Graco 231 824 Operation manual

308–754
Rev. D
Supercedes Rev. C
First choice when
quality counts. 
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
ELECTRIC, 110 Vac, 50 Hz
290 Easy Airless Paint Sprayer
2750 psi (190 bar , 19 MPa) Maximum Working Pressure
Model 231–824, Series A
Standard mount; complete sprayer with hose, gun,
RAC IV  DripLess  T ip Guard and SwitchT ip

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 5. . . . . . . . . . . .
Setup 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown and Care 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Test 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information 19. . . . . . . . . . . . . . . . . . . . .
Motor Brush 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 22. . . . . . . . . . . . . . . . . . . . .
Motor 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Start Board 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON/OFF Switch 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing, Connecting Rod, Crankshaft 25. . . . . .
Pressure Control 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer 28. . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Hose 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain V alve 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sprayer Parts Drawing 30. . . . . . . . . . . . . . . . . . . . . . . . .
Sprayer Parts List 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco W arranty 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
his 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.
 Use only with a grounded outlet that matches the grounded plug of this equipment.

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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 10 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 10 to prevent the
equipment from starting unexpectedly
.

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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
T echnical 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.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 29 to order .

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7150D
Component Identification and Function
C
Fig. 1
G
E
F
D
A
M
B
J
L
K
H
N
05963
AMotor DC motor , 1 10 V ac, 50 Hz, 6.5A, 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 1 10 V ac power to sprayer
E Fluid Outlet Hose and spray gun is connected here
F Displacement Pump Pressurizes fluid to be sprayed through spray gun
G 15 m Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
H RAC IV T ip Guard Reverse-A-Clean (RAC) ti p g uard reduce s t he ris k o f f lui d i njectio n i njury
J BLACK MAX Gun High pressure spray gun with gun safety latch
K RAC IV Switch T ip RAC switch tip atomizes fluid and removes clogs from spray tip without
removing tip from spray gun
L Pressure Drain V alve Relieves fluid pressure when open
M Pressure Control Controls motor to maintain fluid pressure. W orks with pressure
adjusting knob.
N Spray Gun Safety Latch Inhibits accidental triggering of spray gun

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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 2750 psi (190 bar , 19 MPa) Working Pres -
sure
. 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 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 Fig. 4.
1. Plug the power cord (57) into the inlet receptacle
located below the motor . T ighten the screws (A) of
the cord wire clamp (65) securely . See Fig 2. If the
power cord you are using does not have a male
plug attached, have a qualified electrician install an
appropriate plug.
57
65
A
Fig. 2
2. Connect the hose (74) and gun (67) and screw it
onto the outlet nipple (28). Don’t use thread
sealant, and don’t install the spray tip yet!
3. Fill the wet–cup (102). Pry of f the wet-cup seal.
Fill the cup 1/3 full with Graco Throat Seal Liquid
(TSL), supplied. Install the wet-cup seal.
4. Check the electrical service. It must be 1 10 V ac,
50 Hz, 6.5A (minimum) and protected by a fuse or
circuit breaker with a rating of not more than 16A.
Y ou may use a 3-wire, 1.0 mm
2
(16 A WG) (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
5. 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
6. Flush the pump to remove the lightweight oil
which was left in to protect pump parts after fac -
tory testing. See page 13.
7. 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.

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Setup
7150D
Fig. 4
1
3
4
2
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
32
33
64
28
74
102
52
12
3
4
5
67

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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 manual 307–821, supplied.
Fig. 5
1
2
Gun
safety latch
shown engaged
2
Gun safety latch
shown disengaged
1
05971
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 of f 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 7105A
Closed, or spray position
Open or drain, position
1
2
1
2
How to use the pressure control.
The pressure control controls the motor operation so
the sprayer maintains constant fluid pressure at the
pump outlet. T urn the pressure control knob fully
counterclockwise to obtain the minimum setting. T urn
the knob clockwise to increase pressure. See Fig. 7.
Fig. 7 7105A

308-754 9
Operation
How to use the RAC IV tip guard.
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 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.
T urn handle 180 ,
trigger gun to clear clog
1
2
2
1
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. T rigger 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
of f and unplug the sprayer , and open the pressure
drain valve to relieve pressure. Clean the spray tip
as shown in manual 307–821, supplied.

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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 . T o 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. T urn 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. T rigger
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 , VER Y SLOWL Y 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. T urn 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. T o 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.