Page 1
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
Page 2
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
Page 3
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
Page 4
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
Page 5
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
Page 6
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
Page 7
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
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332257A 7
Page 8
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
Page 9
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
Page 10
Troubleshooting
Troubleshooting
Type of Problem
What to Check
(if check is OK, go to next)
What to Do
(When check is not OK, refer to this
column)
Basic fluid pressure problems Pressure control knob setting. Motor
will not run if at minimum setting (fully
counter-clockwise).
Spray tip or fluid filter may be
clogged.
Basic Mechanical Problems Pump frozen or paint hardened in
pump.
Displacement pump connecting rod
pin must be completely pushed into
connecting rod and retaining spring
must be firmly in groove of pump pin.
See page 15.
Motor. Remove drive housing assembly. See page 17. Try to rotate fan by
hand.
Motor control board. Board shuts
down and displays error code.
Slowly increase pressure to see if
motor starts.
Relieve pressure, page 8 and clear
clog, or clean filter; refer to separate
gun or tip instruction manual.
Thaw sprayer if water or water-based
paint has frozen in sprayer. Place
sprayer in warm area to thaw. Do not
start sprayer until thawed completely.
If paint hardened (dried) in sprayer,
replace pump packings. See Dis-
placement Pump Replacement,
page 15.
Push pin into place and secure with
spring retainer.
Replace motor if fan won’t turn. See
page 17.
See Motor Control Board Diagnos-
tics, page 21.
10 332257A
Page 11
Type of Problem
What to Check
(if check is OK, go to next)
Troubleshooting
What to Do
(When check is not OK, refer to this
column)
Basic Electrical Problems Electric supply. Meter must read:
• 210-255 VAC for 220-240V
models
Extension cord. Check extension
cord continuity with volt meter.
Sprayer power supply cord. Inspect
for damage such as insulation or
wires.
Motor leads are securely fastened
and properly mated.
NOTE: For the following electric
problems, refer to Wiring Diagram,
page 24, to identify Test Points (TP).
Power supply cord. Connect volt
meter between L1 and L2. Plug in
sprayer. Meter must read:
• 210-255 VAC for 220-240V
models
Unplug sprayer.
ON/OFF Switch. Connect volt meter
between L1 and L2 terminal on
ON/OFF switch. Plug in sprayer and
turn ON. Meter must read:
Reset building circuit breaker.
Replace building fuse. Try another
outlet.
Replace extension cord.
Replace power supply cord, page 24.
Replace loose terminals; crimp to
leads. Be sure terminals are firmly
connected.
Clean circuit board terminals.
Securely reconnect leads.
Replace power supply cord, page 24.
Replace ON/OFF switch. See page
19.
• 210-255 VAC for 220-240V
models
All terminals for damage or loose fit. Replace damaged terminals and
reconnect securely.
332257A 11
Page 12
Troubleshooting
What to Do
Type of Problem
What to Check
(if check is OK, go to next)
(When check is not OK, refer to this
column)
Low Output For worn spray tip. Relieve pressure, page 8. Then
replace tip. See your separate gun
manual for additional instruction.
Verify pump does not continue to
Service pump. See page 15.
stroke when gun trigger is released.
Filter clogged. Relieve pressure, page 8. Check
and clean filter.
Prime valve leaking. Relieve pressure, page 8. Repair
prime valve.
Suction hose kinks and/or loose
connection.
Electric supply with volt meter. Low
voltages reduce sprayer
performance. Meter must read:
Correct kink and/or tighten any loose
connections.
Reset building circuit breaker;
replace building fuse. Repair
electrical outlet or try another outlet.
• 210-255 VAC for 220-240V
models
Extension cord size and length; must
be at least 12 gauge wire and no
Replace with a correct, grounded,
extension cord.
longer than 300 ft. Longer cord
lengths reduce sprayer performance.
Low Output Leads from motor to pressure control
circuit board for damaged or loose
wires or connectors. Inspect wiring
insulation and terminals for signs of
overheating.
Be sure male terminal blades are
centered and firmly connected to
female terminals. Replace any loose
terminal or damaged wiring. Securely
reconnect terminals.
Low stall pressure. Do either or both:
a. Turn pressure control knob
fully clockwise. Make sure
pressure control knob is
properly installed to allow full
clockwise position.
b. Try a new transducer.
12 332257A
Page 13
What to Do
Type of Problem
What to Check
(if check is OK, go to next)
(When check is not OK, refer to this
column)
Motor runs and pump strokes Low paint supply. Refill and reprime pump.
Intake strainer clogged. Remove and clean, then reinstall.
Suction tube or fittings loose. Tighten; use thread sealant or
sealing tape on threads if necessary.
See if intake valve ball and piston ball
are seating properly. See pump
manual.
Remove intake valve and clean.
Check balls and seats for nicks,
replace if necessary. Strain paint
before using to remove particles that
could clog pump. See pump manual.
Leaking around throat packing nut
which may indicate worn or damaged
packings. See pump manual.
Replace packings. Also check piston
valve seat for hardened paint or nicks
and replace if necessary. Tighten
packing nut/wet-cup. See pump
manual.
Pump rod damage. Replace pump, page 15.
Motor runs but pump does not stroke Displacement pump pin damaged or
missing.
Replace pump pin if missing. Be sure
retainer spring is fully in groove all
around connecting rod, page 15.
Connecting rod assembly damaged. Replace connecting rod assembly.
See pump manual.
Gears or drive housing, page 17. Inspect drive housing assembly and
gears for damage and replace if
necessary, page 17.
Motor is hot and runs intermittently Determine if sprayer was operated at
high pressure with small tips, which
Decrease pressure setting or
increase tip size.
causes low motor RPM and
excessive heat buildup.
Be sure ambient temperature where
sprayer is located is not more than
Move sprayer to shaded, cooler area
if possible.
90°F (32.22°C) and sprayer is not
located in direct sun.
Troubleshooting
332257A 13
Page 14
Troubleshooting
Type of Problem
What to Check
(if check is OK, go to next)
What to Do
(When check is not OK, refer to this
column)
Building circuit breaker opens as
soon as sprayer switch is turned on
CAUTION
Any short in any part of the motor
power circuit will cause the control
circuit to inhibit sprayer operation.
Correctly diagnose and repair all
shorts before checking and replacing
control board.
Building circuit breaker opens as
soon as sprayer is plugged into outlet
and sprayer is NOT turned on.
Sprayer quits after sprayer operates
for 5 to 10 minutes.
All electrical wiring for damaged
insulation and all terminals for loose
fit or damage. Also, wires between
pressure control and motor. See
page 20.
For missing inspection plate gasket,
see page 22, bent terminal forks or
other metal to metal contact points
which case a short.
Motor control board by performing
control board diagnostics. See page
15. If diagnostics indicate, substitute
with a good board.
NOTICE: Do not perform this check
until motor armature is determined to
be good. A bad motor armature can
burn out a good board.
Basic Electric Problems, page 10 of
Troubleshooting.
ON/OFF switch. See page 19.
Be
sure sprayer is unplugged!
Disconnect wires from switch. Check
switch with ohmmeter. Reading must
be infinity with ON/OFF switch OFF,
and zero when switch is ON.
For damaged or pinched wires in
pressure control. See page 22.
Basic Electric Problems, page 10 of
Troubleshooting.
Electrical supply volt meter. Meter
must read:
Repair or replace any damaged
wiring or terminals. Securely
reconnect all wires.
Correct faulty conditions.
Replace with a new pressure control
board. See page 22.
Perform necessary procedures.
Replace ON/OFF switch. See page
19.
Replace damaged parts. See page
22.
Perform necessary procedures.
If voltage is too high, do not operate
sprayer until corrected.
14 332257A
• 210-255 VAC for 220-240V
models
Tightness of pump packing nut. Over
tightening tightens packings on rod,
restricts pump action, and overloads
motor.
Loosen packing nut. Check for
leaking around throat. Replace pump
packings, if necessary. See pump
manual.
Page 15
Displacement Pump Replacement
Displacement Pump Replacement
See manual 309250 for pump repair instructions.
Removal
1. Cycle motor until pump pin (32)is in position to be
removed.
32
ti21089a
2. Perform Pressure Relief Procedure, page 8.
3. Loosen screws (12). Push cover (70) up and pull off
sprayer.
12
5. Using a flat screwdriver, push retaining spring (31)
up. Push out pump pin (32).
31
32
6. Loosen pump jam nut (29). Unscrew and remove
pump (41).
29
ti21093a
70
ti21095a
4. Remove suction tube (60) and hose (45).
45
60
ti21096a
41
ti21094a
332257A 15
Page 16
Displacement Pump Replacement
Installation
If pump pin works loose, parts could break off due to
force of pumping action, project through the air, and
result in serious injury or property damage. To avoid,
ensure the retainer spring is installed properly.
NOTICE
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 (A) or inside connecting rod (43). Install
jam nut (29) on pump threads.
43
A
5. Screw in pump until threads are flush with top of
drive housing opening.
ti6111a
6. Align pump outlet (P) to back.
P
ti21087a
7. Turn jam nut (29) counter-clockwise until it 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).
29
29
ti21094a
2. Install pump rod (A) into connecting rod (43).
43
A
ti21094a
3. Install pump pin (32). Slide retainer spring (31)
down into groove over pump pin.
31
ti21097a
8. Install suction tube (60) and high pressure hose
(45). Tighten fittings.
45
60
ti21096a
9. Fill packing nut with Graco TSL until fluid flows onto
top of seal.
32
4. Push pump (41) up until pump threads engage.
16 332257A
ti21086a
10. Replace cover (70) over screws. Push cover down
into place. Tighten screws (12).
Page 17
Drive Housing Replacement
Drive Housing Replacement
NOTICE
Do not drop gear cluster (44) and (40) when removing
from drive housing (42). Gear cluster may stay
engaged in motor front end bell or drive housing.
Removal
23
117
12
54
A
ti21090a
10
1. Perform Pressure Relief Procedure, page 8.
2. Remove pump (41), Displacement Pump
Replacement, page 15.
3. Remove screws (12) from front cover (22).
4. Remove bracket (147) and screw (148).
5. Remove screws (47).
6. Pull drive housing (42) off motor (54).
7. Remove gear cluster (44) and (40) and thrust
washer (25) from drive housing.
8
40
9
1
10
44
25
42
147
148
12
43
Installation
1. Apply a heavy coat of grease to gears and needle
bearing surfaces.
2. Install washers (8, 10) on back of gear (40). Install
gear in motor end bell. Using grease for retention,
place washer (10) over bearing inside housing (42).
3. Install washers (1, 9) on back of gear (44). Install in
motor endbell.
4. Install thrust washer (25) on gear (44).
332257A 17
5. Push drive housing (42) on motor endbell as you
guide gear crank (44) through hole in connecting
rod (43).
6. Install screws (47). Torque to 16 - 18 N•m.
7. Install bracket (147) and screw (148).
Torque to 16 - 18 N•m.
8. Install cover (22) and screws (12).
Torque to 1 - 1.2 N•m.
9. Install pump (41); Displacement Pump
Replacement, page 15.
47
70
12
22
Page 18
Fan Replacement
Fan Replacement
Removal
1. Perform Pressure Relief Procedure, page 8.
Unplug power cord.
2. Remove four screws (12) and shroud (23).
3. Loosen tensioning screw (126) on fan (125).
4. Pull off fan (125).
Installation
1. Slide new fan (125) in place on back of motor. Be
sure blades of fan face motor as shown.
2. Tighten screw (126). Torque to 1 - 1.2 N•m.
3. Replace shroud (23) and four screws (12).
Torque to 1 - 1.2 N•m.
23
117
12
12
ti21091a
125
126
18 332257A
Page 19
ON/OFF Switch/Power Cord Board Kit
ON/OFF Switch/Power Cord Board Kit
Removal
1. Perform Pressure Relief Procedure, page 8.
Unplug power cord.
2. Remove four screws (12) and control box cover
(51).
Power Cord
3. Remove green ground screw (6) and disconnect
blue and black leads.
4. Slide black power cord strain relief out of slot in
control box (48) to remove it.
ON/OFF Switch
5. Remove switchboard mounting screw (128).
6. Using a 5/8 in. deep socket wrench, remove
ON/OFF switch toggle boot (58).
7. Slide switch (30) through opening in control box
housing.
8. Disconnect black and blue leads between control
boards.
9. Remove switch board from box.
Installation
1. Reconnect black and blue leads between control
and switch boards.
2. Slide ON/OFF switch (30) through opening in control box housing and position switch board.
3. Place toggle boot (58) over ON/OFF switch. Use a
5/8 in. deep socket wrench to tighten securely.
4. Install switchboard mounting screw (128).
Torque to no more than 2.0 N•m.
5. Slide power cord strain relief into opening in control
box (48).
6. Reattach black and blue power cord leads to control
and switch boards.
7. Replace power cord and ground lead and tighten
green ground screw (6). Torque to 3.4 - 4.0 N•m.
8. Install pressure control cover (51) with four screws
(12). Torque to 3.4 - 4.0 N•m.
129
37
56
58
30
128
12
6
127
113
105
51
11
37a
47
49
5
54
20
48
38
3
15
ti21088a
332257A 19
Page 20
Motor Control Board
Motor Control Board
Installation
1. Connect motor control enclosure to transducer (38)
and tighten two screws (47).
NOTE: See Wiring Diagram, page 24.
Removal
1. Perform Pressure Relief Procedure, page 8, and
unplug sprayer.
2. Remove four screws (12) and remove display cover
(51).
3. Remove four screws (12) and remove motor shroud
(23).
4. Disconnect motor and thermistor connections.
5. Disconnect pressure transducer (J11) from board.
6. Disconnect potentiometer lead (J12) from board.
7. Remove ground screw (6). Unplug brown and blue
power cord leads from control board and slide
power cord out of strain relief to remove cord.
8. Remove two screws (47) and remove motor control
enclosure. Pull motor control enclosure to the left to
remove from transducer (38).
2. Route power cord through strain relief and connect
brown and blue cord leads to control board. Install
and tighten ground screw (6).
Torque to 3.4 - 4.0 N•m.
3. Connect potentiometer lead (J12) to board.
4. Connect pressure transducer (J11) to board.
5. Install motor shroud (23) and tighten four screws
(12). Torque to 1.0 - 1.2 N•m to prevent stripping
plastic bracket.
6. Install display cover (51) and tighten four screws
(12) to 3.4 - 4.0 N•m.
20 332257A
Page 21
Motor Control Diagnostics
NOTE:
• Keep a new transducer on hand to use for test.
• No display does not mean the sprayer is not pressurized. Before repair, perform Pressure Relief
Procedure, page 8.
Motor Control Diagnostics
NOTICE
Do not allow sprayer to develop fluid pressure without
transducer installed. Leave drain valve open if test
transducer is used.
1. For sprayers with digital display, see Digital Display
Messages.
2. Remove screws (12) and cover (50).
3. Turn ON/OFF switch ON.
4. Observe LED operation and reference following
table:
DISPLAY
No Display Never
psi/bar/MPa Once Sprayer is pressurized.
E=02 Two times
E=03 Three times
E=05 Five times
E=06 Six times
- - - Power is applied. Pressure less than 200
E=10 Blinks 10
LED
BLINKS
blinks
repeatedly
repeatedly
repeatedly
repeatedly
times
repeatedly
SPRAYER OPERATION INDICATES WHAT TO DO
Sprayer stops. Power is not
applied. Sprayer must be
pressurized.
Power is applied. (Pressure
varies with tip size and pressure control setting.)
Sprayer may continue to run.
Power is applied.
Sprayer shuts down and LED
continues to blink three times
repeatedly
Sprayer does not start or
stops and LED continues to
blink five times repeatedly.
Power is applied.
Sprayer stops and LED
blinks six times repeatedly.
Power is applied.
Sprayer does not start or
stops and LED continues to
blink 10 times repeatedly.
Power is applied.
Loss of power. Check power source. Relieve pres-
Normal operation Do nothing
Run away pressure.
Pressure greater than
4500 psi (310 bar, 31
MPa) or damaged pressure transducer
Pressure transducer is
faulty or missing
Motor fault Check for locked rotor, shorted wiring
Motor is too hot or there
is a fault in motor thermal device
psi (14 bar, 1.4 MPa).
High control board temperature.
sure before repair or disassembly.
Replace motor control board or pressure transducer
Check transducer connection. Open
drain valve. Substitute new transducer
for transducer in sprayer. If sprayer
runs, replace transducer
or disconnected motor. Repair or
replace failed parts.
Allow sprayer to cool. If sprayer runs
correctly when cool, check motor fan
function and air flow. Keep sprayer in
cool location. If sprayer does not run
when cool and continues to blink six
times, replace motor.
Increase pressure if desired. Drain
valve may be open.
•
Make sure motor air intake in not
blocked.
•
Make sure control board is properly
connected to the back plate and
that conductive thermal paste is
used on the power components.
332257A 21
Page 22
Pressure Control Transducer
Pressure Control Transducer
Removal
1. Perform Pressure Relief Procedure, page 8.
Unplug power cord.
2. Remove screws (12) and cover (51).
3. Disconnect transducer lead from motor control
board (48).
4. Remove two screws (47) and remove filter housing.
Pull transducer to the right to remove from control
box housing (48).
5. Remove pressure control transducer (38) and o-ring
(3) from filter housing (15).
Installation
1. Install o-ring (3) and pressure transducer (38) into
filter housing (15). Torque to 50 - 58 ft-lb.
2. Thread transducer lead plastic connector through
transducer grommet (20) and slide grommet into
slot in control box housing (48).
3. Install filter housing (15) with screws (47).
Torque to 17 N•m.
Pressure Adjust Potentiometer
Removal
1. Perform Pressure Relief Procedure, page 8.
Unplug power cord.
2. Remove screws (12) from cover (51).
3. Disconnect potentiometer lead from motor control
board (48).
4. Remove potentiometer knob (11), o-ring (129), nut
(37a) and pressure adjust potentiometer (37).
Installation
1. Install pressure adjust potentiometer (37) and nut
(37a).
a. Turn potentiometer fully clockwise.
b. Install knob (11) at full clockwise position.
2. Connect potentiometer lead (J12) to motor control
board (48). See Wiring Diagram, page 24.
3. Install cover (51) with screws (12). Torque to 3.4 -
4.0 N•m.
4. Connect transducer lead (J11) to motor control
board (48).
5. Install cover (51) with screws (12).
Torque to 3.4 - 4.0 N•m.
SmartControl
The SmartControl contains stored data to assist with
troubleshooting and maintenance. To view this stored
data on the digital display:
1. Perform Pressure Relief Procedure, page 8.
2. Plug in sprayer.
3. Hold down display button and turn sprayer ON.
Data Point Definition
1 Serial Number of sprayer.
2 Number of hours motor has been running.
3 Last error code. Press and hold display button to clear error code to E=00
4 Software revision
4. Release display button about 1 second after turning
on sprayer. Sprayer model number displays for a
few seconds and then data point 1 is displayed.
5. Push display button and next data point displays.
6.
Turn sp
rayer OFF and then ON to exit stored
mode.
data
22 332257A
Page 23
Motor Replacement
Motor Replacement
NOTICE
Do not drop gear cluster (44) and (40) when removing
from drive housing (42). Gear cluster may stay engaged
in motor front end bell or drive housing.
Removal
1. Perform Pressure Relief Procedure, page 8. Unplug
power cord.
2. Remove four screws (12) and shroud (23).
3. Remove two screws (12) and front cover (22)
4. Remove pump (41); Displacement Pump
Replacement, page 15.
5. Remove drive housing (42); Drive Housing
Replacement, page 17.
6. Disconnect motor leads and thermistor leads.
7. Remove screws (47) and manifold (15).
8. Remove screws (47) and control box (48).
9. Remove two screws (12) and remove shroud bracket
(117).
10. Remove screws (47) and motor (54) from frame (59).
Installation
1. Install new motor (54) on frame (59) with screws (47).
Torque to 16.0 - 18.0 N•m
2. Install control housing (48) with screws (47).
Torque to 16.0 - 18.0 N•m
3. Install manifold (15) with screws (47).
Torque to 16.0 - 18.0 N•m
4. Connect motor leads. See Wiring Diagram on page
24.
5. Install shroud bracket (117) and tighten screws (12).
Torque to 3.4 - 4.0 N•m
6. Install drive housing (42); Drive Housing
Replacement, page 15.
7. Install pump (41); Displacement Pump
Replacement, page 15.
8. Replace front cover (22) and screws (12).
Torque to 3.4 - 4.0 N•m
9. Replace shroud (23) and screws (12). Torque to
1.0 - 1.2 N•m to prevent stripping shroud bracket (117).
.
.
.
.
.
23
117
12
12
48
127
47
12
47
15
59
ti21092a
12
54
40
44
22
12
41
332257A 23
47
Page 24
Wiring Diagram
Wiring Diagram
MOTOR
DIGITAL DISPLAY
BROWN
POWER PLUG
BLUE
GREEN
BLACK
BLUE
ON/OFF
SWITCH
POTENTIOMETER
TRANSDUCER
ti21098a
24 332257A
Page 25
Notes
Notes
332257A 25
Page 26
Notes
Notes
26 332257A
Page 27
Notes
Notes
332257A 27
Page 28
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-Graco component 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
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.
. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call 1-800-690-2894 to identify the nearest distributor.
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.
For patent information, see www.graco.com/patents.
Original instructions.
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2012, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
This manual contains English. MM 332257
Graco Headquarters: Minneapolis
www.graco.com
Revision A - February 2013
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