Page 1
Repair and Parts
RTX 1500 Electric Texture Sprayer
U.S. Patent No. D580,517S
Europe Patent No. 1511575
- For Water-Based Materials Only -
(Consult your Material Supplier for Warnings and Application Requirements)
Models: Page 2
Maximum Working Air Pressure: 45 psi (3.1 bar)
Maximum Working Fluid Pressure: 100 psi (6.9 bar)
Read all warnings and instructions.
310645K
NOTICE
Use RTX 1500 non-bleeder texture gun 248091. All
other guns will damage sprayer.
ti4305a
Graco Inc. P.O. Box 1441 Minneapolis, MN
55440-1441
www.graco.com
Copyright 2004
Page 2
Models
Models
Manual
Model Electric
Requirements
248201 120V, 60 Hz, 15 A N. America 310624 310694 310616 English
248370 / 248315 230V. 50 Hz, 10 A Europe 310624 310616 French
248370 230V. 50 Hz, 10 A Europe 310624 Dutch
248370 230V. 50 Hz, 10 A Europe 310625 310616 Spanish
248370 / 248315 230V. 50 Hz, 10 A Europe 310625 Italian
248370 230V. 50 Hz, 10 A Europe 310625 Portuguese
248370 / 248315 230V. 50 Hz, 10 A Europe 310625 German
248315 230V. 50 Hz, 10 A Europe 310697 Swiss
248315 230V. 50 Hz, 10 A Europe 310697 Danish
248370 230V. 50 Hz, 10 A Europe 310697 Norwegian
248370 230V. 50 Hz, 10 A Europe 310697 Swedish
248370 230V. 50 Hz, 10 A Europe 310698 Polish
248370 230V. 50 Hz, 10 A Europe 310698 Russian
248370 230V. 50 Hz, 10 A Europe 310698 Greek
Country
Operation
287328*
Gun
Languages
248315 230V. 50 Hz, 10 A Asia 310699 Chinese
248315 230V. 50 Hz, 10 A Asia 310699 Japanese
248315 230V. 50 Hz, 10 A Asia 310699 Korean
248315 230V. 50 Hz, 10 A Australia 310699 310694 310616 English
*Auxiliary Air Hookup Kit
RELATED MANUALS
Model Country Manual Languages
ALL ALL
310645 English
2 310645K
Page 3
Warnings
The following are general Warnings 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
WARNING
This symbol alerts you to the possibility of serious injury or death if you do not follow the
instructions.
Caution
CAUTION
Alerts you to the possibility of damage or destruction
of equipment if you do not follow the instructions.
Warnings
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:
• Use equipment only in well ventilated area.
• Keep work area free of debris, including solvent, rags, and gasoline.
• Ground equipment in the work area. See Grounding instructions.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
Equipment Misuse Hazard
Equipment misuse can cause death or serious injury.
• Do not exceed maximum working pressure or temperature rating of lowest rated system compo-
nent. See Technical Data, in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not alter or modify this equipment.
• Use the equipment only for its intended purpose. Call your Graco distributor for information.
• For professional use only.
• Route hoses away from traffic areas, sharp edges, moving parts and hot surfaces.
• Do not use hoses to pull equipment.‘
•
• Comply with all applicable safety regulations.
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-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
310645K 3
Page 4
Warnings
WARNINGS
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 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.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
Cleaning Solvent Hazard with Plastic Parts
Use only compatible water-based solvents to clean plastic structural or pressure-containing parts. Many
solvents can degrade plastic parts to the point where they could fail. Such failure could cause serious
injury or property damage. See Technical Data on page 34 of this instruction manual and in all other
equipment manuals. Read fluid and solvent manufacturer’s warnings.
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.
Personal Protective Equipment
Wear appropriate protective equipment when operating, servicing or when in the operating area of this
equipment to help protect yourself 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 fluid and solvent manufacturer
• hearing protection
•gloves
CAUTION
Water or material remaining in unit when temperatures are below freezing can damage pump and/or delay startup.
To insure water and material are completely drained out of unit:
• remove hose from material outlet,
• tip sprayer forward 45° to allow material (water) to flow out of pump inlet.
Before adding material or starting unit in cold weather, circulate warm water through pump.
4 310645K
Page 5
Component Identification
Component Identification
B
C
R
P
K
A
E
F
ti4500a
S
D
H
U
W
M
V
310645K 5
L
T
Page 6
Component Identification
Component Identification
ITEM
A Main Power Switch
B Nozzle Storage
C Hopper
D Hopper Connect/Disconnect
E Graco RotoFlex™ HD Pump
F Material Outlet
H Air Outlet
K Fluid Flow Regulator and Pressure Gauge
L Gun Nozzle (5 sizes)
M Gun (see manual 310616)*
PPrime Switch
RPower Cord
S Pump Access Screw
T Hose - 25-ft.
COMPONENT
U Material Thickness Gauge
V Cleaning Ball
W Spare Hose Gaskets
6 310645K
Page 7
Preparation
Preparation
Pressure Relief Procedure
1 Turn Main Power Switch
(A) OFF.
2 Turn fluid flow regulator
(K) all the way down to
reduce pressure.
3 Open gun air valve (aa).
ti4303a
Grounding and Electric Requirements
The sprayer must be grounded. Grounding reduces the
risk of electrical shock by providing an escape wire for
the electrical current.
WARNING
Read warnings, page 3.
• The sprayer cord includes a
grounding wire with an appro-
K
priate grounding prong.
• The plug must be plugged into
an outlet that is properly
installed and grounded in
accordance with all local codes
A
and ordinances.
Ground
ti4295a
ti4296a
4 Trigger gun, spraying
material back into
hopper (C).
ti4000a
ti4294a
• Do not modify plug! If it will not
fit in outlet, have grounded outlet installed by a qualified electrician.
• Sprayer model electric requirements are provided on page 2.
Extension Cords
• Only use an extension cord with
an undamaged 3-prong plug.
• For up to 100 ft (30.48 m) cord,
use 3-wire, 12 AWG (2.5 mm
2
)
minimum.
ti4297a
Ground
ti4295a
310645K 7
Page 8
Preparation
Auxiliary Air Compressor
• Use Auxiliary Air Hookup Kit 287328 when additional
atomization air is necessary.
CAUTION
Attaching auxiliary air to sprayer without using the
Auxiliary Air Hookup Kit will damage sprayer.
Generators
7500 W (7.5 KW) minimum.
Tips for Using Generators
• Before running sprayer, make sure it is at room temperature. This will reduce startup current.
• Run generator at full throttle.
Hose Lengths
• The system comes with a twin line hose set consisting of a 1 in. ID x 25 ft (25 mm x 7.6 m) material hose
and a 3/8 in. ID air hose. Additional hose sections can
be added. Total final length of hose used should not
exceed 100 feet in length.
CAUTION
Sprayer air hose fitting can get hot! Allow sprayer to
cool down 5 minutes before removing air hose.
8 310645K
Page 9
Removing and Replacing Hopper, Front and Back Covers
Removing and Replacing Hopper, Front and Back Covers
Before performing any service on sprayer
always:
• Read all warnings, page 3.
• Read operating instructions manual, page 2.
• Relieve Pressure, page 7.
• Turn main power switch (A) OFF.
• Unplug sprayer from outlet.
• Remove air and material hoses.
• Clean sprayer. See Operation Manual 310624 or
310625.
Hopper
Removing Hopper
1 To remove hopper
loosen fitting.
Fittings are
hand-tightened
and should not
require tools to
loosen.
Front Cover
Removing Cover
1 Remove hopper.
2 Unscrew and
remove knob
(S).
3 Place you
hand under
front, bottom
edge of
cover.
(3a) Lift
cover up,
(3b) then pull
bottom
toward you
and out to remove cover.
Replacing Cover
3a
ti4408a
3b
S
2 Lift hopper straight
up, off frame.
Replacing Hopper
1 To replace
hopper, position
drain over fitting
as far as it will
go, making sure
identification label
faces out.
2 Hand tighten fit-
ting.
1 Place your
ti4503a
hand under
front, bottom
edge of cover.
(1a) Position
top edge of
cover under
1a
ti4411a
top metal lip
on sprayer
frame.
1b
(1b) Then
push up on
S
cover so lower
plastic edge
ti4504a
of cover has room to clear front metal frame and slide
cover into place. To position cover correctly, it will go
in at an angle.
2 Replace knob (S). Hand tighten fitting.
3 Replace hopper.
310645K 9
Page 10
Removing and Replacing Hopper, Front and Back Covers
Back Cover
To access the motor and all other components, it is
necessary to remove the hopper, front and back covers.
Removing Cover
1 Completely
remove 6
screws (2 on top
and each side)
from cover.
ti4430a
2 Lift cover up and
then tilt it back
and off sprayer
frame.
Replacing Cover
1 To reposition cover
on sprayer frame,
tip the cover back,
toward you and
slide it down, into
place in the base of
the frame. Then
push the top back
into place. Align
screw holes in side
and top of cover
with holes in frame.
ti4432a
2 Replace and
tighten screws.
ti4431a
ti4433a
10 310645K
Page 11
RotoFlex™ HD Pump
RotoFlex™ HD Pump
Use RotoFlex HD Pump Replacement Kit 287314.
IMPORTANT
• After replacing RotoFlex HD Pump hose, always
follow Hose Break-In Procedure, page 13,
before operating sprayer.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 9.
Then remove hopper and front cover, page 9.
1 Loosen and remove hose
extension.
ti4377a
4 Rotate pump assembly
sideways. Pull entire
assembly out of front of
sprayer frame.
ti4376a
.
5 Separate the inner and
outer hose brackets.
2 Loosen and remove knob.
3 Slide RotoFlex HD hose
off rollers.
ti4374a
ti4378a
ti4519a
6 Slide hose ends out of
slots in outer hose
bracket.
• Slide out of short slot
first.
7 Pull hose out of inner
hose bracket.
ti4379a
8 Discard pump hose.
310645K 11
Page 12
RotoFlex™ HD Pump
Reassembly
1 Bend and kink new
pump hose from kit in
the middle as shown,
making sure dots on
hose fittings face each
other.
2 Insert hose ends
through holes in inner
hose bracket, keeping
dots on fittings facing
each other and kinked
portion of hose horizontal to the underside of
bracket.
3 Slide hose ends into
outer hose bracket,
making sure dots on fittings face each other
and alignment holes are
together.
• Slide into long slot
first.
4 Slide plates together, inserting inner plate in outer
plate, matching alignment holes.
DOTS
5 Replace bracket
assembly in housing
making sure the
mounting screw hole,
located in the top center of the inner plate,
faces up.
ti3127a
ti4383a
6 Slide pump hose
around rollers. Make
sure the rollers are
horizontally parallel to
each other.
ti4520a
alignment
holes
7 Slide feet on the bot-
tom of hose bracket,
into the slot on the bottom of sprayer.
ti4429a
8 Replace knob. Hand
tighten.
9 Reattach hose extension.
10 Replace front cover and
hopper. See Removing
and Replacing Hopper,
ti4381a
Front and Back Cover,
page 9.
ti4386a
12 310645K
Page 13
RotoFlex™ HD Pump
Hose Break-In Procedure
1 Make sure fluid flow regulator
(K) is turned all the way down.
2 Pour approxi-
mately 1 gallon hot
water in sprayer
hopper to lubricate the pump.
WATER
ti4303a
3 Turn power switch (A) on.
4 Hold in prime switch (P).
K
5 Turn fluid flow regulator
(K) up to full pressure.
ti4301a
ti4653a
P
ti4364a
K
ti4655a
6 Run sprayer dry for 1 to 1-1/2 minutes.
310645K 13
Page 14
Compressor and Motor Repair
Compressor and Motor Repair
For 120 V sprayer use Compressor and Motor
Replacement Kit, 287315.
For 230 V sprayer use Compressor and Motor
Replacement Kit, 287344.
Kits include motor/compressor and mounting hardware.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 9.
Then remove hopper, front and back covers, page 9.
Remove hose extension and RotoFlex HD Pump
assembly from frame, page 11.
1 Remove two screws and
access cover on the left
side of the motor.
4 Loosen 4 bolts (2 each
side) to loosen tension on
belt.
ti4388b
5 Slide belt off motor pully.
ti4459a
6 Disconnect air line from
compressor to cooler and
remove.
2 Remove ground nut and
disconnect green ground
wire.
3 Disconnect black and white
wires to motor.
ti4457a
ti4460a
7 Remove 3 screws on
right side of cover and
remove cover.
ti4458a
ti4479a
ti4405a
ti4478a
14 310645K
Page 15
Compressor and Motor Repair
8 Loosen 2 shoulder bolts
about 2-3 turns. Do not
remove them.
9 Remove single shoulder
bolt on other side of
motor completely.
10 Slide out motor
assembly.
ti4425a
ti4463a
Reassembly
1 Using two new shoulder
bolts and rubber mounts
included in your kit, insert
bolts into openings until
they start to snug up on
rubber mounts.
ti4465a
2 Slide new motor into
sprayer frame, aligning
motor frame opening
under bolts. Tighten bolts.
ti4468a
3 Replace shoulder bolt
on left side with new
bolt from your kit.
Tighten bolt.
ti4462a
11 Completely remove
old shoulder bolts and
rubber mounts.
ti4464a
12 Thoroughly clean inside housing to remove dust and
debris.
ti4424a
4 Replace end cover.
Replace and tighten 3
screws.
ti4484a
ti4485a
5 Reattach air line to cooler
and compressor. Tighten
fitting.
ti4516a
310645K 15
Page 16
Compressor and Motor Repair
6 Slide belt over pulleys and set tension. See Replacing
Belt, page 19.
7 Reattach black and white
wires to motor.
Wires are not polarity
sensitive.
ti4412a
8 Replace reattach green
ground wire and grounding
nut.
9 Replace cover plate and
screws.
10 Replace RotoFlex HD
Pump and hose extension, page 12.
11 Replace front and back
covers and hopper. See
Removing and Replacing
Hopper, Front and Back
Cover, page 9.
ti4470a
ti4471a
16 310645K
Page 17
Compressor Rebuild Kit
Compressor Rebuild Kit
To replace piston, seals and sleeve.
For 120 V sprayer use Compressor Rebuild Kit 287330.
For 230 V sprayer use Compressor Rebuild Kit 287331.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 9.
Then remove back cover, page 9.
1 Disconnect air line to
motor.
ti4460a
2 Remove 3 screws in
side of motor cover.
Remove cover.
4 Remove 3/8 in. bolt
holding piston to
motor shaft.
ti4707a
5 Loosen 4 bolts on top
of motor housing.
ti4708a
6 Remove bolts and
housing from motor.
ti4479a
3 Remove fan bolt from
center of fan and
remove fan from housing.
ti4478a
7 Remove piston rod
from motor.
8 Using parts in kit
replace piston, seals
ti4709a
and sleeve.
ti4710a
ti4706a
310645K 17
Page 18
Compressor Rebuild Kit
Reassembly
1 Insert new piston rod from
kit in motor housing.
2 Replace and tighten
piston bolt.
3 Replace top motor
hosing and 4 bolts.
4 Tighten bolts.
ti4700a
ti4701a
5 Replace motor fan
and center fan bolt.
6 Tighten bolt.
ti4704a
7 Replace motor
cover and screws.
ti4485a
8 Reconnect air line
from motor to
cooler.
9 Replace back cover.
See Removing and
Replacing Hopper,
Front and Back
Cover, page 9.
ti4703a
18 310645K
Page 19
Removing and Replacing Belt
Removing and Replacing Belt
Use Belt Replacement Kits 118845.
First read and follow instructions in the Before
performing any service on sprayer section, page 9.
Then remove hopper, front and back covers, page 9.
Remove hose extension and RotoFlex HD Pump
assembly from frame, page 11.
Removing Belt
1 Loosen 4 bolts (2 each
side) to loosen tension on
belt.
2 Loosen 2 bolts (1 each
side) holding down support rod.
Replacing Belt
1 Using new belt from Kit,
position new belt around
pulleys making sure the
teeth in the belt are
properly engaged with
teeth on pulleys.
2 Replace support rod.
Tighten 2 bolts (1 each
side) to secure supporting rod.
ti4388b
3 Insert crow bar under
assembly as shown and
raise motor assembly
until desired belt tension is achieved.
ti4392a
ti4393a
3 Using a screw driver for
leverage, lift up on motor
support rod on one side
of motor and ease it out of
the holding bracket far
enough to remove old
belt. Discard old belt.
At the same time, slide in
the new belt.
ti4459a
ti4388a
ti4469a
4 While holding motor
assembly in place with
crow bar. Spin pulley to
assure proper belt
engagement. Adjust
motor assembly position
as necessary.
ti4391a
ti4472a
310645K 19
Page 20
A correctly tensioned belt will feel very tight. To
measure correct tension, apply 4-5 lbs pressure
at belt midpoint with thumb. Belt should have
approximately 1/8 in. (3.175 mm) deflection.
Removing and Replacing Belt
5 Tighten all 4 bolts.
ti4394a
6 Turn belt one more
time with your hand to
make sure teeth are
properly engaged and
tension is correct.
ti4477a
A loose belt will not last long. If in doubt, tighten
more.
7 Replace RotoFlex HD
Pump and hose extension, page 12.
8 Replace back and front
ti4473a
covers and hopper.
See Removing and
Replacing Hopper, Front and Back Cover, page 9.
20 310645K
Page 21
Roller Replacement
Roller Replacement
Use Roller Replacement Kit 287321.
Kit includes 2 rollers, 4 nylon washer, and 2 retaining
rings.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 9.
Then remove hopper, front and back covers, page 9.
Remove hose extension and RotoFlex HD Pump
assembly from frame, page 11.
1 Remove snap ring.
ti4396a
2 Remove roller assembly
from rotor pins (a).
3 Clean rotor pins (a) and
check for damage. If pins
are worn or damaged,
replace rotor assembly,
(Rotor Assembly
Replacement, page 22).
ti4397a
a
Reassembly
1 Replace roller assembly.
ti4398a
2 Reinstall snap ring.
ti4399a
3 Replace RotoFlex HD Pump and hose extension,
page 12.
4 Replace back and front covers and hopper. See
Removing and Replacing Hopper, Front and Back
Cover, page 9.
310645K 21
Page 22
Rotor Assembly Replacement
Rotor Assembly Replacement
Use Pump Assembly Replacement Kit 287255.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 9.
Then remove hopper, front and back covers, page 9.
Remove hose extension and RotoFlex HD Pump
assembly from frame, page 11.
1 To prevent rotor assembly
from moving, insert a long
screw driver or pry bar in the
pulley.
2 Remove large bolt and
washer in center of rotor
assembly.
3 Pull rotor assembly off shaft.
ti4711a
Reassembly
1 Put new rotor assembly from kit on shaft.
2 Insert a wrench in the
pulley to prevent it from
moving.
ti4714a
3 Replace bolt. Torque to
40 ft. lb.
ti4714a
ti4712a
4 Replace RotoFlex HD Pump and hose extension,
page 12.
5 Replace back and front covers and hopper. See
Removing and Replacing Hopper, Front and Back
Cover, page 9.
22 310645K
Page 23
Air Cylinder and Solenoid Valve
Air Cylinder and Solenoid Valve
Use Cylinder Replacement Kit, 287323.
For 120 V sprayer use Solenoid Replacement Kit
287324.
For 230V sprayer use Solenoid Replacement Kit
287351.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 9.
Then remove hopper, front and back covers, page 9.
Remove hose extension and RotoFlex HD Pump
assembly from frame, page 11.
1 Remove hose from quick
release fitting by using your
fingers on one hand to push
in on ring while at the same
time, using the other hand,
gently pull the hose out of the
fitting.
2 Remove electric wire ter-
minal connections.
ti4406a
4 Gently push cylinder forward,
relieving tension on pin. Pull
out pin.
ti4409a
If replacing solenoid valve only, it can be done at
this time.
a Using an adjustable wrench, rotate entire solenoid
valve assembly counter clockwise from cylinder.
b Replace solenoid valve and continue with step 4 of
reassembly.
5 Lift cylinder up and pull it
back.
6 Remove dampening
grommet.
ti4518a
7 Using a 15/16 in. wrench,
loosen nut, located inside
sprayer frame at the end of
the air cylinder.
ti4415a
3 Remove cotter key located
on the end of the cylinder pin,
by using a pliers to straighten
the ends and pull it out of the
hole.
ti4416a
8 Using a 15/16 in. wrench,
loosen nut on the other
side of the sprayer frame.
9 Pull cylinder out of sprayer
frame.
If replacing cylinder only,
remove solenoid valve (see
a and b above) and reinstall on new cylinder.
ti4453a
ti4414a
310645K 23
Page 24
Air Cylinder and Solenoid Valve
Reassembly
1 Insert crowned backing
nut on shaft of cylinder.
2 Using new cylinder
from kit, position cylinder in sprayer frame,
inserting end of cylinder through pump
bracket mounting hole.
3 Install locking nut flush to end of shaft.
4 Install dampening grommet.
5 Align hole in end of air cylin-
der and replace pin.
ti4421a
ti4410a
6 Replace cotter pin
through hole in pin,
bending ends to secure.
7 Reattach electric wire
terminals. Terminals are
not polarity sensitive and
ti4417a
can be connected to
either post.
8 Gently push hose in
quick release fitting.
ti4407a
9 Replace RotoFlex HD Pump and hose extension,
page 12.
ti4456a
ti4455a
10 Replace front cover and hopper. See Removing and
Replacing Hopper, Front and Back Cover, page 9.
24 310645K
Page 25
Relief Valve and Flow Sensor Manifold
Relief Valve and Flow Sensor Manifold
For 120 V sprayer use Relief Valve Replacement Kit
287325.
For 230 V sprayer use Relief Valve Replacement Kit
287350.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 9.
Then remove hopper, front and back covers, page 9.
1 Remove air line to
regulator.
2 Remove air line from
cooler to manifold.
3 Disconnect wires to Relief Valve. Pay attention to their
location to insure they are reattached correctly.
4 Remove 2 nuts securing
Relief Valve to sprayer.
ti4423a
Reassembly
1 Position new relief valve from Kit in back of sprayer.
2 Replace and tighten screws.
3 Reattach wires to Relief Valve.
4 Reattach air line from cooler to manifold.
5 Reattach air line to regulator.Replace RotoFlex HD
Pump and hose extension, page 12.
6 Replace front cover and hopper. See Removing and
Replacing Hopper, Front and Back Cover, page 9.
5 Remove Relief Valve
from sprayer frame.
ti4418a
ti4419a
310645K 25
Page 26
Air Flow Sensor Replacement
Air Flow Sensor Replacement
For 120 V sprayer use Sensor Replacement Kit 287326.
For 230 V sprayer use Sensor Replacement Kit 287345.
If you are just replacing the sensor, you do not
have to remove the motor first.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 9.
Then remove hopper, front and back covers, page 9.
Remove hose extension and RotoFlex HD Pump
assembly from frame, page 11.
1 Disconnect all
wire connections.
ti4481a
2 Rotate coun-
ter-clockwise to
remove sensor
from manifold.
ti4480a
Reassembly
1 Rotate new sensor
from kit clockwise, all
the way into opening
in Relief Valve
housing. Lightly
tighten nut.
ti4486a
2 Reconnect all wires.
WHITE WIRE
ti4482a
3 Replace RotoFlex HD
Pump and hose extension, page 12.
4 Replace back and front
covers and hopper. See
Removing and Replacing Hopper, Front and
Back Cover, page 9.
ti4487a
ti4488a
WHITE WIRE
26 310645K
Page 27
Pressure Relief, page 7
Problem Cause Solution
Sprayer won’t run or stops intermittently
Pump won’t pump material or low
output
Soft start won’t work/pump, always
loaded
Troubleshooting
Troubleshooting
Power switch not on Turn switch on.
No power at wall outlet Check outlet by plugging in another
appliance. If appliance does not
work, try another outlet.
Wrong size generator Use a 7500 watt or larger generator.
Refer to Generator Requirements,
page 8.
Temperature too cold Allow unit to warm up.
Too many items on same circuit Unplug other items from circuit.
Internal thermal switch tripped Self-resetting. Allow unit to cool down
15 minutes and restart. Usually
occurs when wrong size extension
cord is used.
Extension cord too long or wrong
gauge
Breaker tripped Reset breaker.
Air lock Open air valve on gun.
Mix too thick Add water to thin material. Use Mate-
Loose fittings Check and retighten all fittings.
Plugged gun Relieve Pressure, page 7. Remove
RotoFlex HD Pump worn out Replace hose.
Pump cold or material frozen in pump Move pump to warm room and allow
Sensor is bad Replace, page 26
Check air system for leaks Remove shroud and examine for air
Loose wire Remove shroud and examine wiring
No air pressure Rebuild compressor
Sensor is bad Change sensor, page 26
Air leak due to bad seal keeps valve
open
Normal soft start system delay Release trigger for 10-15 seconds.
Switch is not operating properly Replace switch
Damaged solenoid valve on cylinder Check gun supply, hose and sprayer
AIr leak
Use a 12 gage extension cord or
remove extension cord. Refer to
Grounding and Electric Require-
ments, page 7.
rial Thickness Gauge.
gun from hose. Clean gun.
it to warm up or run hot water through
sprayer.
leaks
Replace seal
Retry.
for leaks
310645K 27
Page 28
Troubleshooting
Problem Cause Solution
Material runs out of bottom of sprayer RotoFlex HD Pump worn out Replace hose.
Loose fittings Check and retighten all fittings.
No air from compressor Gun air valve closed Open gun air valve.
Gun needle plugged Clean needle and retry.
Lines not connected Check all quick disconnect connec-
tions to gun and hoses.
Damaged hose Replace hose.
Worn compressor Service compressor. Contact a quali-
fied Graco Service Center.
Speed of application too slow Material too thick Thin material.
Nozzle too small Change nozzles to a larger size. See
Operation Manual, Recommended
Nozzle Selection Chart, page 20.
Speed of application too slow (cont.) Flow control set too low Increase flow control setting
Plugged or dirty gun Relieve Pressure, page 7. Clean
gun.
Kinked hose Unkink hose.
Gun fluid flow adjustment set too low Increase flow adjustment with flow
adjustment nut.
Intermittent flow/sputtering or air in
material
Air quick disconnect does not stay
connected.
Gun will not shut off Worn nozzle or needle. Relieve Pressure, page 7. Replace
Fluid leaking at Flow Adjustment Nut Damaged seal. Relieve Pressure, page 7. Replace
Needle adjustment won’t adjust Dirty threads Clean threads
Hopper connection not tight Check gasket. TIghten connection.
Debris in system Clean
Dirty or corroded fitting Clean thoroughly. Soak in oil. Apply a
few drops of light oil.
worn parts.
Debris in needle passage Relieve Pressure, page 7. Clean.
seal.
Nozzle not on gun Put nozzle on gun
Flow nut set to maximum adjustment Turn flow nut adjustment the other
way
28 310645K
Page 29
Air Cylinder
Air Diagram
Air Diagram
Air Compressor
Guage
Regulator
One Way Valve
Air Cylinder
Air Cooler
One Way Valve
Air Flow Control
Wiring Diagram
Air Compressor
Gun
ti4369a
39
51
32
Prime
Switch
50
Power
Switch
Air Flow
Control
150/151
Green
White
Black
50
8
50
ti4370d
310645K 29
Page 30
Parts
102
49A
49C
Parts
19
34
1D
49B
1A
1C
42
52
49
31
53
57
36
45
22
38
9
63
21
40
1B
88
9
43
33
52
38A
1
1E
ti4371b
73
38B
101
55
62
37
41
13
62
88
63
4
56
67
30 310645K
Page 31
Parts List
Item
No. Part No. Description Qty
1 287315 KIT, compressor replacement
(includes 1A and 1B-1E),
120V sprayers
287330 KIT, compressor rebuild,
120V sprayers
287344 KIT, compressor replacement
(includes 1A, and 1B-1D),
230V sprayers
287331 KIT, compressor rebuild,
230V sprayers
1A 119872 SCREW, shoulder 3
1B 118886 GROMMET, isolator 2
1C 118889 GROMMET, isolator 1
1D 119381 COVER, terminal 1
1E 121479 CAPACITOR, start 1
4 118845 BELT 1
9 117728 FITTING, compression, union 2
13 15D156 PULLEY, rotor 1
16 118888 HOSE, air (includes 1/4 in. tubing
and one-way valve)
19 15D862 NUT, hand 1
21 118876 TUBE, air, aluminum 1
22 117637 NUT, compression 1
31 112395 SCREW, cap 4
32 15D633 WIRE, jumper 1
33 103473 STRAP, tie, wire 2
34 15B815 COOLER 1
36 101242 RING, retaining, ext. 2
37 287255 ROTOR, pump, assbly
(includes 38, 38A, 38B)
38 287321 KIT, roller replacement
(includes 38A, 38B and two rollers)
38A 113983 RING, retaining, ext 2
38B 117726 WASHER, nylon 4
Item
No. Part No. Description Qty
39 15D628 CONDUCTOR, ground 1
40 103785 RIVET 2
1
41 287327 KIT, repair, shaft, bracket, pump
assbly.
42 287256 BRACKET, compressor 1
43 118869 TUBE 1
45 15D610 SHAFT, motor, mount 1
49 287346 SHIELD, rear, assbly
(includes 19, 49A, 49B, 49C)
49A 15D561 COVER, tool tray 1
49B▲ 15D939 LABEL, warning, English, French,
Spanish
287336 KIT, label, warning, all languages
except those included in 15D939
49C▲ 15D940 LABEL, identification
51 15D634 WIRE, jumper 1
52 116937 BEARING, flanged, bronze 2
53 117630 SCREW, torx, tri lob 8
54 116666 TUBE, air 1
55 287304 HOSE SET, twin line, 1 in. x 25-ft 1
1
56 15C090 GAUGE, thickness, fluid 1
57 183401 KEY, parallel 2
58 116720 COUPLER, air, quick disconnect 1
62 108851 WASHER, plain 2
63 106276 SCREW, cap, hex head 2
67 113397 BALL, sponge, 30 mm 2
73 112785 SCREW, flanged, hex head 2
74 115498 SCREW, mach, slot, hex, wash hd 1
82 118887 HOSE, air (includes 1/4 in. tubing
1
88 118866 WASHER, flat 1
101 248091 GUN, non-bleeder 1
2
102 122104 VALVE PLATE, compressor 1
▲ Replacement Danger and Warning labels, tags and
cards are available at no cost.
and one-way valve)
Parts List
1
1
1
310645K 31
Page 32
18
Parts
Parts
24
90
25
26
93
29
27
81
66
154
91
A
30
92
12
17
6
3
7
10
70
71
35
ti4372C
55
93
19
28
153
151
23
14
58
83
20
59
60
77
8
72
5B
89
5A
5
15
A
150a
150b 150c152a 152c 152d152b 152e
32 310645K
Page 33
Parts List
Parts List
Item
No. Part No. Description Qty
3 118844 REGULATOR, air, 1/8 in. NPT 1
5 287323 KIT, cylinder, replacement,
(includes 5A, 5B, 89)
5A 15D576 SPACER, crowned 1
5B 118871 NUT, lock, 1/2-20 1
6 117720 GAUGE, pressure 1
7 115244 NUT, regulator 1
8▲ 186620 LABEL, ground, symbol 1
10 117693 SWITCH, power 1
12 119064 SWITCH, power 1
14 15D559 VALVE, assembly, 120V (includes
sensor) sprayer
287350 VALVE, assembly, 230V (includes
sensor) sprayer
15 15D560 VALVE, cylinder, 120V sprayer 1
287351 VALVE, cylinder, 230V sprayer 1
16 118888 HOSE, air (includes 1/4 in. tubing
and one-way valve)
17 15C968 TUBE, air 1
18 287347 HOPPER, texture (includes
bracket)
19 15D862 NUT, hand 1
20 287326 KIT, sensor only, 120V 1
287345 KIT, sensor only, 230V
23 287348 SHIELD, front (includes 28) 1
24 108471 KNOB, pronged 1
25 15D589 BRACKET, hose, outer 1
26 15D588 BRACKET, hose, inner 1
27 287314 KIT, RotoFlex HD Pump 1
28▲ 189286 LABEL, warning 1
29 118885 HOSE, coupled (includes grommet) 1
30 287254 FRAME, texture, blue 1
32 15D633 WIRE, jumper 1
35 116478 WHEEL, pneumatic 2
49B▲ 15D939 LABEL, warning, English, French,
Spanish
287336 KIT, label, warning, all languages
except those included in 15D939
49C▲ 15D940 LABEL, identification
Item
No. Part No. Description Qty
51 15D634 WIRE, jumper 1
54 116666 TUBE, air 1
1
55 287304 HOSE SET, twin line, 1 in. x 25-ft 1
58 116720 COUPLER, air, quick disconnect 1
59 104641 FITTING, bulkhead 1
60 116658 FITTING, tube, male, 1/4 NPT 1
66 116171 BUSHING, strain relief 1
70 116411 SPRING, compression 2
71 116477 WASHER, flat, nylon 2
72 116342 CAP, end 2
74 115498 SCREW, mach, slot, hex, wash hd 1
1
77 102040 NUT, lock, hex 2
81▲ 198492 LABEL, warning 2
82 118887 HOSE, air (includes 1/4 in. tubing
and one-way valve)
83▲ 15D089 LABEL, warning, hot surface 1
89 801012 GROMMET 1
1
90▲ 15D951 LABEL, identification 1
91▲ 15D953 LABEL, identification 1
92▲ 15D952 LABEL, identification 1
1
93 118872 GASKET 4
150 CORD, power
150a 15D630 Americas/Canada, 120V, 60 Hz 1
150b 15E056 Europe/Asia, 230V, 50 Hz
(hardwired, rubber cord)
150c 15E061 United Kingdom, 110V, 60, Hz 1
151 15D902 CORD, power, Europe/Austra-
lia/China, 230V, 50 Hz (requires
cordset adapter, 152, following)
152 ADAPTER, cordset, (for 15D902),
152a 242001 Europe 1
152c 242002 Italy 1
152d 242003 Denmark 1
152d 242004 Switzerland 1
152e 242005 Australia/China 1
153 195551 RETAINER, (for 15D902) 1
154 15F966 BAFFLE, hopper 1
1
1
1
310645K 33
Page 34
Technical Data
Technical Data
Maximum working fluid pressure 100 psi (6.9 bar)
Maximum working air pressure 45 psi (3.1 bar)
Material pressure operating range 0-100 psi (0 to 6.9 bar)
Compressor
Ty pe Oilless
Air delivery 6.5 CFM @ 40 psi (184.1 lpm @ 2.8 bar)
Motor
120V, 60 Hz 15A
230V, 50 Hz 10A
Hopper capacity 15 US gallons (57 liters)
Maximum delivery with texture material 2.0 gpm (7.57 lpm)
Dimensions
Length 27 in. (685.8 mm) with handles
Width 26 in. (660.4 mm)
Height 40 in. (1016 mm)
Weight
With hoses and gun 147 lb (66.68 kg)
Without hoses and gun 131 lb (59.47 kg)
Wetted parts PVC, Buna-N, anodized aluminum, powder coat
aluminum, brass, polyethylene, SST, UHMW
Sound data
Sound pressure level* 85.8 db(A)
Sound power level# 100.1 db(A)
Generator (minimum size requirement) 7500W (7.5 kW)
Maximum external working air pressure (must use
External Air Hookup Kit 287328 ONLY)
120 psi (8.3 bar)
*Measured while spraying at 1 m.
#Measured per ISO-3744
34 310645K
Page 35
Warranty
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. 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.
POUR LES CLIENTS DE GRACO PARLANT FRANCAIS
Les parties reconnaissent avoir convenu que la rédaction du présent document ainsi que de tous les documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées, sera en anglais.
PARA LOS CLIENTES DE GRACO QUE HABLAN ESPAÑOL
Las partes reconocen haber convenido que el presente documento, así como todos los documentos, notificaciones y procedimientos judiciales
emprendidos, presentados o establecidos que tengan que ver con estas garantías directa o indirectamente, estarán redactados en inglés.
PER I CLIENTI GRACO ITALIANI
Le controparti riconoscono di aver richiesto che il presente documento, e tutti gli altri documenti, avvisi e informazioni di natura legale sottoscritti,
conferiti o istituiti direttamente o indirettamente, siano redatti in lingua inglese.
PARA CLIENTES PORTUGUESES DA GRACO
As partes confirmam que solicitaram que o presente documento, assim como todos os demais documentos, notas e processos legais inseridos,
atribuídos ou instituídos de acordo com o mesmo ou relacionados directa ou indirectamente com este documento, fossem redigidos em inglês.
VOOR GRACO-KLANTEN IN NEDERLAND
De partijen zijn zich ervan bewust dat zij hebben geëist dat het onderhavige document, evenals alle documenten, berichtgevingen en wettelijke
procedures die worden aangegaan, overhandigd of in gang gezet hetzij als gevolg van hetzij rechtstreeks hetzij indirect in relatie tot het
onderhavige worden opgesteld in de Engelse taal.
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty Program”.
310645K 35
Page 36
Warranty
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.
MM 310645
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
www.graco.com
3/2004 Rev. 08/2009
36 310645K
Loading...