Graco TEXSPRAY 1030 User's Manual
Contents
1. Fig 17 TI3110A 8710A 309662 19 Parts Sprayer ia DETAIL A tui T14365a 58 page 21 Ref 8h D A S SL A I a S7 Q Y fa Q A p A Danger and warning labels tags and cards are free 20 309662 Ref No Part No 187604 2 108803 3 235706 4 157705 6 116354 7 15B560 8 287128 9 234234 12 116252 13 15B935 14 183350 16 193682 17 110837 18 110838 19 241308 21 114818 22 111836 23 114263 23 104172 24 237686 25 112798 26 224442 27 187111 28 15c004 29 100214 30 111834 31 157785 32 114530 33 245162 34 113084 35 192014 36 104008 37 183169 38 183210 39 287129 40 114666 41 15C088 42 108842 43 105510 44 117740 45 111457 46 164856 47 234231 49 15B680 50 234232 51 104811 52 112827 53 115244 54 15B558 55 15B684 56 106115 58 245399 59 101864 60 240997 61 102478 62 194125 63a 287130 63b 15C238 64 235738 66 117741 68 111831 69 109466 70 15B671 724 194126 73 188509 754 290228 Parts Sprayer Qty Description SLEEVE cart SCREW hex socket head PUMP texture 3 gom UNION swivel BUSHING strain relief SPACER bolt KIT repair drive housing KIT control board SCREW 8 taptite phil WIRE jumper WASHER PLUG tube SCREW flange hex NUT lock COVER drive SCREW self tap filhd CYLINDER air FITTING connector male for 1030fc FITTING conn2. Air Requirements Elastomerics textured 30 scfm at 90 psi 0 84 m3 min at 0 63 MPa 6 3 bar Simulated Accoustical 20 scfm at 60 psi 0 56 m min at 0 42 MPa 4 2 bar Splatter Coat 15 scfm at 40 psi and 0 42 m min at Knockdown 0 28 MPa 2 8 bar Orange Peel 20 scfm at 60 psi 0 56 m3 min at 0 42 MPa 4 2 bar Material temperature and volume affect cfm needed to properly atomize material Maintenance CAUTION e For detailed engine maintenance and specifica tions refer to separate HONDA engine manual Close black fuel shutoff lever whenever you are transporting sprayer to prevent fuel from flooding engine Keep sprayer upright and level when operating it and when transporting it This prevents crankcase oil from leaking into combustion chamber which makes startup very difficult Daily Check engine oil level and fill as needed Daily Check and fill gas tank Daily Check sprayer air filter clean and replace element as needed 6 309662 After first 20 hours of operation and each 100 hours thereafter Change oil Weekly Remove engine air filter cover and clean element In very dusty environments check filter daily Replace element as needed Replacement elements can be purchased from your local HONDA dealer Spark plug Use only a NGK BP6ES or BPR6ES plug Gap plug to 0 025 to 0 030 in 0 7 to 0 8 mm Always use a spark plug wrench 6 months Clean Air Flow Sensor a
3. 213 Hand tight en nut firmly 4 Install ball 220 in piston housing 206 5 Apply blue Loctite to piston seat 213 threads and screw assembly onto rod hand tight TIP Draw a line across male gland nut and piston housing for an alignment reference before tightening piston and nut Place piston seat 213 in a vise Hold packing nut 208 steady with one wrench and use a torque wrench to tighten rod assembly to 90 125 ft lb 122 170 N m Make sure reference line made in step 5 is aligned 7 Grease throat of intake housing 227 Assemble into throat male gland 204 flat side first alter nate white packings 225 and purple packings 203 and then female gland all with lips facing down Install packing nut 202 and hand tighten firmly 8 Grease piston packings and inside throat pack ings 9 Grease new o rings 205 and install on cylinder 221 Slide cylinder into bottom of intake housing 227 until you hear it snap 10 Guide piston rod assembly into cylinder so piston rod flats are aligned with opening in front of pump Push down until you hear another snap Turn pump over and push assembly in completely 11 Align rod hole to front of pump with a screw driver 12 Grease o ring 223 install on plug 224 install plug and screws 222 loosely Torque screws to 50 70 in lb 5 6 8 N m in a crosswise pattern 13 Install ball 216 and ball guide 217 into foot valve Place pump assembl
4. DO NOT use this kit at sprayer outlet as it does not have a spring guard on material hose 26 309662 Technical Data Honda GX160 Engine Power Rating 3600 rpm ANS eset ats feiss eet ee eee 5 5 Horsepower DIN 6270 DIN 6271 NA oia dente heh acu Shain 2 9 Kw 4 0 Ps NB aaam i bint teen E aa es 3 6 Kw 4 9 Ps Maximum Working Pressure 1000 psi 7 0 MPa gt bar Cycles gallon liter onnan naana 2 11 Maximum Delivery 3 gpm 11 enin Fuel Tank Capacity 0 95 gallon 3 7 liter Pump Inlet Size 2 inch quick disconnect Fluid Outlet Size 005 3 4 npsm f Wetted Parts Displacement Pump Nickle plated carbon steel Stainless steel Chrome plated stainless steel Poly Tungsten carbide fluoroelastomer Sound Data Sprayer Sound Pressure Level 97dB A Sound Power Level 45 105dB A Measured readings at 1 m normal load Gun Sound Pressure Level 96dB A Sound Power Level 104dB A Measured while spraying simulated acoustical texture under typical conditions as specified by material manufacturer Dimensions Weight dry without packaging 150 pound 68 kg 0 See ee ee 32 inch 813 mm Length ssi 2 a ted 2 08 30 inch 762 mm Width 5 banner e aE a tated 23 inch 584 mm 309662 27 Graco Warranty and Disclaimers Graco warrants all equipment referenced in this
5. NUT lock hex LABEL instruction KIT digital display TUBE nylon GASKET Kit 234231 contains seat sst tip and o rings Kit 246606 contains items 12 28 76 and 146 Kit 241113 contains items 89 and 94 Danger and warning labels tags and cards are free 309662 Bae424n4 ps Ae panna ae aan ann nn nn OPRAWDBNNOANNA BANNAHHHOHOKRANYD BBB Bannan np Awana a 21 Parts Flow Control See page 21 for parts description and page 20 for location on sprayer 176 Kit 248327 163 53 55 50 YI ti4366b A Danger and warning labels tags and cards are free Ref B No Part No Description Qty 138t 112774 SCREW mach 9 157f 115492 SCREW mach slot hex washhd 2 160t 102040 NUT hex 1 4 20 2 S 162 15D885 LABEL instructions 1 167t 15D864 BRACKET 1030FC air filter 1 168 155494 UNION swivel 90 degree 1 169 155665 UNION adapter 1 170t 155699 ELBOW street 1 9 171 C20483 NIPPLE hex 3 8 npt 1 172 106148 FILTER air 3 8 npt 1 173 15D863 SPACER standoff 1030FC filter 2 _ 174 119251 SCREW self tap filhd 8 32 2 pe G 176t 106151 VALVE drain auto 1 fue Senay cere 180 156823 UNION swivel 1 ON eee 181 162453 ADAPTER 1 R ti4366a 1824 FLOW SWITCH 1 cae t Included in Kit 248327 which may b
6. See page 12 damaged Intermittent material flow out Material supply is low or empty Refill and prime pump See Startup proce of gun dure in operator manual Check material supply often to prevent running pump dry Air control on gun is set too high Reduce the air flow through the gun by turning the air control knob on the back of the gun Hose too long or material too Change to a shorter hose or less coarse coarse material Heavy or poorly atomized mate Fluid pressure was not allowed to Wait longer between releasing gun trigger rial when gun is first triggered fully self relieve after releasing gun and re triggering lack of soft start trigger Gun was not fully triggered immedi Always squeeze trigger fully to prevent ately when squeezed causing gun just air from turning on which starts pump air passages to clog with material and pressurizes hoses Disassemble and clean gun Air valve failure Check and replace as needed Air flow sensor dirty or damaged Check air filter Clean air flow sensor see page 4 or re place as needed Pump does not shut off after f Air leaks in the system after the air Check and tighten all connections be gun trigger is released flow sensor tween the air flow sensor and the gun Air leaks in gun Check gun for excessive air leaks and re pair See manual 309661 Air flow sensor dirty or damaged Check air filter Clean air flow sensor see page 4 or re place as needed Prem
7. air control or volume Gun air passages clogged with After releasing gun trigger make sure at gun material system is fully depressurized before trig gering gun again This helps prevent material backing into gun passages Air filter dirty Clean or replace element Air flow sensor dirty or damaged Check air filter Clean air flow sensor see page 4 or re place as needed Displacement pump output Piston ball 220 not seating Clean piston area See page 12 low on upstroke Piston packings worn or damaged Replace packings See page 12 Siphon hose coupling gasket 1e Replace or install gasket worn or missing Pump cylinder o ring 205 worn or f Replace o ring missing 8 309662 Troubleshooting Continued PROBLEM CAUSE SOLUTION Displacement pump output Siphon hose strainer is clogged low on downstroke or both r z strokes Piston packings worn or damaged Replace packings See page 12 Material leaks into wet cup Intake valve ball 216 not seating Clean and service intake valve See properly page 12 Clutch 9 worn or damaged Replace clutch See page 18 Air leak at pump foot valve or Be sure foot valve is tight each day siphon tube elbow Be sure seal in elbow is in place and is not worn or damaged Material leaks into wet cup Loose wet cup 202 Tighten wet cup enough to stop leakage Throat packings worn or damaged Replace packings See page 12 Displacement rod 201 worn or Replace displacement rod
8. 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 equipmentis 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 sub stitution 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 Ifthe claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the o
9. housing worn or damaged Replace drive housing See page 15 Pinion assembly worn or damaged Service pinion assembly See page 16 Engine operates displace Flow control is set to PRIME Set flow control to LOW MED HIGH while ment pump operates but no triggering gun material pressure at gun Fluid system over pressurized Spraying material is too thick or the mate rial hose is too long Use a less course material or a shorter hose Gun nozzle disk is clogged Check and clean nozzle disk as needed Switch to a larger nozzle disk Material flowing out drain line Check for air leaks to dump valve Check dump valve for wear replace as needed Air flow sensor dirty or damaged Pump is packed out Disassemble and clean pump see page 8 hose s and gun Low fluid delivery Siphon hose strainer is clogged Engine RPM too low Increase engine speed See Startup procedure in operator manual Flow control set too low Increase flow control to MED or HIGH Hose too long or material too Change to a shorter hose or less coarse coarse material Material flowing out drain line Check drain line for a constant flow of material when sprayer is operating in LOW MED HIGH mode Check for air leaks to prime valve Check dump valve for wear replace as needed Gun nozzle disk is clogged Check and clean nozzle disk as needed Switch to a larger nozzle disk Pump is packed out Disassemble and clean pump see page 8 hose s and gun Loss of
10. is not removed from clutch housing 88 do 1 through 4 Otherwise start at 5 1 Remove drive housing 8 page 15 2 Disconnect field cable from flow control Fig 10 Remove five screws 99 and lockwashers 43 and pinion assembly 58 58 8700A Fig 10 4 Fig 11 Place pinion assembly 58 on bench with rotor side up 5 Remove four screws 95 and lockwashers 43 Install two screws in threaded holes E in rotor Alternately tighten screws until rotor comes off 95 43 8701B Fig 11 16 309662 6 Fig 12 Remove retaining ring 58e 7 Tap pinion shaft 58d out with plastic mallet 8703B Fig 12 8 Fig 13 Use an impact wrench or wedge something between armature 89 and clutch housing to hold engine shaft during removal 9 Remove four screws 2 and lockwashers 43 10 Remove armature 89 Fig 13 ia 1 Pinion Assembly Rotor Field Shaft Clutch Installation Fig 14 Lay two stacks of two dimes on smooth bench surface 6 10 11 Fig 12 Tap pinion shaft 58d in with plastic mallet Install retaining ring 58e with beveled side facing field Fig 11 Place pinion assembly 58 on bench with rotor side up Apply locktite to screws Install four screws 2 and lockwashers 43 Alternately torque screws to 125 in Ib until rotor is secure Use threaded holes to hold rotor Fig 10 Install pinio
11. 241440 114699 114686 101682 100020 100644 114678 113802 114984 111483 206994 108795 245245 198723 198720 114331 111482 108068 115522 241279 116891 112774 235490 15C005 189246 15B668 188634 235737 15B683 117780 110980 117781 C27076 15C190 115492 15C173 150174 102040 150040 246606 150283 111340 Description LABEL display LCD Qty FITTING elbow male swivel for 1030fc 5 32 in tubing FITTING elbow male swivel for 1030 1 4 in tubing LABEL identification CLIP retainer SCREW cap sch KIT dump valve see pg 23 WASHER thrust MANIFOLD dump valve COLLAR shaft HUB armature HOUSING clutch ARMATURE clutch 5 in KEY parallel GEAR combination WASHER thrust SCREW cap socket hd ROTOR clutch 5 SCREW cap sch WASHER lock SCREW cap sch BUSHING strain relief SCREW hex hd flanged SCREW tapping phillips pan hd CLAMP cable FLUID TSL 8 oz bottle SCREW mach pnh HANDLE cart CLIP axle WHEEL semi pneumatic 12 in SCREW mach pnh sems RIVET snap PIN spring straight SCREW mach pnh ROD connecting WASHER SCREW mach GUN texture see manual 308274 LABEL flow control LABEL warning LABEL instruction LABEL outlet HOSE SET 1 2 air x 3 4 fluid VALVE air FITTING tee male branch CLAMP hose SCREW machine pnh NUT PLATE retaining SCREW mach slot hex wash hd HOSE 5 32 blue tubing HOSE 5 32 black tubing
12. G NUT 215 235963 INTAKE HOUSING 216 102973 BALL intake 1 25 in Dia 217 187064 BALL GUIDE 218 188558 U CUP SEAL poly fluoroelastomer 219 187072 V PACKING poly 220 102972 BALL piston 0 875 in Dia 221 187066 CYLINDER 225 187071 V PACKING poly 226 187070 GLAND female 227 187933 HOUSING outlet 228 183210 PIN 232 235962 SEAL foot valve a Ss Ss Ss WM SH HSH WH SB SB SB SB SB Ss SP KH HSB VB VSB DO OAH DPD AH TI3020A Included in Repair Kit 235186 purchased separately Kit includes pressure drain valve u cup packing 111829 24 309662 Parts Pinion and Drive Housing Repair Kits Ref No 58 and 8 Pinion Housing Repair Kit Ref No Part No Description 58 245399 KIT repair pinion housing 58b 105489 PIN 58d 241114 PINION SHAFT 58e 112770 RETAINING RING large Must be ordered separately A Pinion housing assembly 58 includes clutch field and connector Qty a Na Ref No 8 Drive Housing Repair Kit Ref No Part No 8 287128 8g 194173 8h 116192 8p 290228 Description KIT repair drive housing WASHER WASHER LABEL caution Qty oo ce T10177B 309662 25 Accessories USE ONLY GENUINE GRACO PARTS AND ACCESSORIES Air And Material Hose Kit 235737 Max Working Pressure Fluid 750 psi 5 18 MPa 51 7 bar Air 300 psi 2 07 MPa 20 7 bar 50 ft 15 2 m hoses to supplement 50 ft 15 2 m hose kit supplied with sprayer Use up to three more hose kits
13. 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 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 PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in this equipment Such use could result in a serious chemical reaction with the possibility of explosion which could cause death serious injury and or substantial property damage 309662 3 A WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury E Ja ka INSTRUCTIONS Read all instruction manuals tags and labels before operating the equipment Use equipment only for its intended purpose Call your Graco distributor for information Do not exceed the maximum working pressure or temperature rating of the lowest rated system component This gun has a 150 psi 10 bar maximum fluid working pressure at a 125 psi 9 bar maximum incoming air pressure Read Technical Data in all equipment manuals Do not al
14. Oil level low Add oil to engine crankcase Engine operates but Flow control set to OFF Set flow control to PRIME mode or LOW displacement pump does not MED HIGH while triggering gun Air compressor not on or insufficient Start air compressor air flow from compressor Increase SCFM or compressor size Check air passages and tips for obstruc tions Check air filter element for clogs Air pressure set to low Check display for air pressure System requires a minimum of 40 psi 0 28 MPa 2 8 bar to operate Increase pressure by adjusting air control knob Sprayer engine RPM too low Increase engine speed Clutch connector into back of circuit Check and ensure a tight connection board is loose Air filter dirty Clean or replace filter element Air flow sensor dirty or damaged Check air filter Clean air flow sensor See page 4 or re place as needed Air transducer failed Check display for correct air pressure reading Replace circuit board as need ed Fluid transducer failed Check connection at circuit board Replace fluid transducer Clutch not engaging Worn or damaged clutch See page 18 Fluid transducer failure Air transducer failure Displacement pump rod seized by Service pump See page 10 dry coating 309662 7 Troubleshooting Continued PROBLEM CAUSE SOLUTION Engine operates but Connecting rod worn or damaged Replace connecting rod See page 14 displacement pump does not 7 Continued Drive
15. Repair G TexSpray 1030 FC German Patent No P 43 18 679 3 09 309662J For portable spray application of architectural paints and coatings 0 9 to 3 0 gpm 3 4 to 11 4 Ipm Flow Rate 750 psi 5 1 MPa 51 bar Maximum Working Pressure 500 psi 3 4 MPa 34 bar Recommended Maximum Working Pressure Model 234113 Series A TexSpray 1030 FC sprayer 235490 TexSpray gun and 50 ft 15 m air and fluid hose set Important Safety Instructions Read all warnings and instructions in this manual Save these instructions lf ee 309663 CONTENTS 7 Warnings ssena r asenne tesen on aa 2 Component Description 5 A E 308274 Nz Maintenance 00 00 c eee eee eee 6 Troubleshooting 0000 000 7 ti3005b 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 Specifications This equipment is not intended for use with flammable or combustible materials used in places such as cabinet shops or other factory or fixed locations If you intend to use this equipment in this type of application you must comply with NFPA 33 and OSHA requirements for the use of flammable and combustible materials Warnings Warning Symbol Caution Symbol This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the inst
16. ature prime valve fail Pump does not shut off after gun Read Pump does not shut off after gun ures trigger is released trigger is released and fix appropriate problem Repair or replace Prime Valve See page 19 309662 9 Displacement Pump Repair Removal A WARNING To reduce risk of injury due to sprayer starting unexpectedly shut off engine before performing checks or service 1 Fig 4 Flush sprayer Remove suction hose elbow 150a pump outlet hose A and drain hose 64 A MOVING PARTS HAZARD Neo To reduce risk of amputating fingers al keep fingers away from connecting rod and pin while jogging engine 128 he 27 AN 61 3 AN Torque to 20 ft lb 27 N m A Back of pump Cutaway view shows how pin 38 goes through connecting rod Fig 5 10 309662 0407 2 Fig 5 Start engine Jog flow control between PRIME and OFF until connecting rod stops near bottom of stroke Shut off engine 3 Loosen two quick disconnect screws 27 4 Pry retaining spring 37 up on connecting rod 128 Push pin 38 out with a screwdriver 5 Fig 6 Remove cover C to control housing 54 by removing four screws 12 Detach pressure transducer cord 63 Fig 4 from control board 9 at port D Remove pressure transducer cord from control box 6 Fig 4 Remove air hoses 158 and 159 from prime valve manifold 85 Note correc
17. cting rod assembly off drive housing 5 Inspect crank A for excessive wear and replace drive housing if necessary page 15 Installation 1 Evenly lubricate inside of bronze bearing E in bearing housing 23 with high quality motor oil Liberally pack top roller bearing B lower bearing C inside connecting rod assembly 22 with bearing grease 2 Assemble connecting rod 22 and bearing housing 23 3 Clean mating surfaces of bearing housing 23 and drive housing 20 A CAUTION Do not use bearing housing screws 48 to align or seat bearing housing with drive housing Align these parts with locating pins D to avoid premature bearing wear 14 309662 4 Align connecting rod with crank A and carefully align locating pins D in drive housing 20 with holes in bearing housing 23 Push bearing hous ing onto drive housing or tap it into place with a plastic mallet 5 Install four screws 48 and lockwashers 49 on bearing housing 23 Torque screws evenly to 25 ft lb 84 N m 6 Do steps 2 5 of Displacement Pump Installa tion page 10 AN Liberally pack with bearing grease 20d supplied AA Lubricate with high quality motor oil AN Torque to 25 ft lb 34 N m See page 10 to remove pump TI3021A Fig 8 Drive Housing A WARNING To reduce risk of injury due to sprayer starting unexpectedly shut off engine before performing checks or service 1 Fig 9 Disconn
18. e ordered separately Included in Kit 248328 which may be ordered separately 180 A 181 182 22 309662 Parts Dump Manifold See page 21 for parts description and page 20 for location on sprayer 159 black 158 blue TI3122A TI3008e Detail A A Prime Valve Repair Kit 234231 Installation 1 Replace all parts shown for 47 2 Apply blue LockTite to threads of screw 68 3 Detail A Hold piston assembly of air cylin der 22 with 3 16 in hex driver and torque screw 68 to 40 to 50 in lb 4 Detail C Place valve seat b with rounded end out toward screw head Place dark color o ring c carbide seat d either side up and white o ring e Torque screw 82 to 40 to 50 in lb Detail B Dump valve adapter 41 must be installed with smaller ID bore and OD orientation groove if present toward air cylinder assembly y Parts included in kit 287127 309662 23 Parts Displacement Pump Model 235166 Series A Includes items 201227 202 aC ia 206 NZ ae aaa i gee 208 Ref 228 on 207 No PartNo Description Qty eo O A 209 201 188437 PISTON ROD 202 187068 PACKING NUT 203 188560 V PACKING poly 204 187939 GLAND male 205 188557 O RING 206 187934 PISTON HOUSING 207 188559 O RING fluoroelastomer 208 188434 NUT 209 188432 GLAND male 210 188561 V PACKING poly 211 188433 GLAND female 212 188627 BACKUP WASHER nylon 213 235165 PISTON SEAT 214 187929 LU
19. ect siphon hose elbow 150a drain hose 64 and material hose not shown from pump outlet Disconnect cables Remove screws 21 and front cover 19 2 Remove four screws 40 and lockwashers 56 from bearing housing 89 3 Lightly tap back of bearing housing 39 with a plastic mallet Pull pump bearing housing and connecting rod away from drive housing 8 as one assembly 4 Remove bearing housing screws 93 and lock washer 36 and pinion housing screws 59 and lockwashers 36 AN Torque to 25 ft lb 34 N m Apply remaining grease to these areas 5 Lightly tap around drive housing 8 to loosen drive housing Pull drive housing straight off pinion housing 58 Be prepared to support combination gear 91 which may also come out 6 Liberally apply bearing grease supplied with combination gear to combination gear 91 and to areas called out by note 2 7 Place bronze colored washer 8g and then silver colored washer 8g on shaft protruding from big bearing of drive housing 8 Align gears and push new drive housing straight onto pinion housing and locating pins A ee 8 Reassemble sprayer Or go to next section in this Fig 9 manual if further service is needed 309662 15 Pinion Assembly Rotor Field Shaft Clutch Removal A WARNING To reduce risk of injury due to sprayer starting unexpectedly shut off engine before performing checks or service If pinion assembly 58
20. ector male for 1030 CLAMP grounding assy SCREW thread forming hex hd KIT repair suction 55 gal SCREW quick disc LABEL crtl box cover WASHER lock NIPPLE pipe hex UNION swivel ENGINE gas 5 5 hp Honda FRAME cart RIVET blind PLATE indicator WASHER lock spring SPRING retaining PIN str hdls HOUSING bearing SCREW cap socket hd ADAPTER dump valve SCREW cap hex hd WASHER lock spring hi collar KNOB switch PACKING o ring FITTING nipple reducing KIT dump valve repair PLATE control box KIT flow sensor CAP hub BUTTON snap NUT regulator HOUSING control PANEL control WASHER lock spring hi collar KIT repair pinion housing SCREW cap sch CONDUCTOR ground STRAP tie wire LABEL danger English TRANSDUCER pressure for 1030fc PLUG manifold for 1030 HOSE drain 12 ft SCREW mach phillips SCREW cap skt button hd NUT lock hex SWITCH rotary LABEL warning CLIP spring LABEL caution nMeoe2hpNhMH 224242 Ra Ronn pHYBBaB Bann GRA RBA AMA MPA Baan Aap BBB ansn nt Pan pHNMNNNDA BAB E E a anu Dp Ref No Part No 76 79 89t 90 91 92 93 94t 95 96 99 100 101 102 104 105 112 117 118 119 120 122 123 124 128 130 138 140 144 1454A 146 148 150 151 152 153 154 155 156 157 158 159 160 162 163 164 185 po 15C003 114151 15C002 114687 111832 287127 114672 15B766 193680 193510 193531 183401
21. elieves system pressure and stops the pump when the gun trigger is released TexSpray Gun 235490 A WARNING EQUIPMENT MISUSE HAZARD The TexSpray Gun 235490 is for use only with the GM 1030 TexSpray 234113 which is designed so the fluid pressure of the gun will not exceed the working pressure rating of the components The maximum fluid work ing pressure of the GM 1030 TexSpray is 750 psi 5 1 MPa 51 bar but the recommended maximum is 500 psi 3 4 MPa 34 bar INSTRUCTIONS Fig 2 Air flow is controlled at the gun During priming turn the gun air control valve D in fully to prevent air from mixing with the fluid which allows you to check and adjust the fluid flow accurately When this valve is closed the air exits the rear of the gun During opera tion open the air control valve to introduce air at the correct volume for the desired spray pattern The gun also has a trigger bail E to reduce operator fatigue when spraying large surfaces Fig 2 TexSpray Hoses CAUTION Use Graco hoses designed for this sprayer Using other hoses will damage the flow control 309662 5 Component Description Compressor Requirements NOTE This sprayer requires an external air compres sor CAUTION Install an air filter on external air compressor to reduce contamination to spray system Air compressor range 10 scfm to 35 scfm 30 to 140 psi 0 2 0 97 MPa 2 to 9 7 bar Minimum Compressor Size
22. injury due to sprayer starting unexpectedly shut off engine before performing checks or service Disassemble Pump 1 See Displacement Pump Repair on page 10 to remove pump 2 Use a hammer on tabs of lug nut 214 to loosen foot valve housing 3 Fig 7 Disassemble pump but do not disassemble piston rod 201 from piston housing 206 unless either needs to be replaced These two parts are joined with high strength red Loctite Joint must be heated to disassemble Clean and Inspect All Parts 1 Clean all traces of sealant from all parts with a compatible solvent 2 Inspect all part for nicks and scratches Replace worn or damaged parts as they cause packings to wear more quickly and may result in poor pump performance Repair Kit Packing Repair Kit 235186 is available Replace all parts in kit for best results Parts included in kit are marked with an asterisk in text and drawings For example 208 Assemble Pump 1 Fig 7 If piston rod 201 and piston housing 206 were disassembled clean threads thoroughly Apply Loctite primer and then red Loctite to threads and torque to 80 to 100 ft lb 110 to 135 N m Allow to dry at least 1 hour 2 Assemble onto piston seat 213 washer 212 u cup seal 218 with lips toward ring female gland 211 and then alternate white 210 and purple packings 219 all with lips facing up male gland 209 12 309662 3 Install nut 208 on piston seat
23. n assembly 58 with five screws 99 and lockwashers 43 Connect field cable to flow control Collar 2 Lay armature 89 on two stacks of dimes 3 Press center of clutch down on bench surface 4a 0 12 01 in 3 0 25 mm om et Fig 14 8705A 4 Install armature 89 on engine drive shaft 5 Install four screws 2 and lockwashers 43 with torque of 125 in lb Removal 1 Fig 15 Loosen two screws 2 on collar 86 2 Push screwdriver into slot in collar 86 and re move collar Installation 1 Fig 15 Install engine shaft key 90 2 Tap collar 86 on engine shaft A with plastic mallet 3 Press collar 86 onto engine shaft A Maintain dimension shown note 2 in Fig 15 Chamfer must face engine Check dimension Place rigid straight steel bar B across face of clutch housing 88 Use accurate measuring device to measure distance between bar and face of collar Adjust collar as necessary Torque two screws 16 to 125 10 in lb 14 1 1 N m AN Face of clutch housing 1 812 010 in 46 02 25 mm A Torque to 125 10 in lb 14 1 1 N m Chamfer this side 03483 Fig 15 309662 17 Clutch Housing Removal 1 Fig 16 Remove four capscrews 42 and lock washers 29 which hold clutch housing 88 to engine 2 Remove screw 101 from under mounting plate D 3 Remove engine key 90 4 Pull off clutch ho
24. riginal 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 mak ing any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco s
25. ructions or destruction of equipment if you do not follow the instructions 2 309662 The following are general Warnings related to the safe setup use maintenance and repair of this equipment Additional more specific warnings may be found throughout the text of this manual where applicable A 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 Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop clothes potential static arc Sprayer generates sparks When flammable liquid is used in or near sprayer or for flushing or cleaning keep sprayer at least 20 ft 6 m away from explosive vapors Do not clean with materials having flash points lower than 70 F 21 C Use water based materi als or mineral spirits type material only For complete information about your fluid request the MSDS from the fluid distributor or retailer Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn lights on or off when flammable fumes are present Ground equipment and conductive objects in work area Read Grounding instructions If there is static sparking or you feel a shock stop operating immediately Do not use equipment until you identify and correct the problem SKIN INJECTION
26. s follows 1 Fig 3 Loosen adapter A Pull down quick re lease C and swing out flow sensor regulator Disconnect connector B 2 Remove inlet fitting D retainer ring E piston F and spring G from flow sensor regulator H CAUTION Do not scratch or nick piston F or inside of flow sensor regulator H 3 Clean all parts D E F G Clean inside of H with a pipe cleaner 4 Assemble all parts and install flow sensor regula tor gt I L awe ilS ee Flo rH Sensor Regulator i 7 F gJ ana Pir Flow Sensor Regulator ti4366a Fig 3 Troubleshooting A WARNING To reduce risk of injury due to sprayer starting unexpectedly shut off engine before performing checks or service Check everything in chart before disassembling sprayer PROBLEM CAUSE SOLUTION Engine does not start Engine switch not ON Turn engine switch ON Spark plug cable disconnected or Connect spark plug cable or replace spark plug damaged spark plug Oil seepage into combustion Remove spark plug Pull starter rope 3 or chamber 4 times Clean and install spark plug Try to start Keep sprayer upright and do not overfill engine crankcase to avoid oil seepage
27. t air hose connection to ports on air cylinder 22 Use 5 16 inch wrench to hold ring on hose fitting while removing hose from fitting 7 Support weight of pump 3 and remove two quick disconnect screws 27 8 Unscrew assembled dump valve manifold 85 and air cylinder 22 from pump 3 7 ti3007b 54 Fig 6 Repair See page 12 for pump repair instructions Displacement Pump Repair Installation 3 Lift pump 3 into position and push in pin 38 Be 1 Fig 4 Screw assembled dump valve manifold 85 ae retaining Spring 97 shape downever and ol and air cylinder 22 into pump 3 pin 2 Fig 5 Pull piston rod 201 out of pump 3 2 to 3 4 Support weight of pump 3 and fasten two quick inches 50 to 75 mm disconnect screws 27 Torque screws to 20 ft lb 27 N m A WARNING l 5 Fig 4 Reattach air hoses 158 and 159 to prime MOVING PARTS HAZARD valve manifold 85 Ensure air hoses are attached If pin works loose parts could break off to the correct port on air cylinder 22 due to force of pumping action Parts could project through the air and result in 6 Fig 6 Route the pressure transducer cord 63 serious injury or property damage Make sure pin Fig 4 to the control box and attach to port D on and retaining spring are properly installed control board 9 Assemble cover C to control housing 54 using four screws 12 309662 11 Pump Repair A WARNING To reduce risk of
28. ter or modify equipment Check equipment daily Repair or replace worn or damaged parts immediately Do not lift pressurized equipment Route the hoses away from the traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 180 F 82 C or below 40 F 40 C Do not use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in this equipment which contains aluminum and or zinc parts Such use could result in a serious chemical reaction with the possibility of explosion which could cause death serious injury and or substantial property damage Wear eye and ear protection when operating this equipment Keep body parts away from front of gun See Sound Data in TECHNICAL DATA TOXIC FLUID HAZARD Toxic fluid or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to all applicable guide lines PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injur
29. upplying 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 reconnais sent 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 procedures concern es TO PLACE AN ORDER contact your Graco distributor or call 1 800 690 2894 to identify the nearest distributor All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice This manual contains English MM309662 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P 0 BOX1441 MINNEAPOLIS MN 55440 1441 www graco com Written in USA 12 2002 Rev 01 2008 28 309662
30. using 88 Installation 1 Fig 16 Push on clutch housing 88 2 Install four capscrews 42 and lockwashers 29 and secure clutch housing 88 to engine Torque to 200 in Ib 22 6 Nem 3 Install capscrew 101 from beneath mounting plate D Torque to 26 ft lb 35 2 Nem 18 309662 Fig 16 8708A Engine Removal Installation 1 Remove Pinion Assembly Rotor Field Pinion 1 Lift engine carefully and place on cart Clutch Clamp and Clutch Housing as in Siue oN pagos 18 17 ANe 18s 2 Fig 18 Install two screws 17 in base of engine 2 Fig 17 Disconnect all necessary wiring and secure with locknuts 18 Torque to 200 in Ib 22 6 Nem 3 Fig 18 Remove two locknuts 18 and screws 17 from base of engine 3 Fig 17 Connect all necessary wiring 4 Lift engine carefully and place on work bench 4 Install Pinion Assembly Rotor Field Pinion NOTE All service to the engine must be performed by Clutch Clamp and Clutch Housing as an authorized HONDA dealer instructed on pages 16 and 17 and 18 PRAYER WIRING DIAGRAM EERE S G o Flow control 6 Wires al Red Yellow Green Blue White Black E al QO Transducer M E 2X Red p O gt Black O Air valve CCI Flow sensor regulator
31. y 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 4 309662 Component Description Flow and Air Control Fig 1 The flow control A has a shut off and pressure relief feature to soft start each time the gun is trig gered instead of a blast of unatomized material The flow control has three modes e LOW MED HIGH Triggering the gun sends an air signal to the flow control that closes the prime valve and starts the pump which fills the material hose When the gun trigger is released the prime valve opens and relieves the system pressure into the supply container When the gun is triggered the automatic pressure relief special TexSpray hoses and pump design eliminate blasts of material and spray pulsing to ensure consistent atomization e OFF Puts the sprayer in neutral relieve pressure neither the pump nor the gun will operate and there is no material pressure in the pump hose or gun e PRIME The prime valve remains open so material circulates through the pump and back to the supply container through the drain hose The air control B increases or decreases the air pressure to the sprayer from the air supply OFF PRIME LOW MED HIGH TI3010A 158 TI3101A Blue Fig 1 Prime Valve Fig 1 The prime valve C r
32. y on foot valve and push into place 14 Screw on lug nut 214 Tighten lug nut securely with a hammer TIP Lug nut must be tight or pump will not prime Draw a line between intake housing and lug nut for an alignment reference during operation PPPRP PEED Grease inside of throat before installing packings Lips of v packings in throat must face down Grease inside of packings after installing Torque piston housing to piston seat 213 to 90 125 ft Ib 122 170 N m without changing alignment of packing nut Lips of v packings on piston must face up Grease outside of packings after installing Lips of u cup seal on piston must face down If piston seat and rod were separated apply Loctite primer then red Loctite and torque to 80 100 ft Ib 110 135 N m Tighten with hammer Fig 7 Pump Repair TI3015A 309662 TI3015A 13 Bearing Housing amp Connecting Rod Removal A WARNING To reduce risk of injury due to sprayer starting unexpectedly shut off engine before performing checks or service 1 Fig 8 Perform steps 1 8 of Displacement Pump Removal page 10 2 Remove four screws 40 and front cover 21 3 Remove four screws 48 and lockwashers 49 from bearing housing 23 4 Pull connecting rod assembly 22 and lightly tap lower rear of bearing housing 23 with a plastic mallet to loosen it from drive housing 20 Pull bearing housing and conne
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