Graco Inc ti5641a User Manual

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Repair

390Airless Sprayer

310824D

- For portable spray applications of architectural paints and coatings -

3300 psi (22.7MPa, 227bar) Maximum Working Pressure

IMPORTANT SAFETY INSTRUCTIONS!

Read all warnings and instructions. Save these instructions. Contact Graco Customer Service or your local Graco distributor to obtain a manual in your language.

Related Manuals

310820

309639

309250

Stand

ti11608a

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

310876

 

 

 

 

ti11626a

 

 

 

Hi-Boy

 

 

 

 

ProStep

 

ti11583a

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model*

 

VAC

Country

 

 

 

 

 

 

 

 

 

 

 

 

262019, 253958

 

120

North America

 

 

 

 

 

 

 

 

 

 

 

 

254968, 254969, 256391

240

Europe / Europe

 

 

 

 

 

multicord

 

 

 

 

 

 

 

 

 

 

 

254998, 262024, 256392

240

Asia / Australia

 

 

 

 

 

 

 

 

 

 

 

 

256481, 253961

 

110

UK

 

 

 

 

 

 

 

 

 

 

 

 

*all models not available in all countries

Graco Inc., PO Box 1441, Minneapolis, MN55440-1441

Copyright 2004, Graco Inc. is registered to I.S. EN ISO 9001

Contents

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Component Identification . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 7

General Repair Information . . . . . . . . . . . . . . . . . . 8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Displacement Pump Replacement . . . . . . . . . . . . 13

Drive Housing Replacement . . . . . . . . . . . . . . . . . 15

Spin Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Manual Conventions

WARNING

Hazard Symbol

WARNING: a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Warnings in the instructions usually include a symbol indicating the hazard. Read the general Warnings section for additional safety information.

Manual Conventions

Motor Brush Replacement . . . . . . . . . . . . . . . . . . 18

Control Board Replacement . . . . . . . . . . . . . . . . . 19

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pressure Control Assembly Replacement . . . . . . 22

Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . 23

Power Cord Replacement . . . . . . . . . . . . . . . . . . . 24

Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 25

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 29

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 30

CAUTION

CAUTION: a potentially hazardous situation which, if not avoided, may result in property damage or destruction of equipment.

Note

Additional helpful information.

2

310824D

Warning

Warning

The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specificrisks. Refer back to these warnings. Additional,product-specificwarnings may be found throughout the body of this manual where applicable.

Grounding Instructions

This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This product is equipped with a cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

WARNING

GROUNDING

Improper installation of the grounding plug is able to result in a risk of electric shock.

When repair or replacement of the cord or plug is required, do not connect the grounding wire to either flat blade terminal.

The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire.

Check with a qualified electrician or serviceman when the grounding instructions are not completely understood, or when in doubt as to whether the product is properly grounded.

Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a qualified electrician.

This product is for use on a nominal 120V circuit and has a grounding plug similar to the plug illustrated in the figure below.

Only connect the product to an outlet having the same configuration as the plug.

Do not use an adapter with this product.

Extension Cords:

Use only a 3-wireextension cord that has a3-bladegrounding plug and a3-slotreceptacle that accepts the plug on the product.

Make sure your extension cord is not damaged. If an extension cord is necessary, use 12 AWG (2.5 mm2) minimum to carry the current that the product draws.

An undersized cord results in a drop in line voltage and loss of power and overheating.

310824D

3

Warning

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

Do not spray flammable or combustible materials near an open flame or sources of ignition such as cigarettes, motors, and electrical equipment.

Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity creates a risk of fire or explosion in the presence of paint or solvent fumes. All parts of the spray system, including the pump, hose assembly, spray gun, and objects in and around the spray area shall be properly grounded to protect against static discharge and sparks. Use Graco conductive or grounded high-pressureairless paint sprayer hoses.

Verify that all containers and collection systems are grounded to prevent static discharge.

Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2adapter.

Do not use a paint or a solvent containing halogenated hydrocarbons.

Keep spray area well-ventilated.Keep a good supply of fresh air moving through the area. Keep pump assembly in a well ventilated area. Do not spray pump assembly.

Do not smoke in the spray area.

Do not operate light switches, engines, or similar spark producing products in the spray area.

Keep area clean and free of paint or solvent containers, rags, and other flammable materials.

Know the contents of the paints and solvents being sprayed. Read all Material Safety Data Sheets (MSDS) and container labels provided with the paints and solvents. Follow the paint and solvents manufacturer’s safety instructions.

Fire extinguisher equipment shall be present and working.

Sprayer generates sparks. When flammable liquid is used in or near the sprayer or for flushing or cleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors.

SKIN INJECTION HAZARD

Do not aim the gun at, or spray any person or animal.

Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with any part of the body.

Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.

Use Graco nozzle tips.

Use caution when cleaning and changing nozzle tips. in the case where the nozzle tip clogs while spraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing the nozzle tip to clean.

Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn off the unit and follow the Pressure Relief Procedure for turning off the unit.

High-pressurespray is able to inject toxins into the body and cause serious bodily injury. In the event that injection occurs,get immediate surgical treatment.

Check hoses and parts for signs of damage. Replace any damaged hoses or parts.

This system is capable of producing 3300 psi. Use Graco replacement parts or accessories that are rated a minimum of 3300 psi.

Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.

Verify that all connections are secure before operating the unit.

Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.

4

310824D

Warning

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

Always wear appropriate gloves, eye protection, and a respirator or mask when painting.

Do not operate or spray near children. Keep children away from equipment at all times.

Do not overreach or stand on an unstable support. Keep effective footing and balance at all times.

Stay alert and watch what you are doing.

Do not operate the unit when fatigued or under the influence of drugs or alcohol.

Do not kink or over-bendthe hose.

Do not expose the hose to temperatures or to pressures in excess of those specified by Graco.

Do not use the hose as a strength member to pull or lift the equipment.

Misuse of the sprayer platform can cause death or serious injury.

Do not exceed platform rating.

Make sure sprayer is on firm, level, non-slippery,secure foundation before accessing sprayer platform.

Make sure platform has been properly secured to frame before standing on platform.

If you are unable to step up to sprayer platform, use a stable intermediate stepping device for stepping up to sprayer platform or stepping down from sprayer platform.

Keep both feet squarely and firmly on platform.

Do not allow sprayer frame to come in contact with live electrical wires.

Do not over reach while on sprayer platform.

Do not position sprayer behind any doors when on sprayer platform.

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

Turn off and disconnect power cord before servicing equipment.

Use only grounded electrical outlets.

Use only 3-wireextension cords.

Ensure ground prongs are intact on sprayer and extension cords.

Do not expose to rain. Store indoors.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1, 1, 1-trichloroethane,methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.

BURN HAZARD

Equipment surfaces can become very hot during operation. To avoid severe burns, do not touch hot equipment. Wait until equipment has cooled completely.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

Keep clear of moving parts.

Do not operate equipment with protective guards or covers removed.

Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

Read MSDS’s to know the specific hazards of the fluids you are using.

Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

Protective eye wear

Clothing and respirator as recommended by the fluid and solvent manufacturer

Gloves

Hearing protection

310824D

5

Component Identification

Component Identification

P

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S

 

 

 

 

 

 

 

 

R

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

U

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

U

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K

 

 

 

 

 

 

 

 

E

 

 

 

 

 

 

 

 

 

 

A

 

 

 

 

 

 

A

 

 

 

 

 

 

 

 

 

 

 

 

 

E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

M

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

F

 

 

 

 

 

 

 

 

 

 

 

 

 

H

 

 

 

 

 

 

 

 

H

 

 

 

 

 

 

 

 

 

 

 

 

 

F

 

 

 

 

 

 

 

D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ti12008a

 

 

 

 

 

 

 

 

K

 

 

 

 

 

 

 

 

 

 

 

 

 

D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T

 

 

 

 

 

 

 

 

 

 

 

 

 

T

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Item English

APressure Control

BON/OFF switch

DPower Cord

EFluid Outlet

FPrime Valve

H

Pump

 

 

J

Suction Hose

 

 

K

Drain Hose

MFluid Hose

NGun

P Tip

RGuard

STrigger Safety Lock

TModel/Serial Tag

UFilter

VPlatform

6

310824D

Installation

Installation

Grounding and Electric

Requirements

WARNING

Your system must be grounded. Read warnings, page 3.

The sprayer cord includes: a grounding wire with an appropriate grounding contact.

The sprayer requires:

110-120VUnits:100-130VAC,50/60 Hz, 11A, 1 phase, circuit with a grounding receptacle.

240V Units: 210-255VAC, 50/60 Hz, 7.5A, 1 phase, circuit with a grounding receptacle.

Never use an outlet that is not grounded or an adapter.

Do not use the sprayer if the electrical cord has a damaged ground contact. Only use an extension cord with an undamaged ground contact.

Recommended extension cords for use with this sprayer:

110-120V:3-wire,12 AWG (2.5 mm2) minimum, 300 ft. (90 m) maximum length.

240V: 3-wire,16 AWG (1.0 mm2) minimum, 300 ft (90 m) maximum length.

Smaller gauge or longer extension cords may reduce sprayer performance.

Spray gun: ground through connection to a properly grounded fluid hose and pump.

Fluid supply container: follow local code.

Solvent and Oil-basedfluids:follow local code. Use only conductive metal pails placed on a grounded surface such as concrete. Do not place the pail on a nonconductive surface such as paper or cardboard, which interrupts grounding continuity.

Grounding the metal pail: connect a ground wire to the pail by clamping one end to pail and other end to ground such as a water pipe.

To maintain grounding continuity when flushing or relieving pressure: hold metal part of the spray gun firmly to the side of a grounded metal pail, then trigger the gun.

310824D

7

Pressure Relief Procedure

WARNING

Follow this Pressure Relief Procedurewhenever you are instructed to relieve pressure, stop spraying, check or service equipment or install or clean spray tip. Read

Injection Hazard Warning, page 3.

1.Turn OFF power and turn pressure control to lowest pressure setting.

2.Hold gun against side of grounded metal flushing pail. Trigger gun to relieve pressure.

ti5310a

FLUSH

Pressure Relief Procedure

3. Turn prime valve down.

ti5304a

If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Clear hose or tip obstruction.

4.Engage trigger safety lock on gun if unit is being shut down or left unattended.

8

310824D

General Repair Information

General Repair Information

WARNING

Read Electric Shock Warning, page 3 and Burn Hazard Warning, page 4.

WARNING

Flammable materials spilled on hot, bare, motor could cause fire or explosion. To reduce risk of burns, fire or explosion, do not operate sprayer with cover removed.

Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts usually are not provided with replacement kits.

Test repairs after problems are corrected.

If sprayer does not operate properly, review repair procedure to verify you did it correctly. See Troubleshooting, page10.

Overspray may build up in the air passages. Remove any overspray and residue from air passages and openings in the enclosures whenever you service sprayer.

Do not operate the sprayer without the motor shroud in place. Replace if damaged. Motor shroud directs cooling air around motor to prevent overheating and insulate the control board from accidental electric shock.

WARNING

To reduce risk of serious injury, including electric shock:

Do not touch moving or electric parts with fingers or tools while testing repair.

Unplug sprayer when power is not required for testing.

Install all covers, gaskets, screws and washers before you operate sprayer.

CAUTION

Do not run sprayer dry for more than 30 seconds. Doing so could damage pump packings.

Protect the internal drive parts of this sprayer from water. Openings in the cover allow for air cooling of the mechanical parts and electronics inside. If water gets in these openings, the sprayer could malfunction or be permanently damaged.

Prevent pump corrosion and damage from freezing. Never leave water or water-basepaint in sprayer when its not in use in cold weather. Freezing fluids can seriously damage sprayer. Store sprayer with Pump Armor to protect sprayer during storage.

310824D

9

Troubleshooting

Troubleshooting

WARNING

Read Electric Shock Warning, page 3, Burn Hazard Warning, page 4 and Pressure Relief Procedure, page 8.

Problem

 

What To Check

What To Do

 

(If check is OK, go to next check)

(When check is not OK, refer to this column)

 

 

 

 

 

 

 

 

Motor Won’t Operate

 

 

 

 

 

 

 

 

 

 

 

Basic Fluid Pressure

1.

Pressure control knob setting.

Slowly increase pressure setting to see if motor

 

 

Motor will not run if set at mini-

starts.

 

 

mum (fully counter-clockwise).

 

 

 

 

 

 

2.

Spray tip or fluid filter may be

Relieve pressure, page8. Then clear clog or

 

 

clogged.

clean gun filter. Refer to gun instruction manual,

 

 

 

309639.

 

 

 

 

Basic Mechanical

1.

Pump frozen or hardened paint

Thaw sprayer if water or water-basedpaint has

 

 

 

frozen in sprayer. Place sprayer in warm area to

 

 

 

thaw. Do not start sprayer until thawed com-

 

 

 

pletely. If paint hardened (dried) in sprayer,

 

 

 

replace pump packings. See page 14, Dis-

 

 

 

placement Pump Replacement.

 

 

 

 

 

2.

Displacement pump connecting

Push pin into place and secure with spring

 

 

rod pin. Pin must be completely

retainer. See page 14, Displacement Pump

 

 

pushed into connecting rod and

Replacement.

 

 

retaining spring must be firmly in

 

 

 

groove or pump pin.

 

 

 

 

 

 

3.

Motor. Remove drive housing

Replace motor if fan won’t turn. See page 27,

 

 

assembly. See page 16, Drive

Motor Replacement.

 

 

Housing Replacement. Try to

 

 

 

rotate fan by hand.

 

 

 

 

 

10

310824D

 

 

 

Troubleshooting

 

 

 

 

Problem

 

What To Check

What To Do

(If check is OK, go to next check)

(When check is not OK, refer to this column)

 

 

 

 

 

 

 

 

Basic Electrical

1.

Electric supply. Meter must read

Reset building circuit breaker, replace building

See wiring diagram, page

 

100-130VAC for110-120VAC

fuses. Try another outlet.

28

 

models and 210-255VAC for 240

 

 

 

VAC models.

 

 

 

 

 

 

2.

Extension cord. Check extension

Replace extension cord.

 

 

cord continuity with volt meter.

 

 

 

 

 

 

3.

Sprayer power supply cord.

Replace power supply cord. See page 26,

 

 

Inspect for damage such as bro-

Power Cord Replacement.

 

 

ken insulation or wires.

 

 

 

 

 

 

4.

Fuse. Check replaceable fuse on

Replace fuse after completing motor inspection.

 

 

control board (next to ON/OFF

See page 22, Fuse Replacement.

 

 

switch).

 

 

 

 

 

 

5.

Motor leads are securely fas-

Replace loose terminals; crimp to leads. Be

 

 

tened and properly connected to

sure terminals are firmly connected.

 

 

control board.

Clean circuit board terminals. Securely recon-

 

 

 

 

 

 

nect leads.

 

 

 

 

 

6.

Motor thermal switch. Yellow

Replace motor. See page 27, Motor Replace-

 

 

motor leads must have continuity

ment.

 

 

through thermal switch.

 

 

 

 

 

 

7.

Brush cap missing or loose brush

Install brush cap or replace brushes if leads are

 

 

lead connections.

damaged. See page 19, Motor Brush

 

 

 

Replacement.

 

 

 

 

 

8.

Brush length which must be 1/4

Replace brushes. See page 19, Motor Brush

 

 

in. (6mm) minimum.

Replacement.

 

 

NOTE: Brushes do not wear at

 

 

 

the same rate on both sides of

 

 

 

motor. Check both brushes.

 

 

 

 

 

 

9.

Motor armature commutator for

Remove motor and have motor shop resurface

 

 

burn spots, gouges and extreme

commutator if possible. See page 27, Motor

 

 

roughness.

Replacement.

 

 

 

 

 

10.

Motor armature for shorts using

Replace motor. See page 27, Motor Replace-

 

 

armature tester (growler) or per-

ment.

 

 

form spin test, page 17.

 

 

 

 

 

 

11.

Pressure control not plugged in

Insert pressure control connector into control

 

 

to control board.

board.

 

 

 

 

310824D

11

 

 

 

Troubleshooting

 

 

 

 

Problem

 

What To Check

What To Do

(If check is OK, go to next check)

(When check is not OK, refer to this column)

 

 

 

 

 

 

 

 

Low Output

1.

Worn spray tip.

Relieve pressure, page8. Replace tip. Refer to

 

 

 

gun instruction manual, 309639.

 

 

 

 

 

2.

Verify pump does not continue to

Service pump. See page 14, Displacement

 

 

stroke when gun trigger is

Pump Replacement.

 

 

released.

 

 

 

 

 

 

3.

Prime valve leaking.

Relieve pressure, page8. Then repair prime

 

 

 

valve. See page 24, Manifold Replacement.

 

 

 

 

 

4.

Suction hose connections.

Tighten any loose connections. Check o-rings

 

 

 

on suction hose swivel.

 

 

 

 

 

5.

Electric supply with volt meter.

Reset building circuit breaker; replace building

 

 

Meter must read 100-130VAC for

fuse. Repair electrical outlet or try another

 

 

110-120VAC models and

outlet.

 

 

210-255for 240 VAC models.

 

 

 

Low voltages reduce sprayer per-

 

 

 

formance.

 

 

 

 

 

 

6.

Extension cord size and length.

7. Replace with a correct, grounded extension

 

 

 

cord. See page 7, Grounding and Electric

 

 

 

Requirements.

 

 

 

 

 

8.

Leads from motor to circuit board

Be sure male terminal pins are centered and

 

 

for damaged or loose wire con-

firmly connected to female terminals. Replace

 

 

nectors. Inspect wiring insulation

any loose terminals or damaged wiring.

 

 

and terminals for signs of over-

Securely reconnect terminals.

 

 

heating.

 

 

 

 

 

 

9.

Worn motor brushes which must

Replace brushes. See page 19. Motor Brush

 

 

be 1/4 in. (6 mm) minimum.

Replacement.

 

 

 

 

 

10.

Motor brushes binding in brush

Clean brush holders. Remove carbon dust by

 

 

holders.

using compressed air to blow out brush dust.

 

 

 

 

 

11.

Low stall pressure. Turn pressure

Replace pressure control assembly. See page

 

 

control knob fully clockwise.

 

 

23, Pressure Control Assembly Replace-

 

 

 

 

 

 

ment.

 

 

 

 

 

12.

Motor armature for shorts by

Replace motor. See page 27, Motor

 

 

using an armature tester

Replacement.

 

 

(growler) or perform spin test,

 

 

 

page 17.

 

 

 

 

 

12

310824D

 

 

 

Troubleshooting

 

 

 

 

Problem

 

What To Check

What To Do

 

(If check is OK, go to next check)

(When check is not OK, refer to this column)

 

 

 

 

 

 

 

 

Motor runs and pump

1.

Prime Valve Open.

Close prime valve.

strokes

 

 

 

2.

Paint supply.

Refill and reprime pump.

 

 

 

 

 

 

3.

Intake strainer clogged.

Remove and clean, then reinstall.

 

 

 

 

 

4.

Suction hose leaking air.

Tighten nut. Check o-ringson swivel.

 

 

 

 

 

5.

Intake valve ball and piston ball

See Pump Manual 309250. Strain paint before

 

 

are seating properly.

using to remove particles that could clog pump.

 

 

 

 

 

6.

Leaking around throat packing

See Pump Manual 309250.

 

 

nut which may indicate worn or

 

 

 

damaged packings.

 

 

 

 

 

 

7.

Pump rod damaged.

See Pump Manual 309250.

 

 

 

 

Motor runs but pump does

1.

Displacement pump pin dam-

Replace pump pin if missing. Be sure retaining

not stroke

 

aged or missing.

spring is fully in groove all around connecting

 

 

 

rod. See page 14, Displacement Pump

 

 

 

Replacement.

 

 

 

 

 

2.

Connecting rod assembly for

Replace connecting rod assembly. See page

 

 

damage.

14, Displacement Pump Replacement.

 

 

 

 

 

3.

Gears or drive housing.

Inspect drive housing assembly and gears for

 

 

 

damage and replace if necessary. See page 16,

 

 

 

Drive Housing Replacement.

 

 

 

 

Motor is hot and runs

1.

Be sure ambient temperature

Move sprayer to shaded, cooler area if possible.

intermittently

 

where sprayer is located is not

 

 

 

more than 115°F (46°C) and

 

 

 

sprayer is not located in direct

 

 

 

sun.

 

 

 

 

 

 

2.

Motor has burned windings indi-

Replace motor. See page 27, Motor

 

 

cated by removing positive (red)

Replacement.

 

 

brush and seeing burned adja-

 

 

 

cent commutator bars.

 

 

 

 

 

 

3.

Tightness of pump packing nut.

Loosen packing nut. Check for leaking around

 

 

Overtightening tightens packings

throat. Replace pump packings if necessary.

 

 

on rod, restricts pump action and

See pump manual 309250.

 

 

damages packings.

 

 

 

 

 

310824D

13

Displacement Pump Replacement

Displacement Pump Replacement

See manual 309250 for pump repair instructions.

4.Cycle pump until pin (32) is in position to be removed.

Removal

WARNING

Read Injection Hazard Warning, page 3, Moving Parts Hazard Warning, page 4 and Pressure Relief Procedure, page 8.

1.Relieve pressure, page 8.

2.Loosen two screws (30) and rotate cover (44).

ti6104a

44

30

3.Loosen nut (A) and remove hose set (35). Loosen nut (B) and remove the high pressure hose (14).

14

B

A

ti6105a

35

5.Disconnect power cord from outlet.

6.Using a flat screwdriver, push retaining spring (C) up. Push out pump pin (32).

C

32

ti6106a

7.Using a hammer, loosen pump jam nut (11). Unscrew and remove pump (9).

ti6107a

11

9

11

14

310824D

Installation

WARNING

If pump pin works loose, parts could break off due to force of pumping action. Parts could project through air and result in serious injury or property damage.

CAUTION

If the pump jam nut loosens during operation, the threads of the drive housing will be damaged.

1.Extend pump piston rod full. Apply grease to top of pump rod at (D) or inside connecting rod (7). Install jam nut (11) on pump threads.

$

TI A

2.Install pump rod (D) into connecting rod (7).

3.Install pump pin (32). Verify retainer spring (C) is in groove over pump pin.

#

TI A

4. Push pump (9) up until pump threads engage.

Displacement Pump Replacement

5.Screw in pump until threads are flush with top of drive housing opening.

6. Align pump outlet (E) to back.

%

7.Screw jam nut (11) up onto pump until nut stops. Tighten jam nut by hand, then tap 1/8 to 1/4 turn with a 20 oz (maximum) hammer to approximately 75 ft-lb(102 N•m).

8.Install suction tube (35) and high pressure hose

(14). Tighten nuts (A) and (B).

.

14

B

A

ti6105a

35

9.Fill packing nut with Graco TSL until fluid flows onto top of seal.

30

44

ti5735a

10. Rotate cover (44). Tighten screws (30).

310824D

15

Drive Housing Replacement

Drive Housing Replacement

WARNING

Read Injection Hazard Warning, page 3 and page8.

Removal

1.Relieve pressure, page 8.

2.Remove pump (9). Displacement Pump Replacement, page 14. Disconnect power cord from outlet.

3

4

5

7

6

32

ti5641a

2

30

 

6

Installation

1.Apply a liberal coat of grease to gears and needle bearing surfaces. Install thrust bearing (4) and gears (2) and (3) in front endbell housing.

Needle bearing surfaces

3

4

2

ti6121a

2.Push drive housing into front endbell housing. Insert gear crank (3) through hole in connecting rod (7).

3.

Remove two screws (30) and cover (32).

3

 

4.

Remove four screws (6).

7

 

 

5. Pull drive housing (5) out of motor front endbell.

6. Remove gear cluster (2) and (3) and thrust bearing

(4) from drive housing.

ti6124a

CAUTION

Do not drop gear cluster (3) and (2) when removing drive housing (5). Gear cluster may stay engaged in motor front endbell or drive housing.

3. Install four screws (6).

4. Install cover (32) with two screws (30).

5. Install pump (9). Displacement Pump Replacement, page 14.

16

310824D

Spin Test

See Wiring Diagram, page 28.

WARNING

Read Electric Shock Warning, page 3 and Pressure Relief Procedure, page8.

To check armature, motor winding and brush electrical continuity:

1.Relieve pressure, page8. Disconnect power cord from outlet.

2.Remove two screws (30) and shroud (29).

3.Remove drive housing (5), page 16.

4.Disconnect motor connector (F).

Spin Test

2.If uneven or no resistance, check for missing brush caps, broken brush springs, brush leads, and worn brushes. Repair as needed, page 19.

3.If still uneven or no resistance, replace motor, page 27.

30

29

ti5638a

Armature Short Circuit Test

Quickly turn motor fan by hand. If motor coasts two or three revolutions before complete stop, there are no electrical shorts. If motor does not spin freely, armature is shorted. Replace motor, page 27.

Armature, Brushes, and Motor Wiring Open

Circuit Test (Continuity)

1.Connect red and black motor leads with test lead. Turn motor fan by hand at about two revolutions per second.

F

4.Reattach motor connector (F).

5.Replace drive housing, page 16.

6.Replace shroud (29) and two screws (30).

310824D

17

Fan Replacement

Removal

WARNING

Read Electric Shock Warning, page 3 and Pressure Relief Procedure, page8.

1.Relieve pressure, page8. Disconnect power cord from outlet.

2.Remove two screws (30) and shroud (29).

100

30

101

 

29

Fan Replacement

3.Remove spring clip (101) on back of motor.

4.Pull off fan (100).

Installation

1.Slide new fan (100) in place on back of motor. Be sure blades of fan face motor as shown.

2.Install spring clip (101).

3.Replace shroud (29) and two screws (30).

ti5769a

18

310824D

Motor Brush Replacement

See Wiring Diagram, page 28.

Removal

Replace brushes worn to less than 1/4 in. (6mm). Brushes wear differently on each side of motor, check both sides.

WARNING

Read Electric Shock Warning, page 3 and Pressure Relief Procedure, page8.

1.Relieve pressure, page8. Disconnect power cord from outlet.

2.Remove two screws (30) and shroud (29).

3.Disconnect motor connector (D) from control board (33).

4.Cut tie wrap (F).

5.Locate two yellow wires (C) (thermal leads). Cut each yellow wire at the center.

6.Using a flat screwdriver, pry off (two) brush caps

(A). Remove brushes (B) from motor.

7.Discard old brush harness.

8.While rotating fan by hand, using compressed air, blow air into positive (top) brush holder to remove brush dust.

To contain the dust, turn on your shop vac. Place the end of the hose over the negative (lower) brush holder while blowing compressed air into the positive (top) brush holder.

Installation

\

Use all new parts included in your brush kit. Do not reuse old parts if new replacement parts are provided.

1.With wires facing toward front of motor, install new brushes (B) in motor. Be sure to install the positive (red) brush lead in the top of the motor (as shown) and the negative (black) brush lead in the side of the motor.

Motor Brush Replacement

2.Push each cap (A) into place over brush. Orient each cap with the 2 projections on either side of the brush lead. You will hear a “snap” when cap is securely in place.

3.Using a wire stripper, strip off wire insulation approximately 1/4 inch (6 mm) from the end of each yellow wire (C) to the motor.

4.Insert stripped end into end of a butt splice (E) on new brush assembly.

5.Use a crimping tool to squeeze the ends of the butt splice (E) tightly around each wire. Pull gently on each wire to be sure it will not pull out of the butt splice.

6.Using new tie wrap (F) from kit, wrap tie around motor and wires only. Trim off excess. Be sure pressure hose and wire leads are not caught in tie wrap.

7.Reconnect motor connector (D) to control board (33).

30

D

29

A

E

 

33

ti5637a

 

 

A

 

+

 

Red

 

 

C

D B

- Black

ti5637a

F

8. Replace shroud (29) and two screws (30).

310824D

19

Control Board Replacement

Control Board Replacement

See Wiring Diagram, page 28.

WARNING

Read Electric Shock Warning, page 3 and Pressure Relief Procedure, page8.

6.Pull control board out slightly and then slide it back and off of frame.

Make sure power cord is free and NOT wrapped around cord wrap.

7. Remove grommet and wires from strain relief.

Removal

1.Relieve pressure, page8. Disconnect power cord from outlet.

2.Remove two screws (30) and shroud (29).

3.Disconnect pressure switch connector (A) from control board (33).

4.Disconnect motor connector (B) from control board (33).

5.Remove 3 screws (30) securing control board to housing (2 are located on the front and one on the back next to the power cord).

33

30

30

ti6119a

A

B

B

A

33

33

120V

240V

 

.

Ground wire will remain attached to sprayer with grounding screw.

8.Remove 2 power cord connectors from control board.

20

310824D

Installation

1.Position grommet and power cord wires through strain relief in control board (33).

ti6122a

33

2.Reconnect the power cord connectors to the correct terminals indicated on the control board (120V, black and white, 240V, blue and brown) on control board (33).

Be sure power cord is routed between the blue high pressure hose to the manifold and the sprayer frame.

33

30

J

30

Control Board Replacement

ti6125a

3.Carefully slide control board back into place on the side of the motor frame.

4.Replace 3 screws (30). Torque to 30-35in-lbs(3.4-3.9N.m)

5.Reattach motor connector (B) and pressure control assembly connector (A).

6.Install shroud (29) and two screws (30).

B

A

33

120V

B

A

D

E

F

G

ti5639a

H

310824D

21

Fuse Replacement

Removal

1.Relieve pressure, page8. Disconnect power cord from outlet.

2.Remove two screws (30) and shroud (29).

3.Remove fuse from control board.

4.Remove spare fuse from motor.

Spare Fuse (included n 110V and 120 models only)

Fuse Replacement

Installation

1.Replace fuse on control board with spare fuse.

2.Install shroud (29) and two screws (30).

Replaceable Fuse

ti9134b

22

310824D

Pressure Control Assembly Replacement

Pressure Control Assembly Replacement

See Wiring Diagram, page 28.

WARNING

Read Electric Shock Warning, page 3 and Pressure Relief Procedure, page 8.

Removal

1.Relieve pressure, page8. Disconnect power cord from outlet.

2.Remove two screws (30) and shroud (29).

3.Disconnect pressure switch connector (A) from control board (33).

4.Remove tape (22) holding wires to manifold.

5.Pull wires back through hole (K) in housing.

 

A

2221

K

TI C

 

30

29

ti5766a

If you plan to reuse the pressure control assembly, be very careful not to damage or tangle the wires while unscrewing the assembly.

8. Remove pressure control assembly.

Installation

Inspect pressure control assembly before installation to verify theo-ringis installed and in place.

1.Align grommet collar (17) on fluid manifold so opening faces toward motor.

2.Apply loctite to pressure control assembly threads (16)

3.Screw pressure control assembly (16) into manifold and torque to 150 in-lbs(17.0 N.m)

Be careful when tightening pressure control knob that wires do not get pinched between the pressure control assembly and fluid manifold.

6.Turn the pressure control knob (16) counter clockwise as far as you can to access the flats on either side of the pressure control assembly.

7.Using a 1 in. (26 mm) wrench loosen and unscrew pressure control assembly.

4.Wrap wires around knob and feed through slot in grommet (21).

5.Insert grommet (21) in hole (K) in housing. Secure wires to manifold housing with tape (22).

6.Reconnect pressure switch connector (A) to control board (33).

7. Install shroud (29) and two screws (30).

310824D

23

Manifold Replacement

See Wiring Diagram, page 28.

WARNING

Read Electric Shock Warning, page 3 and Pressure Relief Procedure, page 8.

Removal

1.Relieve pressure, page8. Disconnect power cord from outlet.

2.Remove drain line (40) and barbed fitting (20) from manifold. See Drain Line Replacement, page25.

3.Remove two screws (30) and shroud (29).

4.Disconnect fluid hose at pump outlet.

5.Disconnect pressure switch connector (A) from control board (33).

6.Remove tape (22) holding wires to manifold.

7.Pull wires back through hole (K) in housing.

8.If required, remove pressure switch from manifold. See Pressure Control Assembly Replacement, page23.

9.Remove two screws (6) to disconnect Manifold from housing.

Installation

1.Position manifold on sprayer frame.

2.Replace screws (6) and torque to 150 in-lbs(17 N.m).

3.If removed, install pressure control assembly. See

Pressure Control Assembly Replacement, page 23.

4.Feed pressure switch wires through hole in housing

(K).

5.Insert grommet (21) in hole (K) in housing. Secure wires to manifold housing with tape (22).

6.Reconnect pressure switch connector (A) to control board (33).

Manifold Replacement

7.Reconnect fluid hose at pump outlet.

8.Replace barbed fitting (20) and drain line (40). See

Drain Line Replacement, page 25.

9.Install shroud (29) and two screws (30).

 

 

 

A

 

18

33

 

 

 

 

 

A

 

 

 

17

 

 

 

15

Ref 14

 

 

13

 

 

C

 

 

 

 

23

6

20

 

 

 

24

 

B

 

25

 

26

 

40

 

 

 

 

 

 

ti5771a

 

A

 

33

18

A

 

17

ProStep

13

Ref 14

 

6

 

 

20

 

23

24

40

25

 

26

ti12077a

 

24

310824D

Drain Line Replacement

Drain Line Replacement

This procedure should be used whenever you replace the manifold and reinstall an existing drain line or install a new drain line using the Drain Line Kit.

Removal

To remove the drain line (40) from the manifold:

1. Cut drain line (40) from barbed fitting (20).

2. Unscrew barbed fitting (20) from manifold.

If you are only replacing the manifold and will be reusing the existing barbed fitting (20) and drain line (40), you will need to use a sharp knife to cut the remaining drain line material off the end of the barbed fitting (20).

Installation

1.Screw barbed fitting (20) into manifold.

2.Push drain line (40) onto barbed fitting (20).

To make the drain line more pliable and easier to install over barbed fitting, heat end of drain line (40) with a hair dryer or by placing end in hot water a few seconds.

310824D

25

Power Cord Replacement

See Wiring Diagram, page 28.

WARNING

Read Electric Shock Warning, page 3 and Pressure Relief Procedure, page 8.

Removal

1.Follow Control Board Replacementremoval instructions, steps 1-8, page 20.

2.Disconnect green ground wire (G) from sprayer by loosening grounding screw (31).

Power Cord Replacement

Installation

1.Follow Control Board Replacementinstallation instructions, steps 1-4, page 20.

2.Reconnect, green ground wire (G) to green grounding screw (31) on frame. Be sure terminal on ground faces UP or wires could get caught in shroud.

3.Reattach motor connector (B) and pressure control switch connect (A).

4.Install shroud (29) and two screws (30).

33

33

120V

240V

 

G

31

26

310824D

Motor Replacement

See Wiring Diagram, page 28.

WARNING

Read Electric Shock Warning, page 3 and Pressure Relief Procedure, page 8.

CAUTION

Do not drop gear cluster (3) and (2) when removing drive housing (5). Gear cluster may stay engaged in motor frontend bell or drive housing.

Removal

1.Relieve pressure, page8. Disconnect power cord from outlet.

2.Remove pump (9). Displacement Pump Replacement, page 14.

3.Remove drive housing, Drive Housing Replacement, page 16.

4.Remove Pressure (Fluid) Manifold, Manifold Replacement, page24.

31

34

33

30

30

15

6 45

1 Liberally apply grease

Motor Replacement

5.Disconnect all leads from board (33) and remove control board. Control Board Replacement, page20.

6.Remove ground wire (G) from motor endbell.

7.Remove four screws (6) and motor (1) from frame (45).

Installation

1.Install new motor (1) on frame (45) with four screws

(6).

2.Install manifold (15) with two screws (6). Manifold Replacement, page24

3.Install control board (33) with three screws (30). Connect all leads to board. See Control Board Replacement, page20 andWiring Diagram, page28.

4.Connect ground wire (G) to motor with green ground screw (31).

5.Install Drive Housing. Drive Housing Replacement, page16.

6.Install pump (9). Displacement Pump Replacement, page 14.

7.Install shroud (29) with two screws (30).

1

3

1

2

1

6

ti5642a

310824D

27

Wiring Diagram

Wiring Diagram

120V Model

from Motor

2 x Yellow

Pressure

Control

Assembly

ti5643a

Power

Plug White

240V Model

from Motor

 

Capacitor

2 x Yellow

Red (+)

Black (-)

Replaceable Fuse

ON/OFF

Switch

Black

Capacitor

Green

Pressure Control

Assembly

Red (+)

Black (-)

Replaceable Fuse

ON/OFF

Switch

ti5857a

Blue

Brown

Power

Plug

Green

28

310824D

Technical Data

Technical Data

Power requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . .

Cycles per gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum delivery gpm (lpm) . . . . . . . . . . . . . . . . . . . . . .

Maximum tip size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid outlet npsm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions (Stand):

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions (Hi-Boy):

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions (ProStep):

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Noise level*

Sound power (IS0 3744)

Sound pressure (ISO 3744)

100/120V AC, 50/60 hz, 11A, 1 phase 230V AC, 50/60 hz, 7.5A, 1 phase 3000 w minimum

3300 psi (22.7 MPa, 227 bar)

680(180)

0.43(1.6)

0.020 1/4 in.

15.75in. (40.0 cm)

14.0in. (36.0 cm)

17in. (43.0 cm)

30lb (13.6 kg)

22.0in. (55.9 cm)

20.5in. (52.1 cm)

38.8in. (98.6 cm)

58.0lb (25.9 kg)

20.0in. (50.8 cm)

15.5in. (39.4 cm)

19.25in. (48.9 cm)

40.0lb (18.1 kg)

zinc and nickel-platedcarbon steel, nylon, stainless steel,

PTFE, Delrin®, leather, UHMWPE, aluminum, tungsten carbide

100dBa* 90 dBa*

Delrin® is a registered trademark of the DuPont Company. *Measured 3 feet (1 meter) from equipment.

310824D

29

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Gracocomponent parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice.

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441www.graco.com

Printed in USA 310824D 4/2008