P ARA USO PROFESIONAL. RESPETE LOS A VISOS DE ADVERTENCIA. Lea y entienda todo el manual de instrucciónes antes de manejar el equipo. PELIGRO DE INYECCIÓN DE FLUIDO Seguridad general Este equipo genera un fluido a una presión muy alta. El rociado de la pisto[...]

307–758 9 PELIGRO POR MAL USO DEL EQUIPO Seguridad general Cualquier mal uso del equipo pulverizador o los accesorios, tal como sobre presurización, modificación de piezás, uso de matériales y productos quimicos incompatibles, o utilización de piezás dañadas o desgastadas, puede hacen que se rompan y causen la inyección de fluido u otras [...]

10 307–758 SETUP W ARNING To reduce the risk of serious bodily injury from static sparking, fluid injection, or over pressurization and rupture of the hose or gun, all hoses must be electri - cally conductive, the gun must have a tip guard, and each part must be rated for at least 2750 psi (195 bar) Maximum Working Pressure. To avoid damaging the[...]

307–758 11 SETUP  RAC IV TIP GUARD MAIN HOSE 1/4 in. x 50 ft ON/OFF SWITCH 1/4 npsm(m) FLUID OUTLET NIPPLE DO NOT INST ALL ANY SHUT OFF DEVICE HERE PRESSURE ADJUSTING KNOB PRESSURE DRAIN V AL VE 3/16 in. x 3 ft. HOSE P ACKING NUT/ WET–CUP FILL 1/3 FULL WITH TSL Fig 11-1[...]

12 307–758 OPERA TION Use this procedure each time you start the sprayer to help ensure the sprayer is ready to operate and that you start it safely . W ARNING To reduce the risk of serious injury , follow the illus - trated Pressure Relief Procedure warning on page 4 whenever you are instructed to relieve pres - sure. NOTE: Flush the sprayer if [...]

307–758 13 MAINTENANCE Cleaning a Clogged Tip W ARNING To reduce the risk of serious injury , follow the illus - trated Pressure Relief Procedure warning on page 4 whenever you are instructed to relieve pres - sure. W ARNING To reduce the risk of serious bodily injury from from fluid injection: NEVER operate the spray gun with the tip guard re - [...]

14 307–758 SHUTDOWN AND CARE W ARNING To reduce the risk of serious injury , follow the illus - trated Pressure Relief Procedure warning on page 4 whenever you are instructed to relieve pres - sure. 1. Check the packing nut/wet-cup daily . First relieve pressure. Keep the wet-cup 1/3 full of TSL at all times to help prevent fluid buildup on the p[...]

307–758 15 FLUSHING GUIDELINES 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 b[...]

16 307–758 TROUBLESHOOTING GUIDE W ARNING Pressure Relief Procedure T o reduce the risk of serious bodily injury , including fluid injection, injury from splashing fluid or solvent in the eyes or on the skin, moving parts or electric shock, always follow this procedure whenever you shut of f the sprayer , when checking or servicing any part of th[...]

307–758 17 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 1 . Check leads from bridge (308) to motor to be sure they are securely fastened and properly mated. 1. Replace loose terminals; crimp to leads. Be sure male terminal blades are straight and firmly connected to mating[...]

18 307–758 MOTOR WON’T OPERA TE 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 Condition B (continued) Both lamps of f 6. Check motor thermal cutout switch. Connect volt meter to TP6 female and TP9 female. Plug in sprayer and turn on. Meter should read 105 to 125 V AC. T u[...]

307–758 19 LOW OUTPUT 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 1. Check for worn spray tip. 1. Follow Pressure Relief Procedure W arn- ing then replace tip. See your separate gun or tip manual. 2. Check to see that pump does not continue to stroke when gun t[...]

20 307–758 NO OUTPUT 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 Motor runs and pump strokes 1. Check paint supply . 1. Refill and reprime pump. 2. Check for clogged intake strainer . 2. Remove and clean, then reinstall. 3. Check for loose suction tube or fittings. 3. T i[...]

307–758 21 MOTOR IS HOT AND RUNS INTERMITTENTL Y 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 1. Determine if sprayer was operated at high pressure with small tips, which causes low motor RPM and excessive heat build up. 1. Decrease pressure setting or increase tip size. 2[...]

22 307–758 SPIN TEST W ARNING To reduce the risk of serious injury , follow the illus - trated Pressure Relief Procedure warning on page 24 whenever you are instructed to relieve pressure. For checking armature, motor winding and brush electri - cal continuity . Setup Relieve pressure. Remove the drive housing. See page 33. Remove the pressure co[...]

307–758 23 BRIDGE TEST W ARNING To reduce the risk of serious injury , follow the illus - trated Pressure Relief Procedure warning on page 24 whenever you are instructed to relieve pressure. Remove the bridge from the pressure control box and perform this test to determine if the bridge is functional. See BRIDGE RECTIFIER REPLACEMENT , page 27. U[...]

24 307–758 GENERAL REP AIR INFORMA TION Pressure Relief Procedure To reduce the risk of serious bodily injury , including fluid in - jection, splashing fluid or solvent in the eyes or on the skin, or injury from moving parts or electric shock, always follow this procedure whenever you shut off the sprayer , when checking or servicing any part of [...]

307–758 25 MOTOR BRUSH REPLACEMENT NOTE: Replace the brushes when they have worn to less than 1/2 in. See STEP 1, Fig 25–3. Note that the brushes wear dif ferently on each side of the motor , so check them both. Brush Repair Kit 220–853 is available. A new spring clip, P/N 1 10–816 may be purchased separately . W ARNING To reduce the risk o[...]

26 307–758 POWER SUPPL Y CORD REPLACEMENT W ARNING To reduce the risk of serious injury , follow the illus - trated Pressure Relief Procedure warning on page 24 whenever you are instructed to relieve pressure. NOTE: Read the GENERAL REP AIR INFORMA TION on page 24 before doing this procedure. NOTE: Refer to Fig 26–1 for this procedure. 1. Relie[...]

307–758 27 BRIDGE RECTIFIER REPLACEMENT W ARNING To reduce the risk of serious injury , follow the Pres- sure Relief Procedure warning on page 24 when - ever you are instructed to relieve pressure. NOTE: Read the GENERAL REP AIR INFORMA TION on page 24 before doing this procedure. NOTE: The most common cause of bridge failure is a faulty motor . [...]

28 307–758 CIRCUIT BOARD REPLACEMENT W ARNING To reduce the risk of serious injury , follow the illus - trated Pressure Relief Procedure warning on page 24 whenever you are instructed to relieve pressure. NOTE: Read the GENERAL REP AIR INFORMA TION on page 24 before doing this procedure. NOTE: Refer to Fig 28–1 and 28–2 for this procedure. 1.[...]

307–758 29 PRESSURE CONTROL REPLACEMENT W ARNING T o reduce the risk of serious injury , follow the illustrated Pressure Relief Procedure warning on page 24 when- ever you are instructed to relieve pres- sure. NOTE: Read the GENERAL REP AIR INFORMA TION on page 24 before doing this procedure. NOTE: Refer to Fig 29–1 for this procedure. 1. Relie[...]

30 307–758 PRESSURE CONTROL ADJUSTMENT This procedure sets the sprayer to 2750 psi (195 bar) MAXIMUM WORKING PRESSURE and sets the overpressurization switch (microswitch) to approxi- mately 3600 psi (242 bar). Perform this procedure whenever the pressure con- trol assembly is removed and reinstalled or replaced, or a new circuit board is installe[...]

307–758 31 PRESSURE CONTROL ADJUSTMENT 6. Plug in the sprayer . 7. T urn the pressure control knob (B) to the minimum setting (fully counterclockwise), and turn the sprayer ON. THE DISPLACEMENT PUMP SHOULD NOT CYCLE If it does cycle , remove the plug (15) from the bottom of the pressure control. Insert a 3/8 in. nut driver through the opening, an[...]

32 307–758 DRIVE HOUSING, CONNECTING ROD & CRANKSHAFT REPLACEMENT W ARNING To reduce the risk of serious injury , follow the illus - trated Pressure Relief Procedure warning on page 24 whenever you are instructed to relieve pressure. NOTE: Read the GENERAL REP AIR INFORMA TION on page 24 before doing this procedure. NOTE: Stop the sprayer at [...]

FILL CA VITY WITH SAE 10 NON–DETERGENT MOT OR OIL Fig 33–2 39 68 8 71 8 75 18 14 58 69a 69 69b 73 18 25 70 57 22 41 43 42 63 LUBRICA TE LIBERALL Y P ACK WITH GREASE LIBERALL Y P ACK WITH GREASE LIBERALL Y P ACK WITH GREASE 01580 60 44 33 32 30 307–758 33 DRIVE HOUSING, CONNECTING ROD & CRANKSHAFT REPLACEMENT 14. Screw the displacement pum[...]

34 307–758 MOTOR REPLACEMENT W ARNING To reduce the risk of serious injury , follow the illus - trated Pressure Relief Procedure warning on page 24 whenever you are instructed to relieve pressure. NOTE: Read the GENERAL REP AIR INFORMA TION on page 24 before doing this procedure. NOTE: See Fig 35–1 except where noted. 1. Remove the pressure con[...]

307–758 35 MOTOR REPLACEMENT Fig 35–1 32 345 1 DET AIL Shows position of conduit seal (26) in conduit connector (345) 26 345 68 8 7 9 57 25 18 73 69a 69 71 69b 75 18 54 58 39 or 5 01581 WIRING DIAGRAM 01221 MOTOR LEADS AC1 AC2 G1 G2 _ + WHITE BLUE YELLOW RED GREEN BLACK WHITE GROUND WIRE BLACK POWER SUPPL Y CORD THERMAL SWITCH MOTOR 33 35 22 10[...]

36 307–758 DISPLACEMENT PUMP REP AIR W ARNING To reduce the risk of serious injury , follow the Pres- sure Relief Procedure warning on page 24 when - ever you are instructed to relieve pressure. NOTE: Read the GENERAL REP AIR INFORMA TION on page 24 before doing this procedure. Fig 36–1 204* 221* 220 219 202* 223 205 216 224 INT AKE VA LV E Fig[...]

307–758 37 DISPLACEMENT PUMP REP AIR 3. T ighten the packing retaining nut (21 1) against the piston valve (222) to 19 ft-lb (27 N.m). Note the alignment of the piston (222) to the pack - ing retainer nut (21 1). Maintain this alignment through Steps 5, 6 and 7. 4. Place the ball (225) on the piston valve (222). See Fig 37–1. CAUTION Step 5 is [...]

38 307–758 DISPLACEMENT PUMP REP AIR 219 PISTON ASSEMBL Y 218 T APERED END Fig 38-1 0030 12. Slide the sleeve/piston rod assembly INT O THE BOTTOM OF THE CYLINDER . This is to prevent packing damage during reassembly . See Fig 38–1. 13. Screw down the cylinder locknut (41) until it is finger tight at the bottom of the external cylinder threads.[...]

307–758 39 P ARTS DRA WING & LIST – DISPLACEMENT PUMP Model 222–584, Series A Sleeved Displacement Pump Includes items 202 to 225 REF NO. P ART NO. DESCRIPTION QTY 202 108–954* P ACKING, o–ring, PTFE  2 203 105–522* SEAL, u–cup, polyurethane 1 204 105–445* BALL, sst 1 205 180–656 PLUG 1 206 176–749* V–P ACKING, leather [...]

40 307–758 P ARTS – COMPLETE SPRA YER Model 231–032, Series C Basic Sprayer with Upright Cart Includes items 1 to 98 Model 231–041, Series B Complete Sprayer with Upright Cart Includes items 1 to 102  100 101 102 42 43 68 39 41 74 44 60 63 22 70 25 18 73 69b 8 69 71 69a 37 11 49,12 67b REF 95 76 38 46 67 67a 7 64 20 35 1 62 C[...]

307–758 41 P ARTS DRA WING – UPRIGHT SPRA YER Model 231–032, Series C Includes items 1 to 98 Model 231–041, Series B Includes items 1 to 102 REF NO. P ART NO. DESCRIPTION QTY REF NO. P ART NO. DESCRIPTION QTY 1 065–099 CONDUIT , specify length when ordering 0.8 ft 7 1 10–963 SCREW , serrated flange, hex hd, 5/16–18 x 3/4” 7 8 100–[...]

42 307–758 P ARTS DRA WING – LO-BOY SPRA YER Model 231–054, Series D Basic Sprayer with Lo-Boy Cart Includes items 1 to 98 Model 231–055, Series B Complete Sprayer with Lo-Boy Cart Includes items 1 to 102 01554   55 ID LABEL, THIS SIDE 56 ID LABEL, OTHER SIDE 58 DANGER LABEL 47 33 30 DANGER LABEL 40 14 18 75 8 69 71 69a 69b 73 18 25 7[...]

307–758 43 P ARTS LIST – LO-BOY SPRA YER Model 231–054, Series D Includes items 1 to 98 Model 231–055, Series B Includes items 1 to 102 REF NO. P ART NO. DESCRIPTION QTY REF NO. P ART NO. DESCRIPTION QTY 1 065–099 CONDUIT , specify length when ordering 0.8 ft 3 154–636 W ASHER, 5/8” ID 2 5 156–823 UNION, 1/4 npsm swivel x 1/4 npt 1 [...]

44 307–758 P ARTS DRA WING & LIST – PRESSURE CONTROL PRESSURE CONTROL ASSEMBL Y 220–455 Includes all items listed below , except the terminals. The terminals are included with the circuit board (item 72). The terminals listed in this parts list are shown on the wiring diagram on page 45. Part numbers for items 15, 23, 26, 50, 72, 75a, 75b[...]

307–758 45 WIRING DIAGRAM AC1 AC2 G1 G2 _ + WHITE BLUE YELLOW RED GREEN BLACK WHITE GROUND WIRE BLACK POWER SUPPL Y CORD THERMAL SWITCH MOTOR CIRCUIT BOARD 218–405, 5 WIRES  336 Ref 23,50 75a 323 320 302 317 318 316 324 306 304 309 322 321 (75c) 312 337 308 323 319 75b 75a 72 303 314[...]

46 307–758 ACCESSORIES 5 6 7 8 9 10 2 1 0162 3 4 Ref Part No. No. Name Qty 1 156–589 UNION 1 2 214–961 HOSE, 3/4 ID, 6 ft 1 3 156–591 ELBOW 1 4 156–593 P ACKING 1 5 100–220 THUMBSCREW 6 176–684 ADAPTER 1 7 156–592 TUBE 1 8 159–100 RET AINER 1 9 161–377 SCREEN 1 10 159–101 NUT 1 SUCTION TUBE KIT 208–259 55 gallon (200 liter) [...]

307–758 47 TECHNICAL DA TA Power Requirements 120 V AC, 60Hz, . . . . . . . . . . . . . . . . . . . 1 phase, 15 amp minimum or 2500 W att generator Motor 1/2 HP , DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working Pressure Range 0 – 2750 psi (0 – 195 bar) . . . . . . . . Cycles/Gallon (liter) 470 (124) . . [...]

48 307–758 THE GRACO W ARRANTY AND DISCLAIMERS W ARRANTY Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workman - ship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser ’ s sole remedy for breach of this warranty , Graco will, for [...]