Magnum XR Series, XR5, XR7, XR9 Service Instructions Manual
Service Instructions
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
t
XR Series Airless Sprayers
MAGNUM XR5, Model 232740, Series A
0.24 gpm (0.91 lpm) stand-mount sprayer, 25 ft (7.6 m) hose, and
SG1 spray gun with reversible spray tip and tip guard
2800 psi (19 MPa, 193 bar) Maximum Working Pressure
MAGNUM XR7, Model 232745, Series A
0.31 gpm (1.17 lpm) sprayer on heavy-duty cart, 50 ft (15.2 m) hose, and
SG2 metal spray gun with reversible spray tip and tip guard
3000 psi (21 MPa, 207 bar) Maximum Working Pressure
Form No. 309044
Rev. B
This manual contains service
instructions only. See manual
309043 for operating instructions.
MAGNUM XR9, Model 232750, Series A
0.38 gpm (1.44 lpm) sprayer on heavy-duty deluxe cart, 50 ft (15.2 m) hose, and
SG3 pro metal spray gun with reversible spray tip and tip guard
3000 psi (21 MPa, 207 bar) Maximum Working Pressure
9557A
MAGNUM XR5
Model 232740
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
9558A
MAGNUM XR7
Model 232745
ECOPYRIGHT 2000, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
9559A
MAGNUM XR9
Model 232750
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 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Diagnostics 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Board Diagnostics 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Board Kit 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Kit 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Service
Packing Module Kit 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Switch Kit 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Valve Kit 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outlet Valve Kit 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Replacement Kit 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear/Yoke Kit 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray–Prime/Drain Valve Kit 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts
Model 232740 XR5 Magnum Sprayer 30. . . . . . . . . . . . . . . . . . . . . . . . . .
Model 232745 XR7 Magnum Sprayer 32. . . . . . . . . . . . . . . . . . . . . . . . . .
Model 232750 XR9 Magnum Sprayer 34. . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Warranty 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 309044
Warnings
WARNING
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 by
– Using only grounded electrical outlets.
– Using only 3-wire extension cords.
– Making sure ground prongs are intact
on sprayer and extension cords.
D The motor in this sprayer is a source of
sparks. Keep sprayer in a well-ventilated
area, at least 20 feet (6 meters) away from
spray 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 static
electricity from plastic drop cloths, open
flames such as pilot lights, hot objects
such as cigarettes, and arcs from connecting or disconnecting power cords
and turning light switches off or on.
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.
FLUID INJECTION HAZARD
If high-pressure fluid pierces your skin,
the injury might look like “just a cut,” but it
is a serious wound. Get immediate
medical attention.
To help prevent injection
D Always put gun trigger safety 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 on page 6.
D Never allow children to use this equip-
ment.
D Keep clear of spray tip, and never point
spray gun at yourself or anyone else.
FLUID SPLASHBACK HAZARD
To avoid splashback of fluid while
spraying, make sure the spray gun is
assembled with the correct gasket for the
fluid being sprayed. See Operating
Instructions manual.
AGNUM or Graco airless paint hoses.
psi/MPa/bar
WARNING
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 spray gun. Such use could
result in a chemical reaction, with the possibility of explosion.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause
serious injury or death if splashed in the
eyes or on the 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.
PRESSURIZED EQUIPMENT HAZARD
AGNUM sprayers are capable of
M
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.
This sprayer is equipped with a drain/prime valve that
automatically relieves overpressure in the event of a fault.
This automatic overpressure relief may cause splashing of
fluid. Correct the fault before you resume spraying.
NOTE: Inadequate flushing and/or dried paint in drain
system may prevent proper overpressure relief.
STARTUP HAZARD AFTER THERMAL
OVERLOAD
The motor has a thermal overload switch
to shut down the motor if it overheats. To
reduce the risk of serious injury from the
motor restarting unexpectedly when it cools,
always turn the Power switch (B) OFF if the motor shuts
down.
ELECTRIC SHOCK HAZARD
The spray gun, hose, and sprayer are
grounded through the electrical cord
of the 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 enclosures dry.
OFF
309044 3
Component Identification and Function
ON
MAGNUM XR7
W
B
A
X
K
N
9558A
F
C
D
K
OFF
J
E
G
H
MAGNUM XR5
W
P
L
Y
W
X
K
MAGNUM XR9
4 309044
9559A
9560A
M
Component Identification and Function
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 D Filters fluid coming out of pump to reduce tip plugging and improve finish
D Self cleans during pressure relief
F Power-Pistont pump (behind cover) Pumps and pressurizes fluid and delivers it to paint hose
G Suction tube Draws fluid from paint pail into pump
H Drain 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)
D Directs fluid to drain tube in PRIME/DRAIN position (pointing down)
D Automatically relieves system pressure in overpressure situations
K Fluid inlet connection Where suction tube connects to pump
L Inlet screen Prevents debris from entering pump
M Paint hose For transporting high-pressure fluid from pump to spray gun
N Cord wrap bracket For stowing electrical cord (MAGNUM XR5 only)
P Airless spray gun Manually-controlled, hand-held on/off device for fluid being sprayed
Q Spray gun tip guard Reduces risk of fluid injection injury
R Spray gun reversible spray tip D Atomizes fluid being sprayed, forms spray pattern, and controls fluid flow
according to hole size
D Reverses for unplugging without disassembly
S Spray gun trigger safety lever Prevents accidental triggering of spray gun
T Spray gun fluid inlet fitting Threaded connection for paint hose
U Smooth Glidet swivel
(SG3 spray gun only)
V Spray gun fluid filter (in handle) Filters fluid entering spray gun to reduce tip plugging and improve finish
W Hose/Cord wrap bracket For stowing 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) For hooking up garden hose to suction tube for power flushing water-base
Allows spray gun to swivel without twisting paint hose
fluids
SG1 Spray Gun
included with
AGNUM XR5
M
S
R
Q
T
SG2 Spray Gun
included with
AGNUM XR7
M
Q
V
9561A
SG3 Spray Gun
included with
AGNUM XR9
M
S
R
S
R
Q
V
T
9562A
U
T
309044 5
Pressure Relief
A
e
e
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.
OFF
9565A
Electrical Requirements
WARNING
This sprayer requires a 120V AC, 60 Hz, 15
circuit with a grounding receptacle. Never us
an outlet that is not grounded. Do not use th
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
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 309044
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.
D Test repairs after problems are corrected.
Do not operate the sprayer without the enclosure,
and 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
Do not run sprayer dry for more than 30 seconds.
Doing so could damage pump packings.
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.
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.
309044 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.
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.
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.
InstaClean fluid filter is
clogged.
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
23.
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
23.
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.
See Spray–Prime/Drain Valve Kit on page 28.
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 309044
Basic Troubleshooting
g
intermittentl
NOTE: This is a thermal
page 3. Damage can occur if
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 on
p
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.
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
UNPLUG position.
Pressure control switch is
worn.
System is overpressurizing. See Excessive Pressure is Building Up on page 15.
Pump packings are worn. Replace pump packings. See Pump Service on page 20.
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.
See Pressure Control Switch Kit on page 22.
Rotate trigger safety lever (S) to SAFETY OFF position.
Rotate arrow-shaped handle on spray tip so it points forward in
SPRAY position.
See Pressure Control Switch Kit on page 22.
p
309044 9
Advanced Troubleshooting
t
See Electric Shock Hazard on
page 7.
See Pressure Relief
Procedure on page 6.
NOTE: See Basic Troubleshooting on page 8 for the problems that are more easily remedied.
General Problem: Motor Does Not Operate
SPECIFIC PROBLEM CAUSE SOLUTION
Power switch is on and
p
sprayer is plugged in, bu
pump does not cycle.
Basic Mechanical
Problems
Basic Electrical Problems Motor is overheated. Allow to cool for 30 minutes. Retry.
p
See Basic Troubleshooting page 8.
Paint is frozen or hardened in pump. Unplug sprayer from electrical outlet.
NOTE: If frozen, do not try to start sprayer
until completely thawed, or damage to motor,
control board, and/or drivetrain may occur.
Make sure power switch (B) is OFF. Place
sprayer in warm area for several hours, then
plug in and turn on. Slowly increase pressure
setting to see if motor starts.
If paint hardened in sprayer, replace pump
packings and remove all residue from valves.
See Pump Service on page 20.
Motor is damaged. Remove gear, and try to rotate motor shaft by
hand. See Motor Diagnostics on page 16.
Replace motor if shaft will not turn.
See Motor Kit on page 18.
Yoke is broken, because pump is locked up by
dried paint or worn packings.
Electrical outlet is damaged. Reset building circuit breaker or replace
Control board leads are improperly fastened or
improperly mated.
Motor brushes are worn.
NOTE: Brushes do not wear at the same rate on
both sides of motor. Check both brushes.
Motor armature commutator is damaged. Check for burn spots, gouges and extreme
Repair as necessary.
See Gear/Yoke Kit on page 27.
building fuse. Try another outlet.
Check electric supply with volt meter. Meter
must read 85 to 130V AC. If voltage is too
high, do not plug sprayer in until outlet is
corrected.
Replace any loose terminals. Make sure all
leads and harnesses are firmly connected.
Check pressure control harness connection on
front side of drive housing.
Clean control board terminals. Securely
reconnect leads.
Check length of brushes. Brush length must
be 0.25 in. (6.4 mm) minimum. Replace motor
if brushes are worn.
See Motor Kit on page 18.
roughness. Have motor shop resurface
commutator if possible, or replace motor.
See Motor Kit on page 18.
10 309044
Advanced Troubleshooting
General Problem: Motor Does Not Operate (continued)
SPECIFIC PROBLEM CAUSE SOLUTION
Basic Electrical Problems
(Continued)
Sprayer Wiring Problems
NOTE: Remove right
enclosure mounting
screws, and pull right
enclosure away from drive
housing. Take care to not
pull on the leads from
the electrical cord and
the Power switch (B).
Motor armature is shorting. Check for shorts using armature tester (growler), or perform
spin test (see Motor Diagnostics on page 16). Replace
motor if shorts are evident.
See Motor Kit on page 18.
Control board is damaged.
CAUTION: Do not perform control
board diagnostics until you have
determined that the armature is good.
A bad motor armature can burn out a
good control board.
Sprayer electrical cord is damaged. Unplug sprayer electrical cord. Disconnect black electrical
Sprayer power switch (B) is damaged. Unplug sprayer electrical cord. Disconnect black control
Thermal overload cutoff switch is
damaged.
See Startup Hazard After Thermal
Overload on page 3.
Terminals are damaged or loose. Replace any damaged terminals, and make sure all
See Control Board Diagnostics on page 16, and replace
control board if damaged.
See Control Board Kit on page 17.
cord wire at Power switch (B), and unplug in-line connection
of white electrical cord wire. Plug in electrical cord, and test
voltage between black and white electrical cord wires.
Meter must read 85 to130V AC.
Replace electrical cord if no voltage.
board wire at Power switch (B), and unplug in-line
connection of white electrical cord wire. Plug in electrical
cord, turn Power switch ON, and test voltage between open
terminal of Power switch and white electrical cord wire.
Meter must read 85 to130V AC.
Replace Power switch (B) if no voltage.
Unplug sprayer electrical cord. Remove motor harness from
control card, and check for continuity between yellow leads
of motor harness. If thermal relief switch is open (no
continuity), allow motor to cool. If switch remains open after
motor cools, replace motor (see Motor Kit on page 18).
If thermal relief switch closes after motor cools, find and
correct cause of overheating.
terminal connections are tight.
309044 11
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