Graco 235490, 309662L User Manual

Repair

TexSpray 1030

German Patent No. P 43 18 679.3--09

- For portable spray application of architectural paints and coatings -

0.9 to 3.0 gpm (3.4 to 11.4 lpm) Flow Rate

750 psi (5.1 MPa, 51 bar) Maximum Working Pressure

500 psi (3.4 MPa, 34 bar) Recommended Maximum Working Pressure

Model 234113, Series C

TexSpray 1030 FC sprayer, 235490 TexSpray gun and 50 ft (15 m) air and fluid hose set

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

309663.......

308274.......

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309662L

CONTENTS

Warnings 2..............................

Component Description 5..................

Maintenance 6...........................

Troubleshooting 7........................

Repair 10...............................

Parts 20.................................

Accessories 26...........................

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

Dimensions 27...........................

Warranty 28.............................

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

ti3005c

Specifications

This equipment is not intended for use with flammable or combustible materials used in places such as cabinet shops or other “factory” or fixed locations. If you intend to use this equipment in this type of application, you must comply with NFPA 33 and OSHA requirements for the use of flammable and combustible materials.

Warnings

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

2 309662

The following are general W arnings related to the safe setup, use, maintenance and repair of this equipment. Additional, more specific warnings may be found throughout the text of this manual where applicable.

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:

D Use equipment only in well ventilated area.

D Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic

drop clothes (potential static arc).

D Sprayer generates sparks. When flammable liquid is used in or near sprayer or for flushing or

cleaning, keep sprayer at least 20 ft (6 m) away from explosive vapors.

D Do not clean with materials having flash points lower than 70_F(21_C). Use water--based materi-

als or mineral spirits type material only. For complete information about your fluid, request the MSDS from the fluid distributor or retailer.

D Keep work area free of debris, including solvent, rags and gasoline.

D Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

D Ground equipment and conductive objects in work area. Read Grounding instructions.

D If there is static sparking or you feel a shock, stop operating immediately. Do not use equipment

until you identify and correct the problem.

SKIN INJECTION HAZARD

High pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

D Do not point gun at anyone or any part of the body.

D Do not put your hand over the spray tip.

D Do not stop or deflect leaks with your hand, body, glove, or rag.

D Engage trigger lock when not spraying.

D Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

checking or servicing equipment.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in this equipment. Such use could result in a serious chemical reaction, with the possibility of explosion, which could cause death, serious injury and/or substantial property damage.

309662 3

INSTRUCTIONS

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

D Read all instruction manuals, tags, and labels before operating the equipment.

D Use equipment only for its intended purpose. Call your Graco distributor for information.

D Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. This gun has a 150 psi (10 bar) maximum fluid working pressure at a 125 psi (9 bar) maximum incoming air pressure. Read Technical Data in all equipment manuals.

D Do not alter or modify equipment.

D Check equipment daily. Repair or replace worn or damaged parts immediately.

D Do not lift pressurized equipment.

D Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not

expose Graco hoses to temperatures above 180_F(82_C) or below --40_F(--40_C).

D Do not use hoses to pull equipment.

D Keep children and animals away from work area.

D Comply with all applicable safety regulations.

D Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or

fluids containing such solvents in this equipment, which contains aluminum and/or zinc parts. Such use could result in a serious chemical reaction, with the possibility of explosion, which could cause death, serious injury and/or substantial property damage.

D Wear eye and ear protection when operating this equipment. Keep body parts away from front of

gun. See Sound Data in

TECHNICAL DATA.

TOXIC FLUID HAZARD

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

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

D Store hazardous fluid in approved containers and dispose of it according to all applicable guide-

lines.

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:

D Protective eye wear.

D Clothing and respirator as recommended by the fluid and solvent manufacturer.

D Gloves.

D Hearing protection.

4 309662

Component Description

Flow and Air Control

Fig. 1. The flow control (A) has a shut off and pressure relief feature to soft start each time the gun is triggered, instead of a blast of unatomized material. The flow control has three modes:

D LOW/MED/HIGH: Triggering the gun sends an air

signal to the flow control that closes the prime valve and starts the pump which fills the material hose. When the gun trigger is released, the prime valve opens and relieves the system pressure into the supply container. When the gun is triggered the automatic pressure relief, special TexSpray hoses and pump design eliminate blasts of material and spray pulsing to ensure consistent atomization.

D OFF: Puts the sprayer in neutral/relieve pressure --

neither the pump nor the gun will operate and there is no material pressure in the pump, hose or gun.

D PRIME: The prime valve remains open so material

circulates through the pump and back to the supply container through the drain hose.

The air control (B) increases or decreases the air pressure to the sprayer from the air supply.

OFF

PRIME

LOW/MED/HIGH

Prime Valve

Fig. 1. The prime valve (C) relieves system pressure and stops the pump when the gun trigger is released.

TexSpray Gun, 235490

WARNING

EQUIPMENT MISUSE HAZARD

The TexSpray Gun 235490 is for use

INSTRUCTIONS

of the gun will not exceed the working pressure rating of the components. The maximum fluid working pressure of the GM 1030 TexSpray is 750 psi (5.1 MPa, 51 bar), but the recommended maximum is 500 psi (3.4 MPa, 34 bar).

Fig. 2. Air flow is controlled at the gun. During priming, turn the gun air control valve (D) in fully to prevent air from mixing with the fluid, which allows you to check and adjust the fluid flow accurately . (When this valve is closed the air exits the rear of the gun.) During operation, open the air control valve to introduce air at the correct volume for the desired spray pattern. The gun also has a trigger bail (E) to reduce operator fatigue when spraying large surfaces.

only with the GM 1030 TexSpray 234113 which is designed so the fluid pressure

Fig. 1

AB C

159 Black

TI3101b

158 Blue

Fig. 2

01808

TexSpray Hoses

CAUTION

Use Graco hoses designed for this sprayer. Using other hoses will damage the flow control.

309662 5

Component Description

Compressor Requirements

NOTE: This sprayer requires an external air compres-

sor.

CAUTION

Install an air filter on external air compressor to reduce contamination to spray system.

Air compressor range: 10 scfm to 35 scfm, 30 to 140 psi (0.2--0.97 MPa, 2 to 9.7 bar)

Material

Elastomerics (textured)

Simulated Accoustical

Splatter Coat and Knockdown

Air Requirements* Minimum

Compressor

Size*

30 scfm at 90 psi (0.84 m

0.63 MPa, 6.3 bar)

20 scfm at 60 psi (0.56 m

0.42 MPa, 4.2 bar)

15 scfm at 40 psi (0.42 m

0.28 MPa, 2.8 bar)

/min at

15 HP

5.5 HP

8HP

After first 20 hours of operation and each 100 hours thereafter: Change oil.

Weekly: Remove engine air filter cover and clean

element. In very dusty environments, check filter daily. Replace element as needed. Replacement elements can be purchased from your local HONDA dealer.

Spark plug: Use only a (NGK) BP6ES or BPR6ES plug. Gap plug to 0.025 to 0.030 in. (0.7 to 0.8 mm). Always use a spark plug wrench.

6 months: Clean Air Flow Sensor as follows:

1. Fig. 3. Loosen adapter (A). Pull down quick release (C) and swing out flow sensor regulator. Disconnect connector (B).

2. Remove inlet fitting (D), retainer ring (E), piston (F ) and spring (G) from flow sensor regulator (H).

CAUTION

Do not scratch or nick piston (F) or inside of flow sensor regulator (H).

Orange Peel 20 scfm at 60 psi

(0.56 m

0.42 MPa, 4.2 bar)

* Material, temperature and volume affect cfm needed to properly atomize material.

/min at

8HP

Maintenance

CAUTION

D For detailed engine maintenance and specifica-

tions, refer to separate HONDA engine manual.

D Close black fuel shutoff lever whenever you are

transporting sprayer to prevent fuel from flooding engine.

D Keep sprayer upright and level when operating it

and when transporting it. This prevents crankcase oil from leaking into combustion chamber, which makes startup very difficult.

3. Clean all parts (D, E, F, G). Clean inside of (H) with a pipe cleaner.

4. Assemble all parts and install flow sensor regulator.

Flow Sensor Regulator

Daily: Check engine oil level and fill as needed.

Daily: Check and fill gas tank.

Daily: Check sprayer air filter, clean and replace

element as needed.

6 309662

D E FG H

Fig. 3

Flow Sensor Regulator

ti4366a

Troubleshooting

WARNING

To reduce risk of injury due to sprayer starting unexpectedly, shut off engine before performing checks or service.

Check everything in chart before disassembling sprayer.

PROBLEM

Engine does not start Engine switch not ON Turn engine switch ON

Engine operates, but displacement pump does not

CAUSE SOLUTION

Outofgas Fill gas tank

Spark plug cable disconnected or spark plug damaged

Oil seepage into combustion chamber

Oil level low Add oil to engine crankcase

Flow control set to OFF Set flow control to PRIME mode or LOW/

Air compressor not on or insufficient air flow from compressor

Air pressure set to low Check display for air pressure. System

Connect spark plug cable or replace spark plug

Remove spark plug. Pull starter rope 3 or 4 times. Clean and install spark plug. Try to start. Keep sprayer upright and do not overfill engine crankcase to avoid oil seepage.

MED/HIGH while triggering gun

Start air compressor Increase SCFM or compressor size. Check air passages and tips for obstruc-

tions. Check air filter element for clogs.

requires a minimum of 40 psi (0.28 MPa,

2.8 bar) to operate. Increase pressure by adjusting air control knob.

Sprayer engine RPM too low Increase engine speed

Clutch connector into back of circuit board is loose.

Air filter dirty Clean or replace filter element.

Air flow sensor dirty or damaged Check air filter.

Air transducer failed Check display for correct air pressure

Fluid transducer failed Check connection at circuit board.

Clutch not engaging Worn or damaged clutch. See page 18.

Displacement pump rod seized by dry coating

Check and ensure a tight connection.

Clean air flow sensor (see page 4) or replace as needed.

reading. Replace circuit board as needed.

Replace fluid transducer.

Fluid transducer failure. Air transducer failure.

Service pump. See page 10.

309662 7

Troubleshooting (Continued)

ispl

(

)

(Continued)

PROBLEM

Engine operates, but

acement pumpdoes not

Continued

Engine operates, displacement pump operates, but no materialpressure at gun.

Low fluid delivery

CAUSE SOLUTION

Connecting rod worn or damaged Replace connecting rod. See page 14.

Drive housing worn or damaged Replace drive housing. See page 15.

Pinion assembly worn or damaged Service pinion assembly . See page 16.

Flow control is set to PRIME Set flow control to LOW/MED/HIGH while

triggering gun.

Fluid system over--pressurized Spraying material is too thick or the mate-

rial hose is too long. Use a less course material or a shorter hose.

Gun nozzle/disk is clogged Check and clean nozzle/disk as needed.

Switch to a larger nozzle/disk.

Material flowing out drain line Check for air leaks to dump valve.

Check dump valve for wear, replace as needed.

Air flow sensor dirty or damaged.

Pump is packed out Disassemble and clean pump (see page

8), hose(s) and gun.

Siphon hose strainer is clogged. Clean or remove strainer

Engine RPM too low Increase engine speed. See Startup,

procedure in operator manual.

Loss of air control or volume at gun

Flow control set too low Increase flow control to MED or HIGH

Hose too long or material too coarse

Change to a shorter hose or less coarse material.

Material flowing out drain line Check drain line for a constant flow of

material when sprayer is operating in LOW/MED/HIGH mode.

Check for air leaks to prime valve. Check dump valve for wear, replace as

needed.

Gun nozzle/disk is clogged Check and clean nozzle/disk as needed.

Switch to a larger nozzle/disk.

Pump is packed out Disassemble and clean pump (see page

8), hose(s) and gun.

Gun air passages clogged with material

After releasing gun trigger, make sure system is fully depressurized before triggering gun again. This helps prevent material backing into gun passages.

Air filter dirty Clean or replace element

Air flow sensor dirty or damaged Check air filter.

Clean air flow sensor (see page 4) or replace as needed.

Displacement pump output

Piston ball (220) not seating Clean piston area. See page 12.

ow on upstroke

Piston packings worn or damaged Replace packings. See page 12.

Siphon hose coupling gasket (1e)

Replace or install gasket

worn or missing.

Pump cylinder o-ring (205) worn or

Replace o-ring

missing

8 309662

Troubleshooting (Continued)

(

)

PROBLEM

Displacement pump output

ow ondownstrokeorbot

strokes Material leaks into wet-cup

Material leaks into wet-cup

Intermittent material flow out of gun

CAUSE SOLUTION

Siphon hose strainer is clogged Clean strainer

Piston packings worn or damaged Replace packings. See page 12.

Intake valve ball (216) not seating properly

Clean and service intake valve. See page 12.

Clutch (9) worn or damaged Replace clutch. See page 18.

Air leak at pump foot valve or siphon tube elbow

Be sure foot valve is tight each day. Be sure seal in elbow is in place and is not worn or damaged.

Loose wet-cup (202) Tighten wet-cup enough to stop leakage

Throat packings worn or damaged Replace packings. See page 12.

Displacement rod (201) worn or

Replace displacement rod. See page 12.

damaged

Material supply is low or empty Refill and prime pump. See Startup proce-

dure in operator manual. Check material supply often to prevent running pump dry .

Air control on gun is set too high. Reduce the air flow through the gun by

turning the air control knob on the back of the gun.

Heavy or poorly atomized mat erial when gun is first triggered (lack of soft start)

Pump does not shut off after gun trigger is released

Premature prime valve failures

Hose too long or material too coarse

Fluid pressure was not allowed to fully self relieve after releasing gun

Change to a shorter hose or less coarse material.

Wait longer between releasing gun trigger and re--triggering.

trigger

Gun was not fully triggered immediately when squeezed, causing gun air passages to clog with material.

Always squeeze trigger fully to prevent just air from turning on, which starts pump and pressurizes hoses. Disassemble and clean gun.

Air valve failure Check and replace as needed

Air flow sensor dirty or damaged Check air filter.

Clean air flow sensor (see page 4) or replace as needed.

Air leaks in the system after the air flow sensor

Check and tighten all connections between the air flow sensor and the gun.

Air leaks in gun Check gun for excessive air leaks and re-

pair. See manual 309661

Air flow sensor dirty or damaged Check air filter.

Clean air flow sensor (see page 4) or replace as needed.

Pump does not shut off after gun trigger is released.

Read “Pump does not shut off after gun trigger is released” and fix appropriate problem.

Repair or replace Prime Valve. See page 19.

309662 9

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