Graco 231832 Operation manual

308753

Rev. D

First choice when

quality counts.

INSTRUCTIONS-PARTS LIST

INSTRUCTIONS

This manual contains important

warnings and information.

READ AND KEEP FOR REFERENCE.

ELECTRIC, 100 Vac, 50 or 60 Hz

595st Airless Paint Sprayer

20.7 MPa (207 bar, 3000 psi) Maximum Working Pressure

Model 231832, Series A

Low profile cart sprayer

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

Graco Inc. is registered to I.S. EN ISO 9001

7299B

2 308753

Table of Contents

Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Identification and Function 5. . . . . . . . . . . .

Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutdown and Care 12. . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Repair Information 18. . . . . . . . . . . . . . . . . . . . .

Motor Test 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Brush 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pump Repair 22. . . . . . . . . . . . . . . . . . . . .

Motor 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Start Board 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Supply Cord 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON/OFF Switch 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Housing, Connecting Rod, Crankshaft 25. . . . . .

Pressure Control 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Transducer 28. . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Hose 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain Valve 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model 231832 Sprayer Parts Drawing 30. . . . . . . . . . . .

Model 231832 Sprayer Parts List 31. . . . . . . . . . . . . . . .

Technical Data 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Warranty 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious

injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to

or destruction of equipment if you do not follow the

instructions.

WARNING

FIRE AND EXPLOSION HAZARD

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and

result in a fire or explosion and serious injury.

If there is any static sparking or you feel an electric shock while using this equipment, stop spray-

ing immediately. Do not use the equipment until you identify and correct the problem.

Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid

being sprayed.

Keep the spray area free of debris, including solvent, rags, and gasoline.

Electrically disconnect all equipment in the spray area.

Extinguish all open flames or pilot lights in the spray area.

Do not smoke in the spray area.

Do not turn on or off any light switch in the spray area while operating or if fumes are present.

Do not operate a gasoline engine in the spray area.

Use only with a grounded outlet that matches the grounded plug of this equipment.

308753 3

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.

Do not stop or deflect leaks with your hand, body, glove or rag.

Do not “blow back” fluid; this is not an air spray system.

Always have the tip guard and the trigger guard on the gun when spraying.

Check the gun diffuser operation weekly. Refer to the gun manual.

Be sure the gun trigger safety operates before spraying.

Lock the gun trigger safety when you stop spraying.

Follow the Pressure Relief Procedure on page 10 if the spray tip clogs and before cleaning,

checking or servicing the equipment.

Tighten all fluid connections before operating the equipment.

Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not

repair high pressure couplings; you must replace the entire hose.

Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by

kinks or bends near the couplings.

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 national guidelines.

Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and

solvent manufacturer.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

Keep clear of all moving parts when starting or operating the pump.

Before servicing the equipment, follow the Pressure Relief Procedure on page 10 to prevent the

equipment from starting unexpectedly.

4 308753

WARNING

INSTRUCTIONS

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 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.

Do not exceed the maximum working pressure of the lowest rated system component. Refer to the

Technical Data on page 32 for the maximum working pressure of this equipment.

Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-

nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or

fluids containing such solvents in pressurized aluminum equipment. Such use could result in a

chemical reaction, with the possibility of explosion.

Do not use hoses to pull equipment.

Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose

Graco hoses to temperatures above 82C (180F) or below –40C (–40F).

Do not lift pressurized equipment.

Comply with all applicable local, state, and national fire, electrical, and safety regulations.

Liquids can be injected into the body by high pressure airless spray or

leaks –especially hose leaks.

Keep body clear of the nozzle. Never stop leaks with any part of the

body. Drain all pressure before removing parts.Avoid accidental trigger-

ing of gun by always setting safety latch when not spraying.

Never spray without a tip guard.

In case of accidental skin injection, seek immediate

“Surgical Treatment”.

Failure to follow this warning can result in amputation or serious injury.

FIRE AND

EXPLOSION HAZARD

SKIN INJECTION

HAZARD

READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE

Spray painting, flushing or cleaning equipment with flammable liquids in

confined areas can result in fire or explosion.

Use outdoors or in extremely well ventilated areas. Ground equipment,

hoses, containers and objects being sprayed.

Avoid all ignition sources such as static electricity from plastic drop

cloths, open flames such as pilot lights, hot objects such as cigarettes,

arcs from connecting or disconnecting power cords or turning light

switches on and off.

Failure to follow this warning can result in death or serious injury.

NOTE: This is an example of the DANGER label on

your sprayer. This label is available in other

languages, free of charge. See page 31 to order.

308753 5

7299B

Component Identification and Function

Fig. 1

AMotor DC motor, 100 Vac, 10A, 1 phase

BDrive Assembly Transfers power from DC motor to the displacement pump

CPressure Adjusting Knob Controls fluid outlet pressure

DON/OFF Switch Power switch that controls 100 Vac power to sprayer

EFluid Outlet Hose and spray gun is connected here

FDisplacement Pump Pressurizes fluid to be sprayed through spray gun

GPressure Drain Valve Relieves fluid pressure when open

HPressure Control Controls motor to maintain fluid pressure. Works with pressure

adjusting knob.

6 308753

Setup

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 207 bar (20.7 MPa, 3000 psi) 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.

CAUTION

To avoid damaging the pressure control, which may

result in poor equipment performance and compo-

nent damage, follow these precautions:

1. Always use a nylon spray hose at least 15 m

long.

2. Never use a wire braid hose as it is too rigid to

act as a pulsation dampener.

3. Never install any shutoff device between the filter

and the hose. See Fig. 4.

1. Plug the power cord (57) into the inlet receptacle

located below the motor. Tighten the screw (A) of

the cord clamp (65) securely. See Fig 2.

Fig. 2 9299A

2. Attach the fluid filter (85) to the sprayer.

3. Connect the hose and gun and screw it onto the

outlet nipple (28). Don’t use thread sealant, and

don’t install the spray tip yet! See Fig 4.

4. 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.

5. Check the electrical service. It must be 100 Vac,

50/60 Hz, 13A (minimum) and protected by a fuse

or circuit breaker with a rating of not more than

16A.

You may use a 3-wire, 2.0 mm2(14 AWG) (mini-

mum) extension cord up to 45 m long.

WARNING

FIRE AND EXPLOSION HAZARD

Proper electrical grounding is essential

to reduce the risk of fire or explosion

which can result in serious injury and

property damage. Also read FIRE OR

EXPLOSION HAZARD on page 2

6. Plug in the sprayer. Be sure the ON/OFF switch

(52) is OFF. Plug the cord into a grounded outlet at

least 6 m away from the spray area.

Fig. 3

Grounded

Outlet

9248A

7. Flush the pump to remove the lightweight oil

which was left in to protect pump parts after fac-

tory testing. See page 13.

8. Prepare the paint according to the manufacturer’s

recommendations. Remove any paint skin. Strain

the paint through a fine nylon mesh bag (available

at most paint dealers) to remove particles that

could clog the spray tip. This is an important step

toward trouble-free paint spraying.

308753 7

Setup

Fig. 4

1/4 npsm(m) fluid outlet

Rotate clockwise to increase pressure

Do not install any shutoff device here

Fill 1/3 full with TSL

Shown in closed or spray position

3364

102

04784B

8 308753

Operation

How to use the gun trigger safety

When engaged, the gun safety latch prevents the gun

from accidental triggering. See Fig. 5.

WARNING

INJECTION HAZARD

If the gun still sprays when the gun

trigger safety is locked, repair the gun.

See your spray gun manual.

7186A

Fig. 5

Gun safety latch

shown engaged

Gun safety latch

shown disengaged

How to use the pressure drain valve.

Use the pressure drain valve to relieve fluid pressure

from the pump and to help prime the pump. If the valve

senses an over pressure condition, it opens automati-

cally to relieve fluid pressure. If this happens, stop

spraying immediately, shut off and unplug the sprayer.

Determine the cause of the problem and correct it

before operating the sprayer again. Refer also to the

Troubleshooting , page 14. See Fig. 6.

Fig. 6

Closed, or spray position

Open or drain, position

7105A

How to use the pressure control.

The pressure control controls the motor operation so

the sprayer maintains constant fluid pressure at the

pump outlet. Turn the pressure control knob fully

counterclockwise to obtain the minimum setting. Turn

the knob clockwise to increase pressure. See Fig. 7.

Fig. 7

7105A

308753 9

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 10.

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. 10. The tip guard holds a reversing

spray tip. The tip is in the spraying position when the

tip handle points forward. See Fig. 8.

Clean the front of the tip frequently during the day’s

operation. First, follow the Pressure Relief Procedure

on page 10.

Fig. 8

Tip handle shown in

spraying position.

Turn handle 180,

trigger gun to clear clog

04647

How to remove a tip clog.

1. Release the gun trigger. Lock the safety latch.

Rotate the RAC IV tip handle 180. See Fig. 8.

2. Unlock the safety latch. Trigger the gun into a pail

or onto the ground to remove the clog.

3. Lock the safety latch. Rotate the tip handle to the

spraying position.

4. If the tip is still clogged, lock the safety latch, shut

off and unplug the sprayer, and open the pressure

drain valve to relieve pressure. Clean the spray tip

as shown in your spray gun manual.

10 308753

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.

Pressure Relief Procedure

1. Engage the gun safety latch.

2. Turn the ON/OFF switch to OFF.

3. Unplug the power supply cord.

4. Disengage the gun safety latch. Hold a metal part

of the gun firmly to a grounded metal pail. Trigger

the gun to relieve pressure.

5. Engage the gun safety latch.

6. Open the pressure drain valve. Leave the pressure

drain valve open until you are ready to spray

again.

If you suspect that the spray tip or hose is completely

clogged, or that pressure has not been fully relieved

after following the steps above, VERY SLOWLY loos-

en the tip guard retaining nut or hose end coupling to

relieve pressure gradually, then loosen completely.

Now clear the tip or hose obstruction.

Startup Procedure

Use this procedure each time you start the sprayer to

help ensure the sprayer is ready to operate and that

you start it safely.

NOTE: If this is a first-time startup, flush the sprayer.

See page 13.

NOTE: Refer to Fig. 4 and the other figures referenced

in the text as you start the sprayer.

1. Open the pressure drain valve (42). See Fig. 9.

2. Don’t install the spray tip until the pump is

primed!

3. Put the suction hose (32) into the paint. If you

are pumping from a pail, push the drain hose (33)

down below the top of the pail to avoid splashing

paint when the drain valve is opened.

01021A

Open or drain, position

Fig. 9

4. Turn the pressure knob (64) to the minimum

setting.

5. Disengage the gun trigger safety. See Fig. 5,

page 8.

CAUTION

Do not run the sprayer dry for more than 30 seconds

to avoid damaging the pump packings.

6. To prime the pump, turn the sprayer switch (52)

on. Slowly increase the pressure until the sprayer

starts. When fluid comes from the pressure drain

valve, close the valve.

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