Duron DURON 231-553, Instructions Manual

Page 1: ...bar Maximum Working Pressure Model 231 553 Series A Complete sprayer with hoses gun RAC IV DripLess Tip Guard and SwitchTip GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1996 GRACO INC Graco Inc is registered to I S EN ISO 9001 This manual contains important warnings and information READ AND RETAIN FOR REFERENCE ...

Page 2: ...Symbol CAUTION This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions 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 s...

Page 3: ...so 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...

Page 4: ... 40 C 40 F Do not lift pressurized equipment Comply with all applicable local state and national fire electrical and safety regulations WARNING WARNING INSTRUCTIONS 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 trig...

Page 5: ...fluid to be sprayed through spray gun G 50 ft 15 m Main Hose 1 4 in ID grounded nylon hose with spring guards on both ends H RAC IV Tip Guard Reverse A Clean RAC tip guard reduces the risk of fluid injection inju ry J FTx Gun High pressure spray gun with gun safety latch K RAC IV Switch Tip RAC switch tip atomizes fluid and removes clogs from spray tip without removing tip from spray gun L Pressur...

Page 6: ...et 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 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...

Page 7: ... 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 be fore operating the sprayer again Refer also to the Troubleshooting page 14 See Fig 4 Closed or spray position Open or drain position Fig 4 1 2 1 2 04646 How to use the pr...

Page 8: ...ee Fig 6 Clean the front of the tip frequently during the day s operation First follow the Pressure Relief Procedure on page 9 Fig 6 Tip handle shown in spraying position Turn 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 Ro tate the RAC IV tip handle 180 See Fig 6 2 Unlock the safety latch Trigger the gun into a pail or...

Page 9: ...hat 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...

Page 10: ...Engage the gun safety latch 9 Install the spray tip and tip guard Install the spray tip If you are using the RAC IV tip guard refer to manual 307 848 for installation instruc tions 10 Adjust the spray pattern a Increase the pressure until spray from the gun is completely atomized To avoid excessive overspray and fogging and to extend tip and sprayer life always use the lowest pressure needed to ge...

Page 11: ...up 05993 Fig 9 1 3 4 2 32 33 64 28 74 102 52 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 5 1 2 3 4 5 67 ...

Page 12: ...100 hours of operation Remove the front cover Fill the bearing housing cavity A with SAE 10 non detergent oil See Fig 11 5 Flush the sprayer at the end of each work day and fill it with mineral spirits to help prevent pump corrosion and freezing See page 13 To prevent pump corrosion and to reduce the chance of fluid freezing in the pump in cold weather never leave water or any type of paint in the...

Page 13: ...lon 2 liters of compatible solvent into a grounded metal flushing pail Put the suction hose in the pail 4 Open the pressure drain valve See Fig 4 page 7 5 To save the paint still in the pump and hose follow Step 6 except put the drain tube in the paint pail When solvent appears close the drain valve Put the drain tube in the flushing pail Trigger the gun into the paint pail When solvent appears re...

Page 14: ...e with spring retainer 3 Check for motor damage Remove drive hous ing assembly 11 See page 28 Try to rotate motor fan by hand 3 Replace motor 4 if fan won t turn See page 26 Electrical 1 Check electrical supply with volt meter Meter should read 105 125 VAC 1 Reset building circuit breaker replace building fuse Try another outlet 2 Check extension cord for visible damage Use a volt meter or test la...

Page 15: ...h and connect volt meter between exposed terminal on switch and power cord s white wire Plug in sprayer and turn ON Meter should read 105 125VAC Turn off and unplug sprayer 10 Replace ON OFF switch See page 27 11 Check motor thermal cutout switch Connect ohmmeter between motor s red leads Meter should read 1 ohm maximum 11 Allow motor to cool Correct cause of overheating If switch remains open aft...

Page 16: ...akage from transducer is normal 1 Periodically remove residue from its cyl inder port See page 31 No output 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 See page 34 3 Tighten use thread sealant on npt threads of adapter 38 4 Check to see if intake valve bal...

Page 17: ... wires 2 Check for missing motor brush inspection plate gasket see page 18 bent terminal forks or other metal to metal contact points which could cause a short 2 Correct faulty conditions 3 Check motor armature for shorts Use an arma ture tester growler or perform motor test See page 18 Inspect windings for burns 3 Replace motor See page 26 4 Check motor start board 47 by substituting with a good ...

Page 18: ...e motor fan by hand If there are no shorts the motor will coast two or three revolutions before coming to a complete stop If the motor does not spin freely the armature is shorted and the motor must be re placed See page 26 Armature Brushes and Motor Wiring Open Circuit Test Continuity Connect the two black motor leads together with a test lead Turn the motor fan by hand at about two revolu tions ...

Page 19: ...re operating the sprayer WARNING HOT SURFACE HAZARD During operation the motor and drive housing become very hot and could burn your skin if touched Flammable materi als spilled on the hot bare motor could cause a fire or explosion CAUTION To reduce the risk of a pressure control malfunc tion be sure to properly mate connectors and never pull on a wire to disconnect it Pulling on a wire could loos...

Page 20: ...he spring clip See Fig 15 3 Slide off the brush lead terminal E off the blade connector Remove the old brush C See Fig 15 Fig 15 F G E D C B H 1 1 Motor lead do not disconnect 2 Minimum 0 5 12 5 mm 03881 3 Included in Brush Repair Kit 236 967 3 2 4 Inspect the commutator for excessive pitting burn ing or gouging A black color on the commutator is normal Have the commutator resurfaced by a qualifie...

Page 21: ...ull speed d Inspect the brush and commutator contact area for excessive arcing Arcs should not trail or circle around the commutator surface WARNING MOVING PARTS HAZARD Do not touch the brushes leads springs or brush holders while the sprayer is plugged in to reduce the risk of electric shock and serious injury 10 Install the brush inspection covers and gaskets 11 Break in the brushes Operate the ...

Page 22: ...spring 18 up and push out the pin 17 4 Loosen the screws 21 Remove the pump 20 Installing the pump See Fig 18 and 19 1 Mount the pump on the drive housing Tap it into the alignment pins with a soft hammer Tighten the screws 21 to 50 ft lb 68 N m WARNING MOVING PARTS HAZARD Be sure the retaining spring 18 is firmly in the groove all the way around to pre vent the pin 17 from working loose due to vi...

Page 23: ...lats of the piston rod in a smooth jaw vise Use an open end wrench to loosen the nut 110 and then unscrew the piston valve 108 7 Remove all parts from the piston valve 108 Reassembling the pump NOTE Alternate plastic and leather packings See Fig 19 The lips of the throat V packings face down The lips of the piston V packings face up Incorrect installa tion damages the packings and causes pump leak...

Page 24: ...0 contacts the rod See Fig 21 7 Place the flats of the rod 107 in a smooth jaw vise 8 CAREFULLY tighten the nut 110 against the pis ton rod to 30 ft lb 40 N m See Fig 21 Use two wrenches to maintain the alignment men tioned in NOTE below Step 3 Fig 20 01070 Torque to 5 in lb 0 57 N m 107 109 110 108 Apply one drop of sealant to these threads Fig 21 01071 108 110 107 Torque nut against rod to 30 ft...

Page 25: ...ue cylinder 115 into manifold 101 to 53 ft lb 71 N m Torque intake valve 116 into cylinder 115 to 53 ft lb 71 N m 1 2 3 4 Piston assembly 4 14 Place the ball guide 120 stop pin 122 and ball 121 in the cylinder 115 Screw the intake valve into the cylinder and torque to 53 ft lb 71 N m This will also properly torque the cylinder into the manifold See Fig 23 15 Torque the cylinder jam nut 117 to 73 f...

Page 26: ...ee drive housing screws and lockwashers 19 6 Also see Fig 26 6 Remove the two motor screws 19 and and re move the sprayer handle 24 7 Tap the lower rear of the drive housing 11 with a plastic mallet to loosen the motor Pull the drive housing straight off the motor while guiding the harness A from the motor Do not allow the gear 16 to fall Read the CAUTION on page 28 8 Remove the two screws 46 and ...

Page 27: ... 56 and lower the junction box 59 3 Disconnect the power supply cord leads including the green wire to the grounding screw 49 4 Loosen the strain relief bushing 51 Remove the power supply cord 50 5 Install the new cord 50 in the reverse order of disassembly 6 Install the junction box Be sure no leads are pinched against the motor or by the motor start board Also be sure the gasket 89 is installed ...

Page 28: ...them fall between the gears which will damage the drive housing if not removed The balls which are heav ily covered with grease usually stay in the gear re cesses but could be dislodged If the balls are not in place the bearings will wear prematurely 6 Remove and inspect the crankshaft 12 and the connecting rod 15 7 Install the connecting rod 8 Lubricate the inside of the drive housing bearing wit...

Page 29: ...g Rod Crankshaft 6 19 15 13 64 11 19 12a 12 12b 59 11a 4a A 34 31 REF A 16 47 Fig 29 1 Torque to 80 in lb 9 N m 3 2 Quantity of three Quantity of one 1 1 2 3 Apply a total of 3 fl oz 29 cc of grease to gears 4 4 C 04657 24 56 ...

Page 30: ...d tip the pressure control 64 forward and up to detach it from the drive housing 11 4 Guide the harness A through the motor and drive housing and remove the pressure control 5 Guide the harness of the new pressure control through the drive housing and motor passages 6 Install the new pressure control Tip the pressure control down and back into the drive housing 11 Do not pinch or damage the harnes...

Page 31: ... 22 2 Use a pull twist motion to remove the transducer 29 from the pump manifold 101 3 Clean paint residue from the hole in the manifold do not scratch the surface of the hole 4 Lightly apply oil to the o ring of the new transducer 5 Install the transducer in the pump manifold while guiding the o ring and backup ring into place 6 Align the holes in the transducer as shown by the arrows in Fig 31 7...

Page 32: ...so the lapped side is toward the ball Apply a small amount of grease to the new gasket 42a and in stall it in the valve body NOTE The gasket will protrude from the end of the valve until the valve is tightened into pump which cor rectly seats the gasket Replacement 1 Apply a small amount of thread sealant 42e onto the valve 42 threads Tighten the valve into the pump manifold to 185 in lb 21 N m 2 ...

Page 33: ...ston 1 115 236 786 CYLINDER pump 1 116 108 526 PACKING o ring PTFE 1 117 187 614 NUT jam 1 3 8 18 unef 2b 1 118 224 966 INLET VALVE 1 119 111 603 PACKING o ring PTFE 1 120 176 760 GUIDE ball 1 121 105 445 BALL 1 2 inlet 1 122 176 759 PIN ball stop 1 123 180 656 PLUG 1 124 102 969 SEALANT not shown 1 127 188 663 LABEL Warning 1 Supplied in Repair Kit 235 703 Keep a repair kit on hand to reduce down...

Page 34: ... 37 29 32 25 12b 12a 64 30 19 19 6 17 31 34 21 38 36 46 4 39 28 56 43 42 42a 42b 4e 44 REF 32 REF 33 11 23 63 HOSE AND GUN NOT SHOWN IN PROPORTION TO SPRAYER 67 74 42c 42d 11b 14 4g INSIDE LABEL 35 OUT SIDE LABEL 4f See detail on page 31 24 1 2 Label 1 1 1 89 50 13 66 2 11a 79 ...

Page 35: ... 190 336 DRAIN TUBE 1 34 111 705 SCREW filh 8 32 x 2 1 2 3 35 290 237 LABEL identification 1 36 237 696 ELBOW drain 1 37 190 334 LEG sprayer 2 38 190 451 ADAPTER union 1 39 237 820 STRAINER 1 42 235 014 DRAIN VALVE KIT 1 Includes items 42a to 42e 42a 111 699 GASKET valve seat 1 42b 187 615 SEAT drain valve 1 42c 224 968 STEM drain valve 1 42d 168 110 O RING stem 1 42e 110 110 SEALANT pipe not show...

Page 36: ...l not be liable for any malfunction damage or wear caused by faulty installation misapplication abra sion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility with Graco equipment of structures accessories equipment or mate rials not supplied by ...