Graco Magnum DX 232735 Service Instructions Manual
Service Instructions
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
t
Airless Sprayers
MAGNUM DX
Model 232735
MAGNUM DX, Model 232735, Series A
0.24 gpm (0.91 lpm) stand–mount sprayer, 25 ft (7.6 m)
3/16” hose and SG1t–EF spray gun with reversible spray
tip and guard.
2800 psi (19 MPa, 193 bar) Maximum Working Pressure
MAGNUM XR5
Model 232740
Form No. 309226
Rev. A
This manual contains service
instructions only. See manual
309316 Operators Quick Guide and
309225 Operating Instructions for
complete operating instructions.
9558A
MAGNUM XR7
Model 232745
M
AGNUM XR5, Model 232740, Series A
0.27 gpm (1.02 lpm) stand–mount sprayer, 25 ft (7.6 m)
1/4” hose and SG1–EF spray gun with reversible spray tip
and guard.
3000 psi (21 MPa, 207 bar) Maximum Working Pressure
MAGNUM XR7, Model 232745, Series A
0.31 gpm (1.17 lpm) stand–mount sprayer, 50 ft (15.2 m)
1/4” hose and SG2t metal spray gun with reversible spray
tip and guard.
3000 psi (21 MPa, 207 bar) Maximum Working Pressure
MAGNUM XR9, Model 232750, Series A
0.38 gpm (1.44 lpm) stand–mount sprayer, 50 ft (15.2 m)
1/4” hose and SG3t pro metal spray gun with reversible
spray tip and guard.
3000 psi (21 MPa, 207 bar) Maximum Working Pressure
9558A
9559A
MAGNUM XR9
Model 232750
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 2001, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding and Electrical Requirements 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Information 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Advanced Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Kits 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Diagnostics 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Board Diagnostics 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Diagnostics 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts
Model 232735 DX Magnum Sprayer 24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 232740 XR5 Magnum Sprayer 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Model 232745 XR7 Magnum Sprayer 26. . . . . . . . . . . . . . . . . . . . . . . . . .
Model 232750 XR9 Magnum Sprayer 28. . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Warranty 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 309226
FIRE AND EXPLOSION HAZARD
A Fire and explosion hazard exists
any time you spray or flush flammable fluids.
To help prevent fire or explosion when
spraying flammable fluids
D Be sure sprayer is adequately grounded
through electrical outlet as follows:
– Use only grounded electrical outlets.
– Use only 3-wire extension cords.
– Make sure ground prongs are intact
on sprayer and extension cords.
D Motor in this sprayer is a source of
sparks. Keep sprayer in well-ventilated
area, at least 20 feet (6 meters) away
from gun when spraying or flushing.
D Do not use plastic drop cloths when
spraying or flushing flammable fluids.
D Avoid all ignition sources, such as pilot
lights, cigarettes, and plastic drop cloths
(static arc hazard). Do not plug in or
unplug power cords or turn lights on or
off in spray area.
D Tape wall switches to prevent them from being turned
off or on.
D Do not smoke in spray area.
D Use only M
D Use outdoors or in a well-ventilated area.
EQUIPMENT MISUSE HAZARD
Do not use 1,1,1–trichloroethane, methylene
chloride, other halogenated hydrocarbon
solvents or fluids containing such solvents
in pressurized aluminum equipment such as
this sprayer and gun. Such use could result in
chemical reaction and possible explosion.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause
serious injury or death if splashed in eyes
eyes or on skin, inhaled, or swallowed.
To help prevent injury or death from
toxic fluids
D Know specific hazards of fluid you are using; store
hazardous fluid in approved tub; dispose of
hazardous fluid according to all local, state, and
national guidelines.
D Always wear protective eyewear, gloves, clothing, and
respirator as recommended by fluid and solvent
manufacturer.
AGNUM or Graco airless paint hoses.
FLUID INJECTION HAZARD
If high-pressure fluid pierces skin,
the injury might look like “just a cut”
but is a serious wound. Get
immediate medical attention.
To help prevent injection
D Always put trigger safety lever in SAFETY
ON position when not spraying.
D Always shut off power and relieve pressure
when you stop spraying and before you
service or clean sprayer, remove parts, or
repair leaks. See Pressure Relief
Procedure below.
D Do not allow children to use this equipment.
D Keep clear of tip, and never point gun at
yourself or anyone else.
STARTUP HAZARD AFTER THERMAL OVERLOAD
Motor has thermal overload switch to
shut itself down if overheated. To reduce risk of injury
from motor restarting unexpectedly when it cools, always
turn Power switch OFF if motor shuts down.
FLUID SPLASHBACK HAZARD
Wear protective eyewear at all times.
To avoid splashing fluid when spraying
into pail, always aim at inside wall of pail.
Make sure gun is assembled with correct
gasket for fluid being sprayed. See Installing Tip &
Guard in enclosed Operator’s Quick Guide.
PRESSURIZED EQUIPMENT HAZARD
M
AGNUM sprayers are capable of
producing up to 3000 psi (21 MPa, 207 bar)
maximum working pressure. To avoid
component rupture and injury, do not operate sprayer
with components rated less than pressure of sprayer.
Sprayer is equipped with a pressure drain that
automatically relieves overpressure in the event of a fault
condition. This automatic pressure relief may cause
splashing of fluid. Correct fault before you resume spraying.
NOTE: Inadequate flushing and/or dried paint in drain
system may prevent proper overpressure relief.
ELECTRIC SHOCK HAZARD
Gun, hose, and sprayer are grounded
through electrical cord of sprayer.
To help prevent electric shock
D Use only grounded electrical outlets.
D Only use 3-wire extension cords.
D Make sure ground prongs are intact on sprayer and
extension cords.
D Keep electrical connections and inside of shroud dry.
SAFETY ON
pressure
309226 3
Component Identification and Function
W
A
B
X
N
J
MAGNUM XR7
9558A
K
MAGNUM XR5
W
F
C
D
K
P
G
E
H
L
Y
9560A
M
D
W
X
9559A
K
MAGNUM XR9
4 309226
B
MAGNUM DX
Component Identification and Function
9
A Electric motor (inside of enclosures) Provides mechanical power to pump
B Power switch For manually turning on/off electrical power to motor (“I” is ON / “0” is OFF)
C Pressure Control knob For manually increasing (turn clockwise) and decreasing (turn
counter-clockwise) fluid pressure in pump, hose, and spray gun
D Pump fluid outlet fitting Threaded connection for paint hose
E InstaCleant fluid filter (XR models
only)
F Power-Pistont pump (behind Easy
Access door)
G Suction tube Draws fluid from paint pail into pump
H Prime tube (with diffuser) Drains fluid in system during priming and pressure relief
J Spray/Prime/Drain valve control D Directs pressurized fluid to paint hose in SPRAY position (pointing forward)
K Fluid inlet connection and inlet valve Where suction tube connects to pump and inlet valve
L Inlet screen Prevents debris from entering pump
M Paint hose Transports high-pressure fluid from pump to spray gun
N Cord wrap bracket Stows electrical cord (XR5 model only)
P Airless spray gun Manually-controlled, hand-held on/off device for fluid being sprayed
Q Tip guard Reduces risk of fluid injection injury
R Reversible spray tip D Atomizes fluid being sprayed, forms spray pattern, and controls fluid flow
S Trigger safety lever Prevents accidental triggering of spray gun
T Gun fluid inlet fitting Threaded connection for paint hose
U Smooth Glidet swivel
(SG3 spray gun only)
V Gun fluid filter (in handle) Filters fluid entering spray gun to reduce tip plugging and improve finish
W Hose/Cord wrap bracket Stows paint hose and electrical cord (MAGNUM XR7 and XR9 only)
X Pail hanger For transporting pail by its handle (MAGNUM XR7 and XR9 only)
Y Power Flush attachment (included) Connects garden hose to suction tube for power flushing water-base fluids
D Filters fluid coming out of pump to reduce tip plugging and improve finish
D Self cleans during pressure relief
Pumps and pressurizes fluid and delivers it to paint hose If necessary, Easy
Access door permits quick removal of outlet valve.
D Directs fluid to drain tube in PRIME/DRAIN position (pointing down)
D Automatically relieves system pressure in overpressure situations
according to hole size
D Reverses for unplugging without disassembly
Allows spray gun to swivel without twisting paint hose
S
R
Q
T
SG1–EF Spray Gun
included with
AGNUM DX and XR5
M
V
Q
SG2 Spray Gun
9561A
T
included with
AGNUM XR7
M
S
R
S
R
Q
V
U
T
SG3 Spray Gun
included with
AGNUM XR9
M
309226 5
Pressure Relief
Grounding and
Procedure
WARNING
To help prevent injection injuries, follow
this procedure when you stop spraying
and before you service or clean the
psi/MPa/bar
1. Turn Power switch (B) to OFF, and unplug sprayer.
B
2. Turn Spray–Prime/Drain valve (J) to PRIME/
DRAIN to relieve pressure. Trigger gun to relieve
pressure that might be in hose.
sprayer, remove parts, or repair leaks.
9565A
Electrical Requirements
WARNING
This sprayer requires a 120V AC, 60 Hz, 15A
circuit with a grounding receptacle. Never use
an outlet that is not grounded. Do not use the
sprayer if the electrical cord has a damaged ground
prong. Use only an extension cord with an
undamaged, 3-prong plug.
Recommended extension cords for use with this
sprayer are
D 25 ft (7.6 m) 18 AWG
D 50 ft (15.2 m) 16 AWG
D 100 ft (30.5 m) 14 AWG
D 150 ft (45.7 m) 12 AWG
NOTE: Smaller-gauge or longer extension cords may
reduce sprayer performance.
J
3. Put trigger safety (S) in SAFETY ON position.
SG1–EF
S
NOTE: Leave Spray–Prime/Drain
valve in the PRIME/DRAIN position
until you are ready to spray again.
If you suspect that the spray tip or hose is completely
clogged or that pressure has not been fully relieved
after following the steps above, VERY SLOWLY loos-
en the tip guard retaining nut or hose end coupling to
relieve pressure gradually. Then loosen it completely.
Then clear the tip or hose obstruction.
SG2 / SG3
9565A
S
9565A
6 309226
General Repair Information
WARNING
HOT SURFACES HAZARD
EXPLOSION HAZARD
Motor and drive housing may be very hot
during operation and could burn skin if
touched.
Flammable materials spilled on hot, bare
motor could cause fire or explosion.
Have enclosures in place during
operation to reduce risk of burns, fire, or
explosion.
D Keep all screws, nuts, washers, gaskets, and
electrical fittings that you remove during repair
procedures. These parts are not normally provided
with replacement assemblies.
Do not operate the sprayer without the enclosure.
Replace if damaged. Enclosures direct cooling air
around the motor to prevent overheating. They also
reduce the risk of burns, fire or explosion. Read the
following WARNING.
WARNING
ELECTRIC SHOCK HAZARD
MOVING PARTS HAZARD
To reduce risk of serious injury, including
electric shock, do not touch moving or
electrical 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.
CAUTION
D Test repairs after problems are corrected.
D If the sprayer does not operate properly, review
the repair procedure to verify that you did it correctly. See Troubleshooting on page 8 and
Advanced Troubleshooting on page 10.
D Overspray may build up in the air passages.
Remove any overspray and residue from the air
passages and openings in the enclosures whenever
you service the sprayer.
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 enclosures allow for air
cooling of the mechanical parts and electronics
inside. If water gets into 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
the sprayer when it is not in use in cold weather.
Freezing fluids can seriously damage the sprayer.
Store the sprayer with mineral spirits/paint thinner or
Graco Pump Armor to protect equipment during
storage.
309226 7
Basic Troubleshooting
does not cycle
does not cycle
y
The following troubleshooting guidelines from the Operating Instructions manual are included here as preemptive
measures against Advanced Troubleshooting on page 10.
PROBLEM CAUSE SOLUTION
Power switch is on and
sprayer is plugged in, but
motor does not run, and pump
.
.
Pump does not prime. Spray–Prime/Drain valve is in
Spray gun stopped spraying. Spray tip is plugged. Unplug spray tip. See manual 309225 Operating Instructions.
Pump cycles but does not
build up pressure.
Pump cycles, but paint only
dribbles or spurts when spray
gun is triggered.
Spray pattern is inconsistent
or is leaving stripes.
Pressure is set at zero
pressure.
Motor or control is damaged. See Motor Does Not Operate on page 10.
Electrical outlet is not
providing power.
Extension cord is damaged. Replace extension cord. See Grounding and Electrical
Sprayer electrical cord is
damaged.
Paint is frozen or hardened in
pump.
SPRAY position.
Inlet screen is clogged, or
suction tube is not immersed.
Balls in check valve are stuck,
or check valves are damaged.
Suction tube is leaking. Tighten suction tube connection (K). Inspect for other cracks
Pump is not primed. Prime pump.
Inlet screen is clogged, or
suction tube is not immersed.
Paint pail is empty. Refill paint pail, and reprime sprayer.
Suction tube is leaking. Tighten suction tube connection (K). Inspect for other cracks
Pump check valves are dirty
or damaged. (Usually only
one valve)
Spray–Prime/Drain valve is
worn or obstructed with debris
Pressure is set too low. Slowly turn Pressure Control knob (C) clockwise to Increase
Spray tip is plugged. Unplug spray tip. See manual 309225 Operating Instructions.
InstaClean fluid filter is
clogged. (XR models only)
Spray gun fluid filter is
clogged.
Pressure is set too low. Turn Pressure Control knob (C) clockwise to increase
Spray tip is worn beyond
capability of sprayer.
Turn Pressure Control knob (C) clockwise to increase
pressure setting.
D Try a different outlet, or plug in something that you know is
working to test outlet.
D Reset building circuit breaker, or replace fuse.
Requirements on page 6.
Check for broken insulation or wires. Replace electrical cord if
damaged.
See Motor Does Not Operate on page 10.
Turn Spray–Prime/Drain valve (J) to PRIME/DRAIN position
(pointing down).
Clean debris off inlet screen (L), and make sure suction tube
(G) is at bottom of paint pail.
Clean or replace check valves. See Pump Service on page
20. Do not store in water.
or vacuum leaks.
Clean debris off inlet screen (L), and make sure suction tube
(G) is at bottom of paint pail.
or vacuum leaks.
Clean or replace check valves. See Pump Service on page
20.
Check Spray–Prime/Drain valve for debris trapped on seat
and worn parts. Torque to 185 in-lb (21 NSm). Replace if parts
are worn.
pressure setting to check if sprayer develops more pressure.
Clean or replace InstaClean fluid filter (E).
Clean or replace spray gun fluid filter (V).
pressure.
Replace spray tip.
8 309226
Basic Troubleshooting
g
intermittentl
NOTE: This is a thermal
WARNINGS section on
OR
PROBLEM CAUSE SOLUTION
Pressure is set at maximum,
but cannot achieve a good
spray pattern.
Motor is hot and runs
y.
NOTE: This is a thermal
overload condition. Motor
automatically shuts off due to
excessive heat.
See Startup Hazard After
Thermal Overload in the
page 3. Damage can occur if
cause is not corrected.
Building circuit breaker opens
after sprayer operates for 5 to
10 minutes.
OR
Building circuit breaker opens
as soon as sprayer is plugged
into outlet, and sprayer is
turned on.
Fan pattern varies
dramatically while spraying
OR
Sprayer does not turn on
promptly when resuming
spraying.
Cannot trigger spray gun. Spray gun trigger safety lever
Spray comes out of spray gun
in two thick streams.
Paint is coming out of
pressure control switch.
Spray–Prime/Drain valve
actuates automatically,
relieving pressure through
drain tube.
Paint leaks down outside of
pump.
Spray tip is too big for
sprayer.
Spray tip is worn beyond
capability of sprayer.
Extension cord is too long or
not a heavy enough gauge.
Spray gun fluid filter is
clogged.
InstaClean fluid filter is
clogged. (XR models only)
Inlet screen is clogged. Clean debris off inlet screen (L).
Pump valves are worn. See Output is Low or Fluctuating on page 13.
Vent holes in enclosures are
p
plugged, or sprayer is
covered.
Extension cord is too long or
not a heavy enough gauge.
Unregulated electrical
generator being used has
excessive voltage.
Sprayer was operated at high
pressure with very small tip,
which causes frequent motor
starts and excessive heat
build up.
Too many appliances are
plugged in on same circuit.
Sprayer electrical cord is
damaged.
Pressure control switch is
worn and causing excessive
pressure variation.
is in SAFETY ON position.
Reversible spray tip is in
UNCLOG position.
Pressure control switch is
worn.
System is overpressurizing. See Excessive Pressure is Building Up on page 16.
Pump packings are worn. Replace pump packings. See Pump Service on page20.
p
Select a smaller spray tip.
Replace spray tip.
Replace extension cord. See Grounding and Electrical
Requirements on page 6.
Clean or replace spray gun fluid filter (V).
Clean or replace InstaClean fluid filter (E).
Keep vent holes clear of obstructions and overspray, and keep
p
sprayer open to air.
Replace extension cord. See Grounding and Electrical
Requirements on page 6.
Use electrical generator with a proper voltage regulator.
Sprayer requires a 120V AC, 60 Hz, 1500-Watt generator.
Decrease pressure setting or increase tip size.
Free up circuit (unplug things), or use a less busy circuit.
Check for broken insulation or wires. Replace electrical cord if
damaged.
Replace Pressure Control knob using Pressure Control
Switch Kit 244266 for DX models or 244267 for XR models.
Rotate trigger safety lever (S) to SAFETY OFF position.
Rotate arrow-shaped handle on spray tip so it points forward in
SPRAY position.
Replace Pressure Control knob using Pressure Control
Switch Kit 244266 for DX models or 244267 for XR models.
p
309226 9
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