Repair
TexSpray 1030
German Patent No. P 43 18 679.3--09
- For portable spray application of architectural paints and coatings -
0.9 to 3.0 gpm (3.4 to 11.4 lpm) Flow Rate
750 psi (5.1 MPa, 51 bar) Maximum Working Pressure
500 psi (3.4 MPa, 34 bar) Recommended Maximum Working Pressure
Model 234113, Series A
TexSpray 1030 FC sprayer, 235490 TexSpray gun
and 50 ft (15 m) air and fluid hose set
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
309663.......
308274.......
‘
FC
309662J
CONTENTS
Warnings 2..............................
Component Description 5..................
Maintenance 6...........................
Troubleshooting 7........................
Repair 10...............................
Parts 20.................................
Accessories 26...........................
Technical Data 27........................
Dimensions 27...........................
Warranty 28.............................
t
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440- 1441
Copyright 2002, G raco Inc. is registered to I.S. EN ISO 9001
ti3005b
Specifications
This equipment is not intended for use with flammable or combustible materials used in places such as
cabinet shops or other “factory” or fixed locations. If you intend to use this equipment in this type of
application, you must comply with NFPA 33 and OSHA requirements for the use of flammable and
combustible materials.
Warnings
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
2 309662
The following are general W arnings 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
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:
D Use equipment only in well ventilated area.
D Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop clothes (potential static arc).
D Sprayer generates sparks. When flammable liquid is used in or near sprayer or for flushing or
cleaning, keep sprayer at least 20 ft (6 m) away from explosive vapors.
D Do not clean with materials having flash points lower than 70_F(21_C). Use water--based materi-
als or mineral spirits type material only. For complete information about your fluid, request the
MSDS from the fluid distributor or retailer.
D Keep work area free of debris, including solvent, rags and gasoline.
D Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
D Ground equipment and conductive objects in work area. Read Grounding instructions.
D If there is static sparking or you feel a shock, stop operating immediately. Do not use equipment
until you identify and correct the problem.
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.
D Do not point gun at anyone or any part of the body.
D Do not put your hand over the spray tip.
D Do not stop or deflect leaks with your hand, body, glove, or rag.
D Engage trigger lock when not spraying.
D Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking or servicing equipment.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in this equipment. Such use could result in a serious chemical reaction,
with the possibility of explosion, which could cause death, serious injury and/or substantial property
damage.
309662 3
INSTRUCTIONS
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use equipment only for its intended purpose. Call your Graco distributor for information.
D Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. This gun has a 150 psi (10 bar) maximum fluid working pressure at a 125 psi (9
bar) maximum incoming air pressure. Read Technical Data in all equipment manuals.
D Do not alter or modify equipment.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not lift pressurized equipment.
D Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180_F(82_C) or below --40_F(--40_C).
D Do not use hoses to pull equipment.
D Keep children and animals away from work area.
D Comply with all applicable safety regulations.
D Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in this equipment, which contains aluminum and/or zinc parts. Such
use could result in a serious chemical reaction, with the possibility of explosion, which could cause
death, serious injury and/or substantial property damage.
D Wear eye and ear protection when operating this equipment. Keep body parts away from front of
gun. See Sound Data in
TECHNICAL DATA.
TOXIC FLUID HAZARD
Toxic fluid or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
D Read MSDS’s to know the specific hazards of the fluids you are using.
D Store hazardous fluid in approved containers and dispose of it according to all applicable guide-
lines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes, but is not limited to:
D Protective eye wear.
D Clothing and respirator as recommended by the fluid and solvent manufacturer.
D Gloves.
D Hearing protection.
4 309662
Component Description
Flow and Air Control
Fig. 1. The flow control (A) has a shut off and pressure
relief feature to soft start each time the gun is triggered, instead of a blast of unatomized material. The
flow control has three modes:
D LOW/MED/HIGH: Triggering the gun sends an air
signal to the flow control that closes the prime valve
and starts the pump which fills the material hose.
When the gun trigger is released, the prime valve
opens and relieves the system pressure into the
supply container. When the gun is triggered the
automatic pressure relief, special TexSpray hoses
and pump design eliminate blasts of material and
spray pulsing to ensure consistent atomization.
D OFF: Puts the sprayer in neutral/relieve pressure --
neither the pump nor the gun will operate and there
is no material pressure in the pump, hose or gun.
D PRIME: The prime valve remains open so material
circulates through the pump and back to the supply
container through the drain hose.
The air control (B) increases or decreases the air
pressure to the sprayer from the air supply.
OFF
PRIME
LOW/MED/HIGH
Prime Valve
Fig. 1. The prime valve (C) relieves system pressure
and stops the pump when the gun trigger is released.
TexSpray Gun, 235490
WARNING
EQUIPMENT MISUSE HAZARD
The TexSpray Gun 235490 is for use
INSTRUCTIONS
of the gun will not exceed the working pressure
rating of the components. The maximum fluid working pressure of the GM 1030 TexSpray is 750 psi
(5.1 MPa, 51 bar), but the recommended maximum
is 500 psi (3.4 MPa, 34 bar).
Fig. 2. Air flow is controlled at the gun. During priming,
turn the gun air control valve (D) in fully to prevent air
from mixing with the fluid, which allows you to check
and adjust the fluid flow accurately. (When this valve is
closed the air exits the rear of the gun.) During operation, open the air control valve to introduce air at the
correct volume for the desired spray pattern. The gun
also has a trigger bail (E) to reduce operator fatigue
when spraying large surfaces.
only with the GM 1030 TexSpray 234113
which is designed so the fluid pressure
Fig. 1
D
TI3010A
Fig. 2
E
01808
159
Black
AB
C
TexSpray Hoses
CAUTION
TI3101A
158
Blue
Use Graco hoses designed for this sprayer. Using
other hoses will damage the flow control.
309662 5
Component Description
Compressor Requirements
NOTE: This sprayer requires an external air compres-
sor.
CAUTION
Install an air filter on external air compressor to
reduce contamination to spray system.
Air compressor range: 10 scfm to 35 scfm, 30 to 140
psi (0.2--0.97 MPa, 2 to 9.7 bar)
Material
Elastomerics
(textured)
Simulated
Accoustical
Splatter Coat
and
Knockdown
Air Requirements* Minimum
Compressor
Size*
30 scfm at 90 psi
(0.84 m
0.63 MPa, 6.3 bar)
20 scfm at 60 psi
(0.56 m
0.42 MPa, 4.2 bar)
15 scfm at 40 psi
(0.42 m
0.28 MPa, 2.8 bar)
3
/min at
3
/min at
3
/min at
15 HP
5.5 HP
8HP
After first 20 hours of operation and each 100
hours thereafter: Change oil.
Weekly: Remove engine air filter cover and clean
element. In very dusty environments, check filter daily.
Replace element as needed. Replacement elements
can be purchased from your local HONDA dealer .
Spark plug: Use only a (NGK) BP6ES or BPR6ES
plug. Gap plug to 0.025 to 0.030 in. (0.7 to 0.8 mm).
Always use a spark plug wrench.
6 months: Clean Air Flow Sensor as follows:
1. Fig. 3. Loosen adapter (A). Pull down quick release (C) and swing out flow sensor regulator.
Disconnect connector (B).
2. Remove inlet fitting (D), retainer ring (E), piston (F)
and spring (G) from flow sensor regulator (H).
CAUTION
Do not scratch or nick piston (F) or inside of flow
sensor regulator (H).
Orange Peel 20 scfm at 60 psi
(0.56 m
0.42 MPa, 4.2 bar)
* Material, temperature and volume affect cfm needed
to properly atomize material.
3
/min at
8HP
Maintenance
CAUTION
D For detailed engine maintenance and specifica-
tions, refer to separate HONDA engine manual.
D Close black fuel shutoff lever whenever you are
transporting sprayer to prevent fuel from flooding
engine.
D Keep sprayer upright and level when operating it
and when transporting it. This prevents crankcase
oil from leaking into combustion chamber, which
makes startup very difficult.
3. Clean all parts (D, E, F, G). Clean inside of (H)
with a pipe cleaner.
4. Assemble all parts and install flow sensor regulator.
Flow
Sensor Regulator
C
B
A
Daily: Check engine oil level and fill as needed.
Daily: Check and fill gas tank.
Daily: Check sprayer air filter, clean and replace
element as needed.
6 309662
D E FG H
Fig. 3
Flow
Sensor Regulator
ti4366a
Troubleshooting
WARNING
To reduce risk of injury due to sprayer starting
unexpectedly, shut off engine before performing
checks or service.
Check everything in chart before disassembling sprayer.
PROBLEM
Engine does not start Engine switch not ON Turn engine switch ON
Engine operates, but
displacement pump does not
CAUSE SOLUTION
Outofgas Fill gas tank
Spark plug cable disconnected or
spark plug damaged
Oil seepage into combustion
chamber
Oil level low Add oil to engine crankcase
Flow control set to OFF Set flow control to PRIME mode or LOW/
Air compressor not on or insufficient
air flow from compressor
Air pressure set to low Check display for air pressure. System
Connect spark plug cable or replace
spark plug
Remove spark plug. Pull starter rope 3 or
4 times. Clean and install spark plug. Try
to start. Keep sprayer upright and do not
overfill engine crankcase to avoid oil
seepage.
MED/HIGH while triggering gun
Start air compressor
Increase SCFM or compressor size.
Check air passages and tips for obstruc-
tions.
Check air filter element for clogs.
requires a minimum of 40 psi (0.28 MPa,
2.8 bar) to operate. Increase pressure by
adjusting air control knob.
Sprayer engine RPM too low Increase engine speed
Clutch connector into back of circuit
board is loose.
Air filter dirty Clean or replace filter element.
Air flow sensor dirty or damaged Check air filter.
Air transducer failed Check display for correct air pressure
Fluid transducer failed Check connection at circuit board.
Clutch not engaging Worn or damaged clutch. See page 18.
Displacement pump rod seized by
dry coating
Check and ensure a tight connection.
Clean air flow sensor (see page 4) or replace as needed.
reading. Replace circuit board as needed.
Replace fluid transducer.
Fluid transducer failure. Air transducer
failure.
Service pump. See page 10.
309662 7
Troubleshooting (Continued)
d
ispl
(
)
(Continued)
l
PROBLEM
Engine operates, but
acement pumpdoes not
Continued
Engine operates, displacement pump operates, but no
materialpressure at gun.
Low fluid delivery
CAUSE SOLUTION
Connecting rod worn or damaged Replace connecting rod. See page 14.
Drive housing worn or damaged Replace drive housing. See page 15.
Pinion assembly worn or damaged Service pinion assembly . See page 16.
Flow control is set to PRIME Set flow control to LOW/MED/HIGH while
triggering gun.
Fluid system over--pressurized Spraying material is too thick or the mate-
rial hose is too long. Use a less course
material or a shorter hose.
Gun nozzle/disk is clogged Check and clean nozzle/disk as needed.
Switch to a larger nozzle/disk.
Material flowing out drain line Check for air leaks to dump valve.
Check dump valve for wear, replace as
needed.
Air flow sensor dirty or damaged.
Pump is packed out Disassemble and clean pump (see page
8), hose(s) and gun.
Siphon hose strainer is clogged. Clean or remove strainer
Engine RPM too low Increase engine speed. See Startup,
procedure in operator manual.
Loss of air control or volume
at gun
Flow control set too low Increase flow control to MED or HIGH
Hose too long or material too
coarse
Change to a shorter hose or less coarse
material.
Material flowing out drain line Check drain line for a constant flow of
material when sprayer is operating in
LOW/MED/HIGH mode.
Check for air leaks to prime valve.
Check dump valve for wear, replace as
needed.
Gun nozzle/disk is clogged Check and clean nozzle/disk as needed.
Switch to a larger nozzle/disk.
Pump is packed out Disassemble and clean pump (see page
8), hose(s) and gun.
Gun air passages clogged with
material
After releasing gun trigger, make sure
system is fully depressurized before triggering gun again. This helps prevent
material backing into gun passages.
Air filter dirty Clean or replace element
Air flow sensor dirty or damaged Check air filter.
Clean air flow sensor (see page 4) or replace as needed.
Displacement pump output
Piston ball (220) not seating Clean piston area. See page 12.
ow on upstroke
Piston packings worn or damaged Replace packings. See page 12.
Siphon hose coupling gasket (1e)
Replace or install gasket
worn or missing.
Pump cylinder o-ring (205) worn or
Replace o-ring
missing
8 309662
Troubleshooting (Continued)
l
h
(
)
PROBLEM
Displacement pump output
ow ondownstrokeorbot
strokes
Material leaks into wet-cup
Material leaks into wet-cup
Intermittent material flow out
of gun
CAUSE SOLUTION
Siphon hose strainer is clogged Clean strainer
Piston packings worn or damaged Replace packings. See page 12.
Intake valve ball (216) not seating
properly
Clean and service intake valve. See
page 12.
Clutch (9) worn or damaged Replace clutch. See page 18.
Air leak at pump foot valve or
siphon tube elbow
Be sure foot valve is tight each day.
Be sure seal in elbow is in place and is
not worn or damaged.
Loose wet-cup (202) Tighten wet-cup enough to stop leakage
Throat packings worn or damaged Replace packings. See page 12.
Displacement rod (201) worn or
Replace displacement rod. See page 12.
damaged
Material supply is low or empty Refill and prime pump. See Startup proce-
dure in operator manual. Check material
supply often to prevent running pump dry .
Air control on gun is set too high. Reduce the air flow through the gun by
turning the air control knob on the back of
the gun.
Heavy or poorly atomized mat erial when gun is first triggered
(lack of soft start)
Pump does not shut off after
gun trigger is released
Premature prime valve failures
Hose too long or material too
coarse
Fluid pressure was not allowed to
fully self relieve after releasing gun
Change to a shorter hose or less coarse
material.
Wait longer between releasing gun trigger
and re--triggering.
trigger
Gun was not fully triggered immediately when squeezed, causing gun
air passages to clog with material.
Always squeeze trigger fully to prevent
just air from turning on, which starts pump
and pressurizes hoses. Disassemble and
clean gun.
Air valve failure Check and replace as needed
Air flow sensor dirty or damaged Check air filter.
Clean air flow sensor (see page 4) or replace as needed.
Air leaks in the system after the air
flow sensor
Check and tighten all connections between the air flow sensor and the gun.
Air leaks in gun Check gun for excessive air leaks and re-
pair.
See manual 309661
Air flow sensor dirty or damaged Check air filter.
Clean air flow sensor (see page 4) or replace as needed.
Pump does not shut off after gun
trigger is released.
Read “Pump does not shut off after gun
trigger is released” and fix appropriate
problem.
Repair or replace Prime Valve.
See page 19.
309662 9
Displacement Pump Repair
Removal
WARNING
To reduce risk of injury due to sprayer starting
unexpectedly, shut off engine before performing
checks or service.
1. Fig. 4. Flush sprayer. Remove suction hose elbow
(150a), pump outlet hose (A) and drain hose (64).
150a
A
63
27
159
158
22
85
3
2. Fig. 5. Start engine. Jog flow control between
PRIME and OFF until connecting rod stops near
bottom of stroke. Shut off engine.
3. Loosen two quick disconnect screws (27).
4. Pry retaining spring (37) up on connecting
rod (128). Push pin (38) out with a screwdriver.
5. Fig. 6. Remove cover (C) to control housing (54)
by removing four screws (12). Detach pressure
transducer cord (63, Fig. 4) from control board (9)
at port (D). Remove pressure transducer cord from
control box.
6. Fig. 4. Remove air hoses (158) and (159) from
prime valve manifold (85). Note correct air hose
connection to ports on air cylinder (22). Use 5/16
inch wrench to hold ring on hose fitting while
removing hose from fitting.
7. Support weight of pump (3) and remove two quick
disconnect screws (27).
8. Unscrew assembled dump valve manifold (85) and
air cylinder (22) from pump (3).
Fig. 4
3
Fig. 5
64
WARNING
MOVING PARTS HAZARD
To reduce risk of amputating fingers,
keep fingers away from connecting rod
and pin while jogging engine.
38
23
37
128
1
27
1
Torque to 20 ft-- lb (27 N.m)
2
Back of pump
Cutaway view shows how pin (38) goes
3
through connecting rod
38
201
128
61
TI3021B
3
D
9
2
ti3007b
54
12
C
Fig. 6
Repair
0407
See page 12 for pump repair instructions.
10 309662
Displacement Pump Repair
Installation
1. Fig. 4. Screw assembled dump valve manifold (85)
and air cylinder (22) into pump (3).
2. Fig. 5. Pull piston rod (201) out of pump (3) 2 to 3
inches (50 to 75 mm).
WARNING
MOVING PARTS HAZARD
If pin works loose, parts could break off
due to force of pumping action. Parts
could project through the air and result in
serious injury or property damage. Make sure pin
and retaining spring are properly installed.
3. Lift pump (3) into position and push in pin (38). Be
sure retaining spring (37) snaps down over end of
pin.
4. Support weight of pump (3) and fasten two quick
disconnect screws (27). Torque screws to 20 ft-lb
(27 N.m).
5. Fig. 4. Reattach air hoses (158) and (159) to prime
valve manifold (85). Ensure air hoses are attached
to the correct port on air cylinder (22).
6. Fig. 6. Route the pressure transducer cord (63,
Fig. 4) to the control box and attach to port (D) on
control board (9). Assemble cover (C) to control
housing (54) using four screws (12).
309662 11
WARNING
Pump Repair
3. Install nut (208*) on piston seat (213). Hand tighten nut firmly.
To reduce risk of injury due to sprayer starting
unexpectedly, shut off engine before performing
checks or service.
Disassemble Pump
1. See Displacement Pump Repair on page 10 to
remove pump.
2. Use a hammer on tabs of lug nut (214) to loosen
foot valve housing.
3. Fig. 7. Disassemble pump, but do not disassemble
piston rod (201) from piston housing (206) unless
either needs to be replaced. These two parts are
joined with high-strength (red) Loctiter. Joint must
be heated to disassemble.
Clean and Inspect All Parts
1. Clean all traces of sealant from all parts with a
compatible solvent.
2. Inspect all part for nicks and scratches. Replace
worn or damaged parts as they cause packings to
wear more quickly and may result in poor pump
performance.
4. Install ball (220*) in piston housing (206).
5. Apply blue Loctite to piston seat (213) threads and
screw assembly onto rod, hand tight.
TIP: Draw a line across male gland, nut and piston
housing for an alignment reference before tightening
piston and nut.
6. Place piston seat (213) in a vise. Hold packing nut
(208) steady with one wrench and use a torque
wrench to tighten rod assembly to 90--125 ft-lb
(122--170 N.m). Make sure reference line made in
step 5 is aligned.
7. Grease throat of intake housing (227). Assemble
into throat: male gland (204*), flat side first; alternate white packings (225*) and purple packings
(203*) and then female gland, all with lips facing
down. Install packing nut (202) and hand tighten,
firmly.
8. Grease piston packings and inside throat packings.
9. Grease new o-rings (205*) and install on cylinder
(221). Slide cylinder into bottom of intake housing
(227) until you hear it snap.
Repair Kit
Packing Repair Kit 235186 is available. Replace all
parts in kit for best results.
Parts included in kit are marked with an asterisk in text
and drawings. For example, 208*.
Assemble Pump
1. Fig. 7. If piston rod (201) and piston housing (206),
were disassembled, clean threads thoroughly .
Apply Loctite primer and then red Loctite to
threads and torque to 80 to 100 ft-lb (110 to
135 N.m). Allow to dry at least 1 hour.
2. Assemble onto piston seat (213): washer (212);
u-cup seal (218*) with lips toward ring; female
gland (211*) and then alternate white (210*) and
purple packings (219*), all with lips facing up; male
gland (209*).
10. Guide piston rod assembly into cylinder so piston
rod flats are aligned with opening in front of pump.
Push down until you hear another snap. Turn
pump over and push assembly in completely.
1 1. Align rod hole to front of pump with a screw driver.
12. Grease o-ring (223*), install on plug (224), install
plug and screws (222) loosely. Torque screws to
50--70 in--lb (5.6--8 N.m) in a crosswise pattern.
13. Install ball (216*) and ball guide (217) into foot
valve. Place pump assembly on foot valve and
push into place.
14. Screw on lug nut (214). Tighten lug nut securely
with a hammer.
TIP: Lug nut must be tight or pump will not prime.
Draw a line between intake housing and lug nut for an
alignment reference during operation.
12 309662
Grease inside of throat
1
before installing packings
Lips of v-packings in throat
2
must face down
Grease inside of packings
3
after installing
Torque piston housing to piston seat
5
(213) to 90--125 ft--lb (122-- 170
N.m) without changing alignment of
packing nut
Lips of v-packings on
6
piston must face up
Grease outside of packings
7
after installing
Lips of u-cup seal on
8
piston must face down
If piston seat and rod were
9
separated, apply Loctite primer,
then red Loctite, and torque to
80-- 100 ft--lb (110--135 N.m)
10
Tighten with hammer
Pump Repair
202
1
227
*226
3
2
*203
*204
5
206
*209
7
6
*210
*21 1
*218
8
225*
201
9
205*
220*
207*
208*
219*
32
76
Fig. 7
212
221
215
TI3015A
214
217
205*
216*
10
TI3015A
309662 13
Bearing Housing & Connecting Rod
Removal
WARNING
To reduce risk of injury due to sprayer starting
unexpectedly, shut off engine before performing
checks or service.
1. Fig. 8. Perform steps 1--8 of Displacement Pump,
Removal, page 10.
2. Remove four screws (40) and front cover (21).
3. Remove four screws (48) and lockwashers (49)
from bearing housing (23).
4. Pull connecting rod assembly (22) and lightly tap
lower rear of bearing housing (23) with a plastic
mallet to loosen it from drive housing (20). Pull
bearing housing and connecting rod assembly off
drive housing.
4. Align connecting rod with crank (A) and carefully
align locating pins (D) in drive housing (20) with
holes in bearing housing (23). Push bearing housing onto drive housing or tap it into place with a
plastic mallet.
5. Install four screws (48) and lockwashers (49) on
bearing housing (23). Torque screws evenly to 25
ft-lb (34 N.m).
6. Do steps 2 -- 5 of Displacement Pump, Installa-
tion, page 10.
20
A
B
1
C
1
22
3
23
48,49
40
5. Inspect crank (A) for excessive wear and replace
drive housing, if necessary , page 15.
Installation
1. Evenly lubricate inside of bronze bearing (E) in
bearing housing (23) with high-quality motor oil.
Liberally pack top roller bearing (B), lower bearing
(C) inside connecting rod assembly (22) with
bearing grease.
2. Assemble connecting rod (22) and bearing housing
(23).
3. Clean mating surfaces of bearing housing (23) and
drive housing (20).
CAUTION
Do not use bearing housing screws (48) to align or
seat bearing housing with drive housing. Align these
parts with locating pins (D), to avoid premature
bearing wear.
85b
Liberally pack with
1
bearing grease
(20d), supplied
Lubricate with
2
high quality
motor oil
Torque to
3
25 ft-- lb (34 N.m)
See page 10 to
4
remove pump
Fig. 8
21
D
E
4
2
86
1f
TI3021A
14 309662
Drive Housing
19
21
91
8g
1
40
8h
A
56
84
39
93
36
59
36
58
To reduce risk of injury due to sprayer starting
WARNING
unexpectedly, shut off engine before performing
2
92
84
8
checks or service.
1. Fig. 9. Disconnect siphon hose elbow (150a), drain
hose (64) and material hose (not shown) from
pump outlet. Disconnect cables. Remove screws
(21) and front cover (19).
2. Remove four screws (40) and lockwashers (56)
from bearing housing (39).
3. Lightly tap back of bearing housing (39) with a
plastic mallet. Pull pump, bearing housing and
connecting rod away from drive housing (8) as one
assembly.
4. Remove bearing housing screws (93) and lockwasher (36) and pinion housing screws (59) and
64
lockwashers (36).
1
2
Fig. 9
Torque to
25 ft-- lb
(34 N.m)
Apply remaining
grease to these
areas
150a
TI3023A
5. Lightly tap around drive housing (8) to loosen drive
housing. Pull drive housing straight off pinion
housing (58). Be prepared to support combination
gear (91), which may also come out.
6. Liberally apply bearing grease (supplied with
combination gear) to combination gear (91) and to
areas called out by note 2.
7. Place bronze colored washer (8g) and then silvercolored washer (8g) on shaft protruding from big
bearing of drive housing (8). Align gears and push
new drive housing straight onto pinion housing and
locating pins (A).
8. Reassemble sprayer. Or, go to next section in this
manual if further service is needed.
309662 15
Pinion Assembly/Rotor/Field/Shaft/Clutch
Removal
6. Fig. 12. Remove retaining ring (58e).
WARNING
To reduce risk of injury due to sprayer starting
unexpectedly, shut off engine before performing
checks or service.
If pinion assembly (58) is not removed from clutch
housing (88), do 1. through 4. Otherwise, start at 5.
1. Remove drive housing (8); page 15.
2. Disconnect field cable from flow control.
3. Fig. 10. Remove five screws (99) and
lockwashers (43) and pinion assembly (58).
99
43
58
99
Fig. 10
4. Fig. 11. Place pinion assembly (58) on bench with
rotor side up.
5. Remove four screws (95) and lockwashers (43).
Install two screws in threaded holes (E) in rotor.
Alternately tighten screws until rotor comes off.
43
95
43
E
8700A
7. Tap pinion shaft (58d) out with plastic mallet.
58e
58d
8703B
Fig. 12
8. Fig.13. Use an impact wrench or wedge something
between armature (89) and clutch housing to hold
engine shaft during removal.
9. Remove four screws (2) and lockwashers (43).
10. Remove armature (89).
Fig. 11
16 309662
8701B
Fig. 13
89
43
2
8704A
Pinion Assembly/Rotor/Field/Shaft/Clutch
Installation
1. Fig. 14. Lay two stacks of two dimes on smooth
bench surface.
6. Fig. 12. Tap pinion shaft (58d) in with plastic
mallet.
2. Lay armature (89) on two stacks of dimes.
3. Press center of clutch down on bench surface.
4a
0.12 ±.01 in. (3.0 ±.25 mm)
Fig. 14
4. Install armature (89) on engine drive shaft.
5. Install four screws (2) and lockwashers (43) with
torque of 125 in-lb.
Collar
Removal
1. Fig. 15. Loosen two screws (2) on collar (86),
2. Push screwdriver into slot in collar (86) and remove collar.
8705A
7. Install retaining ring (58e) with beveled side facing
field.
8. Fig. 11. Place pinion assembly (58) on bench with
rotor side up.
9. Apply locktite to screws. Install four screws (2) and
lockwashers (43). Alternately torque screws to 125
in-lb until rotor is secure. Use threaded holes to
hold rotor.
10. Fig. 10. Install pinion assembly (58) with five
screws (99) and lockwashers (43).
1 1. Connect field cable to flow control.
1
Face of clutch housing
2
1.812 ±.010 in. (46.02 ±.25 mm)
3
Torque to 125 ±.10 in-lb (14 ±1.1 N¡m)
4
Chamfer this side
Installation
1. Fig.15. Install engine shaft key (90).
2. Tap collar (86) on engine shaft (A) with plastic
mallet.
3. Press collar (86) onto engine shaft (A). Maintain
dimension shown note 2 in Fig. 15. Chamfer must
face engine.
Check dimension: Place rigid, straight steel bar (B)
across face of clutch housing (88). Use accurate
measuring device to measure distance between
bar and face of collar . Adjust collar as necessary.
Torque two screws (16) to 125 ±10 in-lb (14 ±1.1
N¡m).
90
Fig. 15
1
88
2
86
B
A
4
2
3
03483
309662 17
Clutch Housing
Removal
1. Fig. 16. Remove four capscrews (42) and lockwashers (29) which hold clutch housing (88) to
engine.
2. Remove screw (101) from under mounting
plate (D).
3. Remove engine key (90).
4. Pull off clutch housing (88).
90
88
Installation
1. Fig. 16. Push on clutch housing (88).
2. Install four capscrews (42) and lockwashers (29)
and secure clutch housing (88) to engine. Torque
to 200 in-lb (22.6 NSm).
3. Install capscrew (101) from beneath mounting
plate (D). Torque to 26 ft-lb (35.2 NSm).
Fig. 16
29
42
D
101
8708A
18 309662
Engine
Removal
1. Remove Pinion Assembly/Rotor/Field/Pinion/
Clutch, Clamp and Clutch Housing,asin-
structed on pages 16, 17, and 18.
2. Fig. 17. Disconnect all necessary wiring.
3. Fig. 18. Remove two locknuts (18) and
screws (17) from base of engine.
4. Lift engine carefully and place on work bench.
NOTE: All service to the engine must be performed by
an authorized HONDA dealer.
SPRAYER WIRING DIAGRAM
6Wires
Red, Yellow, Green,
Blue, White, Black
Installation
1. Lift engine carefully and place on cart.
2. Fig. 18. Install two screws (17) in base of engine
and secure with locknuts (18). Torque to 200 in-lb
(22.6 NSm).
3. Fig. 17. Connect all necessary wiring.
4. Install Pinion Assembly/Rotor/Field/Pinion/
Clutch, Clamp and Clutch Housing,as
instructed on pages 16 and 17 and 18.
Flow control
Fig. 17
70
Transducer
Air valve
2X Red
2X Black
Flow sensor regulator
TI3110A
71
Fig. 18
8710A
309662 19
Parts - Sprayer
61
C
TI4365a
100
122
BOTTOM VIEW
104
A
24
Page 22
117
17
24
25
72
34
1
35
13
60
164
81
32
99
95
43
29,
42
88
43
90
43
101
86
94
DETAIL A
52
1
59
84
89
2
87
33
36
158
43
185
58, page 21
Ref 8h
Ref 8g
91
62
1
159
2
36
83,
page
23
8, page 21
92
93
85
75
27
14
112
123
1
128
38
37
40
39
64
19
56
80
3, page 20
21
118
51
119
20 309662
140
150
130
162
18
102
16
105
ti4365c
26
153
73
1
Danger and warning labels, tags, and cards are free.
152
Parts - Sprayer
Ref No. Part No. Description Qty
1 187604 SLEEVE, cart 2
2 108803 SCREW, hex, socket head 6
3 235706 PUMP, texture, 3 gpm 1
4 157705 UNION, swivel 1
6 116354 BUSHING, strain relief 1
7 15B560 SPACER, bolt 1
8 287128 KIT , repair, drive housing 1
9 234234 KIT , control board 1
12** 116252 SCREW, #8 taptite phil 4
13 15B935 WIRE, jumper 1
14 183350 WASHER 2
16 193682 PLUG, tube 2
17 110837 SCREW, flange, hex 2
18 110838 NUT, lock 2
19 241308 COVER, drive 1
21 114818 SCREW, self--tap, filhd 4
22 111836 CYLINDER, air 1
23 114263 FITTING, connector, male (for 1030fc) 1
23 104172 FITTING, connector, male (for 1030) 1
24 237686 CLAMP, grounding assy 1
25 112798 SCREW, thread forming, hex hd 1
26 224442 KIT, repair, suction, (55 gal) 1
27 187111 SCREW, quick disc 2
28** 15c004 LABEL, crtl box cover 1
29 100214 WASHER, lock 4
30 111834 NIPPLE, pipe, hex 1
31 157785 UNION, swivel 1
32 114530 ENGINE, gas, 5.5 hp, Honda 1
33 245162 FRAME, cart 1
34 113084 RIVET, blind 2
35 192014 PLA TE, indicator 1
36 104008 WASHER, lock, spring 6
37 183169 SPRING, retaining 1
38 183210 PIN, str, hdls 1
39 287129 HOUSING, bearing 1
40 114666 SCREW, cap, socket hd 4
41 15C088 ADAPTER, dump valve 1
42 108842 SCREW, cap, hex hd 4
43 105510 WASHER, lock, spring (hi--collar) 15
44 117740 KNOB, switch 1
45 111457 PACKING, o--ring 1
46 164856 FITTING, nipple, reducing 1
47 234231* KIT , dump valve, repair 1
49 15B680 PLATE, control box 1
50 234232 KIT, flow sensor 1
51 104811 CAP, hub 2
52 112827 BUTTON, snap 2
53 115244 NUT, regulator 1
54 15B558 HOUSING, control 1
55 15B684 PANEL, control 1
56 106115 WASHER, lock spring (hi--collar) 4
58 245399 KIT, repair, pinion housing 1
59 101864 SCREW, cap, sch 4
60 240997 CONDUCTOR, ground 1
61 102478 STRAP, tie, wire 1
62 194125 LABEL, danger, English 1
63a 287130 TRANSDUCER, pressure, (for 1030fc) 1
63b 15C238 PLUG, manifold, (for 1030) 1
64 235738 HOSE, drain, 12 ft 1
66 117741 SCREW, mach, phillips 2
68 111831 SCREW, cap, skt, button hd 1
69 109466 NUT, lock, hex 2
70 15B671 SWITCH, rotary 1
72Y 194126 LABEL, warning 1
73 188509 CLIP, spring 2
75Y 290228 LABEL, caution 1
Ref No. Part No. Description Qty
76** 15C003 LABEL, display LCD 1
79 114151 FITTING, elbow, male, swivel (for 1030fc,
5/32 in. tubing) 1...................
79 112698 FITTING, elbow, male, swivel (for 1030,
1/4 in. tubing) 1....................
80 15C002 LABEL, identification 1
81 114687 CLIP, retainer 1
82 111832 SCREW, cap, sch 3
83 287127 KIT, dump valve (see pg 23) 1
84 114672 WASHER, thrust 2
85 15B766 MANIFOLD, dump valve 1
86 193680 COLLAR, shaft 1
87 193510 HUB, armature 1
88 193531 HOUSING, clutch 1
89† ARMATURE, clutch, 5 in 1
90 183401 KEY, parallel 1
91 241440 GEAR, combination 1
92 114699 WASHER, thrust 1
93 114686 SCREW, cap, socket hd 2
94† ROTOR, clutch, 5 1
95 101682 SCREW, cap, sch 4
96 100020 WASHER, lock 3
99 100644 SCREW, cap, sch 5
100 1 14678 BUSHING, strain relief 1
101 1 13802 SCREW, hex hd, flanged 1
102 1 14984 SCREW, tapping, phillips pan hd 2
104 1 11483 CLAMP, cable 2
105 206994 FLUID, TSL 8 oz bottle 1
112 108795 SCREW, mach, pnh 4
117 245245 HANDLE, cart 1
118 198723 CLIP, axle 2
119 198720 WHEEL, semi pneumatic, 12 in. 2
120 1 14331 SCREW, mach, pnh, sems 6
122 1 11482 RIVET, snap 2
123 108068 PIN, spring straight 2
124 1 15522 SCREW, mach, pnh 3
128 241279 ROD, connecting 1
130 1 16891 WASHER 4
138 1 12774 SCREW, mach 9
140 235490 GUN, texture (see manual 308274) 1
144 15C005 LABEL, flow control 1
145Y 189246 LABEL, warning 1
146** 15B668 LABEL, instruction 1
148 188634 LABEL, outlet 1
150 235737 HOSE SET, 1/2” air x 3/4” fluid 1
151 15B683 VALVE, air 1
152 1 17780 FITTING, tee male branch 1
153 1 10980 CLAMP, hose 1
154 1 17781 SCREW, machine, pnh 2
155 C27076 NUT 2
156 15C190 PLATE, retaining 1
157 1 15492 SCREW, mach, slot hex wash hd 2
158 15C173 HOSE, 5/32” blue tubing 1
159 15C174 HOSE, 5/32“ black tubing 1
160 102040 NUT, lock. hex 2
162 15C040 LABEL, instruction 1
163** 246606 KIT, digital display 1
164 15C283 TUBE, nylon 1
185 1 11340 GASKET 1
* Kit 234231 contains: seat, sst tip, and o--rings
** Kit 246606 contains items:12, 28, 76 and 146
† Kit 2411 13 contains items:89 and 94
Y Danger and warning labels, tags, and cards are free.
309662 21
Parts - Flow Control
See page 21 for parts description and page 20 for location on sprayer.
171
172
170
169
168
174
167
176
173
138
55
157
50
Kit 248327
28163
53
146
76
44
124
12
Ref
No. Part No. Description Qty
138† 112774 SCREW, mach 9
157† 115492 SCREW, mach, slot hex wash hd 2
160† 102040 NUT, hex, 1/4-- 20 2
162† 15D885 LABEL, instructions 1
167† 15D864 BRACKET, 1030FC, air filter 1
168† 155494 UNION, swivel, 90 degree 1
169† 155665 UNION, adapter 1
170† 155699 ELBOW, street 1
171† C20483 NIPPLE, hex, 3/8 npt 1
172† 106148 FILTER, air, 3/8 npt 1
173† 15D863 SPACER, standoff, 1030FC, filter 2
174† 119251 SCREW, self-- tap, filhd, 8--32 2
176† 106151 VALVE, drain, auto 1
180‡ 156823 UNION, swivel 1
181‡ 162453 ADAPTER 1
182‡ FLOW SWITCH 1
† Included in Kit 248327 which may be ordered separately
‡ Included in Kit 248328 which may be ordered separately
160
66
C
162
46
69
144
138
160
145
1
54
9
120
148
151
4
154
155
7
70
ti4366b
1
Danger and warning labels, tags, and cards are free.
B
Flow
Sensor Regulator
6
49
C
ti4366a
22 309662
A
182181180
Parts - Dump Manifold
See page 21 for parts description and page 20 for location on sprayer.
159 (black)
158 (blue)
Detail A
23n
22n
TI3122A
79n
1
68n
47n
3
41n
30
63a
63bn
45n
96n
82n
2
85n31
3
3
TI3008e
1
Prime V alve Repair Kit 234231 Installation
1. Replace all parts shown for (47).
2. Apply blue LockTite to threads of screw (68).
3. Detail A. Hold piston assembly of air cylin-
der (22) with 3/16 in. hex driver and torque
screw (68) to 40 to 50 in-lb.
4. Detail C. Place valve seat (b) with rounded
end out toward screw head. Place dark
color o--ring (c), carbide seat (d) either side
up, and white o--ring (e).
Torque screw (82) to 40 to 50 in-lb.
2
Detail B. Dump valve adapter (41) must be installed with
3
smaller ID bore and OD orientation groove (if present)
toward air cylinder assembly.
n Parts included in kit 287127.
Detail B
TI10245e
Detail C
b
TI10246e
309662 23
c
e
d
Parts - Displacement Pump
*
*
*
*
*
*
Model 235166, Series A
Includes items 201227
Ref
No. Part No. Description Qty
201 188437 PISTON ROD 1
202 187068 PACKING NUT 1
203 188560* V-PACKING, poly 2
204 187939* GLAND, male 1
205 188557* O-RING 2
206 187934 PISTON HOUSING 1
207 188559* O-RING, fluoroelastomer 1
208 188434* NUT 1
209 188432* GLAND, male 1
210 188561* V-PACKING, poly 2
21 1 188433* GLAND, female 1
212 188627 BACKUP WASHER, nylon 1
213 235165 PISTON SEA T 1
214 187929 LUG NUT 1
215 235963 INT AKE HOUSING 1
216 102973* BALL, intake, 1.25 in. Dia. 1
217 187064 BALL GUIDE 1
218 188558* U-CUP SEAL, poly/fluoroelastomer1
219 187072* V-PACKING, poly 3
220 102972* BALL, piston; 0.875 in. Dia. 1
221 187066 CYLINDER 1
225 187071* V-PACKING, poly 3
226 187070* GLAND, female 1
227 187933 HOUSING, outlet 1
228 183210 PIN 1
232 235962 SEAL, foot valve 1
* Included in Repair Kit 235186, purchased separately. Kit
includes pressure drain valve u-cup packing, 111829.
202
228
201
*226
*225
*204
227
*205
221
*205
*210
203*
206
208
207
209
219
21 1*
218
212
220
213
217
216*
232
215
214
TI3020A
24 309662
Parts - Pinion and Drive Housing Repair Kits
Ref No. 58 and 8
Pinion Housing Repair Kit Ref No. 8: Drive Housing Repair Kit
Ref
No. Part No. Description Qty
58 245399 KIT, repair, pinion housing 1
58b 105489 PIN 2
58d* 241114 PINION SHAFT 1
58e 112770 RETAINING RING, large 1
*Must be ordered separately.
58e
58d
58b
59 (Ref)
36 (Ref)
Ref
No. Part No. Description Qty
8 287128 KIT, repair, drive housing 1
8g 194173 WASHER 1
8h 116192 WASHER 1
8p 290228 LABEL, caution 1
58
8h
8g
84 (Ref)
8
8p
17 (Ref)
1
91 (Ref)
92 (Ref)
1
Pinion housing assembly (58) includes clutch field and connector
81 (Ref)
TI0177B
309662 25
Accessories
USE ONLY GENUINE GRACO PARTS AND ACCESSORIES
Air And Material Hose Kit 235737
Max. Working Pressure
Fluid: 750 psi (5.18 MPa, 51.7 bar)
Air: 300 psi (2.07 MPa, 20.7 bar)
50 ft (15.2 m) hoses to supplement 50 ft (15.2 m) hose
kit supplied with sprayer. Use up to three more hose
kits. DO NOT use this kit at sprayer outlet as it does
not have a spring guard on material hose.
26 309662
Technical Data
Dimensions
Honda GX160 Engine
Power Rating @ 3600 rpm
ANSI 5.5 Horsepower.........................
DIN 6270/DIN 6271
NA 2.9 Kw--4.0 Ps...........................
NB 3.6 Kw--4.9 Ps...........................
Maximum Working Pressure 1000 psi..............
(7.0 MPa, 70 bar)
Cycles/gallon (liter) 42 (11)........................
Maximum Delivery 3 gpm (11 liter/min).............
Fuel Tank Capacity 0.95 gallon (3.7 liter)............
Pump Inlet Size 2 inch quick disconnect............
Fluid Outlet Size 3/4 npsm(f)......................
Wetted Parts
Displacement Pump Nickle-plated carbon steel,....
Stainless steel, Chrome-plated stainless steel,
Poly, Tungsten carbide, fluoroelastomer
Sound Data
Sprayer:
Sound Pressure Level 97dB(A)*.................
Sound Power Level 105dB(A)*..................
*Measured readings at 1 m, normal load.
Gun:
Sound Pressure Level 96dB(A)**................
Sound Power Level 104dB(A)**.................
**Measured while spraying simulated acoustical texture
under typical conditions as specified by material
manufacturer.
Weight (dry , without packaging) 150 pound (68 kg)...
Height 32 inch (813 mm).........................
Length 30 inch (762 mm).........................
Width 23 inch (584 mm)..........................
309662 27
Graco Warranty and Disclaimers
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 originalpurchaser foruse. With the exceptionof any special, extended,
or limited warranty published by Graco,Graco will, for a period of twelve months from the date of sale, repair orreplace any part of the
equipmentdetermined by Gracoto bedefective. This warranty applies onlywhen the equipmentis installed, operated andmaintained
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 orwear caused by
faultyinstallation, misapplication,abrasion, corrosion, inadequate or improper maintenance, negligence, accident,tampering, orsubstitution 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
equipmentwill be returnedto the original purchasertransportationprepaid. If inspection ofthe equipment doesnot disclose anydefect
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’ssole obligation and buyer’s sole remedyfor any breachof warranty shallbe as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental orconsequential damages for lost profits, lost sales,injury to person or property,or any
other incidental orconsequential loss) shall be available. Any action for breach of warranty must be brought within two (2)years ofthe
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.
FOR GRACO CANADA CUST
The parties acknowledge that they have required that the present document,as well as all documents, noticesand legal proceedings
entered into, given or instituted pursuant hereto or relating directly orindirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsique tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
OMERS
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.
28 309662
This manual contains English. MM309662
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440- 1441
www.graco.com
Written in USA 12/2002, Rev 01/2008
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