Graco 231-406, Series A Operation manual

308–785
Rev. A
First choice when
quality counts. 

INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
120 V AC, 18A
Mark V T exture Sprayer
3000 psi (21.0 MPa, 210 bar) Maximum Working Pressure
Model 231–406, Series A
Includes texture sprayer , 50 foot hose, 3 foot hose,
and texture spray gun
Patents Pending
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1997, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

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Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Components 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Airless Operation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Brush Replacement 14. . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Repair 20. . . . . . . . . . . . . . . . . . . . . . .
Bearing Housing & Connecting Rod 23. . . . . . . . . . . . .
Drive Housing 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sprayer Parts Drawing 26. . . . . . . . . . . . . . . . . . . . . . . . .
Sprayer Parts List 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco W arranty 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 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 of f any light switch in the spray area while operating or if fumes are present.
 Do not operate a gasoline engine in the spray area.

 
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 dif fuser 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 8 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
T ighten 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 P ARTS 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 8 to prevent the
equipment from starting unexpectedly .

4 308-785
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury .
D This equipment is for professional use only .
D
Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
D
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D Check equipment daily . Repair or replace worn or damaged parts immediately .
D
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
T echnical Data on page 30 for the maximum working pressure of this equipment.
D 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.
D 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.
D Do not use hoses to pull equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 180 _F (82_ C) or below –40 _F (–40_C).
D Do not lift pressurized equipment.
D 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.A void 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 T reatment”.
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.
A void 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 of f.
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 30 to order .

 
Major Components
04426A
7148A
C
Fig. 1
J
E
F
A
G
K
R
04463
N
B
H
S
U
L
T
P
V
M
vv
D
A
Motor (Under shield shown) DC motor , 120 V ac, 60 Hz, 18A, 1 phase
B Pressure Adjusting Knob Controls fluid outlet pressure
C ON/OFF Switch Power switch that controls 120 V ac power to sprayer
D Drive Assembly T ransfers power from DC motor to the displacement pump
E Fluid Filter Filter of fluid between source and spray gun
F Secondary Fluid Outlet Second hose and spray gun is connected here
G Pail Hanger Container of fluid to be sprayed may be hung here
H Displacement Pump Pressures fluid to be sprayed through spray gun
J 50 ft (15 m) Main Hose 3/8 in. ID, grounded, nylon hose with spring guards on both ends
K RAC IV T ip Guard Reverse-A-Clean (RAC) tip guard reduces the risk of fluid injection inju -
ry
LT exture Spray Gun 3000 psi (21.0 MPa, 210 bar) texture spray gun with gun safety latch
M RAC IV Switch T ip RAC switch tip atomizes fluid and removes clogs from spray tip without
removing tip from spray gun
N 3 ft (0.9 m) Hose 1//4 in. ID, grounded, nylon hose used between 50 ft hose and spray
gun to allow more flexibility when spraying
P Pressure Drain V alve Relieves fluid pressure when open
R Pressure Control Controls motor speed to maintain fluid pressure. W orks with pressure
adjusting knob.
S Spray Gun Safety Latch Inhibits accidental triggering of spray gun
T Primary Fluid Outlet Hose and spray gun is connected here
U 15/20 Amp Switch Allows sprayer to operate on 15A service with reduced performance
VGauge System pressure indicator , 3000 psi (21.0 MPa, 210 bar)

6 308-785
Setup
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.
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 (21.0 MPa, 210 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.
CAUTION
T o 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 50 ft
(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 shutof f device between the filter
and the hose. See A, Fig. 2.
1. Connect gun (B) and 50 ft hose (C). Don’t install
the spray tip yet. See Fig. 2.
2. Fill wet-cup (D) 1/3 full with Graco Throat Seal
Liquid, supplied.
3. Check electrical service. Be sure electrical service
is 120 V ac, 60 Hz, 20 A. Use properly grounded
outlet. Do not remove grounding prong of power
supply cord or of any extension cords used. Do not
use an adapter . Extension cords must have 3
wires of minimum 12 gauge size. Long extension
cords reduce sprayer performance. If 20 amp
service is not available, set 15/20 amp switch (C)
to 15 amp to avoid nuisance tripping of circuit
breakers.
4. With switch (E) to OFF , plug power supply cord
into grounded electrical outlet
located at least 20 ft
away from spray area.
5. Flush pump before using it. See page 10.
04426A
7148A
Fig 2
E
A
D
C
B

 
Airless Operation
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure on page 8.
Startup
Always use this procedure to help ensure the sprayer
is ready to operate and that you start it safely . See
Fig. 3
1. For first time startup, flush sprayer . See page 10.
2. Close pressure drain valve (A).
3. Don’t install spray tip until pump is primed!
4. Put pump (B) into supply pail .
5. T
urn pressure adjusting knob (C) counterclockwise
to lowest setting.
6. Disengage gun safety latch.
WARNING
FIRE AND EXPLOSION HAZARD
T o reduce static sparking and splashing,
always remove the spray tip from the
gun, and hold a metal part of the gun
firmly to the side of a grounded metal pail when
flushing.
7. T o prime pump, squeeze gun trigger and hold it
open, turn ON/OFF switch (D) to ON, and slowly
increase pressure setting (C) until sprayer starts.
Keep gun triggered until all air is forced out of
system and material flows freely from gun. Re -
lease gun trigger and engage gun safety latch.
CAUTION
Do not run the sprayer dry for more than 30 seconds
to avoid damaging the pump packings.
8. Check all fluid connections for leaks. If any leaks
are found, relieve pressure before tightening
connections.
WARNING
FIRE AND EXPLOSION HAZARD
T o reduce the risk of fluids entering
control box, check weep hole (Fig.16, C)
regularly . Replace o–ring when any
leakage is seen. Also read FIRE OR
EXPLOSION HAZARD on page 2.
9. Check weep hole (Fig. 16, B) of pressure control
for leakage at start up and during operation. If
leakage, replace o–ring as instructed in Pressure
Control T ransducer and O–Ring Replacement on
page 20.
10. Engage gun safety latch. Install spray tip and tip
guard (E) according to instructions supplied with
tip guard.
11. Adjust pressure.
a. T urn pressure adjusting knob (C) clockwise
until spray from gun is just completely atom
-
ized. T o reduce overspray , fogging, and tip
wear and to extend life of sprayer , use lowest
possible pressure needed to get good atom -
ization.
a.
If more coverage is needed, use larger tip
rather than increasing pressure.
a. T est spray pattern. T o adjust direction of spray
pattern, engage gun safety latch, loosen
retaining nut, position tip guard horizontally for
horizontal pattern or vertically for vertical
pattern and tighten retaining nut.
04426A
7148A
Fig 3
C
D
A
E
B

 
Operation
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally . To
reduce the risk of an injury from accidental spray
from the gun, splashing fluid, or moving parts,
follow the Pressure Relief Procedure whenever
you:
D
are instructed to relieve the pressure,
D stop spraying,
D check or service any of the system equipment,
D or install or clean the spray nozzle.
1. Engage gun safety latch.
2. T urn ON/OFF switch to OFF .
3.
Unplug power cord.
4. Disengage gun safety latch. Hold metal part of gun
against grounded metal pail and trigger gun into
pail to relieve pressure.
5. Engage gun safety latch.
6. Open any fluid drain valves in system. Leave drain
valve open until ready to dispense again.
Cleaning a Clogged Tip
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure.
1. If spray tip clogs, release gun trigger,
engage gun safety latch (B), and rotate RAC IV
handle (A) 180 _ . See Fig 4.
2. Disengage gun safety latch (C) and trigger gun
into waste container . Engage gun safety latch
again.
3.
Return tip handle to original position,
disengage gun safety latch, and resume spraying.
4. If tip is still clogged, engage gun safety latch, shut
of f and unplug sprayer , and open pressure drain
valve to relieve pressure. Remove tip and soak it
in solvent. Do not scrape or chip of
f debris which
could damage tip.
03966
Fig 4
A
B






The tip handle (A) is shown in spraying position.
Rotate the tip handle 180 _ in direction
of the arrow for clearing a clog.
C
Engaged.
Disengaged.

308-785 9
Operation
Shutdown and Care
1. Check wet-cup (A) daily . See Fig 5. First relieve
pressure and remove wet-cup plug. Keep wet-cup
1/3 full with Graco Throat Seal Liquid at all times
to help prevent material from building up on piston
rod which causes packings to wear prematurely .
T
ighten wet-cup, which is also packing nut, just
enough to stop leakage. Overtightening wet-cup
may cause packings to bind and wear out quickly .
Use screwdriver and light hammer to adjust wet-
cup.
2.
Clean fluid filter (B) often and whenever sprayer is
stored. First relieve pressure. See manual
307–273 for cleaning procedure.
3. Fill connecting rod cavity (C) with motor oil every
100 hours of operation. First relieve pressure and
then remove front cover .
4.
For short shutof f periods, leave pump in the mate -
rial, relieve pressure, and clean spray tip.
04347A
Fig 5
C
A
B
5.
Before storing sprayer , flush thoroughly , leaving a
coating of mineral spirits, then relieve pressure.
6. Coil hose and hang on cart handle for protection.

10 308-785
Flushing
1
Use this category for flushing a brand new sprayer
and flushing after storage.
System has
this fluid in it:
Next fluid to be
sprayed:
Flushing order:
Before you spray:
this fluid in it: sprayed:
Flush 1 Flush 2 Flush 3
1Oil-based
solvent or fluid
Oil-based fluid –
new color
Mineral spirits none none Prime with oil-based fluid
Oil-based
solvent or fluid
W ater-based fluid Mineral spirits W arm soapy
water
Clean water Prime with water-based
fluid
Water or water-
based fluid
W ater-based fluid
– new color
W arm soapy
water
Clean water none Prime with water
Water or water-
based fluid
Oil-based fluid W arm soapy
water
Clean water Mineral spirits Prime with oil
The following sections are for preparing a sprayer for storage.
Oil-based
solvent or fluid
Prepare for
storage
Mineral spirits none none Relieve pressure,
Leave drain valve open
Water or water-
based fluid
Prepare for
storage
W arm soapy
water
Clean water Mineral spirits Relieve pressure,
Leave drain valve open
CAUTION
Never allow water to freeze in the pressure control.
Doing so prevents the sprayer from being started
and causes serious damage to the pressure control.
Push the water out with mineral spirits.
1. Relieve pressure.
2. Remove filter bowl (A) and screen (B). Install bowl
(A) and filter support (C) without screen (B). See
Fig 6.
3. Close pressure drain valve (D).
4. Pour 2 quarts of compatible solvent into grounded
metal pail. Put pump in pail.
5. Remove spray tip from gun.
6. T urn pressure adjusting knob (E) counterclockwise
to lowest pressure setting.
WARNING
FIRE AND EXPLOSION HAZARD
T o reduce static sparking and splashing,
always remove the spray tip from the
gun, and hold a metal part of the gun
firmly to the side of a grounded metal pail when
flushing.