Haier MAGNUM 232738 User's Manual
Contents
1. 1 Relieve pressure 2 Unplug electrical cord 3 Remove four cover screws and front cover XR9 Remove motor enclosure dx 4 Remove yoke and guide rods XR9 model only 5 Remove gear XR9 model only 6 Remove pressure control harness from control board Using fingernail or tip of small flat blade screwdriver press tab on right side connector to release 7 Attach harness from a control board you know is functioning correctly to control board Pressure control switch does not have to be installed in pump 8 Turn pressure control adjustment knob to maximum pressure setting 9 Plug electrical cord into 220 240 V AC receptacle 10 Turn power switch ON e If motor runs replace pressure switch Pressure Control Switch Kit page 18 e If motor does not run replace control board repeat test Control Board Kit page 18 Pump Diagnostics A CAUTION When repairing or cleaning the pump never submerge pump in water or allow fluid to enter pressure control When pump packings wear paint begins to leak down outside of pump Replace pump packings at the first sign of leaking or additional damage to drive train could occur Use Pump Repair Kit page 18 Pump Service A CAUTION When repairing or cleaning pump never submerge pump in water or allow fluid to enter pressure control 20 If sprayer continues to cycle motor and pump run when the spray gun trigger is2. Suction tube is leaking Tighten suction tube connection Inspect for other cracks or vacuum leaks Spray gun stopped spraying Spray tip is plugged Unplug spray tip Manual 309097 Pump cycles but does not build up pressure Pump is not primed Inlet screen is clogged or suction tube is not immersed Prime pump Clean debris off inlet screen and make sure suction tube is at bottom of paint pail Paint pail is empty Refill paint pail and reprime sprayer Suction tube is leaking Tighten suction tube connection Inspect for other cracks or vacuum leaks Pump check valves are dirty or damaged Usually only one valve Clean or replace check valves See Pump Service page 20 Prime Spray valve is worn or obstructed with debris Check Prime Spray valve for debris trapped on seat and worn parts Torque to 21 N m 185 in lb Pump cycles but paint only dribbles or spurts when spray gun is triggered Pressure is set too low Slowly turn pressure control knob clockwise to increase pressure setting Sprayer should develop more pressure Spray tip is plugged Unplug spray tip Manual 309097 InstaClean fluid filter is clogged XR9 only Spray gun fluid filter is clogged Clean or replace InstaClean fluid filter Clean or replace spray gun fluid filter 309477F Basic Troubleshooting Problem Cause Solution Spray pattern is inconsisten
3. 245077 dx Pump Inlet Valve Module 245070 XR9 Pump Inlet Valve Module 15A473 dx XR9 Series A Suction Tube 15D883 XR9 Series B C Suction Tube 15A475 All Drain Tube 245076 dx Pump Outlet Valve Module 243094 XR9 Pump Outlet Valve Module 244035 AII Drain Tube Diffuser 246286 All Pressure Control Switch 245677 dx Control Board 245665 XR9 Control Board 243281 XR9 Series A B Fan Shroud Brace 287770 XR9 Series C Fan 245062 XR9 Shaft Gear Yoke Guides 245064 XR9 Front Cover with ID label 245667 XR9 Series A B Motor Drive Housing includes fan shroud brace 287784 XR9 Series C Motor Drive Housing includes fan 245595 XR9 Series A B Enclosure includes both sides labels and screws 287785 XR9 Series C Enclosure includes both sides labels and screws 245078 dx Pump Repair 245646 dx Motor Repair 245053 XR9 XR Pump Replacement complete pump Does not include Pressure Control Switch 244267 Reuse pressure control switch from pump being replaced or order separately 245647 dx Enclosure includes labels and screws 245678 dx Cover includes labels bushings and dowel pins 245821 All Gear Lubrication Repair 248202 XR9 Lacquer Conversion lacquer compatible suction tube and seals 18 309477F Motor Diagnostics Motor Diagnostics Check for electrical continuity in motor armature windings and brush as follows If Motor Diagnostics reveal a damaged motor or if motor brushes are shorter than 6 4 mm 1 4 in or if the motor shaft cannot turn
4. 245064 245725 245726 245727 245728 245729 115478 117223 119904 195433 15D923 195434 15D924 195439 195438 Description PUMP housing KIT pump repair KIT outlet valve includes 17 PACKING o ring outlet valve FILTER adapter PUMP filter InstaClean KIT inlet valve intergral hose barb includes 25 PACKING o ring inlet valve CLAMP spring 0 88 diameter KIT pressure switch repair KIT spray prime valve repair CAM drain valve HANDLE drain valve DRIVE PIN drain valve CLIP retainer KIT motor drive housing Series A B KIT motor drive housing Series C KIT fan and shield Series A B KIT fan Series C KIT control board 230V SCREW thread forming 8 KIT gear yoke guide repair SCREW M3 washerhead DOWEL pin 5 16 RECEPTACLE IEC 320 RETAINER power cord BRACKET filter COVER front includes ID labels ADAPTER power cord Schuko CEE7 7 POWER CORD Italy POWER CORD Denmark POWER CORD Australia POWER CORD Switzerland SCREW torx slt 1 4 in SWITCH rocker dpst Series A B SWITCH rocker dspt Series C SUPPORT right Series A SUPPORT right Series B C SUPPORT left Series A SUPPORT right Series B C FRAME cart HANDLE cart Qty ZA Cee Ada a AL LA SG H A A AA AA ose AAA ppm Ss Ss A4 dd dA AAA AA AA Ref No Part No 71 15D650 72 116630 73 115480 74 195366 75 195367 76 11509 77 112612 78 105521 80 195105 83 115099 84 154473 15D883 85 24308
5. Board Kit page 18 Sprayer Wiring Problems NOTE Remove enclosure mounting screws and pull enclosure away from drive housing Take care not to pull on leads from electrical cord and power switch Sprayer electrical cord damaged Unplug sprayer electrical cord 2 Disconnect black electrical cord wire at power switch 3 Unplug in line connection white cord wire 4 Plug in electrical cord 5 Test voltage between black and white wires Meter must read 200 260 V AC 6 Replace electrical cord if no voltage Sprayer power switch damaged Unplug sprayer electrical cord Disconnect black control board wire at power switch Unplug in line connection white cord wire Plug in electrical cord Turn power switch ON Test voltage between open terminal of power switch and white electrical cord wire Meter must read 200 260 V AC 7 Replace power switch if no voltage N DD NU WwW 12 309477F Advanced Troubleshooting Specific Problem Cause Solution Sprayer Wiring Problems cont Motor thermal overload cutoff switch damaged Thermal Overload page 7 Unplug sprayer electrical cord Remove motor harness from control card 3 Check for continuity between yellow leads or motor harness 4 If thermal relief switch is open no continu ity allow motor to cool 5 If switch remains open after motor cools replace motor using Moto
6. GUN spray models 232736 amp 232737 includes manual 309097 GUN spray model 232738 includes manual 309097 KIT label warning SCREM machine pan head FITTING drain VALVE shutoff power flush SCREW M3 washerhead CLAMP power cord FILTER EM BRACKET filter ROLLER ACCESSORY manual 3W9470 3X9470 3Y9470 329470 VALVE roller manual 3W9470 3X9470 3Y9470 329470 ADAPTER Geka to 3 4 in GHT not shown KIT pressure gage not shown included with models 232736 and 232737 only A Replacement Danger and Warning labels tags and cards are available at no cost Parts Qty A Add LA dA A dA AMT A 21 Parts dx Pressure Roller Spray System Model 232736 232737 232738 A Apply light coat of lithium based grease 53 30 32 38 16 ti2083b ti2083a 22 309477F Pressure Roller Assembly Model 245589 75a 15A586 75b 245999 75c 246277 75d 15B065 75e 186678 75f 197106 309477F TUBE extension CAP end roller CAP end roller CORE roller BRUSH roller 9 in x 1 2 in nap CLIP roller Parts 23 Parts XR9 Spray System Model 232751 232752 232753 Ref No 65 66 67 68 69 70 24 Part No 195126 243090 243094 103338 195947 243070 245070 103413 116295 246286 235014 224807 187625 111600 114687 245667 287784 243231 287770 245665 115477 245062 117219 194507 245823 115632 15A467
7. nylon plated steel stainless steel UHMWPE zinc 1500 Watt minimum 220 240 V AC 50 60 Hz 1 phase 10A 35 to 71 C 30 to 160 F 4 to 46 C 40 to 115 F Technical Data XR9 Sprayer 0 207 bar 21 MPa 0 3 000 psi 4 5 AMP permanent magnet DC 7 8 1 44 lpm 0 38 gpm 15 2 m 50 ft x 1 4 in 0 48 mm 0 019 in 49 5 cm 19 5 in 48 3 cm 19 in 101 6 cm 40 in Height with folded handle is 66 cm 26 in 3 wire 1 0 mm x2 0 m 78 in 1 4 npsm external thread 450 micron 35 mesh stainless steel brass leather ultra high molecular weight polyethylene UHMWPE carbide nylon aluminum PVC polypropylene fluroelastomer aluminum brass carbide nylon plated steel stainless steel UHMWPE zinc 1500 Watt minimum 220 240 V AC 50 60 Hz 1 phase 10A 35 to 71 C 30 to 160 F 4 to 46 C 40 to 115 F When pump is stored with non freezing fluid Pump damage will occur if water or latex paint freezes in pump lt Damage to plastic parts may result if impact occurs in low temperature conditions VY Changes in paint viscosity at very low or very high temperatures can affect sprayer performance 28 309477F Graco Warranty Graco 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 ex
8. replace the motor using Motor Kit page 18 A WARNING Page 4 Both Models 1 Relieve pressure 2 Remove enclosure and disconnect motor leads from control card 3 Connect standard 9V DC battery using test leads Motor and drive train should slowly rotate if motor functioning and drive train is free Setup XR9 model only 1 Relieve pressure 2 Unplug electrical cord 3 Remove right enclosure Disconnect motor harness from control board 309477F 4 Remove fan brace 5 Remove four screws and front cover 6 Remove yoke and guide rods XR9 model only 7 Remove gear Armature Short Circuit Spin Test XR9 model only Quickly turn motor fan by hand There should not be electrical shorts and fan should coast two or three revolutions before stopping If fan does not spin freely armature is shorted Replace motor using Motor Kit page 18 Armature Brushes and Motor Wiring Open Circuit Test Continuity XR9 model only 1 Connect red and black motor leads together with test lead 2 Turn motor fan by hand about two revolutions per second 3 If there is an uneven resistance or no resistance replace motor using Motor Kit page 18 19 Control Board Diagnostics Control Board Diagnostics Check for motor problems before replacing control board A damaged motor may burn out a good control card Check for a damaged control board or pressure control switch as follows A Page 4 6
9. Sprayer requires 220 240 VAC 50 60 Hz 1500 Watt generator Sprayer was operated at high pressure with very small tip which causes frequent motor starts and excessive heat build up Decrease pressure setting or increase tip size Building circuit breaker opens after sprayer operates for 5 to 10 minutes Too many appliances are plugged in on same circuit Free up circuit unplug things or use a less busy circuit Sprayer electrical cord is damaged Check broken insulation or wires Replace electrical cord if damaged Fan pattern varies dramatically while spraying OR Sprayer does not turn on promptly when resuming spraying Pressure control switch is worn and causing excessive pressure variation Replace pressure control knob using Pressure Control Switch Kit page 18 Cannot trigger spray gun Spray gun trigger safety lever is in SAFETY ON position Rotate trigger safety lever to SAFETY OFF position Spray comes out of spray gun in two thick streams Reversible spray tip is in UNCLOG position Rotate arrow shaped handle on spray tip so it points forward in SPRAY position Paint is coming out of pressure control switch Pressure control switch is worn Replace pressure control using Pressure Control Switch Kit page 18 Spray PRIME valve actuates automatically relieving pressure through drain tube Paint leaks down outside of pump System is over pressurizin
10. 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 negligenc
11. 2 86 154475 87 115489 94 244035 95 243024 96 243238 243382 101 115719 112 115651 123 196001 124 245666 287785 127 245053 147 197211 148 246187 1494 150 245856 1514 1524 Description HOSE rack SCREW square shank KNOB t handle AXLE SPACER WHEEL 10 in CAP PLUG HANGER pail WASHER inlet strainer TUBE suction barb includes 83 Series A TUBE suction Series B C STRAINER TUBE drain CLAMP drain tube DEFLECTOR barbed HOSE 1 4 in x 50 ft GUN spray model 232751 amp 232752 GUN spray model 232753 PACKING o ring filter adapter NUT hex 5 16 in SPACER pump ENCLOSURE includes labels and screws Series A B ENCLOSURE includes labels and screws Series C PUMP replacement includes 1 2 13 17 18 19 20 40 Item 36 must be purchased separately CAP pump outlet included in Kit 245064 ADAPTER Geka to 3 4 in GHT not shown LABEL warning multiple languages see page 27 for specific part numbers KIT pressure gage not shown included with models 232751 and 232752 only LABEL danger multiple languages see page 27 for specific part numbers LABEL danger multiple languages see page 27 for specific part numbers Parts LN A44 AAA NA A A UU UA NNNMNNE MONTE A Replacement Danger and Warning labels tags and cards are available at no cost 309477F Parts XR9 Spray System Model 232751 232752 232753 9 Series A B A Apply light coat of lithi
12. BEL danger Finnish Norwegian Swedish Series C LABEL danger Portuguese Spanish Greek Series A B LABEL danger Portuguese Spanish Greek Series C LABEL danger Chinese Korean English Series A B LABEL danger Chinese Korean English Series C LABEL danger English Spanish French Series A B LABEL danger English Spanish French Series C Parts Qty Replacement Danger and Warning labels tags and cards are available at no cost 27 Working pressure range Electric motor Operating horsepower Maximum delivery with tip Paint hose Maximum tip hole size Weight sprayer only Weight sprayer hose amp gun Dimensions Length Width Height Power cord Fluid inlet fitting Fluid outlet fitting Inlet screen on suction tube Wetted parts pump amp hose Wetted parts gun Generator requirement Electrical power requirement Storage temperature range Operating temperature range Technical Data dx Roller Spray System 0 207 bar 21 MPa 0 3 000 psi 3 5 AMP open frame universal 3 8 0 91 lpm 0 24 gpm 7 6 m 25 ft x 1 4 in 0 38 mm 0 015 in 6 kg 13 Ib 7 8 kg 17 Ib 41 cm 16 in 46 cm 18 in 53 cm 21 in 3 wire 1 0 mm x 2 0 m 78 in 1 4 npsm external thread 450 micron 35 mesh stainless steel brass ultra high molecular weight polyethylene UHMWPE carbide nylon aluminum PVC polypropylene fluroelastomer aluminum brass carbide
13. Repair G by GRACO Airless Sprayer 309477F US Patent 6 752 067 Europe Patent 1 208 287 For portable spray applications of architectural paints and coatings Specifications page 3 Important Safety Instructions Read all warnings and instructions in this manual Save these instructions ti2015b dx Pressure Roller Spray System XR9 Sprayer Models 232736 232737 232738 Series B Models 232751 232752 232753 Series A B C Related Manuals Pressure Haller 3W9470 3X9470 3Y9470 3Z9470 Operation XR9 Operation 3W9478 3X9478 3Y9478 3Z9478 C SG3 Gun 309097 PROVEN QUALITY LEADING TECHNOLOGY Graco Inc P O Box 1441 Minneapolis MN 55440 1441 Copyright 2002 Graco Inc is registered to I S EN ISO 9001 Contents Manual Conventions es Gesa raea de bile el i PEN BR UPN NAN dees deed baite 3 Specifications isti acts an on Ae kita oe ela atea Aaa 3 Warn ventas a tad e pila ae RIS aa een 4 Pressure Relief Procedure ete eee 6 Grounding and Electrical Requirements 7 Thermal Overload iidr ciali Bem Rana Bed a 7 General Repair Information ii 8 Basic Troubleshooting a seua naa dal ana heed a eats na DANA gia lai nina de a Buka dea 9 Advanced Troubleshooting lt a A fa aa 11 General Problem Motor Does Not Operate o oococccccoo teens 11 General Problem Circuit Breaker is Tripping LL 13 General Problem Erratic Motor Operation 14 General Pro
14. blem Low or Fluctuating Output 15 General Problem NO QUtput iii ela E eine ee yw es banat een Pees 17 General Problem Excessive Pressure Build Up 17 EISEOTKIS lai ai ana we ea oa A AE ei DA 18 Motor Diagnostics irene ita atei Pala i A aa PIRE aa Lean 19 Control Board Diagnostics LL 20 Pump DINOS CS tains iena ia bt etsy elvis n AR adan ra SN gio ee 20 PUMP Servicen fa bare fire bed ia DAR A A A A ea 20 Parts ione Hana e Mae nale ee be Eoin e ME ee ad PARA 21 dx Pressure Roller Spray System ci 21 Pressure Roller Assembly seen mane bie maa a aa 23 PAS ria na an Sheed ied ay ane ieee NAM Ra BR Pn kan ian Mam am mana PA en SA AE apg 24 XR9 Spray SYSTEM sei oem aa ee bean kam BRA Pen AA RR BE Kek na Kena aa 24 XR9 Spray System Labels usar peang NON Ra ARE A cad 27 Technical Dita ide pn E BA a he el a ows aio Bae 29 Graco Warranty setae fre Legato eri pianeti Pen ieee E 30 2 309477F Manual Conventions Manual Conventions A WARNING CAUTION CAUTION a potentially hazardous situation which if NY Hazard Symbol not avoided may result in property damage or destruction of equipment WARNING a potentially hazardous situation which if not avoided could result in death or serious injury Warnings in the instructions usually include a symbol Note indicating the hazard Read the general Warnings SN 7 section for additional safety information Additional helpful information Specifi
15. cal cord and power switch Sprayer electrical cord is damaged Unplug sprayer electrical cord Disconnect black electrical cord wire at power switch Unplug in line connection white cord wire Plug in electrical cord Test voltage between black and white wires Meter must read 200 260 V AC Replace electrical cord if no voltage Sprayer power switch damaged _ Unplug sprayer electrical cord 2 Disconnect black control board wire at power switch Check resistance of switch with ohmmeter Reading must be infinity with power switch OFF Reading must be zero with power switch ON Replace power switch if damaged Also Basic Electrical Problems and Sprayer Wiring Problems page 12 General Problem Erratic Motor Operation Specific Problem Cause Solution Sprayer quits after running for 5 to 10 minutes Electrical outlet is damaged Reset building circuit breaker or replace building fuse Electrical outlet supplying wrong voltage Also Basic Electrical Problems Try another outlet Check electric supply with volt meter Meter must read 200 260 V AC If voltage is too high do not use outlet until corrected and Sprayer Wiring Problems page 12 Motor is overheating Motor is Hot page 10 14 309477F Advanced Troubleshooting General Problem Low or Fluctuating Output Specific Pr
16. cations 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 309477F 3 Warnings Warnings The following are general related to the safe setup grounding use maintenance and repair of this equipment Addi tional more specific warnings may be found throughout the text of this manual where applicable WARNING Ch DE 1 AAN 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 e Use equipment only in well ventilated area e Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc e 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 e Do not clean with materials having flash points lower than 70 F 21 C Use water based materials or mineral spirits type material only For complete information about your fluid request the MSDS from the fluid distributor or retailer Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or tur
17. ception 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
18. e 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es ADDITIONAL WARRANTY COVERAGE Graco does provide extended warranty and wear warranty for products described in the Graco Contractor Equipment Warranty Program TO PLACE AN ORDER or to identify the nearest Graco Magnum distributor contact us at 1 888 541 9788 309477F 29 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice MM 309477F Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 www graco com Rev 9 2006 309477F
19. e pump packings if there are leaks Pump Service page 20 Prime Spray Valve leaking Check Prime Spray Valve for debris trapped on seat and for worn parts Torque to 21 Nem 185 in lb If parts are worn replace valve using Prime Spray Drain Valve Kit page 18 Spray pattern has variations pressure fluctuates excessively or motor runs very slowly Leads from motor or pressure switch to control board are damaged loose or overheated Be sure terminals are centered and firmly connected Inspect wiring insulation and terminals for signs of overheating Replace any loose terminals or damaged wiring Securely reconnect terminals Pressure control switch leads are pinched between pump and drive housing or between front cover and drive housing XR9 only Make sure pressure control harness is routed behind pump through retention clip and connected to control board connector on control board connect with tab to right Control board is damaged CAUTION Do not perform control board diagnostics until you have determined the armature is good A bad armature can burn out a good control board See Control Board Diagnostics page 19 If damaged replace control board using Control Board Kit page 18 Pressure control switch is damaged or worn out Replace pressure control switch using Pressure Control Switch Kit page 18 16 309477F Advanced Troubleshooting General Problem No O
20. f motor shuts down General Repair Information General Repair Information A WARNING Me te 2 Page 4 Do not operate the sprayer without the enclosure Replace if damaged Enclosures direct cooling air around the motor to prevent overheating They also reduce the risk of burns fire or explosion Keep all screws nuts washers gaskets and electrical fittings removed during repair procedures These parts are not normally provided with replacement assemblies Test repair after problem is corrected If sprayer does not operate properly review repair procedure to verify you did it correctly See Basic Troubleshooting page 9 and Advanced Troubleshooting page 11 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 A CAUTION Do not run sprayer dry for more than 30 seconds Doing so could damage pump packings Protect internal drive parts of this sprayer from water Openings in enclosures allow for air cooling of 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 based paint in sprayer when it is not in use in cold weather Freezing fluids can seriously damage sprayer Store sprayer with mineral spirits paint thinner or Graco Pump A
21. g Pump packings are worn See Excessive Pressure Build Up page 17 Replace pump packings See Pump Service page 20 10 309477F A WARNING W L Page 4 NA Advanced Troubleshooting Advanced Troubleshooting General Problem Motor Does Not Operate Specific Problem Cause Solution Power switch is on and sprayer is plugged in pump does not cycle See Basic Troubleshooting page 9 Basic mechanical problems Paint is frozen or hardened in pump Unplug sprayer from electrical outlet If paint is frozen in sprayer e Do NOT try to start sprayer until completely thawed or you may damage the motor control board and or drivetrain 1 Turn OFF power switch 2 Place sprayer in warm area for several hours 3 Plug in and turn on sprayer 4 Slowly increase pressure until motor starts If paint hardened in sprayer 1 Replace pump packings 2 Remove all residue from valves Pump Service page 20 Motor is damaged Yoke is broken because pump is locked up due to dried paint or worn packings XR9 only Remove gear and try to rotate motor shaft by hand See Motor Diagnostics page 19 If shaft will not turn replace motor using Motor Kit page 18 Repair or replace using Gear Yoke Kit page 18 Repair pump page 20 309477F 11 Advanced Troubleshooting Specific Problem Cause Solution Basic electrical problems Mo
22. n all equipment manuals e Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings Check equipment daily Repair or replace worn or damaged parts immediately Do not alter or modify equipment Use equipment only for its intended purpose Call your Graco distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hose or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equipment fluid has cooled completely 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 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 accordi
23. n lights on or off when flammable fumes are present Ground equipment and conductive objects in work area See Grounding instructions If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem e Keep a working fire extinguisher in the work area lf E ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause electric shock e Turn off and disconnect power cord before servicing equipment e Use only grounded electrical outlets e Use only 3 wire extension cords Ensure ground prongs are intact on sprayer and extension cords BD SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Engage trigger lock when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment 309477F WARNING Ah WARNING EQUIPMENT MISUSE HAZARD Ly Misuse can cause death or serious injury Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data i
24. ng 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 e Protective eye wear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection Da V E D 309477F 5 Pressure Relief Procedure Pressure Relief Procedure ae f Turn Pri Ive to PRIME Tri N to help prevent injuries follow this procedure 3 eal da E PESEE guo when you stop spraying and before you service or clean the sprayer remove parts or repair leaks 1 Turn OFF power switch a S to2012a 4 Engage trigger safety ti2018a ti2011 dx model XR9 model 2 Unplug sprayer ti2048a N Leave Prime Spray valve in PRIME position until you are ready to spray again D SL Ts If you suspect the spray tip or hose is completely ti2021a1 ES clogged or that pressure has not been fully relieved after following the above steps VERY SLOWLY loosen the tip guard retaining nut or hose end coupling to relieve pressure gradually Then loosen it completely Clear tip or hose obstruction 309477F Grounding and Electrical Requirements Grounding and Electrical Requirements This spraye
25. oblem Cause Solution Pump cycles but output is low or surging See Basic Troubleshooting page 9 Worn or obstructed pump valves Check for worn pump valves as follows 1 Prime sprayer with paint 2 Trigger spray gun momentarily 3 When spray gun trigger is released pump should cycle momentarily and stop 4 If pump continues to cycle pump valves may be worn or obstructed 5 Pump Service page 20 Prime Spray valve is leaking Voltage from electrical outlet is too low Low voltages reduce sprayer performance Check Prime Spray valve for debris trapped on seat and for worn parts Torque to 21 Nem 185 in lb Replace if parts are worn using Prime Spray Drain Valve Kit page 18 Check voltage of outlet Meter must read 200 260 V AC Reset building circuit breaker or replace building fuse Repair electrical outlet or try another outlet Extension cord is too long or not heavy enough gauge Replace extension cord Grounding and Electrical Requirements page 7 Leads from motor or pressure switch to control board are damaged loose pinched or overheated Be sure terminals are centered and firmly connected Inspect for pinched wiring and wiring insulation and terminals for signs of overheating Replace any loose terminals or damaged wiring Securely reconnect terminals Motor brushes are worn Check length of BOTH brushes brushes to not wear evenly on both sides of the m
26. otor Brush length must be 6 4mm 0 25 in If brushes are worn replace motor using Motor Kit page 18 Motor brush springs are broken If springs are broken replace motor using Motor Kit page 18 Motor brushes are binding in brush holders Clean brush holders Remove carbon dust with small cleaning brush Motor stops before sprayer reaches correct pressure stall pressure is too low Replace pressure control using Pressure Control Switch Kit page 18 Motor armature shorted Check for shorts using armature tester growler or perform spin test Motor Diagnostics page 19 If shorts are evident replace motor using Motor Kit page 18 309477F 15 Advanced Troubleshooting Specific Problem Cause Solution Control board is damaged CAUTION Do not perform control board diagnostics until you have determined the armature is good A bad motor can burn out a good control board See Control Board Diagnostics page 19 If damaged replace control board using Control Board Kit page 18 Motor runs and pump cycles but pressure does not build up Intake valve ball or outlet valve ball is not seating properly Remove and clean valves and check balls and seats for nicks replace if necessary Strain paint before spraying to remove particles that could clog pump Pump Service page 20 Pump packings are worn or damaged Check for leaking around throat packing nut Replac
27. r Kit page 18 6 If thermal relief switch closes after motor cools find correct cause of overheating N Terminals are damaged or loose Replace any damaged terminals Make sure all terminal connections are tight General Problem Circuit Breaker is Tripping Specific Problem Cause Solution Building circuit breaker opens as soon as sprayer is turned on Sprayer electrical wiring is pinched or insulation is damaged Wires between pressure control switch and control board are pinched Repair or replace any damaged wiring or terminals Securely reconnect wires Motor armature is shorting Check for shorts using armature tester growler or perform spin test Motor Diagnostics page 19 If shorts are evident replace motor using Motor Kit page 18 Control board is damaged CAUTION Do not perform control board diagnostics until you have determined the armature is good A bad motor armature can burn out a good motor control board See Control Board Diagnostics page 19 Replace control board if damaged using Control Board Kit page 18 309477F 13 Advanced Troubleshooting Specific Problem Cause Solution Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on NOTE Remove enclosure mounting screws and pull enclosure away from drive housing Take care not to pull on leads from electri
28. r requires 220 240 VAC 50 60 Hz 10A circuit with a grounding receptacle Do not use an outlet that is not grounded ti2021a Do not use the sprayer if the electrical cord has a damaged ground prong Only use an extension cord with an undamaged 3 prong plug ti2022a Only use an extension cord with an undamaged 3 prong plug Recommended extension cords for use with this sprayer are e 15m 49 2 ft 1 0 mm e 30m 88 4 ft 1 5 mm e 50m 164 0 ft 2 5 mm Smaller gauge or longer extension cords may reduce sprayer performance 309477F Spray gun ground through connection to a properly grounded fluid hose and pump Fluid supply container follow local code Solvent pails used when flushing follow local code Use only conductive metal pails placed on a grounded surface such as concrete Do not place the pail ona 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 Thermal Overload Motor has a thermal overload switch to shut itself down if overheated A WARNING To reduce risk of injury from motor starting unex pectedly when it cools always turn power switch OFF i
29. released or if performance is poor even with new spray tips and clean filters the pump inlet or outlet valve may be obstructed or worn If a pump is worn replace it List of Kits page 18 309477F Parts dx Pressure Roller Spray System Model 232736 232737 232738 Ref No PartNo Description 2 243082 STRAINER 3 244035 DEFLECTOR barbed 5 15A473 TUBE suction 12 15A475 TUBE spray 13 115489 CLAMP drain tube 15 15A680 FRAME stand 16 15H772 LEG stand 18 113955 SCREW curved head 19 102040 NUT locking 23 246286 KIT pressure switch repair 30 224807 CAM drain valve 31 235014 KIT valve repair 32 111600 DRIVE PIN drain valve 38 187625 HANDLE drain valve 41 245647 KIT motor enclosure 42 245678 KIT cover 43 117220 PLUG snap in 44 245149 KIT gear includes 2 gears and connecting rod 50 245078 _ KIT pump repair 51 245677 KIT control board 230V 52 245646 KIT motor repair 230V 53 245076 KIT outlet valve 54 245077 _ KIT inlet valve 55 116295 CLAMP spring 88 dia 56 115478 SCREW machine pan head 57 245725 CORD Schuko CEE7 7 245726 CORD Italy 309477F LA AA AHA HAK ANTA Mia A CA A Ref No Part No 245727 245728 245729 58 241922 59 243238 243382 61A 243308 63 115477 64 196574 69 115648 70 117219 71 115632 72 245648 73 154467 75 245589 76 245590 77 246187 78 245856 Description CORD Denmark CORD Australia CORD Sweden HOSE paint 1 4 in x 25 ft
30. rmor to protect equipment during storage 309477F Basic Troubleshooting Basic Troubleshooting The following troubleshooting guidelines are included here as preemptive measures against Advanced Troubleshooting page 11 Problem Cause Solution Power switch is on and sprayer is plugged in but motor does not run and pump does not cycle Pressure is set at zero pressure Turn pressure control knob counterclockwise to increase pressure setting Motor control is damaged See Motor Does Not Operate page 11 Electrical outlet is not providing power e Try a different outlet or plug in something that you know is working to test outlet e Reset building circuit breaker or replace fuse Extension cord is damaged Sprayer electrical cord is damaged Replace extension cord See Grounding and Electrical Requirements page 7 Check for broken insulation or wires Replace electrical cord if damaged Paint is frozen or hardened in pump See Motor Does Not Operate page 11 Pump does not prime Spray PRIME valve is in SPRAY position Turn Prime Spray valve to PRIME position pointing down Inlet screen is clogged or suction tube is not immersed Clean debris off inlet screen and make sure suction tube is at bottom of paint pail Balls in check valve are stuck or check valves are damaged Clean or replace check valves See Pump Service page 20 Do not store in water
31. t or is leaving stripes Pressure is set too low Turn pressure control knob clockwise to increase pressure Spray tip is worn beyond capability of sprayer Replace spray tip Pressure is set at maximum but cannot achieve a good spray pattern Spray tip is too big for sprayer Select smaller spray tip Spray tip is worn beyond capability of sprayer Replace spray tip Extension cord is too long or not heavy enough gauge Replace extension cord Grounding and Electrical Requirements page 7 Spray gun fluid filter is clogged Clean or replace spray gun fluid filter InstaClean fluid filter is clogged XR9 only Clean or replace InstaClean fluid filter Inlet screen is clogged Clean debris off inlet screen Pump valves are worn See Low or Fluctuating Output page 15 Motor is hot and runs intermittently This is NOT a thermal overload condition Motor automatically shuts off due to excessive heat Damage can occur if cause is not corrected Thermal Overload page 7 Vent holes in enclosure are plugged or sprayer is covered Keep vent holes clear of obstructions and overspray and keep sprayer open to air Extension cord is too long or not a heavy enough gauge Replace extension cord See Grounding and Electrical Requirements page 7 Unregulated electrical generator being used has excessive voltage Use electrical generator with a proper voltage regulator
32. tor overheated Allow motor to cool for 30 minutes Retry Electrical outlet is damaged Reset building circuit breaker or replace building fuse Try another outlet Check electric supply with volt meter Meter must read 200 260V AC If voltage is too high do not plug sprayer in until outlet is corrected Control board leads are improperly fastened or improperly mated 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 Motor brushes are worn Motor armature commutator damaged Check length of BOTH brushes brushes do not wear evenly on both sides of the motor Brush length must be 6 4mm 0 25 in If brushes are worn replace motor using Motor Kit page 18 Check for burn spots gouges and extreme roughness Have motor shop resurface commutator if possible or replace motor using Motor Kit page 18 Motor armature shorting Check for shorts using armature tester growler or perform spin test Motor Diagnostic page 19 If shorts are evident replace motor using Motor Kit page 18 Control board damaged CAUTION Do not perform control board diagnostics until you have determined the armature is good A bad armature can burn out a good control board See Control Board Diagnostics page 19 Replace control board if damaged using Control
33. um based grease 59 60 a AP 18 Sha O 86 ti2084 309477F 25 Parts Model 232751 232752 232753 Series C XR9 Spray System 309477F 26 XR9 Spray System Labels Ref No Part No 149 195792 195793 195794 195795 151 154673 156238 154675 156240 154677 156242 154708 156237 195834 309477F Description LABEL warning English Japanese Chinese Korean LABEL warning French Spanish German LABEL warning Portuguese Dutch Italian Greek LABEL warning Swedish Danish Finnish Norwegian LABEL danger Italian Danish German Series A B LABEL danger Italian Danish German Series C LABEL danger Finnish Norwegian Swedish Series A B LABEL danger Finnish Norwegian Swedish Series C LABEL danger Portuguese Spanish Greek Series A B LABEL danger Portuguese Spanish Greek Series C LABEL danger Chinese Korean English Series A B LABEL danger Chinese Korean English Series C LABEL danger English Spanish French Series A B Ref No 152 Part No 156188 154674 156239 15A676 15G241 15A678 15G243 15A706 15G236 195835 15G187 Description LABEL danger English Spanish French Series C LABEL danger Italian Danish German Series A B LABEL danger Italian Danish German Series C LABEL danger Finnish Norwegian Swedish Series A B LA
34. utput Specific Problem Cause Solution Power switch is on and sprayer is plugged in but pump does not cycle See Basic Troubleshooting page 9 Motor runs but pump does not cycle Gear and or yoke are damaged XR9 only Replace gear and yoke using Gear Yoke Repair Kit page 18 Motor does not run Water or paint entered pressure control switch or shorted control board Clean out and or dry out and retry Replace if necessary using Pressure Control Switch Kit page 18 General Problem Excessive Pressure Build Up Specific Problem Cause Solution Prime Spray Valve actuates automatically relieving pressure through drain tube Pressure control switch is worn Replace pressure control switch using Pressure Control Switch Kit page 18 Water or paint entered pressure control switch or shorted control board Clean out and or dry out and retry Replace if necessary using Pressure Control Switch Kit page 18 Control board failed See Control Board Diagnostics page 19 Replace damaged control board using Control Board Kit page 18 309477F 17 List of Kits List of Kits Kit Number Models Series Kit Description 235014 All Prime Spray Drain Valve 243082 All Inlet Strainer or inlet of suction tube 243090 XR9 Pump Repair pump packing module
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