Repair
™
390
- For portable spray applications of architectural paints and coatings -
3300 psi (22.7MPa, 227bar) Maximum Working Pressure
IMPORTANT SAFETY INSTRUCTIONS!
Read all warnings and instructions. Save these instructions. Contact Graco Customer Service
or your local Graco distributor to obtain a manual in your language.
Airless Sprayer
310824D
Related Manuals
310820
Stand
ProStep
Model* VAC Country
262019, 253958
254968, 254969, 256391
254998, 262024, 256392
ti11608a
Hi-Boy
ti11583a
120 North America
240 Europe / Europe
multicord
240 Asia / Australia
309639
309250
310876
ti11626a
✔
✔
✔
256481, 253961
*all models not available in all countries
Graco Inc., PO Box 1441, Minneapolis, MN 55440-1441
Copyright 2004, Graco Inc. is registered to I.S. EN ISO 9001
110 UK
✔
Contents
Manual Conventions
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 7
General Repair Information . . . . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Displacement Pump Replacement . . . . . . . . . . . . 13
Drive Housing Replacement . . . . . . . . . . . . . . . . . 15
Spin Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manual Conventions
WARNING
Hazard Symbol
WARNING: a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
Warnings in the instructions usually include a symbol
indicating the hazard. Read the general Warnings
section for additional safety information.
Motor Brush Replacement . . . . . . . . . . . . . . . . . . 18
Control Board Replacement . . . . . . . . . . . . . . . . . 19
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pressure Control Assembly Replacement . . . . . . 22
Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . 23
Power Cord Replacement . . . . . . . . . . . . . . . . . . . 24
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 25
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 29
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 30
CAUTION
CAUTION: a potentially hazardous situation which, if
not avoided, may result in property damage or
destruction of equipment.
Note
Additional helpful information.
2 310824D
Warning
Warning
The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation
point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risks. Refer back to
these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.
Grounding Instructions
This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock
by providing an escape wire for the electric current. This product is equipped with a cord having a grounding wire with
an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in
accordance with all local codes and ordinances.
WARNING
GROUNDING
• Improper installation of the grounding plug is able to result in a risk of electric shock.
• When repair or replacement of the cord or plug is required, do not connect the grounding wire to either flat blade
terminal.
• The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire.
• Check with a qualified electrician or serviceman when the grounding instructions are not completely understood, or when in doubt as to whether the product is properly grounded.
• Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a qualified electrician.
• This product is for use on a nominal 120V circuit and has a grounding plug similar to the plug illustrated in the
figure below.
• Only connect the product to an outlet having the same configuration as the plug.
• Do not use an adapter with this product.
Extension Cords:
• Use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle that accepts the plug
on the product.
• Make sure your extension cord is not damaged. If an extension cord is necessary, use 12 AWG
(2.5 mm
• An undersized cord results in a drop in line voltage and loss of power and overheating.
310824D 3
2
) minimum to carry the current that the product draws.
Warning
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:
• Do not spray flammable or combustible materials near an open flame or sources of ignition such as cigarettes,
motors, and electrical equipment.
• Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity creates a risk
of fire or explosion in the presence of paint or solvent fumes. All parts of the spray system, including the pump,
hose assembly, spray gun, and objects in and around the spray area shall be properly grounded to protect
against static discharge and sparks. Use Graco conductive or grounded high-pressure airless paint sprayer
hoses.
• Verify that all containers and collection systems are grounded to prevent static discharge.
• Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2 adapter.
• Do not use a paint or a solvent containing halogenated hydrocarbons.
• Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area. Keep pump assembly
in a well ventilated area. Do not spray pump assembly.
• Do not smoke in the spray area.
• Do not operate light switches, engines, or similar spark producing products in the spray area.
• Keep area clean and free of paint or solvent containers, rags, and other flammable materials.
• Know the contents of the paints and solvents being sprayed. Read all Material Safety Data Sheets (MSDS) and
container labels provided with the paints and solvents. Follow the paint and solvents manufacturer’s safety
instructions.
• Fire extinguisher equipment shall be present and working.
• Sprayer generates sparks. When flammable liquid is used in or near the sprayer or for flushing or cleaning, keep
sprayer at least 20 feet (6 m) away from explosive vapors.
SKIN INJECTION HAZARD
• Do not aim the gun at, or spray any person or animal.
• Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with any part
of the body.
• Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.
• Use Graco nozzle tips.
• Use caution when cleaning and changing nozzle tips. in the case where the nozzle tip clogs while spraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing the nozzle tip to clean.
• Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn off the unit
and follow the Pressure Relief Procedure for turning off the unit.
• High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that injection occurs, get immediate surgical treatment.
• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.
• This system is capable of producing 3300 psi. Use Graco replacement parts or accessories that are rated a
minimum of 3300 psi.
• Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.
• Verify that all connections are secure before operating the unit.
• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.
4 310824D
Warning
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Always wear appropriate gloves, eye protection, and a respirator or mask when painting.
• Do not operate or spray near children. Keep children away from equipment at all times.
• Do not overreach or stand on an unstable support. Keep effective footing and balance at all times.
• Stay alert and watch what you are doing.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not kink or over-bend the hose.
• Do not expose the hose to temperatures or to pressures in excess of those specified by Graco.
• Do not use the hose as a strength member to pull or lift the equipment.
Misuse of the sprayer platform can cause death or serious injury.
• Do not exceed platform rating.
• Make sure sprayer is on firm, level, non-slippery, secure foundation before accessing sprayer platform.
• Make sure platform has been properly secured to frame before standing on platform.
• If you are unable to step up to sprayer platform, use a stable intermediate stepping device for stepping up to
sprayer platform or stepping down from sprayer platform.
• Keep both feet squarely and firmly on platform.
• Do not allow sprayer frame to come in contact with live electrical wires.
• Do not over reach while on sprayer platform.
• Do not position sprayer behind any doors when on sprayer platform.
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.
• Do not expose to rain. Store indoors.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1, 1, 1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing
such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment
rupture, and result in death, serious injury, and property damage.
BURN HAZARD
Equipment surfaces can become very hot during operation. To avoid severe burns, do not touch hot equipment. Wait
until equipment has cooled completely.
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.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
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:
• Protective eye wear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
310824D 5
Component Identification
P
R
B
A
F
U
E
M
Component Identification
S
B
K
A
N
U
E
H
D
K
T
Item English
A Pressure Control
BON/OFF switch
DPower Cord
E Fluid Outlet
FPrime Valve
HPump
J Suction Hose
KDrain Hose
MFluid Hose
NGun
PTip
R Guard
S Trigger Safety Lock
T Model/Serial Tag
UFilter
VPlatform
H
J
F
D
T
J
ti12008a
V
6 310824D
Installation
Installation
Grounding and Electric
Requirements
WAR NING
Your system must be grounded. Read warnings, page
3.
The sprayer cord includes: a grounding wire with an
appropriate grounding contact.
The sprayer requires:
110-120V Units: 100-130VAC, 50/60 Hz, 11A, 1 phase,
circuit with a grounding receptacle.
Do not use the sprayer if the electrical cord has a damaged ground contact. Only use an extension cord with
an undamaged ground contact.
Recommended extension cords for use with this
sprayer:
• 110-120V: 3-wire, 12 AWG (2.5 mm
ft. (90 m) maximum length.
• 240V: 3-wire, 16 AWG (1.0 mm
(90 m) maximum length.
Smaller gauge or longer extension cords may
reduce sprayer performance.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
2
) minimum, 300
2
) minimum, 300 ft
240V Units: 210-255 VAC, 50/60 Hz, 7.5A, 1 phase, circuit with a grounding receptacle.
Never use an outlet that is not grounded or an
adapter.
Fluid supply container: follow local code.
Solvent and Oil-based fluids: follow local code. Use
only conductive metal pails placed on a grounded surface such as concrete. Do not place the pail on a nonconductive surface such as paper or cardboard, which
interrupts grounding continuity.
Grounding the metal pail: connect a ground wire to the
pail by clamping one end to pail and other end to ground
such as a water pipe.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray gun
firmly to the side of a grounded metal pail, then trigger
the gun.
310824D 7
Pressure Relief Procedure
WAR NING
Pressure Relief Procedure
3. Turn prime valve down.
Follow this Pressure Relief Procedure whenever you
are instructed to relieve pressure, stop spraying, check
or service equipment or install or clean spray tip. Read
Injection Hazard Warning, page 3.
1. Turn OFF power and turn pressure control to lowest
pressure setting.
2. Hold gun against side of grounded metal flushing
pail. Trigger gun to relieve pressure.
ti5310a
FLUSH
ti5304a
If you suspect the spray tip or hose is clogged or that
pressure has not been fully relieved after following the
steps above, VERY SLOWLY loosen tip guard retaining
nut or hose end coupling to relieve pressure gradually,
then loosen completely. Clear hose or tip obstruction.
4. Engage trigger safety lock on gun if unit is being
shut down or left unattended.
8 310824D
General Repair Information
General Repair Information
WAR NING
Read Electric Shock Warning, page 3 and Burn
Hazard Warning, page 4.
WAR NING
Flammable materials spilled on hot, bare, motor could
cause fire or explosion. To reduce risk of burns, fire or
explosion, do not operate sprayer with cover removed.
• Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These
parts usually are not provided with replacement kits.
• Test repairs after problems are corrected.
• If sprayer does not operate properly, review repair
procedure to verify you did it correctly. See Trouble-
shooting, page 10.
• Overspray may build up in the air passages.
Remove any overspray and residue from air passages and openings in the enclosures whenever
you service sprayer.
WARNING
To reduce risk of serious injury, including electric
shock:
• Do not touch moving or electric parts with fingers
or tools while testing repair.
• Unplug sprayer when power is not required for
testing.
• Install all covers, gaskets, screws and washers
before you operate sprayer.
CAUTION
• Do not run sprayer dry for more than 30 seconds.
Doing so could damage pump packings.
• Protect the internal drive parts of this sprayer from
water. Openings in the cover allow for air cooling of
the mechanical parts and electronics inside. If
water gets in these openings, the sprayer could
malfunction or be permanently damaged.
• Prevent pump corrosion and damage from freezing.
Never leave water or water-base paint in sprayer
when its not in use in cold weather. Freezing fluids
can seriously damage sprayer. Store sprayer with
Pump Armor to protect sprayer during storage.
• Do not operate the sprayer without the motor shroud
in place. Replace if damaged. Motor shroud directs
cooling air around motor to prevent overheating and
insulate the control board from accidental electric
shock.
310824D 9
Troubleshooting
WAR NING
Read Electric Shock Warning, page 3, Burn Hazard
Warning, page 4 and Pressure Relief Procedure,
page 8.
Troubleshooting
Problem
What To Check
(If check is OK, go to next check)
(When check is not OK, refer to this column)
What To Do
Motor Won’t Operate
Basic Fluid Pressure 1. Pressure control knob setting.
Motor will not run if set at minimum (fully counter-clockwise).
2. Spray tip or fluid filter may be
clogged.
Basic Mechanical 1. Pump frozen or hardened paint Thaw sprayer if water or water-based paint has
2. Displacement pump connecting
rod pin. Pin must be completely
pushed into connecting rod and
retaining spring must be firmly in
groove or pump pin.
Slowly increase pressure setting to see if motor
starts.
Relieve pressure, page 8. Then clear clog or
clean gun filter. Refer to gun instruction manual,
309639.
frozen in sprayer. Place sprayer in warm area to
thaw. Do not start sprayer until thawed completely. If paint hardened (dried) in sprayer,
replace pump packings. See page 14, Dis-
placement Pump Replacement.
Push pin into place and secure with spring
retainer. See page 14, Displacement Pump
Replacement.
3. Motor. Remove drive housing
assembly. See page 16, Drive
Housing Replacement. Try to
rotate fan by hand.
10 310824D
Replace motor if fan won’t turn. See page 27,
Motor Replacement.
Troubleshooting
Problem
Basic Electrical
See wiring diagram, page
28
What To Check
(If check is OK, go to next check)
1. Electric supply. Meter must read
100-130 VAC for 110-120 VAC
models and 210-255 VAC for 240
VAC models.
2. Extension cord. Check extension
cord continuity with volt meter.
3. Sprayer power supply cord.
Inspect for damage such as broken insulation or wires.
4. Fuse. Check replaceable fuse on
control board (next to ON/OFF
switch).
5. Motor leads are securely fastened and properly connected to
control board.
What To Do
(When check is not OK, refer to this column)
Reset building circuit breaker, replace building
fuses. Try another outlet.
Replace extension cord.
Replace power supply cord. See page 26,
Power Cord Replacement.
Replace fuse after completing motor inspection.
See page 22, Fuse Replacement.
Replace loose terminals; crimp to leads. Be
sure terminals are firmly connected.
Clean circuit board terminals. Securely reconnect leads.
6. Motor thermal switch. Yellow
motor leads must have continuity
through thermal switch.
7. Brush cap missing or loose brush
lead connections.
8. Brush length which must be 1/4
in. (6mm) minimum.
NOTE: Brushes do not wear at
the same rate on both sides of
motor. Check both brushes.
9. Motor armature commutator for
burn spots, gouges and extreme
roughness.
10. Motor armature for shorts using
armature tester (growler) or perform spin test, page 17.
11. Pressure control not plugged in
to control board.
Replace motor. See page 27, Motor Replace-
ment.
Install brush cap or replace brushes if leads are
damaged. See page 19, Motor Brush
Replacement.
Replace brushes. See page 19, Motor Brush
Replacement.
Remove motor and have motor shop resurface
commutator if possible. See page 27, Motor
Replacement.
Replace motor. See page 27, Motor Replace-
ment.
Insert pressure control connector into control
board.
310824D 11
Troubleshooting
What To Check
Problem
Low Output 1. Worn spray tip. Relieve pressure, page 8. Replace tip. Refer to
(If check is OK, go to next check)
2. Verify pump does not continue to
stroke when gun trigger is
released.
3. Prime valve leaking. Relieve pressure, page 8. Then repair prime
4. Suction hose connections. Tighten any loose connections. Check o-rings
5. Electric supply with volt meter.
Meter must read 100-130 VAC for
110-120 VAC models and
210-255 for 240 VAC models.
Low voltages reduce sprayer performance.
6. Extension cord size and length. 7. Replace with a correct, grounded extension
(When check is not OK, refer to this column)
gun instruction manual, 309639.
Service pump. See page 14, Displacement
Pump Replacement.
valve. See page 24, Manifold Replacement.
on suction hose swivel.
Reset building circuit breaker; replace building
fuse. Repair electrical outlet or try another
outlet.
cord. See page 7, Grounding and Electric
Requirements.
What To Do
8. Leads from motor to circuit board
for damaged or loose wire connectors. Inspect wiring insulation
and terminals for signs of overheating.
9. Worn motor brushes which must
be 1/4 in. (6 mm) minimum.
10. Motor brushes binding in brush
holders.
11. Low stall pressure. Turn pressure
control knob fully clockwise.
12. Motor armature for shorts by
using an armature tester
(growler) or perform spin test,
page 17.
Be sure male terminal pins are centered and
firmly connected to female terminals. Replace
any loose terminals or damaged wiring.
Securely reconnect terminals.
Replace brushes. See page 19. Motor Brush
Replacement.
Clean brush holders. Remove carbon dust by
using compressed air to blow out brush dust.
Replace pressure control assembly. See page
23, Pressure Control Assembly Replace-
ment.
Replace motor. See page 27, Motor
Replacement.
12 310824D
Troubleshooting
Problem
Motor runs and pump
strokes
Motor runs but pump does
not stroke
What To Check
(If check is OK, go to next check)
1. Prime Valve Open. Close prime valve.
2. Paint supply. Refill and reprime pump.
3. Intake strainer clogged. Remove and clean, then reinstall.
4. Suction hose leaking air. Tighten nut. Check o-rings on swivel.
5. Intake valve ball and piston ball
are seating properly.
6. Leaking around throat packing
nut which may indicate worn or
damaged packings.
7. Pump rod damaged. See Pump Manual 309250.
1. Displacement pump pin damaged or missing.
(When check is not OK, refer to this column)
See Pump Manual 309250. Strain paint before
using to remove particles that could clog pump.
See Pump Manual 309250.
Replace pump pin if missing. Be sure retaining
spring is fully in groove all around connecting
rod. See page 14, Displacement Pump
Replacement.
What To Do
Motor is hot and runs
intermittently
2. Connecting rod assembly for
damage.
3. Gears or drive housing. Inspect drive housing assembly and gears for
1. Be sure ambient temperature
where sprayer is located is not
more than 115°F (46°C) and
sprayer is not located in direct
sun.
2. Motor has burned windings indicated by removing positive (red)
brush and seeing burned adjacent commutator bars.
3. Tightness of pump packing nut.
Overtightening tightens packings
on rod, restricts pump action and
damages packings.
Replace connecting rod assembly. See page
14, Displacement Pump Replacement.
damage and replace if necessary. See page 16,
Drive Housing Replacement.
Move sprayer to shaded, cooler area if possible.
Replace motor. See page 27, Motor
Replacement.
Loosen packing nut. Check for leaking around
throat. Replace pump packings if necessary.
See pump manual 309250.
310824D 13
Displacement Pump Replacement
Displacement Pump Replacement
See manual 309250 for pump repair instructions.
Removal
WARNING
Read Injection Hazard Warning, page 3, Moving
Parts Hazard Warning, page 4 and Pressure Relief
Procedure, page 8.
1. Relieve pressure, page 8.
2. Loosen two screws (30) and rotate cover (44).
ti6104a
44
30
4. Cycle pump until pin (32) is in position to be
removed.
5. Disconnect power cord from outlet.
6. Using a flat screwdriver, push retaining spring (C)
up. Push out pump pin (32).
C
32
ti6106a
3. Loosen nut (A) and remove hose set (35). Loosen
nut (B) and remove the high pressure hose (14).
14
B
A
35
ti6105a
7. Using a hammer, loosen pump jam nut (11).
Unscrew and remove pump (9).
ti6107a
11
9
11
14 310824D
Displacement Pump Replacement
Installation
WAR NING
If pump pin works loose, parts could break off due to
force of pumping action. Parts could project through
air and result in serious injury or property damage.
CAUTION
If the pump jam nut loosens during operation, the
threads of the drive housing will be damaged.
1. Extend pump piston rod full. Apply grease to top of
pump rod at (D) or inside connecting rod (7). Install
jam nut (11) on pump threads.
$
TIA
2. Install pump rod (D) into connecting rod (7).
3. Install pump pin (32). Verify retainer spring (C) is in
groove over pump pin.
5. Screw in pump until threads are flush with top of
drive housing opening.
6. Align pump outlet (E) to back.
%
7. Screw jam nut (11) up onto pump until nut stops.
Tighten jam nut by hand, then tap 1/8 to 1/4 turn
with a 20 oz (maximum) hammer to approximately
75 ft-lb (102 N•m).
8. Install suction tube (35) and high pressure hose
(14). Tighten nuts (A) and (B).
.
#
9. Fill packing nut with Graco TSL until fluid flows onto
14
B
A
35
ti6105a
top of seal.
TIA
4. Push pump (9) up until pump threads engage.
30
44
ti5735a
10. Rotate cover (44). Tighten screws (30).
310824D 15
Drive Housing Replacement
WAR NING
Read Injection Hazard Warning, page 3 and page 8.
Removal
Drive Housing Replacement
Installation
1. Apply a liberal coat of grease to gears and needle
bearing surfaces. Install thrust bearing (4) and
gears (2) and (3) in front endbell housing.
Needle
bearing
surfaces
1. Relieve pressure, page 8.
2. Remove pump (9). Displacement Pump Replace-
ment, page 14. Disconnect power cord from outlet.
3
ti5641a
4
2
5
7
6
32
30
6
3. Remove two screws (30) and cover (32).
4. Remove four screws (6).
3
4
2
ti6121a
2. Push drive housing into front endbell housing. Insert
gear crank (3) through hole in connecting rod (7).
3
7
5. Pull drive housing (5) out of motor front endbell.
6. Remove gear cluster (2) and (3) and thrust bearing
(4) from drive housing.
ti6124a
CAUTION
Do not drop gear cluster (3) and (2) when removing
drive housing (5). Gear cluster may stay engaged in
motor front endbell or drive housing.
3. Install four screws (6).
4. Install cover (32) with two screws (30).
5. Install pump (9). Displacement Pump Replace-
ment, page 14.
16 310824D
Spin Test
Spin Test
See Wiring Diagram, page 28.
WAR NING
Read Electric Shock Warning, page 3 and Pressure
Relief Procedure, page 8.
To check armature, motor winding and brush electrical
continuity:
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
2. Remove two screws (30) and shroud (29).
3. Remove drive housing (5), page 16.
4. Disconnect motor connector (F).
Armature Short Circuit Test
Quickly turn motor fan by hand. If motor coasts two or
three revolutions before complete stop, there are no
electrical shorts. If motor does not spin freely, armature
is shorted. Replace motor, page 27.
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
2. If uneven or no resistance, check for missing brush
caps, broken brush springs, brush leads, and worn
brushes. Repair as needed, page 19.
3. If still uneven or no resistance, replace motor, page
27.
30
29
ti5638a
F
4. Reattach motor connector (F).
5. Replace drive housing, page 16.
1. Connect red and black motor leads with test lead.
6. Replace shroud (29) and two screws (30).
Turn motor fan by hand at about two revolutions per
second.
310824D 17
Fan Replacement
Removal
Fan Replacement
3. Remove spring clip (101) on back of motor.
WAR NING
Read Electric Shock Warning, page 3 and Pressure
Relief Procedure, page 8.
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
2. Remove two screws (30) and shroud (29).
100
30
101
4. Pull off fan (100).
Installation
1. Slide new fan (100) in place on back of motor. Be
sure blades of fan face motor as shown.
2. Install spring clip (101).
3. Replace shroud (29) and two screws (30).
29
ti5769a
18 310824D
Motor Brush Replacement
Motor Brush Replacement
See Wiring Diagram, page 28.
Removal
Replace brushes worn to less than 1/4 in. (6mm).
Brushes wear differently on each side of motor, check
both sides.
WAR NING
Read Electric Shock Warning, page 3 and Pressure
Relief Procedure, page 8.
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
2. Remove two screws (30) and shroud (29).
3. Disconnect motor connector (D) from control board
(33).
4. Cut tie wrap (F).
2. Push each cap (A) into place over brush. Orient
each cap with the 2 projections on either side of the
brush lead. You will hear a “snap” when cap is
securely in place.
3. Using a wire stripper, strip off wire insulation approximately 1/4 inch (6 mm) from the end of each yellow
wire (C) to the motor.
4. Insert stripped end into end of a butt splice (E) on
new brush assembly.
5. Use a crimping tool to squeeze the ends of the butt
splice (E) tightly around each wire. Pull gently on
each wire to be sure it will not pull out of the butt
splice.
6. Using new tie wrap (F) from kit, wrap tie around
motor and wires only. Trim off excess. Be sure pressure hose and wire leads are not caught in tie wrap.
7. Reconnect motor connector (D) to control board
(33).
30
5. Locate two yellow wires (C) (thermal leads). Cut
each yellow wire at the center.
6. Using a flat screwdriver, pry off (two) brush caps
(A). Remove brushes (B) from motor.
7. Discard old brush harness.
8. While rotating fan by hand, using compressed air,
blow air into positive (top) brush holder to remove
brush dust.
To contain the dust, turn on your shop vac. Place
the end of the hose over the negative (lower) brush
holder while blowing compressed air into the positive (top) brush holder.
Installation
\
Use all new parts included in your brush kit. Do not
reuse old parts if new replacement parts are provided.
1. With wires facing toward front of motor, install new
brushes (B) in motor. Be sure to install the positive
(red) brush lead in the top of the motor (as shown)
and the negative (black) brush lead in the side of the
motor.
D
29
A
E
33
A
ti5637a
+
Red
B
F
C
D
Black
-
ti5637a
8. Replace shroud (29) and two screws (30).
310824D 19
Control Board Replacement
Control Board Replacement
See Wiring Diagram, page 28.
WAR NING
Read Electric Shock Warning, page 3 and Pressure
Relief Procedure, page 8.
Removal
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
2. Remove two screws (30) and shroud (29).
3. Disconnect pressure switch connector (A) from control board (33).
4. Disconnect motor connector (B) from control board
(33).
5. Remove 3 screws (30) securing control board to
housing (2 are located on the front and one on the
back next to the power cord).
6. Pull control board out slightly and then slide it back
and off of frame.
Make sure power cord is free and NOT wrapped
around cord wrap.
7. Remove grommet and wires from strain relief.
A
B
33
240V
.
33
120V
B
A
Ground wire will remain attached to sprayer with
grounding screw.
33
30
8. Remove 2 power cord connectors from control
board.
30
ti6119a
20 310824D
Installation
1. Position grommet and power cord wires through
strain relief in control board (33).
Control Board Replacement
ti6122a
33
2. Reconnect the power cord connectors to the correct
terminals indicated on the control board (120V,
black and white, 240V, blue and brown) on control
board (33).
Be sure power cord is routed between the blue high
pressure hose to the manifold and the sprayer
frame.
ti6125a
3. Carefully slide control board back into place on the
side of the motor frame.
4. Replace 3 screws (30). Torque to 30-35 in-lbs
(3.4-3.9 N.m)
5. Reattach motor connector (B) and pressure control
assembly connector (A).
6. Install shroud (29) and two screws (30).
B
A
33
B
A
33
30
J
30
H
120V
D
E
F
G
ti5639a
310824D 21
Fuse Replacement
Fuse Replacement
Removal
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
2. Remove two screws (30) and shroud (29).
3. Remove fuse from control board.
4. Remove spare fuse from motor.
Spare Fuse
(included n
110V and 120
models only)
Installation
1. Replace fuse on control board with spare fuse.
2. Install shroud (29) and two screws (30).
Replaceable Fuse
ti9134b
22 310824D
Pressure Control Assembly Replacement
Pressure Control Assembly Replacement
See Wiring Diagram, page 28.
WAR NING
Read Electric Shock Warning, page 3 and Pressure
Relief Procedure, page 8.
Removal
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
30
29
2. Remove two screws (30) and shroud (29).
3. Disconnect pressure switch connector (A) from control board (33).
4. Remove tape (22) holding wires to manifold.
5. Pull wires back through hole (K) in housing.
22
TIC
6. Turn the pressure control knob (16) counter clockwise as far as you can to access the flats on either
side of the pressure control assembly.
7. Using a 1 in. (26 mm) wrench loosen and unscrew
pressure control assembly.
21
A
K
ti5766a
If you plan to reuse the pressure control assembly,
be very careful not to damage or tangle the wires
while unscrewing the assembly.
8. Remove pressure control assembly.
Installation
Inspect pressure control assembly before installation to verify the o-ring is installed and in place.
1. Align grommet collar (17) on fluid manifold so opening faces toward motor.
2. Apply loctite to pressure control assembly threads
(16)
3. Screw pressure control assembly (16) into manifold
and torque to 150 in-lbs (17.0 N.m)
Be careful when tightening pressure control knob
that wires do not get pinched between the pressure
control assembly and fluid manifold.
4. Wrap wires around knob and feed through slot in
grommet (21).
5. Insert grommet (21) in hole (K) in housing. Secure
wires to manifold housing with tape (22).
6. Reconnect pressure switch connector (A) to control
board (33).
7. Install shroud (29) and two screws (30).
310824D 23
Manifold Replacement
Manifold Replacement
See Wiring Diagram, page 28.
WAR NING
Read Electric Shock Warning, page 3 and Pressure
Relief Procedure, page 8.
Removal
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
2. Remove drain line (40) and barbed fitting (20) from
manifold. See Drain Line Replacement, page 25.
3. Remove two screws (30) and shroud (29).
4. Disconnect fluid hose at pump outlet.
5. Disconnect pressure switch connector (A) from control board (33).
6. Remove tape (22) holding wires to manifold.
7. Pull wires back through hole (K) in housing.
7. Reconnect fluid hose at pump outlet.
8. Replace barbed fitting (20) and drain line (40). See
Drain Line Replacement, page 25.
9. Install shroud (29) and two screws (30).
A
33
18
A
17
15
20
40
13
C
B
Ref 14
26
25
24
23
6
8. If required, remove pressure switch from manifold.
See Pressure Control Assembly Replacement,
page 23.
9. Remove two screws (6) to disconnect Manifold from
housing.
Installation
1. Position manifold on sprayer frame.
2. Replace screws (6) and torque to 150 in-lbs (17
N.m).
3. If removed, install pressure control assembly. See
Pressure Control Assembly Replacement, page
23.
4. Feed pressure switch wires through hole in housing
(K).
5. Insert grommet (21) in hole (K) in housing. Secure
wires to manifold housing with tape (22).
6. Reconnect pressure switch connector (A) to control
board (33).
Ref 14
26
ti5771a
A
33
18
17
6
23
24
25
A
ProStep
13
20
40
ti12077a
24 310824D
Drain Line Replacement
This procedure should be used whenever you replace
the manifold and reinstall an existing drain line or install
a new drain line using the Drain Line Kit.
Removal
To remove the drain line (40) from the manifold:
1. Cut drain line (40) from barbed fitting (20).
2. Unscrew barbed fitting (20) from manifold.
If you are only replacing the manifold and will be
reusing the existing barbed fitting (20) and drain
line (40), you will need to use a sharp knife to cut
the remaining drain line material off the end of the
barbed fitting (20).
Drain Line Replacement
Installation
1. Screw barbed fitting (20) into manifold.
2. Push drain line (40) onto barbed fitting (20).
To make the drain line more pliable and easier to
install over barbed fitting, heat end of drain line (40)
with a hair dryer or by placing end in hot water a
few seconds.
310824D 25
Power Cord Replacement
Power Cord Replacement
See Wiring Diagram, page 28.
WAR NING
Read Electric Shock Warning, page 3 and Pressure
Relief Procedure, page 8.
Removal
1. Follow Control Board Replacement removal
instructions, steps 1-8, page 20.
2. Disconnect green ground wire (G) from sprayer by
loosening grounding screw (31).
Installation
1. Follow Control Board Replacement installation
instructions, steps 1-4, page 20.
2. Reconnect, green ground wire (G) to green grounding screw (31) on frame. Be sure terminal on ground
faces UP or wires could get caught in shroud.
3. Reattach motor connector (B) and pressure control
switch connect (A).
4. Install shroud (29) and two screws (30).
33
240V
33
120V
G
31
26 310824D
Motor Replacement
Motor Replacement
See Wiring Diagram, page 28.
WAR NING
Read Electric Shock Warning, page 3 and Pressure
Relief Procedure, page 8.
CAUTION
Do not drop gear cluster (3) and (2) when removing
drive housing (5). Gear cluster may stay engaged in
motor frontend bell or drive housing.
Removal
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
2. Remove pump (9). Displacement Pump Replace-
ment, page 14.
3. Remove drive housing, Drive Housing Replace-
ment, page 16.
4. Remove Pressure (Fluid) Manifold, Manifold
Replacement, page 24.
5. Disconnect all leads from board (33) and remove
control board. Control Board Replacement, page
20.
6. Remove ground wire (G) from motor endbell.
7. Remove four screws (6) and motor (1) from frame
(45).
Installation
1. Install new motor (1) on frame (45) with four screws
(6).
2. Install manifold (15) with two screws (6). Manifold
Replacement, page 24
3. Install control board (33) with three screws (30).
Connect all leads to board. See Control Board
Replacement, page 20 and Wiring Diagram, page
28.
4. Connect ground wire (G) to motor with green ground
screw (31).
5. Install Drive Housing. Drive Housing Replace-
ment, page 16.
6. Install pump (9). Displacement Pump Replace-
ment, page 14.
31
33
30
15
6
Liberally apply grease
1
7. Install shroud (29) with two screws (30).
34
1
3
1
30
2
1
6
45
ti5642a
310824D 27
Wiring Diagram
Wiring Diagram
120V Model
Pressure
Control
Assembly
ti5643a
Power
Plug
from Motor
2 x Yellow
White
Red (+)
Black (-)
Replaceable Fuse
Black
Capacitor
Green
ON/OFF
Switch
240V Model
Capacitor
2 x Yellow
ti5857a
Power
Plug
from Motor
Pressure Control
Assembly
Red (+)
Black (-)
Replaceable Fuse
ON/OFF
Switch
Blue
Brown
Green
28 310824D
Technical Data
Technical Data
Power requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100/120V AC, 50/60 hz, 11A, 1 phase
230V AC, 50/60 hz, 7.5A, 1 phase
Generator required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 w minimum
Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . 3300 psi (22.7 MPa, 227 bar)
Cycles per gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . . . . 680 (180)
Maximum delivery gpm (lpm) . . . . . . . . . . . . . . . . . . . . . . 0.43 (1.6)
Maximum tip size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020
Fluid outlet npsm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 in.
Dimensions (Stand):
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.75 in. (40.0 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.0 in. (36.0 cm)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 in. (43.0 cm)
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 lb (13.6 kg)
Dimensions (Hi-Boy):
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.0 in. (55.9 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5 in. (52.1 cm)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.8 in. (98.6 cm)
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 lb (25.9 kg)
Dimensions (ProStep):
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.0 in. (50.8 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 in. (39.4 cm)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.25 in. (48.9 cm)
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.0 lb (18.1 kg)
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . zinc and nickel-plated carbon steel, nylon, stainless steel,
PTFE, Delrin
carbide
Noise level*
Sound power (IS0 3744) 100dBa*
Sound pressure (ISO 3744) 90 dBa*
®
, leather, UHMWPE, aluminum, tungsten
Delrin® is a registered trademark of the DuPont Company.
*Measured 3 feet (1 meter) from equipment.
310824D 29
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material
and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by
Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be
defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance
of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. 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 CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
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.
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
www.graco.com
Printed in USA 310824D
4/2008
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