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308–256
Rev. D
Supersedes Rev. B
and PCN C
INSTRUCTIONS-PARTS
LIST
INSTRUCTIONS
This
manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
ELECTRIC, 120 VAC
Pro
5
01s
t A
irles
s P
ain
t S
prayer
2750 psi (19.0 MPa, 190 bar) Maximum Working Pressure
Model 231–299, Series B
Complete
sprayer with hose, gun, Rac IV

DripLess

T
ip Guard and SwitchT
ip.
GRACO INC. P.O. BOX 1441
MINNEAPOLIS, MN
55440–1441
http://www.graco.com
COPYRIGHT
1994, GRACO INC.
Graco
Inc. is registered to I.S. EN ISO 9001
02821A

Table
of Contents
Warnings 2.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown
and Care
11.
. . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical
Data
35.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 36
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco
Phone Number
36.
. . . . . . . . . . . . . . . . . . . . . . .
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
equipment if the you do not follow the instructions.
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 Graco 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 35 for the maximum working pressure of this equipment.

Use fluids and solvents compatible with the equipment wetted parts. Refer to the
T
echnical Data
section of all equipment manuals. Read the fluid and solvent manufacturer
’
s warnings.

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.
W
ear hearing protection when operating this equipment.

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.
 
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 may look like just a cut, but it is a serious injury
.
Get immediate medi
-
cal 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 9 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
.
FUEL HAZARD
The
fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire.

Do not fill the fuel tank while the engine is running or hot.
EXHAUST HAZARD
The
exhaust contains poisonous carbon monoxide which is colorless and odorless.

Do not operate this equipment in a closed building.
308-2564
WARNING
FIRE AND EXPLOSION HAZARD
Improper
grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re
-
sult 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.

Disconnect all electrical 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.

Ground the sprayer to a true earth ground with the ground wire and clamp (supplied).

Use only electrically conductive hoses.
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 9 to prevent the
equipment from starting unexpectedly
.
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 trig
-
gering
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 liq
-
uids
in confined areas can result in fire or explosion.
Use
outdoors or in extremely well ventilated areas. Ground equip
-
ment,
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 ciga
-
rettes,
arcs from
connecting or disconnecting power cords or turn
-
ing
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 34 to order
.
 
Notes

Setup
Fig. 1




02821A
32
33
64
28
74
102
52
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





67
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 (19.5 MPa, 195 bar) W
orking
Pressure. This is to reduce the risk of serious injury
caused by static sparking, fluid injection or over-
pressurization and rupture 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
pump and the hose. See Fig. 1.
1. Connect the hose (74) and gun (67)
and screw it
onto the outlet nipple (28). Do not use thread
sealant, and do not install the spray tip yet.
2. 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.
3.
Plug in the sprayer
. Be sure the ON/OFF switch
(52) is OFF
. Plug the cord into a grounded outlet at
least 20 feet away from the spray area.
4.
Check the electrical service
. Be sure it is 120 V
,
60HzAC, 15 Amp (minimum). Use a properly
grounded outlet. Do not remove the third (ground
-
ing) prong of the power supply cord, and do not
use an adapter
.
Use a 3-wire, minimum 12 ga (16 AWG), 15 amp
extension cord up to 150 ft. (45 m) long. Longer
lengths af
fect sprayer performance.
 
Setup
5.
Ground the sprayer and spray system
.
WARNING
T
o reduce the risk of static sparking, ground the
pump and all other equipment used or located in
the spray area. Check your local electrical code for
detailed grounding instructions for your area and
type of equipment. Ground all of this equipment.
a.
Sprayer:
plug into a properly grounded outlet.
Do not use an adapter
. Extension cords must
have three wires and be rated for at least 15
amps.
b.
Fluid hoses:
use only grounded hoses with a
maximum of 500 ft (150 m) combined hose
length to ensure grounding continuity
.
c.
Spray gun:
obtain grounding through connec
-
tion to a properly grounded fluid hose and
sprayer.
d.
Object being sprayed:
according to local code.
e.
Fluid supply container:
according to local code.
f.
All solvent pails used when flushing
, according
to local code. Use only metal pails, which are
conductive. Do not place the pail on a non-
conductive surface, such as paper or card
-
board, which interrupts the grounding continu
-
ity.
g.
T
o maintain grounding continuity when flushing
or relieving pressure
, always hold a metal part
of the gun firmly to the side of a grounded
metal pail, then trigger the gun.
6. Flush the pump
to remove the oil which was left
in to protect the pump parts after factory testing.
See page 12.
7.
Prepare the paint
according to the manufacturer
’s
recommendations. Remove any paint skin. Stir the
paint to mix pigments. Strain the paint through a
fine nylon mesh bag (available at most paint
dealers) to remove particles that could clog the
gun filter or spray tip. This is an important step
toward trouble-free spraying.
Operation
How to Use the Gun Trigger Safety
When
locked, the gun trigger safety prevents the gun
from accidental triggering. See Fig. 2.
WARNING
If the gun sprays when the gun trigger safety is
locked, adjust the gun. See manual 307–614,
supplied.
Locked
Unlocked
Fig. 2




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
Troubleshooting
, page 13. See Fig. 3.
Closed,
or spray position
Open or drain, position
Fig.
3




02825A

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 9.
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. 4.
Fig. 4
+
–
02824A
How to Use the RAC IV Tip Guard
WARNING
To
reduce the risk of serious injury from fluid injec
-
tion:
Never operate the spray gun with the tip guard
removed.
Do not hold your hand, body
, or a rag in front of the
spray tip when cleaning or checking a clogged tip.
Always point the gun toward the ground or into a
pail when checking to see if the tip is clear
.
Do not try to “blow back” paint; this is not and air
spray sprayer
.
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 page 10. The tip guard holds a reversing
spray tip. The tip is in the spraying position when the
tip handle points forward. See Fig. 5.
Clean the front of the tip frequently during the day’
s
operation. First,
relieve the pressure
.
0484
Fig. 5
Tip
handle shown in
spraying position.
T
urn handle 180
,
trigger gun to clear clog
1
2
1 2
How to Remove a Tip Clog
1. Release
the gun trigger
. Lock the safety latch.
Rotate the RAC IV tip handle 180

. See Fig. 5.
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 307–848, supplied.
 
Startup
Pressure Relief Procedure
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.
1.
Lock the gun trigger safety
.
2. T
urn the ON/OFF switch to OFF
.
3.
Unplug the power supply cord.
4.
Unlock the trigger safety
. Hold a metal part of the
gun firmly to the side of a grounded metal pail, and
trigger the gun to relieve the pressure.
5.
Lock the gun trigger safety
.
6.
Open the pressure drain valve, having a container
ready to catch the drainage. Leave the 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
loosen the tip guard retaining nut or hose end coupling
to relieve the pressure gradually
, then loosen com
-
pletely
. Now clear the tip or hose.
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 12.
NOTE:
Refer to Fig. 1 and other figures referenced in
the text as you start the sprayer
.
1.
Open the pressure drain valve (42)
.
2. Do not 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 wen the drain valve is opened.
4. T
urn the pressure knob (64) to the minimum
setting.
5. Unlock the gun trigger safety
. See Fig. 2, page
7.
CAUTION
T
o reduce the risk of damage to the displacement
pump packings, never run the pump without fluid in
it for more than 30 seconds.
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.
WARNING
T
o reduce the risk of static sparking and splashing
when flushing, always remove the spray tip from
the gun, and hold a metal part of the gun firmly to
the side of, and aimed into, a grounded metal pail.
See Ref. A in Fig. 6.
Fig. 6 01024
A
7. T
o 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
WARNING
above. Hold the trigger open and
slowly increase the pressure until the pump starts.
Keep the gun triggered until all air is forced out of
the system and the fluid flows freely from the gun.
Release the trigger and lock the gun trigger safety
.
308-25610
Setup
8.
Check all fluid connections for leaks. Relieve the
pressure before tightening any connections.
9.
Install the spray tip. Lock the gun trigger safety
first. See manual 307–848 for how to install the tip.
10.
Adjust the spray pattern.
a.
Increase the pressure just until spray from the
gun is completely atomized. T
o avoid exces
-
sive overspray and fogging, and to extent tip
and sprayer life, always use the lowest pres
-
sure required to get the desired results.
b.
If more coverage is needed, use a larger tip
rather than increasing the pressure.
c. T
est the spray pattern. T
o adjust the direction
of the spray pattern, lock the gun trigger safety
and loosen the retaining nut (A). Position the
tip guard horizontally for a horizontal pattern or
vertically for a vertical pattern. Hold the tip
guard in place while tightening the retaining
nut. See Fig. 7.
NOTE:
Spray patterns will change as tips wear
.
Change the spray tip if adjusting the pressure will not
improve the spray pattern.
For
a horizontal
spray pattern
For a vertical
spray pattern
Fig.
7




A