Repair
Electric Airless Sprayer
- For the application of architectural paints and coatings -
- For professional use only -
Model 278680
3300 psi (22.7 MPa, 227 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
332257A
EN
ti21026a
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification . . . . . . . . . . . . . . . . . . . . 5
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Requirements . . . . . . . . . . . . . . . . . . . . . 6
Extension Cords . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 8
General Repair Information . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Displacement Pump Replacement . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive Housing Replacement . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ON/OFF Switch/Power Cord Board Kit . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Motor Control Board . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Motor Control Diagnostics . . . . . . . . . . . . . . . . . . 21
Pressure Control Transducer . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pressure Adjust Potentiometer . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28
2 332257A
Warnings
Warnings
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 or on warning labels, 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
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-pressure airless paint sprayer hoses.
• Verify that all containers and collection systems are grounded to prevent static discharge. Do not use pail
liners unless they are are antistatic or conductive.
• Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2 adapter.
• 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.
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.
• Connect only to 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
• Wait five minutes after disconnecting power cord before servicing large capacitor units.
332257A 3
Warnings
WARNING
WARNINGWARNINGWARNING
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.
•
Do not spray without tip guard and trigger guard installed.
•
Engage trigger lock when not spraying.
•
Do not point gun at anyone or at any part of the body.
•
Do not put your hand over the spray tip.
•
Do not stop or deflect leaks with your hand, body, glove, or rag.
•
Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equip-
ment.
•
Tighten all fluid connections before operating the equipment.
•
Check hoses and couplings daily. Replace worn or damaged parts immediately.
EQUIPMENT MISUSE HAZAR
Misuse can cause death or serious injury.
•
Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•
Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See
Tec hni cal D ata in all equipment manuals.
•
Use fluid and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS
from distributor or retailer.
•
Do not leave the work area while equipment is energized or under pressure.
•
Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
•
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
•
Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.
•
Make sure all equipment is rated and approved for the environment in which you are using it.
•
Use equipment only for its intended purpose. Call your distributor for information.
•
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•
Do not kink or over bend hoses or use hoses to pull equipment.
•
Keep children and animals away from work area.
•
Comply with all applicable safety regulations.
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.
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 MSDSs 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
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing
loss, inhalation of toxic fumes, and burns. This protective 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.
4 332257A
Component Identification
Component Identification
T
S
A
B
N
M
C
R
P
D
ps
K
E
A Pressure control
BPower Cord
C ON/OFF switch
D Digital Display
E Prime/Spray valve
FFilter
G Fluid outlet
H Siphon tube
F
HJ
G
ti21027a
J Drain tube
KPump
MHose
NSpray Gun
PSwitch Tip
R Tip Guard
S Trigger lock
T Serial Tag
332257A 5
Grounding
Grounding
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes to
ignite or explode. Grounding provides an escape wire
for the electric current.
Sprayer Cord: The sprayer cord includes a grounding
wire with an appropriate grounding contact.
Air and fluid hoses: use only electrically conductive
hoses with a maximum of 500 ft. (150 m) combined hose
length to ensure grounding continuity. Check electrical
resistance of hoses. If total resistance to ground
exceeds 29 megohms, replace hose immediately.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Fluid supply container: follow local code.
The plug must be plugged into an outlet that is properly installed and grounded in accordance with all
local codes and ordinances.
ti11730a
Do not modify plug! If it will not fit in outlet, have
grounded outlet installed by a qualified electrician.
Do not use an adapter.
Power Requirements
230V units require 220-240 VAC, 50/60 Hz, 8A, 1 phase.
Object being sprayed: follow local code.
Extension Cords
If an extension cord is necessary, use a 3-wire, 12 AWG
2
(2.5 mm
) minimum.
6 332257A
Pails
Grounding
Solvent and oil/based fluids: follow local code. Use
only conductive metal pails, placed on a grounded surface. Do not place the pail on a nonconductive surface,
such as paper or cardboard, which interrupts grounding
continuity.
ti5850b
Grounding a metal pail: connect a ground wire to the
pail by clamping one end to pail and other end to a true
earth ground such as a water pipe.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of spray gun firmly
to side of a grounded metal pail. Then trigger gun.
TIAB
ti5851a
332257A 7
Pressure Relief Procedure
WASTE
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning,
checking, or servicing the equipment.
1. Turn power OFF and unplug sprayer.
ti2707a
ti11730a
2. Turn pressure to lowest setting. Trigger gun to
relieve pressure. Turn prime valve down.
ti21028a
ti2599a
WASTE
3. If you suspect spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following these steps,
VERY SLOWLY
loosen
tip guard retaining nut or hose end coupling to
relieve pressure gradually, then loosen completely.
Now clear tip or hose obstruction.
ti2719a
8 332257A
General Repair Information
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.
General Repair Information
• Install motor shroud before operation of sprayer and
replace if damaged. Motor shroud directs cooling air
around motor to prevent overheating. It can reduce
risk of burns, fire or explosion, or cut fingers.
NOTICE
To reduce risk of pressure control malfunction:
• Use needle nose pliers to disconnect wire. Never
pull on wire, pull on connector.
• Mate wire connectors properly. Center flat blade
of insulated male connector in female connector.
• Route wires carefully to avoid interference with
other connections or pressure control. Do not
pinch wires between cover and control box.
• 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 Trouble-
shooting, page 10.
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.
NOTICE
• 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-base paint 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.
332257A 9
Loading...