Graco Inc. 256391 Paint Sprayer User Manual
Contents
1. 40 0 lb 18 1 kg Wetted parts zinc and nickel plated carbon steel nylon stainless steel PTFE Delrin leather UHMWPE aluminum tungsten carbide Noise level Sound power IS0 3744 100dBa Sound pressure ISO 3744 90 dBa All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 www graco com Printed in USA 310824D 4 2008 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty in2. 680 180 Maximum delivery gpm lpm 0 43 1 6 Maximum tip size 0 020 Fluid outlet npsm 1 4 in Dimensions Stand Length 15 75 in 40 0 cm Width 14 0 in 36 0 cm Height 17 in 43 0 cm Weight 30 lb 13 6 kg Dimensions Hi Boy Length 22 0 in 55 9 cm Width 20 5 in 52 1 cm Height 38 8 in 98 6 cm Weight 58 0 lb 25 9 kg Dimensions ProStep Length 20 0 in 50 8 cm Width 15 5 in 39 4 cm Height 19 25 in 48 9 cm Weight
3. 29 3 Disconnect pressure switch connector A from con trol board 33 4 Remove tape 22 holding wires to manifold 5 Pull wires back through hole K in housing 6 Turn the pressure control knob 16 counter clock wise as far as you can to access the flats on either side of the pressure control assembly 7 Using a 1 in 26 mm wrench loosen and unscrew pressure control assembly 8 Remove pressure control assembly Installation 1 Align grommet collar 17 on fluid manifold so open ing faces toward motor 2 Apply loctite to pressure control assembly threads 16 3 Screw pressure control assembly 16 into manifold and torque to 150 in lbs 17 0 N m 4 Wrap wires around knob and feed through slot in grommet 21 5 Insert grommet 21 in hole K in housing Secure wires to manifold housing with tape 22 6 Reconnect pressure switch connector A to control board 33 7 Install shroud 29 and two screws 30 WARNING Read Electric Shock Warning page 3 and Pressure Relief Procedure page 8 A K 21 22 If you plan to reuse the pressure control assembly be very careful not to damage or tangle the wires while unscrewing the assembly Inspect pressure control assembly before installa tion to verify the o ring is installed and in place Be careful when tightening pressure control knob that wires do not get pinched between the pressure control assembly and fluid
4. 6 Install pump 9 Displacement Pump Replace ment page 14 7 Install shroud 29 with two screws 30 WARNING Read Electric Shock Warning page 3 and Pressure Relief Procedure page 8 CAUTION Do not drop gear cluster 3 and 2 when removing drive housing 5 Gear cluster may stay engaged in motor frontend bell or drive housing 6 1 Liberally apply grease 1 1 45 3 2 30 34 31 33 30 1 15 6 ti5642a Wiring Diagram 28 310824D Wiring Diagram Red Black Pressure Control Assembly Power Plug White Green Black from Motor 2 x Yellow ON OFF Switch ti5643a Capacitor Replaceable Fuse Black Power Plug Blue Green Brown ON OFF Switch Pressure Control Assembly Red from Motor 2 x Yellow Capacitor ti5857a Replaceable Fuse 120V Model 240V Model Technical Data 310824D 29 Technical Data Delrin is a registered trademark of the DuPont Company Measured 3 feet 1 meter from equipment Power requirements 100 120V AC 50 60 hz 11A 1 phase 230V AC 50 60 hz 7 5A 1 phase Generator required 3000 w minimum Maximum working pressure 3300 psi 22 7 MPa 227 bar Cycles per gallon liter
5. Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not kink or over bend the hose Do not expose the hose to temperatures or to pressures in excess of those specified by Graco Do not use the hose as a strength member to pull or lift the equipment Misuse of the sprayer platform can cause death or serious injury Do not exceed platform rating Make sure sprayer is on firm level non slippery secure foundation before accessing sprayer platform Make sure platform has been properly secured to frame before standing on platform If you are unable to step up to sprayer platform use a stable intermediate stepping device for stepping up to sprayer platform or stepping down from sprayer platform Keep both feet squarely and firmly on platform Do not allow sprayer frame to come in contact with live electrical wires Do not over reach while on sprayer platform Do not position sprayer behind any doors when on sprayer platform ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power cord before servicing equipment Use only grounded electrical outlets Use only 3 wire extension cords Ensure ground prongs are intact on sprayer and extension cords Do not expose to rain Store indoors PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chlorid
6. in the case where the nozzle tip clogs while spraying fol low the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing the noz zle tip to clean Do not leave the unit energized or under pressure while unattended When the unit is not in use turn off the unit and follow the Pressure Relief Procedure for turning off the unit High pressure spray is able to inject toxins into the body and cause serious bodily injury In the event that injec tion occurs get immediate surgical treatment Check hoses and parts for signs of damage Replace any damaged hoses or parts This system is capable of producing 3300 psi Use Graco replacement parts or accessories that are rated a minimum of 3300 psi Always engage the trigger lock when not spraying Verify the trigger lock is functioning properly Verify that all connections are secure before operating the unit Know how to stop the unit and bleed pressure quickly Be thoroughly familiar with the controls WARNING Warning 310824D 5 EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Always wear appropriate gloves eye protection and a respirator or mask when painting Do not operate or spray near children Keep children away from equipment at all times Do not overreach or stand on an unstable support Keep effective footing and balance at all times Stay alert and watch what you are doing
7. as recommended by the fluid and solvent manufacturer Gloves Hearing protection WARNING Component Identification 6 310824D Component Identification S ti12008a R K A M N P F J H E U B A B U E H V F K J T T D D Item English A Pressure Control B ON OFF switch D Power Cord E Fluid Outlet F Prime Valve H Pump J Suction Hose K Drain Hose M Fluid Hose N Gun P Tip R Guard S Trigger Safety Lock T Model Serial Tag U Filter V Platform Installation 310824D 7 Installation Grounding and Electric Requirements The sprayer cord includes a grounding wire with an appropriate grounding contact The sprayer requires 110 120V Units 100 130VAC 50 60 Hz 11A 1 phase circuit with a grounding receptacle 240V Units 210 255 VAC 50 60 Hz 7 5A 1 phase cir cuit with a grounding receptacle Never use an outlet that is not grounded or an adapter Do not use the sprayer if the electrical cord has a dam aged ground contact Only use an extension cord with an undamaged ground contact Recommended extension cords for use with this sprayer 110 120V 3 wire 12 AWG 2 5 mm2 minimum 300 ft 90 m maximum length 240V 3 wire 16 AWG 1 0 mm2 minimum 300 ft 90 m maximum length Spray gun ground through connection to a properly grounded fluid hose and pump Fluid supply con
8. sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la 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 la suit
9. seeing burned adja cent commutator bars Replace motor See page 27 Motor Replacement 3 Tightness of pump packing nut Overtightening tightens packings on rod restricts pump action and damages packings Loosen packing nut Check for leaking around throat Replace pump packings if necessary See pump manual 309250 Problem What To Check If check is OK go to next check What To Do When check is not OK refer to this column Displacement Pump Replacement 14 310824D Displacement Pump Replacement See manual 309250 for pump repair instructions Removal 1 Relieve pressure page 8 2 Loosen two screws 30 and rotate cover 44 3 Loosen nut A and remove hose set 35 Loosen nut B and remove the high pressure hose 14 4 Cycle pump until pin 32 is in position to be removed 5 Disconnect power cord from outlet 6 Using a flat screwdriver push retaining spring C up Push out pump pin 32 7 Using a hammer loosen pump jam nut 11 Unscrew and remove pump 9 WARNING Read Injection Hazard Warning page 3 Moving Parts Hazard Warning page 4 and Pressure Relief Procedure page 8 44 30 ti6104a 14 B A 35 ti6105a 32 ti6106a C 11 9 11 ti6107a Displacement Pump Replacement 310824D 15 Installation 1 Extend pump piston rod full Apply grease to top of pump rod at D or inside connecting rod 7 Install jam nut 11 on pump thr
10. 21 Installation 1 Position grommet and power cord wires through strain relief in control board 33 2 Reconnect the power cord connectors to the correct terminals indicated on the control board 120V black and white 240V blue and brown on control board 33 3 Carefully slide control board back into place on the side of the motor frame 4 Replace 3 screws 30 Torque to 30 35 in lbs 3 4 3 9 N m 5 Reattach motor connector B and pressure control assembly connector A 6 Install shroud 29 and two screws 30 Be sure power cord is routed between the blue high pressure hose to the manifold and the sprayer frame 33 ti6122a ti6125a A B 33 120V H B A J G F E D ti5639a 30 33 30 Fuse Replacement 22 310824D Fuse Replacement Removal 1 Relieve pressure page 8 Disconnect power cord from outlet 2 Remove two screws 30 and shroud 29 3 Remove fuse from control board 4 Remove spare fuse from motor Installation 1 Replace fuse on control board with spare fuse 2 Install shroud 29 and two screws 30 Replaceable Fuse ti9134b Spare Fuse included n 110V and 120 models only Pressure Control Assembly Replacement 310824D 23 Pressure Control Assembly Replacement See Wiring Diagram page 28 Removal 1 Relieve pressure page 8 Disconnect power cord from outlet 2 Remove two screws 30 and shroud
11. Graco Inc PO Box 1441 Minneapolis MN 55440 1441 Copyright 2004 Graco Inc is registered to I S EN ISO 9001 310824D Repair 390 Airless Sprayer For portable spray applications of architectural paints and coatings 3300 psi 22 7MPa 227bar Maximum Working Pressure all models not available in all countries IMPORTANT SAFETY INSTRUCTIONS Read all warnings and instructions Save these instructions Contact Graco Customer Service or your local Graco distributor to obtain a manual in your language Model VAC Country 262019 253958 120 North America 254968 254969 256391 240 Europe Europe multicord 254998 262024 256392 240 Asia Australia 256481 253961 110 UK Related Manuals 310820 309639 309250 310876 ti11608a ti11583a Stand ProStep ti11626a Hi Boy Manual Conventions 2 310824D Contents Manual Conventions 2 Warnings 3 Component Identification 5 Installation 6 Pressure Relief Procedure 7 General Repair Information 8 Troubleshooting 9 Displacement Pump Replacement 13 Drive Hous
12. What To Do When check is not OK refer to this column Troubleshooting 310824D 13 Motor runs and pump strokes 1 Prime Valve Open Close prime valve 2 Paint supply Refill and reprime pump 3 Intake strainer clogged Remove and clean then reinstall 4 Suction hose leaking air Tighten nut Check o rings on swivel 5 Intake valve ball and piston ball are seating properly See Pump Manual 309250 Strain paint before using to remove particles that could clog pump 6 Leaking around throat packing nut which may indicate worn or damaged packings See Pump Manual 309250 7 Pump rod damaged See Pump Manual 309250 Motor runs but pump does not stroke 1 Displacement pump pin dam aged or missing Replace pump pin if missing Be sure retaining spring is fully in groove all around connecting rod See page 14 Displacement Pump Replacement 2 Connecting rod assembly for damage Replace connecting rod assembly See page 14 Displacement Pump Replacement 3 Gears or drive housing Inspect drive housing assembly and gears for damage and replace if necessary See page 16 Drive Housing Replacement Motor is hot and runs intermittently 1 Be sure ambient temperature where sprayer is located is not more than 115 F 46 C and sprayer is not located in direct sun Move sprayer to shaded cooler area if possible 2 Motor has burned windings indi cated by removing positive red brush and
13. allation 1 Apply a liberal coat of grease to gears and needle bearing surfaces Install thrust bearing 4 and gears 2 and 3 in front endbell housing 2 Push drive housing into front endbell housing Insert gear crank 3 through hole in connecting rod 7 3 Install four screws 6 4 Install cover 32 with two screws 30 5 Install pump 9 Displacement Pump Replace ment page 14 WARNING Read Injection Hazard Warning page 3 and page 8 CAUTION Do not drop gear cluster 3 and 2 when removing drive housing 5 Gear cluster may stay engaged in motor front endbell or drive housing 5 30 6 32 6 3 2 ti5641a 7 4 2 4 3 ti6121a Needle bearing surfaces 3 7 ti6124a Spin Test 310824D 17 Spin Test See Wiring Diagram page 28 To check armature motor winding and brush electrical continuity 1 Relieve pressure page 8 Disconnect power cord from outlet 2 Remove two screws 30 and shroud 29 3 Remove drive housing 5 page 16 4 Disconnect motor connector F Armature Short Circuit Test Quickly turn motor fan by hand If motor coasts two or three revolutions before complete stop there are no electrical shorts If motor does not spin freely armature is shorted Replace motor page 27 Armature Brushes and Motor Wiring Open Circuit Test Continuity 1 Connect red and black motor leads with test lead Turn motor fan by han
14. d at about two revolutions per second 2 If uneven or no resistance check for missing brush caps broken brush springs brush leads and worn brushes Repair as needed page 19 3 If still uneven or no resistance replace motor page 27 4 Reattach motor connector F 5 Replace drive housing page 16 6 Replace shroud 29 and two screws 30 WARNING Read Electric Shock Warning page 3 and Pressure Relief Procedure page 8 30 29 F ti5638a Fan Replacement 18 310824D Fan Replacement Removal 1 Relieve pressure page 8 Disconnect power cord from outlet 2 Remove two screws 30 and shroud 29 3 Remove spring clip 101 on back of motor 4 Pull off fan 100 Installation 1 Slide new fan 100 in place on back of motor Be sure blades of fan face motor as shown 2 Install spring clip 101 3 Replace shroud 29 and two screws 30 WARNING Read Electric Shock Warning page 3 and Pressure Relief Procedure page 8 101 100 30 29 ti5769a Motor Brush Replacement 310824D 19 Motor Brush Replacement See Wiring Diagram page 28 Removal Replace brushes worn to less than 1 4 in 6mm Brushes wear differently on each side of motor check both sides 1 Relieve pressure page 8 Disconnect power cord from outlet 2 Remove two screws 30 and shroud 29 3 Disconnect motor connector D from control board 33 4 Cut tie
15. e de ou en rapport directement ou indirectement avec les proc dures concern es
16. e other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property damage BURN HAZARD Equipment surfaces can become very hot during operation To avoid severe burns do not touch hot equipment Wait until equipment has cooled completely MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure in this manual Disconnect power or air supply TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed Read MSDS s to know the specific hazards of the fluids you are using Store hazardous fluid in approved containers and dispose of it according to applicable guidelines PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to Protective eye wear Clothing and respirator
17. e on a nominal 120V circuit and has a grounding plug similar to the plug illustrated in the figure below Only connect the product to an outlet having the same configuration as the plug Do not use an adapter with this product Extension Cords Use only a 3 wire extension cord that has a 3 blade grounding plug and a 3 slot receptacle that accepts the plug on the product Make sure your extension cord is not damaged If an extension cord is necessary use 12 AWG 2 5 mm2 minimum to carry the current that the product draws An undersized cord results in a drop in line voltage and loss of power and overheating Warning 4 310824D FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Do not spray flammable or combustible materials near an open flame or sources of ignition such as cigarettes motors and electrical equipment Paint or solvent flowing through the equipment is able to result in static electricity Static electricity creates a risk of fire or explosion in the presence of paint or solvent fumes All parts of the spray system including the pump hose assembly spray gun and objects in and around the spray area shall be properly grounded to protect against static discharge and sparks Use Graco conductive or grounded high pressure airless paint sprayer hoses Verify that all containers and collection sys
18. eads 2 Install pump rod D into connecting rod 7 3 Install pump pin 32 Verify retainer spring C is in groove over pump pin 4 Push pump 9 up until pump threads engage 5 Screw in pump until threads are flush with top of drive housing opening 6 Align pump outlet E to back 7 Screw jam nut 11 up onto pump until nut stops Tighten jam nut by hand then tap 1 8 to 1 4 turn with a 20 oz maximum hammer to approximately 75 ft lb 102 N m 8 Install suction tube 35 and high pressure hose 14 Tighten nuts A and B 9 Fill packing nut with Graco TSL until fluid flows onto top of seal 10 Rotate cover 44 Tighten screws 30 WARNING If pump pin works loose parts could break off due to force of pumping action Parts could project through air and result in serious injury or property damage CAUTION If the pump jam nut loosens during operation the threads of the drive housing will be damaged 14 B A 35 ti6105a 44 30 ti5735a Drive Housing Replacement 16 310824D Drive Housing Replacement Removal 1 Relieve pressure page 8 2 Remove pump 9 Displacement Pump Replace ment page 14 Disconnect power cord from outlet 3 Remove two screws 30 and cover 32 4 Remove four screws 6 5 Pull drive housing 5 out of motor front endbell 6 Remove gear cluster 2 and 3 and thrust bearing 4 from drive housing Inst
19. eplacement 4 Suction hose connections Tighten any loose connections Check o rings on suction hose swivel 5 Electric supply with volt meter Meter must read 100 130 VAC for 110 120 VAC models and 210 255 for 240 VAC models Low voltages reduce sprayer per formance Reset building circuit breaker replace building fuse Repair electrical outlet or try another outlet 6 Extension cord size and length 7 Replace with a correct grounded extension cord See page 7 Grounding and Electric Requirements 8 Leads from motor to circuit board for damaged or loose wire con nectors Inspect wiring insulation and terminals for signs of over heating Be sure male terminal pins are centered and firmly connected to female terminals Replace any loose terminals or damaged wiring Securely reconnect terminals 9 Worn motor brushes which must be 1 4 in 6 mm minimum Replace brushes See page 19 Motor Brush Replacement 10 Motor brushes binding in brush holders Clean brush holders Remove carbon dust by using compressed air to blow out brush dust 11 Low stall pressure Turn pressure control knob fully clockwise Replace pressure control assembly See page 23 Pressure Control Assembly Replace ment 12 Motor armature for shorts by using an armature tester growler or perform spin test page 17 Replace motor See page 27 Motor Replacement Problem What To Check If check is OK go to next check
20. ge 8 6 Ref 14 17 A 33 A 18 24 23 20 40 26 13 25 C B 6 17 15 18 A A 20 Ref 14 25 26 23 24 13 40 33 ProStep ti12077a ti5771a Drain Line Replacement 310824D 25 Drain Line Replacement This procedure should be used whenever you replace the manifold and reinstall an existing drain line or install a new drain line using the Drain Line Kit Removal To remove the drain line 40 from the manifold 1 Cut drain line 40 from barbed fitting 20 2 Unscrew barbed fitting 20 from manifold Installation 1 Screw barbed fitting 20 into manifold 2 Push drain line 40 onto barbed fitting 20 If you are only replacing the manifold and will be reusing the existing barbed fitting 20 and drain line 40 you will need to use a sharp knife to cut the remaining drain line material off the end of the barbed fitting 20 To make the drain line more pliable and easier to install over barbed fitting heat end of drain line 40 with a hair dryer or by placing end in hot water a few seconds Power Cord Replacement 26 310824D Power Cord Replacement See Wiring Diagram page 28 Removal 1 Follow Control Board Replacement removal instructions steps 1 8 page 20 2 Disconnect green ground wire G from sprayer by loosening grounding screw 31 Installation 1 Follow Control Board Replacement installation in
21. ing check or service equipment or install or clean spray tip Read Injection Hazard Warning page 3 FLUSH ti5310a ti5304a General Repair Information 310824D 9 General Repair Information Keep all screws nuts washers gaskets and electri cal fittings removed during repair procedures These parts usually are not provided with replacement kits Test repairs after problems are corrected If sprayer does not operate properly review repair procedure to verify you did it correctly See Trouble shooting page 10 Overspray may build up in the air passages Remove any overspray and residue from air pas sages and openings in the enclosures whenever you service sprayer Do not operate the sprayer without the motor shroud in place Replace if damaged Motor shroud directs cooling air around motor to prevent overheating and insulate the control board from accidental electric shock WARNING Read Electric Shock Warning page 3 and Burn Hazard Warning page 4 WARNING Flammable materials spilled on hot bare motor could cause fire or explosion To reduce risk of burns fire or explosion do not operate sprayer with cover removed WARNING To reduce risk of serious injury including electric shock Do not touch moving or electric parts with fingers or tools while testing repair Unplug sprayer when power is not required for testing Install all covers gaskets screws and
22. ing Replacement 15 Spin Test 16 Fan Replacement 17 Motor Brush Replacement 18 Control Board Replacement 19 Fuse Replacement 21 Pressure Control Assembly Replacement 22 Manifold Replacement 23 Power Cord Replacement 24 Motor Replacement 25 Wiring Diagram 26 Technical Data 27 Graco Standard Warranty 29 Graco Information 30 Manual Conventions Note WARNING WARNING a potentially hazardous situation which if not avoided could result in death or serious injury Warnings in the instructions usually include a symbol indicating the hazard Read the general Warnings section for additional safety information Hazard Symbol CAUTION CAUTION a potentially hazardous situation which if not avoided may result in property damage or destruction of equipment Additional helpful information Warning 310824D 3 Warning The following war
23. manifold 29 30 ti5766a Manifold Replacement 24 310824D Manifold Replacement See Wiring Diagram page 28 Removal 1 Relieve pressure page 8 Disconnect power cord from outlet 2 Remove drain line 40 and barbed fitting 20 from manifold See Drain Line Replacement page 25 3 Remove two screws 30 and shroud 29 4 Disconnect fluid hose at pump outlet 5 Disconnect pressure switch connector A from con trol board 33 6 Remove tape 22 holding wires to manifold 7 Pull wires back through hole K in housing 8 If required remove pressure switch from manifold See Pressure Control Assembly Replacement page 23 9 Remove two screws 6 to disconnect Manifold from housing Installation 1 Position manifold on sprayer frame 2 Replace screws 6 and torque to 150 in lbs 17 N m 3 If removed install pressure control assembly See Pressure Control Assembly Replacement page 23 4 Feed pressure switch wires through hole in housing K 5 Insert grommet 21 in hole K in housing Secure wires to manifold housing with tape 22 6 Reconnect pressure switch connector A to control board 33 7 Reconnect fluid hose at pump outlet 8 Replace barbed fitting 20 and drain line 40 See Drain Line Replacement page 25 9 Install shroud 29 and two screws 30 WARNING Read Electric Shock Warning page 3 and Pressure Relief Procedure pa
24. n nect leads 6 Motor thermal switch Yellow motor leads must have continuity through thermal switch Replace motor See page 27 Motor Replace ment 7 Brush cap missing or loose brush lead connections Install brush cap or replace brushes if leads are damaged See page 19 Motor Brush Replacement 8 Brush length which must be 1 4 in 6mm minimum NOTE Brushes do not wear at the same rate on both sides of motor Check both brushes Replace brushes See page 19 Motor Brush Replacement 9 Motor armature commutator for burn spots gouges and extreme roughness Remove motor and have motor shop resurface commutator if possible See page 27 Motor Replacement 10 Motor armature for shorts using armature tester growler or per form spin test page 17 Replace motor See page 27 Motor Replace ment 11 Pressure control not plugged in to control board Insert pressure control connector into control board Problem What To Check If check is OK go to next check What To Do When check is not OK refer to this column Troubleshooting 12 310824D Low Output 1 Worn spray tip Relieve pressure page 8 Replace tip Refer to gun instruction manual 309639 2 Verify pump does not continue to stroke when gun trigger is released Service pump See page 14 Displacement Pump Replacement 3 Prime valve leaking Relieve pressure page 8 Then repair prime valve See page 24 Manifold R
25. nings are for the setup use grounding maintenance and repair of this equipment The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risks Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where appli cable Grounding Instructions This product must be grounded In the event of an electrical short circuit grounding reduces the risk of electric shock by providing an escape wire for the electric current This product is equipped with a cord having a grounding wire with an appropriate grounding plug The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances WARNING GROUNDING Improper installation of the grounding plug is able to result in a risk of electric shock When repair or replacement of the cord or plug is required do not connect the grounding wire to either flat blade terminal The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire Check with a qualified electrician or serviceman when the grounding instructions are not completely under stood or when in doubt as to whether the product is properly grounded Do not modify the plug provided if it does not fit the outlet have the proper outlet installed by a qualified electri cian This product is for us
26. ntil thawed com pletely If paint hardened dried in sprayer replace pump packings See page 14 Dis placement Pump Replacement 2 Displacement pump connecting rod pin Pin must be completely pushed into connecting rod and retaining spring must be firmly in groove or pump pin Push pin into place and secure with spring retainer See page 14 Displacement Pump Replacement 3 Motor Remove drive housing assembly See page 16 Drive Housing Replacement Try to rotate fan by hand Replace motor if fan won t turn See page 27 Motor Replacement Troubleshooting 310824D 11 Basic Electrical See wiring diagram page 28 1 Electric supply Meter must read 100 130 VAC for 110 120 VAC models and 210 255 VAC for 240 VAC models Reset building circuit breaker replace building fuses Try another outlet 2 Extension cord Check extension cord continuity with volt meter Replace extension cord 3 Sprayer power supply cord Inspect for damage such as bro ken insulation or wires Replace power supply cord See page 26 Power Cord Replacement 4 Fuse Check replaceable fuse on control board next to ON OFF switch Replace fuse after completing motor inspection See page 22 Fuse Replacement 5 Motor leads are securely fas tened and properly connected to control board Replace loose terminals crimp to leads Be sure terminals are firmly connected Clean circuit board terminals Securely reco
27. page 3 and Pressure Relief Procedure page 8 To contain the dust turn on your shop vac Place the end of the hose over the negative lower brush holder while blowing compressed air into the posi tive top brush holder Use all new parts included in your brush kit Do not reuse old parts if new replacement parts are pro vided 30 29 33 ti5637a A B C D E ti5637a F D A Red Black Control Board Replacement 20 310824D Control Board Replacement See Wiring Diagram page 28 Removal 1 Relieve pressure page 8 Disconnect power cord from outlet 2 Remove two screws 30 and shroud 29 3 Disconnect pressure switch connector A from con trol board 33 4 Disconnect motor connector B from control board 33 5 Remove 3 screws 30 securing control board to housing 2 are located on the front and one on the back next to the power cord 6 Pull control board out slightly and then slide it back and off of frame 7 Remove grommet and wires from strain relief 8 Remove 2 power cord connectors from control board WARNING Read Electric Shock Warning page 3 and Pressure Relief Procedure page 8 30 33 30 ti6119a Make sure power cord is free and NOT wrapped around cord wrap Ground wire will remain attached to sprayer with grounding screw 33 240V A B 33 120V B A Control Board Replacement 310824D
28. stallation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost
29. structions steps 1 4 page 20 2 Reconnect green ground wire G to green ground ing screw 31 on frame Be sure terminal on ground faces UP or wires could get caught in shroud 3 Reattach motor connector B and pressure control switch connect A 4 Install shroud 29 and two screws 30 WARNING Read Electric Shock Warning page 3 and Pressure Relief Procedure page 8 33 33 240V 120V G 31 Motor Replacement 310824D 27 Motor Replacement See Wiring Diagram page 28 Removal 1 Relieve pressure page 8 Disconnect power cord from outlet 2 Remove pump 9 Displacement Pump Replace ment page 14 3 Remove drive housing Drive Housing Replace ment page 16 4 Remove Pressure Fluid Manifold Manifold Replacement page 24 5 Disconnect all leads from board 33 and remove control board Control Board Replacement page 20 6 Remove ground wire G from motor endbell 7 Remove four screws 6 and motor 1 from frame 45 Installation 1 Install new motor 1 on frame 45 with four screws 6 2 Install manifold 15 with two screws 6 Manifold Replacement page 24 3 Install control board 33 with three screws 30 Connect all leads to board See Control Board Replacement page 20 and Wiring Diagram page 28 4 Connect ground wire G to motor with green ground screw 31 5 Install Drive Housing Drive Housing Replace ment page 16
30. tainer follow local code Solvent and Oil based fluids follow local code Use only conductive metal pails placed on a grounded sur face such as concrete Do not place the pail on a non conductive 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 WARNING Your system must be grounded Read warnings page 3 Smaller gauge or longer extension cords may reduce sprayer performance Pressure Relief Procedure 8 310824D Pressure Relief Procedure 1 Turn OFF power and turn pressure control to lowest pressure setting 2 Hold gun against side of grounded metal flushing pail Trigger gun to relieve pressure 3 Turn prime valve down If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after following the steps above VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually then loosen completely Clear hose or tip obstruction 4 Engage trigger safety lock on gun if unit is being shut down or left unattended WARNING Follow this Pressure Relief Procedure whenever you are instructed to relieve pressure stop spray
31. tems are grounded to prevent static discharge Connect to a grounded outlet and use grounded extensions cords Do not use a 3 to 2 adapter Do not use a paint or a solvent containing halogenated hydrocarbons Keep spray area well ventilated Keep a good supply of fresh air moving through the area Keep pump assembly in a well ventilated area Do not spray pump assembly Do not smoke in the spray area Do not operate light switches engines or similar spark producing products in the spray area Keep area clean and free of paint or solvent containers rags and other flammable materials Know the contents of the paints and solvents being sprayed Read all Material Safety Data Sheets MSDS and container labels provided with the paints and solvents Follow the paint and solvents manufacturer s safety instructions Fire extinguisher equipment shall be present and working Sprayer generates sparks When flammable liquid is used in or near the sprayer or for flushing or cleaning keep sprayer at least 20 feet 6 m away from explosive vapors SKIN INJECTION HAZARD Do not aim the gun at or spray any person or animal Keep hands and other body parts away from the discharge For example do not try to stop leaks with any part of the body Always use the nozzle tip guard Do not spray without nozzle tip guard in place Use Graco nozzle tips Use caution when cleaning and changing nozzle tips
32. washers before you operate sprayer CAUTION Do not run sprayer dry for more than 30 seconds Doing so could damage pump packings Protect the internal drive parts of this sprayer from water Openings in the cover allow for air cooling of the mechanical parts and electronics inside If water gets in these openings the sprayer could malfunction or be permanently damaged Prevent pump corrosion and damage from freezing Never leave water or water base paint in sprayer when its not in use in cold weather Freezing fluids can seriously damage sprayer Store sprayer with Pump Armor to protect sprayer during storage Troubleshooting 10 310824D Troubleshooting WARNING Read Electric Shock Warning page 3 Burn Hazard Warning page 4 and Pressure Relief Procedure page 8 Problem What To Check If check is OK go to next check What To Do When check is not OK refer to this column Motor Won t Operate Basic Fluid Pressure 1 Pressure control knob setting Motor will not run if set at mini mum fully counter clockwise Slowly increase pressure setting to see if motor starts 2 Spray tip or fluid filter may be clogged Relieve pressure page 8 Then clear clog or clean gun filter Refer to gun instruction manual 309639 Basic Mechanical 1 Pump frozen or hardened paint Thaw sprayer if water or water based paint has frozen in sprayer Place sprayer in warm area to thaw Do not start sprayer u
33. wrap F 5 Locate two yellow wires C thermal leads Cut each yellow wire at the center 6 Using a flat screwdriver pry off two brush caps A Remove brushes B from motor 7 Discard old brush harness 8 While rotating fan by hand using compressed air blow air into positive top brush holder to remove brush dust Installation 1 With wires facing toward front of motor install new brushes B in motor Be sure to install the positive red brush lead in the top of the motor as shown and the negative black brush lead in the side of the motor 2 Push each cap A into place over brush Orient each cap with the 2 projections on either side of the brush lead You will hear a snap when cap is securely in place 3 Using a wire stripper strip off wire insulation approx imately 1 4 inch 6 mm from the end of each yellow wire C to the motor 4 Insert stripped end into end of a butt splice E on new brush assembly 5 Use a crimping tool to squeeze the ends of the butt splice E tightly around each wire Pull gently on each wire to be sure it will not pull out of the butt splice 6 Using new tie wrap F from kit wrap tie around motor and wires only Trim off excess Be sure pres sure hose and wire leads are not caught in tie wrap 7 Reconnect motor connector D to control board 33 8 Replace shroud 29 and two screws 30 WARNING Read Electric Shock Warning
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