REPAIR NOVAt/ NOVAprot/ SuperNOVAprot Airless

REPAIR
824191
Rev. A
KEEP FOR REFERENCE.
Read this and all related manuals for
important warnings and instructions.
INSTRUCTIONS
NOVA/ NOVApro/ SuperNOVApro
Airless Paint Sprayers
3000 psi (210 bar, 21 MPa ) Maximum Working Pressure
120 VAC
Type
Series
Stand
Hi-Boy
NOVA
A
824920
NOVApro
A
824932
SuperNOVApro
A
824940 824942
Related Manuals
. . . . . . . 309070
. . . . . . . 824190
. . . . . . . 309054
9546A
. . . . . . . 824192
824920
. . . . . . . 309053
. . . . . . . 309055
Table of Contents
Component Function and Identification . . . . . . . . . . . . 3
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Repair Information . . . . . . . . . . . . . . . . . . . . . . 4
Spin Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . 10
On/Off Switch Replacement . . . . . . . . . . . . . . . . . . . . 12
Pressure Control Repair . . . . . . . . . . . . . . . . . . . . . . . 13
Drive Housing Replacement . . . . . . . . . . . . . . . . . . . . 15
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Displacement Pump Replacement . . . . . . . . . . . . . . . 17
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Sherwin–Williams Standard Warranty . . . . . . . . . . . . 19
Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
The SHERWIN–WILLIAMS COMPANY, CLEVELAND, OHIO 44115
COPYRIGHT 1999, GRACO INC.
WARNING
ADVERTÊNCIA
Fire and explosion hazard: Solvent and paint fumes can ignite or
explode.
To help prevent a fire and explosion:
Use only in an extremely well ventilated area.
Eliminate all ignition sources; such as pilot lights, cigarettes and
static arcs from plastic drop cloths. Do not plug or unplug power
cords or turn lights on or off in spray area.
Ground Sprayer, object being sprayed, paint and solvent pails.
Hold gun firmly to side of grounded pail when triggering into pail.
Use only conductive airless paint hose.
Do not use 1,1,1–trichloroethane, methylene chloride, other
halogenated hydrocarbon solvents or fluids containing such
solvents in pressurized aluminum equipment. Such use could
result in a chemical reaction, with the possibility of explosion.
Poderá ocorrer incêndio e explosão quando for pulverizado ou injetado
líquido inflamável numa área onde houver má circulação de ar; vapores
inflamáveis poderão incendiar-se a partir de uma chama ou fagulhas a
descoberto.
Para ajudar a evitar incêndio e explosão:
Utilize no exterior ou numa área muito bem ventilada.
Não utilize 1,1,1–tricloroetano, cloreto de metileno, outros solventes de
hidrocarbonetos halogenados ou líquidos contendo tais solventes em
equipamento de alumínio pressurizado. Tal utilização poderá resultar
numa reação química, com possibilidade de explosão.
Retire, elimine ou desligue todas as fontes de ignição; coloque fita
adesiva na tomada da parede. Não fume na área de pulverização.
Nunca abasteça o depósito de combustível com o motor em funcionamento ou quente.
Ponha em contato com a terra o pulverizador, o objeto a ser pulverizado, e os baldes de tinta e de solventes.
Segure a pistola firmemente de encontro ao lado de um balde em contato
com a terra, quando estiver descarregando para dentro do mesmo.
Utilize somente tubos flexíveis condutores para pintura a alta pressão.
Nunca faça funcionar o motor numa área fechada.
Fluid injection and high pressure hazard: High pressure spray or
leaks can inject fluid into the body.
To help prevent injection, always:
Engage trigger safety latch when not spraying.
Keep clear of nozzle and leaks.
Never spray without a tip guard.
Do PRESSURE RELIEF if you stop spraying or begin servicing
sprayer.
Do not use components rated less than sprayer Maximum
Working Pressure
Never allow children to use this unit.
A injeção de líquido é um ferimento grave! Se o líquido a alta pressão penetrar na sua pele, o ferimento poderá parecer “simplesmente
um corte”. Mas é um ferimento grave! Procure o médico imediatamente.
Para ajudar a evitar injeção de líquido, faça sempre o seguinte:
Engate o trinco de segurança do gatilho quando não estiver pulverizando.
Sempre aponte a pistola para longe de você mesmo(a) ou de outras
pessoas.
Alivie a pressão antes de verificar ou reparar qualquer vazamento.
Alivie a pressão quando desligar o pulverizador ou parar de pulverizar.
Não utilize componentes classificados para uma pressão nominal
inferior à pressão máxima de trabalho dos sistemas.
If high pressure fluid pierces your skin, the injury might look like
“just a cut”. But it is a serious wound! Get immediate medical attention.
Nunca permita que crianças utilizem esta unidade. Se sofrer algum
ferimento durante a utilização deste equipamento, procure o médico
imediatamente.
MISE EN GARDE
ADVERTENCIA
Risque d’incendie et d’explosion imminent pendant la pulvérisation
ou le rinçage à pression de fluides inflammables dans une zone à mauvaise circulation d’air et en présence de gaz inflammables pouvant
s’allumer par une flamme nue ou des étincelles.
Pour éviter les risques d’incendie et d’explosion:
Manipuler les fluides à l’air libre ou dans une zone extrêmement
bien aérée.
Ne jamais utiliser de trichloroéthane 1,1,1, de chlorure de méthylène,
d’autres solvants à base d’hydrocarbures halogénés, ni de produits
contenant de tels solvants dans un équipement sous pression en
aluminium. Cela pourrait provoquer une réaction chimique avec risque
d’explosion.
Retirer, éteindre ou déboucher toute source d’inflammation, recouvrir
tout interrupteur mural avec du ruban adhésif. Ne pas fumer dans la
zone de pulvérisation.
Ne jamais remplir le réservoir d’essence lorsque le moteur est chaud
ou en marche.
Mettre à la terre le pulvérisateur, l’objet à pulvériser ainsi que les
seaux de peinture et de solvants.
Tenir le pistolet fermement contre la paroi d’un seau mis à la
terre lorsqu’on pulvérise dans le seau.
N’utiliser qu’un flexible pour peinture pulvérisée sans air.
Ne jamais mettre en marche un moteur dans une zone fermée.
Pueden ocurrir incendios y explosiones cuando se pulveriza fluido inflamable o cuando se lava con este tipo de fluido en un área donde la
circulación de aire es deficiente y los vapores inflamables se pueden encender al contacto con el fuego o chispas.
Para prevenir incendios y explosiones:
Use en espacios abiertos o en un área muy bien ventilada.
No utilice nunca tricloretano–1,1,1, cloruro de metileno, u otros disolventes a base de hidrocarburos halógenos o fluidos que contengan
tales disolventes en un equipo a presión de aluminio. El uso de estas
sustancias puede provocar una intensa reacción química, con riesgos
de explosión.
Retire, apague o desconecte todas las fuentes de ignición; asegure el
interruptor de la pared con cinta. No fume en el área de pulverización.
Nunca llene el estanque de combustible mientras el motor esté en
marcha o caliente.
Ponga a tierra el pulverizador, el objeto que recibe el chorro pulverizado,
las cubetas de pintura y disolvente.
Sostenga firmemente la pistola a un lado de la cubeta puesta a
tierra cuando dispare dentro de ella.
Use solamente mangueras para pintura conductora sin aire.
Nunca haga andar el motor dentro de un área cerrada.
L’injection de fluide constitue une lésion grave! Si un fluide haute
pression perce la peau, la blessure peut paraître comme une
«simple coupure». Mais il s’agit bien d’une lésion grave! Consulter
immédiatement un médecin.
Pour éviter les risques d’injection, toujours:
Bloquer le loquet de sécurité de la gâchette à la fin de la pulvérisation.
Pointer le pistolet loin de soi-même et toute autre personne à proximité
Décharger la pression avant de vérifier ou réparer une fuite.
Décharger la pression après la mise hors tension du pulvérisateur ou
à la fin de la pulvérisation.
Ne pas utiliser de composants dont la pression nominale est inférieure
à la pression maximale de service du système.
Ne jamais permettre aux enfants d’utiliser cet appareil. En cas de blessure pour avoir utilisé cet appareil, consulter immédiatement un médecin.
¡La inyección de fluido en la piel es una lesión seria! Si fluido de
alta presión le penetra la piel, la lesión podría parecer “sólo un
corte”. ¡Es una lesión seria! Consulte de inmediato al médico.
Para prevenir la inyección en la piel, siempre:
Enganche el seguro del gatillo cuando no use el pulverizador.
No apunte la pistola ni a sí mismo ni a los demás.
Alivie la presión antes de inspeccionar o reparar cualquier filtración.
Alivie la presión cuando apague el pulverizador o deje de usarlo.
No use componentes cuya capacidad nominal sea inferior a la
presión máxima de operación del sistema.
No permita que niños usen esta unidad. Si se lesiona usando este
equipo, sométase de inmediato a tratamiento médico.
2
824191
Component Identification and Function
H
A
J
B
V
U
R
P
S
T
K
F
D
N
E
G
8050A
M
Fig. 1
A
Motor
DC motor, permanent magnet, totally enclosed, fan cooled
B
Drive Assembly
Transfers power from DC motor to displacement pump
D
Displacement Pump
Transfers fluid to be sprayed from source through spray gun
E
Fluid Outlet
Spray gun is connected here
F
Prime Valve
Used to prime and drain sprayer (also relieves fluid outlet pressure) when
open
G
Fluid Filter
Final filter of fluid to spray gun
H
Pressure Adjusting Knob
Controls fluid outlet pressure
J
Pressure Control
Controls motor speed to maintain fluid outlet pressure at displacement pump
outlet. Works with pressure adjusting knob.
K
ON/OFF Switch
Power switch that controls main power to sprayer
M
50 ft (15 m) Main Hose
1/4 in. ID, grounded, nylon hose with spring guards on both ends
N
Spray Gun
High pressure spray gun with gun safety latch
P
RAC 5 Switch Tip
Uses high pressure fluid to clear tip clogs without removing tip from spray gun
R
HandTite Tip Guard
Tip guard reduces risk of injection injury
S
Thumb Lock Safety
Gun safety latch inhibits accidental triggering of spray gun
T
Power Cord Rack
Holds wrapped power cord for storage
U
Suction Hose
Transfers fluid to be sprayed from source to pump
V
Drain Tube
Fluid outlet used to drain and prime the sprayer
824191
3
General Repair Information
Pressure Relief Procedure
WARNING
INJECTION HAZARD
System pressure must be manually
relieved to prevent system from starting
or spraying accidentally. Fluid under high
pressure can be injected through skin and cause
serious injury. To reduce risk of injury from injection, splashing fluid, or moving parts, follow Pressure Relief Procedure whenever you:
are instructed to relieve pressure,
stop spraying,
check or service any system equipment,
or install or clean spray tip.
1. Lock gun safety latch.
2. Turn ON/OFF switch to OFF.
3. Unplug power supply cord.
4. Unlock gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
5. Lock gun safety latch.
6. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
If suspected that spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Now clear
tip or hose obstruction.
1. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair
procedures. These parts are not normally provided
with replacement assemblies.
WARNING
ELECTRIC SHOCK HAZARD
MOVING PARTS HAZARD
To reduce risk of serious injury, including
electric shock, do not touch moving or
electrical parts with fingers or tools while
testing repair. Shut off and unplug sprayer when inspection is complete. Install all
covers, gaskets, screws and washers
before operating sprayer.
2. Test repair after problem is corrected.
3. If sprayer does not operate properly, review
repair procedure to verify procedure was done
correctly. If necessary, see Troubleshooting Guide,
pages 5 – 9, for other possible solutions.
WARNING
HOT SURFACES HAZARD
EXPLOSION HAZARD
Motor and drive housing may be very hot
during operation and could burn skin if
touched.
Flammable materials spilled on hot, bare
motor could cause fire or explosion.
Have motor shroud in place during
operation to reduce risk of burns, fire or
explosion.
CAUTION
To reduce risk of pressure control malfunction:
Use needle nose pliers to disconnect wire. Never
pull on wire, pull on connector.
Mate wire connectors properly. Center flat blade of
insulated male connector in female connector.
Route wires carefully to avoid interference with
other connections of pressure control. Do not pinch
wires between cover and control box.
4
824191
CAUTION
Do not run sprayer dry for more than 30 seconds to
avoid damaging pump packings.
4. Install motor shroud before operation of
sprayer and replace if damaged. Motor shroud
directs cooling air around motor to prevent
overheating. It can also reduce risk of burns, fire or
explosion; see preceding WARNING.
Grounding
WARNING
Improper installation or alteration of grounding plug
results in risk of electric shock, fire or explosion
that could cause serious injury or death.
Grounding Plug
Grounded
Outlets
1. All models require a 60 Hz, 15A circuit with a
120 Vac grounding receptacle. See Fig. 2.
2. Do not alter ground prong or use adapter.
Fig. 2
3. A 12 AWG, 3-wire with grounding prong, 300 ft
(90 m) extension cord may be used. Long lengths
reduce sprayer performance.
Troubleshooting
Relieve pressure; page 4.
MOTOR WON’T OPERATE
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
Basic Fluid Pressure
Problems
1. Pressure control knob setting. Motor will not 1. Slowly increase pressure setting to see if morun if at minimum setting (fully counterclocktor starts.
wise).
Basic Mechanical
Problems
WHAT TO DO
When check is not OK refer to this column
2. Spray tip or fluid filter may be clogged.
2. Relieve pressure and clear clog or clean filter; refer to separate gun or tip instruction
manual.
1. Pump (13) for frozen or hardened paint.
1. Thaw sprayer if water or water-based paint
has frozen in sprayer. Place sprayer in warm
area to thaw. Do not start sprayer until
thawed completely. If paint hardened (dried)
in sprayer, replace pump packings. See
page 17 (Displacement Pump Replacement).
2. Displacement pump connecting rod pin (9a). 2. Push pin into place and secure with spring rePin must be completely pushed into connecttainer.
ing rod (9) and retaining spring (9b) must be
firmly in groove of pump pin. See Fig. 10.
3. Motor (1). Remove drive housing assembly 3. Replace motor (1) if fan won’t turn. See page
(10). See page 15. Try to rotate fan by hand.
16.
Basic Electrical Problems
1. Motor control board. Board shuts down and 1. See Motor Control Board Diagnostics,
displays error code.
page 13.
2. Electrical supply. Meter must read
85–130 Vac.
2. Reset building circuit breaker; replace building fuse. Try another outlet.
3. Extension cord. Check extension cord conti- 3. Replace extension cord.
nuity with volt meter.
4. Sprayer power supply cord (79). Inspect for 4. Replace power supply cord.
damage such as broken insulation or wires.
824191
5
Troubleshooting
MOTOR WON’T OPERATE (Continued)
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Basic Electrical Problems
(continued)
1. That motor leads are securely fastened and 1. Replace loose terminals; crimp to leads. Be
properly mated.
sure terminals are firmly connected.
Clean circuit board terminals. Securely reconnect leads.
2. For loose motor brush lead connections and ter- 2. Tighten terminal screws. Replace brushes if
minals. See page 10.
leads are damaged. See page 10.
3. Brush length which must be 1/2 in. minimum. 3. Replace brushes. See page 10.
See page 10.
NOTE: Brushes do not wear at the same rate on
both sides of motor. Check both brushes.
4. For broken or misaligned motor brush springs. 4. Replace spring if broken. Realign spring with
Rolled portion of spring must rest squarely on
brush. See page 10.
top of brush. See page 10.
5. Motor brushes may be binding in brush holders. 5. Clean brush holders. Remove carbon with
See page 10.
small cleaning brush. Align brush leads with
slot in brush holder to assure free vertical
brush movement.
6. Motor armature commutator for burn spots, 6. Remove motor and have motor shop resurgouges and extreme roughness.
face commutator if possible. See page 16.
See page 10.
7. Motor armature for shorts using armature tester 7. Replace motor. See page 16.
(growler) or perform spin test. See page 10.
Refer to wiring diagram on 1. Power supply cord (79). Connect volt meter be- 1. Replace power supply cord.
tween TP1 (neutral) and TP2 (L2, 120 Vac).
page 12 to identify test
Plug in sprayer. Meter must read 85–130 Vac.
points (TP).
Unplug sprayer.
2. ON/OFF switch (23). Connect volt meter be- 2. Replace ON/OFF switch. See page 12.
tween L1 and L2 terminal on ON/OFF switch.
Plug in sprayer and turn ON. Meter must read
85–130 Vac.
3. Motor thermal cutoff switch. Turn sprayer OFF. 3. If thermal switch is open (no continuity), allow
Check for continuity between TO1 and TO2 with
motor to cool. If switch remains open after
ohmmeter.
motor cools, replace motor. If thermal switch
closes after motor cools, correct cause of
overheating.
4. All terminals for damage or loose fit.
6
824191
4. Replace damaged terminals and reconnect
securely.
Troubleshooting
LOW OR FLUCTUATING OUTPUT
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Low Output
1. For worn spray tip.
1. Follow Pressure Relief Procedure Warning, then replace tip. See your separate
gun or tip manual.
2. Verify pump does not continue to stroke when 2. Service pump. See page 17.
gun trigger is released.
3. Filter clogged.
3. Relieve pressure. Check and clean filter.
4. Prime valve leaking.
4. Relieve pressure. Repair prime valve.
5. Suction hose connections.
5. Tighten any loose connections.
6. Electrical supply with volt meter.
6. Reset building circuit breaker; replace
Meter must read 85–130 Vac. Low voltages rebuilding fuse. Repair electrical outlet or try
duce sprayer performance.
another outlet.
7. Extension cord size and length; must be at least 7. Replace with a correct, grounded exten12 gauge wire and no longer than 300 ft. Longer
sion cord.
cord lengths reduce sprayer performance.
8. Leads from motor to pressure control circuit 8. Be sure male terminal blades are centered
board (35) for damaged or loose wires or conand firmly connected to female terminals.
nectors. Inspect wiring insulation and terminals
Replace any loose terminal or damaged
for signs of overheating.
wiring. Securely reconnect terminals.
9. For loose motor brush leads and terminals. See 9. Tighten terminal screws. Replace brushes
page 10.
if leads are damaged. See page 10.
10.For worn motor brushes which must be 1/2 in. 10. Replace brushes. See page 10.
minimum. See page 10.
11. For broken and misaligned motor brush 11. Replace spring if broken. Realign spring
springs. Rolled portion of spring must rest
with brush. See page 10.
squarely on top of brush.
12.Motor brushes for binding in brush holders. See 12.Clean brush holders, remove carbon dust
page 10.
with small cleaning brush. Align brush lead
with slot in brush holder to assure free vertical brush movement.
13.Low stall pressure.
13. Do either or both:
a. Turn pressure control knob fully
clockwise. Make sure pressure
control knob is properly installed
to allow full clockwise position.
b. Try a new transducer.
14.Motor armature for shorts by using an armature 14.Replace motor. See page 16.
tester (growler) or perform spin test. See page
10.
824191
7
Troubleshooting
LOW OR FLUCTUATING OUTPUT
TYPE OF 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 runs and pump strokes
1. Paint supply.
1. Refill and reprime pump.
2. Intake strainer clogged.
2. Remove and clean, then reinstall.
3. Suction tube or fittings loose.
3. Tighten; use thread sealant or sealing tape
on threads if necessary.
4. To see if intake valve ball and piston ball are 4. Remove intake valve and clean. Check
seating properly. See page 17.
balls and seats for nicks; replace if necessary, page 17. Strain paint before using to
remove particles that could clog pump.
5. Leaking around throat packing nut which may 5. Replace packings, page 17. Also check
indicate worn or damaged packings. See
piston valve seat for hardened paint or
page 17.
nicks and replace if necessary. Tighten
packing nut/wet-cup.
6. Pump rod damage.
6. Repair pump, page 17.
Motor runs but pump does not 1. Displacement pump pin (9a) (damaged or 1. Replace pump pin if missing. Be sure remissing), page 17.
tainer spring (9b) is fully in groove all
stroke
around connecting rod, page 17.
2. Connecting rod assembly (9) for damage, 2. Replace connecting rod assembly,
page 15.
page 15.
3. Gears or drive housing, page 15.
8
824191
3. Inspect drive housing assembly and gears
for damage and replace if necessary,
page 15.
Troubleshooting
MOTOR IS HOT AND RUNS INTERMITTENTLY
TYPE OF 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 is hot and runs intermit- 1. Determine if sprayer was operated at high 1. Decrease pressure setting or increase tip
pressure with small tips, which causes low
size.
tently.
motor RPM and excessive heat build up.
2. Be sure ambient temperature where sprayer 2. Move sprayer to shaded, cooler area if possible.
is located is no more than 90F and sprayer
is not located in direct sun.
ELECTRICAL SHORT
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Building circuit breaker opens 1. All electrical wiring for damaged insulation, 1. Repair or replace any damaged wiring or
and all terminals for loose fit or damage. Also
terminals. Securely reconnect all wires.
as soon as sprayer switch is
wires between pressure control and motor.
turned on.
See page 16.
CAUTION
Any short in any part of the
motor power circuit will cause
the control circuit to inhibit
sprayer operation. Correctly
diagnose and repair all shorts
before checking and replacing control board.
2. For missing inspection plate gasket (see page 2. Correct faulty conditions.
16), bent terminal forks or other metal to metal
contact points which could cause a short.
3. Motor armature for shorts. Use an armature 3. Replace motor. See page 16.
tester (growler) or perform spin test. See page
10. Inspect windings for burns.
4. Motor control board (35) by performing motor 4. Replace with a new pressure control board
control board diagnostics on page 13. If diag(35). See page 13.
nostics indicate, substitute with a good board.
CAUTION: Do not perform this check until
motor armature is determined to be good. A
bad motor armature can burn out a good
board.
1. Basic Electrical Problems on page 5.
Building circuit breaker opens
as soon as sprayer is plugged
into outlet and sprayer is NOT
turned on.
1. Perform necessary procedures.
2. ON/OFF switch (23) See page 12. Be sure 2. Replace ON/OFF switch. See page 12.
sprayer is unplugged! Disconnect wires from
switch. Check switch with ohmmeter. Reading
must be infinity with ON/OFF switch OFF, and
zero with switch ON.
3. For damaged or pinched wires in pressure 3. Replace damaged parts. See page 13.
control. See page 13.
Sprayer quits after sprayer op- 1. Basic Electrical Problems on page 5.
erates for 5 to 10 minutes.
2. Electrical supply with volt meter.
Meter must read 85–130 Vac.
1. Perform necessary procedures.
2. If voltage is too high, do not operate
sprayer until corrected.
3. Tightness of pump packing nut. Over tighten- 3. Loosen packing nut. Check for leaking
ing tightens packings on rod, restricts pump
around throat. Replace pump packings, if
action, and damages packings.
necessary. See page 17.
.
824191
9
Spin Test
Setup
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
Electric Shock Hazard; page 4.
To check armature, motor winding and brush electrical
continuity:
1.
Relieve pressure; page 4.
1. Connect red and black motor leads together with
test lead. Turn motor fan by hand at about two
revolutions per second.
2. If uneven or no resistance, check for: broken brush
springs, brush leads, motor leads; loose brush
terminal screws, motor lead terminals; worn
brushes. Repair as needed; page 10.
3. If still uneven or no resistance, replace motor;
page 16.
2. Remove drive housing; page 15.
3. Fig. 3. Remove pressure control cover (39).
Disconnect motor leads (F) and (G).
39
F
4. Fig. 4. Remove motor shroud (74) and inspection
covers (A).
G
Armature Short Circuit Test
Quickly turn motor fan by hand. If no electrical shorts,
motor coasts two or three revolutions before complete
stop. If motor does not spin freely, armature is
shorted. Replace motor; page 16.
9578A
Fig. 3
Motor Brush Replacement
Motor Brush Removal
74
Replace brushes worn to less than 1/2 in. Brushes
wear differently on each side of motor, check both
sides. Brush Repair Kit 236967 is available. Spring
clip, 112766, may be purchased separately.
1. Read General Repair Information; page 4.
2.
Relieve pressure; page 4.
7703B
3. Fig. 4. Remove motor shroud (74) and two
inspection covers (A).
(Continued on page 11)
10
824191
A
Fig. 4
Motor Brush Replacement
4. Fig. 5. Push in spring clip (A) to release hook (B)
from brush holder (C). Pull out spring clip (A).
1
5. Fig. 5. Pull brush lead (D) out of terminal (E).
Remove brush (F).
F
1
Motor lead; do not disconnect
2
Minimum 0.5” (12.5 mm)
3
Included in Brush Repair Kit
B
C
E
Fig. 6
03881
2
B
3
1
F
4. Repeat for other side.
5. Test brushes.
A
a. Remove pump (13); Displacement Pump
C
Replacement, page 17.
b. With sprayer OFF, turn pressure control knob
fully counterclockwise to minimum pressure.
Plug in sprayer.
E
D
Fig. 5
03881
c.
6. Inspect commutator for excessive pitting, burning
or gouging. A black color on commutator is normal.
Have commutator resurfaced by a motor repair
shop if brushes wear too fast.
Motor Brush Installation
CAUTION
When installing brushes, follow all steps carefully to
avoid damaging parts.
1. Fig. 6. Install new brush (F) with lead into brush
holder (C).
2. Fig. 5. Slide brush lead (D) into terminal (E).
Turn sprayer ON. Slowly increase pressure
until motor is at full speed.
CAUTION
Do not run sprayer dry for more than 30 seconds
while checking brushes to avoid damaging displacement pump packings.
6. Install brush inspection covers and gaskets.
7. Break in brushes.
a. Operate sprayer 1 hour with no load.
b. Install pump (13); Displacement Pump Replacement, page 17.
3. Fig. 6. Install spring clip (A). Push down to set
hook (B) into brush holder (C).
824191
11
On/Off Switch Replacement
Installation
Removal
1.
1. Install new ON/OFF switch (23). Install locking ring
(24) and toggle boot (25).
Relieve pressure; page 4.
2. Fig. 7. Remove four screws (18) and pressure
control cover (39).
2. Connect two wires (A) to ON/OFF switch.
3. Disconnect two wires (A) from ON/OFF
switch (23).
4. Remove toggle boot (25) and locking ring (24).
Remove ON/OFF switch (23).
25
3. Install pressure control cover (39) with four
screws (18).
37
24
35
A
23
36
18
D
E
52
39
9580A
Wiring Diagram
Ref 60
ON/OFF
Switch
Ref 23
TP1
Red (+) L2
L1
Ref 34
Black
Green
Power
Plug
Ref 29
Pressure
Transducer
Ref 52
White
from Motor
Black (–)
Fig. 7
12
824191
Yellow
Potentiometer
Ref 26
9535A
Pressure Control Repair
Motor Control Board
Removal
Refer to Fig. 7.
1.
Installation
1. Clean pad on rear of motor control board. Apply
small amount of thermal compound 073019 to pad.
2. Fig. 7. Install motor control board (35) with five
screws (36).
Relieve pressure; page 4.
3. Connect to motor control board (35):
2. Remove four screws (18) and cover (39).
Lead (E) to transducer.
3. Disconnect at motor control board (35):
Four motor leads: two yellow, black (+) and
red (–).
Lead (D) to potentiometer.
Lead (D) from potentiometer.
Four motor leads: two yellow, black (+) and
red (–).
Lead (E) from transducer.
4. Bundle and tie all loose wires.
4. Remove five screws (36) and circuit board (35).
5. Install cover (39) with four screws (18).
Motor Control Board Diagnostics
Note: Keep a new transducer on hand to use for test.
CAUTION
Do not allow sprayer to develop fluid pressure without transducer installed. Leave drain valve open if
test transducer is used.
1. Remove four screws (18) and cover (39).
See Fig. 7.
2. Turn ON/OFF switch ON.
3. Observe LED operation and reference following
table:
4.
Relieve pressure and unplug sprayer before servicing control board; page 4.
LED
BLINKS
SPRAYER OPERATION
INDICATES
WHAT TO DO
Once
Sprayer runs
Normal operation
Do nothing
Two times
repeatedly
Sprayer shuts down and LED
continues to blink two times
repeatedly
Run away pressure. Pres- Replace motor control board.
sure greater than 4500 psi See preceding Motor control
(310 bar, 31 MPa).
board removal procedure.
Three times
Sprayer shuts down and LED
continues to blink three times
repeatedly
Pressure transducer is
faulty or missing
Check transducer connection.
Open drain valve. Substitute
new transducer for transducer
in sprayer. If sprayer runs,
replace transducer.
Four times
repeatedly
Sprayer shuts down and LED
continues to blink four times
repeatedly
Line voltage is too high
Check for voltage supply
problems
Five times
repeatedly
Sprayer shuts down and LED
continues to blink five times
repeatedly
Too much current
Check for locked rotor, worn
motor brushes, or shorted
wiring or motor. Repair or
replace failed parts.
repeatedly
824191
13
Pressure Control Repair
Pressure Control Transducer
Pressure Adjust Potentiometer
Removal
Refer to Fig. 7.
Removal
1.
Refer to Fig. 7.
Relieve pressure; page 4.
2. Remove four screws (18) and cover (39).
3. Disconnect lead (E) from motor control
board (35).
4. Remove two screws (22) and filter housing (45).
5. Thread transducer lead plastic connector down
through transducer grommet (28).
6. Remove pressure control transducer (52) and
packing o-ring (51) from filter housing.
Installation
1. Install packing o-ring (51) and pressure control
transducer (52) in filter housing (45). Torque to
30–35 ft-lb.
2. Thread transducer lead plastic connector up
through transducer grommet (28).
3. Install filter housing (45) with two screws (22).
4. Connect lead (E) to motor control board (35).
5. Install cover (39) with four screws (18).
14
824191
1.
Relieve pressure; page 4.
2. Remove four screws (18) and cover (39).
3. Disconnect all leads from motor control board (35).
4. Remove five screws (36) and board (35)
5. Remove potentiometer knob (27), sealing shaft nut
(33) and pressure adjust potentiometer (26).
Installation
1. Install pressure adjust potentiometer (26), sealing
shaft nut (33) and potentiometer knob (27).
a. Turn potentiometer fully clockwise.
b. Install knob at full clockwise position.
2. Install board (35) with five screws (36).
3. Connect all leads to motor control board (35).
4. Install cover (39) with four screws (18).
Drive Housing Replacement
Assembly
CAUTION
1. Push drive housing (10) onto motor (1)
Do not drop gear cluster (7) when removing drive
housing (10). Gear cluster may stay engaged in
motor front end bell or drive housing.
2. Install two front screws (22).
Disassembly
1.
3. Install two back screws (22).
4. Fig. 8. Tip sprayer up. Install shroud (74) with
screw (74c).
Relieve pressure; page 4.
2. Remove pump (13); Displacement Pump
5. Install pump (13); Displacement Pump
Replacement, page 17.
Replacement, page 17.
3. Fig. 8. Tip sprayer up. Remove screw (74c) and
remove shroud (74).
6. Instal new access cover (10a) with two screws
(10b).
4. Remove two front screws (22).
5. Remove two back screws (22).
6. Pull drive housing (10) off of motor (1).
74
1
22
7
A
10
9582A
10a
74c
10b
22
74c
9581A
Fig. 8
824191
15
Motor Replacement
Disassembly
6. Remove strain relief (37, page 12, 13, 14).
1.
7. Remove three screws (22) behind board and
remove control housing (21).
Relieve pressure; page 4.
2. Remove pump (13); Displacement Pump
8. Remove four screws (22) and motor (1) from
frame (63).
Assembly
Replacement, page 17.
1. Install new motor (1) on frame (63) with four
screws (22).
CAUTION
2. Install control housing (21) with three screws (22).
Do not drop gear cluster (7) when removing drive
housing (10). Gear cluster may stay engaged in
motor front end bell or drive housing.
3. Remove drive housing (10); Drive Housing
Replacement, page 15.
3. Install strain relief (37, page 12, 13, 14).
4. Install board (35) with five screws (36). Connect all
leads to board (35).
5. Install drive housing (10); Drive Housing
Replacement, page 15.
4. Remove four screws (18) and cover (39).
6. Install pump (13); Displacement Pump
5. Disconnect all leads from board (35). Remove five
screws (36) and board.
Replacement, page 17.
1
1
35
36
18
39
1
22
22
7699B
1
Fig. 9
16
824191
Liberally apply grease
Displacement Pump Replacement
See manual 309053 for pump repair instructions.
See manual 309057 or 309058 for sprayer part number references.
Removal
1. Flush pump (13).
2.
4. Cycle pump until pump pin (9a) is in position to be
removed. Remove pump pin (9a).
5. Fig. 11. Remove suction tube (78) and hose (19).
Relieve pressure; page 4.
6. Loosen pump jam nut (12). Unscrew pump.
3. Fig. 10. Loosen two screws (10b) and rotate
cover (10a).
19
10b
12
10a
78
9a
Fig. 10
9573A
9574A
Fig. 11
Installation
3. Push pump up until pump threads engage.
WARNING
If pin works loose, parts could break off due to
force of pumping action. Parts could project
through the air and result in serious injury or property damage.
CAUTION
4. Screw in pump until threads are flush with drive
housing opening. Align pump outlet to back.
5. Fig. 11. Install suction tube (78) and hose (19).
6. Fig. 13. Screw jam nut (12) 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" 5 ft–lb (102 Nm).
If the pump locknut loosens during operation, the
threads of the drive housing will be damaged.
1. Fig. 12. Extend pump piston rod fully. Apply grease
to top of pump rod at (A) or inside connecting rod.
9576A
Fig. 13
7. Fig. 14. Fill packing nut with Throat Seal Liquid
(TSL) until fluid flows onto top of seal.
A
10b
10a
9575A
Fig. 12
2. Fig. 10. Install pump pin (9a). Verify retainer spring
(9b) is in groove of pump pin.
9577A
Fig. 14
8. Fig. 10. rotate cover (10a); tighten screws (10b).
824191
17
Technical Data
(120V)
∅, A, Hz
Generator
Minimum
W
Motor HP
(W)
Cycles per
gallon (liter)
Maximum
Delivery gpm
(lpm)
Maximum
Tip size
Fluid Outlet
npsm
NOVA
1, 15, 60
3000
1/2 (373)
680 (180)
0.38 (1.25)
0.019
1/4 in.
NOVApro
1, 15, 60
3400
5/8 (466)
680 (180)
0.46 (1.74)
0.021
1/4 in
SuperNOVApro
1, 15, 60
3750
3/4 (560)
680 (180)
0.54 (2.09)
0.023
1/4 in
Model
Basic Sprayer Wetted Parts:
zinc-plated carbon steel, polyurethane, polyethylene, stainless steel, PTFE , Delrin, chrome plating, leather, V-Max
UHMWPE, aluminum, stainless steel, tungsten carbide
NOTE: Delrin and PTFE Dimensions
Weight lb (kg)
NOVA
NOVApro
SuperNOVApro
Height:
in. (cm)
Length:
in. (cm)
Width:
in. (cm)
Stand
39 (18)
N/A
43 (20)
21 (53.3)
15 (38.1)
14 (35.6)
Hi-Boy
N/A
59 (27)
66 (30)
Handle down:
29.5 (74.9)
21 (53.3)
20.5 (52.1)
Model
Handle up:
39.5 (100.3)
18
824191
Sherwin-Williams 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 by an authorized Graco distributor to the original purchaser for use. With the
exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of
sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment
is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD
BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches,
hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty
Program”.
824191
19
Phone Number
TO PLACE AN ORDER OR FOR SERVICE, contact your Graco distributor, or call 1–800–690–2894 to
identify the nearest distributor.
All written and visual data contained in this document reflect the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
The SHERWIN–WILLIAMS COMPANY, 101 PROSPECT AVENUE, CLEVELAND, OHIO 44115
PRINTED IN U.S.A. 824191 12/1999
20
824191
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