Graco 262300, 258907, 258906, 257100, 262288 User Manual

Repair

Drywall Feed Pump

U.S. Patents Pending: 61/315,288; 61/315/322; 61/316,013; 61/316,010

- For water-based materials only -

- Not for use in explosive atmospheres -

- Not for use with quick-set materials -

READ ALL WARNINGS AND INSTRUCTIONS

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

Maximum Working Pressure 2500 psi (17.2 MPa, 172 bar)

Model 257100: 120V NA ETL Listed Model 258906: 240V Euro Multicord Model 258907: 110V UK, CE Model 262288: 120V NA Model 262300: 240V Euro CE Cord

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ENG

Agency Approvals:

257100 ✓✓✓ 258906 ✓✓ 258907 ✓ 262288 ✓✓ 262300 ✓✓

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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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

WARNINGWARNINGWARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. 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-wire extension cords.

• Ensure ground prongs are intact on power and extension cords.

• Do not expose to rain. Store indoors.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, 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.

• Engage trigger lock when not dispensing.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

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

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing

equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

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 dispense flammable or combustible materials near an open flame or sources of ignition such as cigarettes,

motors, and electrical equipment.

• Material 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 material or solvent fumes. All parts of the system, including the pump, hose assembly, dispenser, and objects in and around the work area shall be properly grounded to protect against static discharge and sparks. Use Graco conductive or grounded high-pressure airless material 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-2 adapter.

• Do not use a material or a solvent containing halogenated hydrocarbons.

• Keep work area well-ventilated. Keep a good supply of fresh air moving through the area. Keep pump assembly in

a well ventilated area.

• Do not smoke in the work area.

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

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

• Know the contents of the materials and solvents being dispensed. Read all Material Safety Data Sheets (MSDS)

and container labels provided with the materials and solvents. Follow the material and solvents manufacturer’s safety instructions.

• Fire extinguisher equipment shall be present and working.

• Drywall feed pump generates sparks. When flammable liquid is used in or near the drywall feed pump or for

flushing or cleaning, keep unit at least 20 feet (6 m) away from explosive vapors.

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Warning

WARNING

WARNINGWARNINGWARNING

MOVING PARTS HAZARD

Moving parts can pinch, cut 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 and disconnect all power sources.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

• Do not operate or dispense 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 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.

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

• Do not kink or over-bend the 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.

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such

solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

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, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

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Pressure Relief Procedure

1. Turn flow control knob to fully counterclockwise to OFF position.

3. Turn prime valve handle to PRESSURE RELIEF position.

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2. Place deflector in hopper or suitable container.

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bar/psi

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4. Display will read “----” when all pressure is relieved.

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Drive and Bearing Housing

NOTICE

Do not drop gear cluster (17a) when removing drive housing (5a). Gear cluster may stay engaged in motor front end bell or drive housing.

Removal

1. Perform Pressure Relief Procedure, page 4.

2. Remove Power Module, see page 7.

3. Remove Pump, page 8.

4. Remove four screws (40) and lift motor shroud (98) off of motor.

6. Remove two screws (5b) from underneath motor base plate. Lift and remove motor/pump assembly from power module.

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7. Loosen four screws (19) on pump housing, and remove bearing housing (9) from motor.

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8. Remove three screws (5c) on motor (8a). Remove motor (8a) from drive housing (5a).

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5. Disconnect three wire harnesses (see Wiring Diagrams, pages 34-36).

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Drive and Bearing Housing

Installation

1. Apply brown lithium grease supplied with drive housing kit (5) to gear cluster (17a) and inside of motor cavity.

17a

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2. Align orientation tab on gear housing with slot on motor and slide gears into motor.

3. Replace and tighten three screws (5c) on motor (8a). Torque to 200-220 in-lb.

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5. Replace motor/pump assembly into pump module. Replace and tighten two screws (5b) underneath motor base plate. Torque to 200 - 220 in-lb.

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6. Reconnect three wire harnesses (see Wiring Diagrams, pages 34-36).

7. Replace motor shroud (98) and tighten four screws (40). Torque to 30-34 in-lb.

4. Attach bearing housing (9) to gear housing (5a) (slowly turn motor fan by hand to align gear into pump connecting rod). Torque four bearing housing screws (19) to 25-30 ft-lb.

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8. Replace Pump, page 8.

9. Replace Power Module, see page 7.

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Power Module

Removal

1. Perform Pressure Relief Procedure, see page 4.

Unplug power cord.

2. Release hopper adapter clamp (158).

158

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3. Loosen rod clamp knob (112) on front of pump module and push rod down.

112

Installation

1. Remove hopper plug (117) if installed.

2. Replace power (153) module and insert pump outlet into hopper inlet.

153

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3. Pull rod clamp up and tighten knob (112) on front of pump module.

112

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4. Lift and pull power module (153) off of unit.

NOTE: Power module weighs approximately 85 lb.

153

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5. Install hopper plug (117) if needed.

117

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4. Fasten hopper adapter clamp (158).

158

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Pump

Removal

1. Perform Pressure Relief Procedure, see page 4.

2. Remove Power Module, see page 7.

3. Disconnect material hose (79) from pump (18a).

18a

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4. Loosen two screws (40) and remove pump rod shield (48).

7. Use hammer to loosen pump retaining nut (22).

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8. Unscrew and remove pump (18a) from module.

18a

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Installation

1. Extend pump piston rod 1.5 in.

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5. Turn flow control knob to a very low setting and turn prime valve handle to TOOL FILL position (JOG mode will appear in display). Use ON/OFF switch or turn control knob OFF to stop pump when pin is visible.

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6. Use screwdriver to press pin (7b) out of pump.

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NOTE: Pin should be removed by pressing the pin out through the bottom side of the pump. Make sure to control the pump pin when removing so that it does not fall into the pump module.

1.5 in.

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2. Install pump pin (7b). Verify retaining spring is in groove of connecting rod.

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NOTE: Pin should be installed from the top side of the pump. Make sure to control the pump pin when installing so that it does not fall into the pump module.

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Pump

3. Push pump up until pump threads engage.

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4. Screw in pump until threads are flush with drive housing opening.

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5. Align pump outlet to right side so that hose can be reassembled.

7. Replace pump rod shield (48) and torque two screws (40) to 30 - 34 in-lb.

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8. Reconnect material hose (79) to pump (18a).

18a

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9. Replace Power Module, see page 7.

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6. Screw jam nut up toward drive housing 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± 5 ft-lb (102 N•m).

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Motor

Removal

1. Perform Pressure Relief Procedure, see page 4.

2. Remove Power Module, see page 7.

3. Disconnect material hose (79) from pump (18a).

18a

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4. Remove four screws (40) and lift motor shroud (98) off of motor.

7. Loosen four screws (19) on bearing housing (9), and remove from gear housing.

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8. Remove three screws (5c) on motor (8a). Remove motor from gear housing.

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Installation

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5. Disconnect three wire harnesses (see Wiring Diagrams, pages 34-36).

6. Remove two screws (5b) from underneath motor base plate. Lift and remove motor/pump assembly from pump module.

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1. Apply brown lithium grease supplied with motor repair kit (8) to gear cluster (17a) and inside of motor cavity.

17a

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2. Align orientation tab on gear housing with slot on motor and slide gears into motor.

3. Replace three screws (5c) on motor (8a). Torque to 200-220 in-lb.

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10 3A0246C

Motor

4. Attach bearing housing (9) to gear housing (5a) (slowly turn motor fan by hand to align gear into pump connecting rod). Torque four bearing housing screws (19) to 25-30 ft-lb.

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5. Replace motor/pump assembly into pump module. Replace and torque two screws (5b) underneath motor base plate to 200 - 220 in-lb.

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6. Reconnect three wire harnesses (see Wiring Diagrams, pages 34-36).

7. Replace motor shroud (98) and torque four screws (40) to 30 - 34 in-lb.

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8. Reconnect material hose (79) to pump (18a).

18a

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9. Replace Power Module, see page 7.

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Motor Control Board

Removal

120V Models:

1. Perform Pressure Relief Procedure, see page 4.

Wait 5 minutes before servicing.

2. Remove Power Module, see page 7.

3. Disconnect material hose (79) from pump (18a).

18a

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4. Remove four screws (40) and lift motor shroud (98) off of motor.

6. Disconnect display connector (A) from motor control board (24) and remove display.

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7. Remove bottom two screws (61) and remove control panel (37).

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8. Disconnect Prime/Tool Fill/Recirculate reed switch connector (E) from motor control board (24).

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5. Remove four screws (33b) and display cover (33k).

33k

33b

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9. Disconnect potentiometer connector (C) from motor control board (24).

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10. Disconnect 15/20A switch connector (X) from motor control board (24).

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