Graco 311737G - 390 Electric Airless Sprayer. Repair Owner's Manual

Repair
390™ Electric Airless Sprayer
311737G
EN
- For portable spray application of architectural paints and coatings Models: 253958, 262019, 254968, 254969, 254998, 253961, 262024, 256392, 256481, 826024
Maximum Working Pressure: 3300 psi (227 bar, 22.7 MPa)
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
US Patent No.: D580,515 S and D580,518 S
Taiwan Patent No.: D129255
Korean Patent No.: 30-548399
Related Manuals
310820, 311732
311861
ti5635b
309250
Stand
311761
ti11626a
Hi-Boy
ProStep
ti11583a
Models
Models
2
Model
VAC
Country
254968, 254969, 256391
230 CCE
Europe / Europe Multicord
✓
253961, 256481
110 UK
UK
✓
254998
230 Asia
Australia
262019, 253958,826084
120
North America
254998, 262024, 256392
240
Asia
✓
✓
✓
311737G
Warning
Warning
The following warnings 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 applicable.
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 understood, 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 electrician.
•
This product is for use 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.
311737G
3
Warning
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
cloths (potential static arc).
• 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.
• 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 operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
4
311737G
Warning
WARNING
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.
•
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.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.
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 as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing protection
311737G
5
Component Identification
Component Identification
P
S
R
U
B
B
U
K
E
A
A
E
M
N
H
F
H
F
D
J
D
K
ti12008a
J
T
T
Item
6
V
Component
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
A
Pressure Control
311737G
Installation
Installation
Grounding and Electric
Requirements
Do not use the sprayer if the electrical cord has a damaged ground contact. Only use an extension cord with
an undamaged ground contact.
The sprayer cord includes a grounding wire with an
appropriate grounding contact.
ti4297
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, circuit with a grounding receptacle.
Never use an outlet that is not grounded or an
adapter.
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.
NOTE: Smaller gauge or longer extension cords may
reduce sprayer performance.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Fluid supply container: follow local code.
Solvent and Oil-based fluids: follow local code. Use
only conductive metal pails placed on a grounded surface such as concrete. Do not place the pail on a nonconductive surface such as paper or cardboard, which
interrupts grounding continuity.
ti5573a
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.
TIA
311737G
7
Pressure Relief Procedure
Pressure Relief Procedure
3. Turn prime valve down.
Follow this Pressure Relief Procedure whenever you
are instructed to relieve pressure, stop spraying, check or
service equipment or install or clean spray tip.
ti8326a
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.
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.
ti8324 c
TIAB
ti5310c
8
311737G
General Repair Information
General Repair Information
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 washers
before you operate sprayer.
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.
•
Keep all screws, nuts, washers, gaskets, and electrical 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 Troubleshooting, page 10.
•
Overspray may build up in the air passages.
Remove any overspray and residue from air passages 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.
311737G
•
NOTICE
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.
9
Troubleshooting
Troubleshooting
Problem
What To Check
What To Do
(If check is OK, go to next check)
(When check is not OK, refer to this column)
Motor Won’t Operate
Basic Fluid Pressure
Basic Mechanical
1. Pressure control knob setting.
Motor will not run if set at minimum (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.
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 until thawed completely. If paint hardened (dried) in sprayer,
replace pump packings. See page 14, Displacement Pump Replacement.
2. Displacement pump connecting Push pin into place and secure with spring
rod pin. Pin must be completely retainer. See page 14, Displacement Pump
pushed into connecting rod and Replacement.
retaining spring must be firmly in
groove or pump pin.
3. Motor. Remove drive housing
assembly. See page 16, Drive
Housing Replacement. Try to
rotate fan by hand.
10
Replace motor if fan won’t turn. See page 28,
Motor Replacement.
311737G
Troubleshooting
Problem
Basic Electrical
See wiring diagram, page
29
What To Check
What To Do
(If check is OK, go to next check)
(When check is not OK, refer to this column)
1. Electric supply. Meter must read Reset building circuit breaker, replace building
100-130 VAC for 110-120 VAC
fuses. Try another outlet.
models and 210-255 VAC for 240
VAC models.
2. Extension cord. Check extension Replace extension cord.
cord continuity with volt meter.
3. Sprayer power supply cord.
Replace power supply cord. See page 27,
Inspect for damage such as bro- Power Cord Replacement.
ken insulation or wires.
4. Fuse. Check replaceable fuse on Replace fuse after completing motor inspection.
control board (next to ON/OFF
See page 22, Fuse Replacement.
switch).
5. Motor leads are securely fasReplace loose terminals; crimp to leads. Be
tened and properly connected to sure terminals are firmly connected.
control board.
Clean circuit board terminals. Securely reconnect leads.
6. Motor thermal switch. Yellow
Replace motor. See page 28, Motor Replacemotor leads must have continuity ment.
through thermal switch.
7. Brush cap missing or loose brush Install brush cap or replace brushes if leads are
lead connections.
damaged. See page 19, Motor Brush
Replacement.
8. Brush length which must be 1/4
in. (6mm) minimum.
Replace brushes. See page 19, Motor Brush
Replacement.
NOTE: Brushes do not wear at
the same rate on both sides of
motor. Check both brushes.
9. Motor armature commutator for Remove motor and have motor shop resurface
burn spots, gouges and extreme commutator if possible. See page 28, Motor
roughness.
Replacement.
311737G
10. Motor armature for shorts using
armature tester (growler) or perform spin test, page 17.
Replace motor. See page 28, Motor Replacement.
11. Pressure control not plugged in
to control board.
Insert pressure control connector into control
board.
11
Troubleshooting
Problem
Low Output
What To Check
What To Do
(If check is OK, go to next check)
(When check is not OK, refer to this column)
1. Worn spray tip.
Relieve pressure, page 8. Replace tip. Refer to
gun instruction manual, 309639.
2. Verify pump does not continue to Service pump. See page 14, Displacement
stroke when gun trigger is
Pump Replacement.
released.
3. Prime valve leaking.
Relieve pressure, page 8. Then repair prime
valve. See page 24, Manifold Replacement.
4. Suction hose connections.
Tighten any loose connections. Check o-rings
on suction hose swivel.
5. Electric supply with volt meter.
Reset building circuit breaker; replace building
Meter must read 100-130 VAC for fuse. Repair electrical outlet or try another
110-120 VAC models and
outlet.
210-255 for 240 VAC models.
Low voltages reduce sprayer performance.
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 connectors. Inspect wiring insulation
and terminals for signs of overheating.
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 Replace brushes. See page 19. Motor Brush
be 1/4 in. (6 mm) minimum.
Replacement.
10. Motor brushes binding in brush
holders.
11. Low stall pressure. Turn pressure
control knob fully clockwise.
12. Motor armature for shorts by
using an armature tester
(growler) or perform spin test,
page 17.
12
Clean brush holders. Remove carbon dust by
using compressed air to blow out brush dust.
Replace pressure control assembly. See page
23, Pressure Control Assembly Replacement.
Replace motor. See page 28, Motor
Replacement.
311737G
Troubleshooting
Problem
Motor runs and pump
strokes
Motor runs but pump does
not stroke
Motor is hot and runs
intermittently
What To Check
What To Do
(If check is OK, go to next check)
(When check is not OK, refer to this column)
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.
1. Displacement pump pin damaged 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.
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 indicated by removing positive (red)
brush and seeing burned adjacent commutator bars.
Replace motor. See page 28, Motor
Replacement.
3. Tightness of pump packing nut. Loosen packing nut. Check for leaking around
Overtightening tightens packings throat. Replace pump packings if necessary.
on rod, restricts pump action and See pump manual 309250.
damages packings.
311737G
13
Displacement Pump Replacement
Displacement Pump Replacement
See manual 309250 for pump repair instructions.
Removal
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).
1. Relieve pressure, page 8. Unplug sprayer from outlet.
C
2. Loosen two screws (30) and rotate cover (44).
32
44
30
TIA
3. Loosen nut (A) and remove suction hose (35).
Loosen nut (B) and remove the high pressure hose
(14).
TIA
7. Using a hammer, loosen pump jam nut (11).
Unscrew and remove pump (9).
11
14
11
ti6107b
B
9
A
35
ti6105b
14
311737G
Displacement Pump Replacement
Installation
5. Screw in pump until threads are flush with top of
drive housing opening.
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.
ti6111a
NOTICE
If the pump jam nut loosens during operation, the
threads of the drive housing will be damaged.
6. Align pump outlet (E) to back.
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 threads.
11
7
E
ti
D
ti6112b
11
ti5732b
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).
2. Install pump rod (D) into connecting rod (7).
8. Install suction tube (35) and high pressure hose
(14). Tighten nuts (A) and (B).
3. Install pump pin (32). Verify retainer spring (C) is in
groove over pump pin.
.
7
14
C
B
ti6108b
A
32
9
35
ti6105b
9. Fill packing nut with Graco TSL until fluid flows onto
top of seal. Rotate cover (44). Tighten screws (30).
30
4. Push pump (9) up until pump threads engage.
44
ti5735b
311737G
15
Drive Housing Replacement
Drive Housing Replacement
Installation
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.
Removal
Needle
Bearing Surfaces
3
1. Relieve pressure, page 8.
4
2. Remove pump (9). Displacement Pump Replacement, page 14.
3. Disconnect power cord from outlet.
3
2
5
ti8329a
7
6
32
2. Push drive housing into front endbell housing. Insert
gear crank (3) through hole in connecting rod (7).
3
2
6
30
4
7
ti8331a
4. Remove two screws (30) and cover (32).
5. Remove four screws (6).
6. Pull drive housing (5) out of motor front endbell.
ti8330a
7. Remove gear cluster (2) and (3) and thrust bearing
(4) from drive housing.
3. Install four screws (6).
NOTICE
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.
16
4. Install cover (32) with two screws (30).
5. Install pump (9). Displacement Pump Replacement, page 14.
311737G
Spin Test
Spin Test
See Wiring Diagram, page 29.
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
28.
30
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.
29
4. Disconnect motor connector (F).
Armature Short Circuit Test
TIA
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 28.
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
1. Connect red and black motor leads with test lead.
Turn motor fan by hand at about two revolutions per
second.
311737G
F
4. Reattach motor connector (F).
5. Replace drive housing, page 16.
6. Replace shroud (29) and two screws (30).
17
Fan Replacement
Fan Replacement
Removal
4. Pull off fan (100).
Installation
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
1. Slide new fan (1a) in place on back of motor. Be
sure blades of fan face motor as shown.
2. Install spring clip (1b).
2. Remove two screws (30) and shroud (29).
3. Replace shroud (29) and two screws (30).
3. Remove spring clip (1b) on back of motor.
1a
1b
30
29
ti5769b
18
311737G
Motor Brush Replacement
Motor Brush Replacement
brush lead. You will hear a “snap” when cap is
securely in place.
See Wiring Diagram, page 29.
Removal
Replace brushes worn to less than 1/4 in. (6mm).
Brushes wear differently on each side of motor, check
both sides.
3. Using a wire stripper, strip off wire insulation approximately 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.
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
2. Remove two screws (30) and shroud (29) (see illustration on page 17).
3. Disconnect motor connector (D) from control board
(33).
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 pressure hose and wire leads are not caught in tie wrap.
7. Reconnect motor connector (D) to control board
(33).
4. Cut tie 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.
A
E
8. While rotating fan by hand, using compressed air,
blow air into positive (top) brush holder to remove
brush dust.
NOTE: 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 positive
(top) brush holder.
D
29
33
A
Red
C
B
Black
Installation
NOTE: Use all new parts included in your brush kit. Do
not reuse old parts if new replacement parts are provided.
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
311737G
F
ti5637a
8. Replace shroud (29) and two screws (30) (see illustration, page 17).
19
Control Board Replacement
Control Board Replacement
6. Pull control board out slightly and then slide it back
and off of frame.
See Wiring Diagram, page 29.
NOTE: Make sure power cord is free and NOT wrapped
around cord wrap.
7. Remove grommet and wires from strain relief.
NOTE: Ground wire will remain attached to sprayer with
grounding screw.
Removal
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
2. Remove two screws (30) and shroud (29) (see illustration, page17).
3. Disconnect pressure switch connector (A) from control board (33).
Strain
Relief
33
A
B
ti6122a
Grommet
B
8. Remove 2 power cord (C) connectors from control
board.
A
33
33
120V
240V
ti6143a
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).
33
33
240V
C
ti6143a
120V
C
33
30
ti6119b
20
311737G
Control Board Replacement
Installation
1. Position grommet and power cord wires through
strain relief in control board (33).
3. Carefully slide control board back into place on the
side of the motor frame.
33
Strain
Relief
33
30
Grommet
ti6122a
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).
ti6119b
4. Replace 3 screws (30). Torque to 30-35 in-lbs
(3.4 - 3.9 N•m).
A
B
B
A
33
33
240V
C
120V
33
C
ti6143a
NOTE: Be sure power cord is routed between the blue
high pressure hose to the manifold and the sprayer
frame.
33
240V
120V
ti6143a
5. Reattach motor connector (B) and pressure control
assembly connector (A).
6. Install shroud (29) and two screws (30) (see illustration, page 17).
Hose
Power
Cord
ti8322a
Bottom View of Sprayer
311737G
21
Fuse Replacement
Fuse Replacement
3. Remove fuse from control board.
Installation
1. Install new fuse on control board.
Removal
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
2. Install shroud (29) and two screws (30) (see illustration, page 17).
2. Remove two screws (30) and shroud (29) (see illustration, page 17).
Replaceable Fuse
TIA
22
311737G
Pressure Control Assembly Replacement
Pressure Control Assembly Replacement
6. Turn the pressure control knob (16) counter clockwise as far as you can to access the flats on either
side of the pressure control assembly.
See Wiring Diagram, page 29.
7. Using a 1 in. (26 mm) wrench loosen and unscrew
pressure control assembly.
Removal
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
2. Remove two screws (30) and shroud (29) (see illustration, page 17).
3. Disconnect pressure switch connector (A) from control board (33).
4. Remove tape (22) holding wires to manifold.
5. Pull wires back through hole (K) in housing.
ti5766a
NOTE: If you plan to reuse the pressure control assembly, be very careful not to damage or tangle the wires
while unscrewing the assembly.
21
8. Remove pressure control assembly.
16
A
17
22
K
ti5768d
Installation
NOTE: Inspect pressure control assembly before installation to verify the o-ring is installed and in place.
4. Wrap wires around knob and feed through slot in
grommet (21).
1. Align grommet collar (17) on fluid manifold so opening faces toward motor.
5. Insert grommet (21) in hole (K) in housing. Secure
wires to manifold housing with tape (22).
2. Apply Loctite® to pressure control assembly threads
(16)
6. Reconnect pressure switch connector (A) to control
board (33).
3. Screw pressure control assembly (16) into manifold
and torque to 150 in-lbs (17.0 N.m)
7. Install shroud (29) and two screws (30) (see illustration, page 15).
NOTE: Be careful when tightening pressure control
knob that wires do not get pinched between the pressure control assembly and fluid manifold.
311737G
23
Manifold Replacement
Manifold Replacement
See Wiring Diagram, page 29.
7. Reconnect fluid hose at pump outlet.
8. Replace barbed fitting (20) and drain line (40). See
Drain Line Replacement, page 26.
9. Install shroud (29) and two screws (30).
Read Electric Shock Warning on page 4, and
Pressure Relief Procedure on page 8.
Removal
A
33
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 26.
18
A
Ref 14
17
3. Remove two screws (30) and shroud (29).
15
4. Disconnect fluid hose at pump outlet.
6
13
5. Disconnect pressure switch connector (A) from control board (33).
C
23
24
25
26
6. Remove tape (22) holding wires to manifold.
7. Pull wires back through hole (K) in housing.
20
40
B
ti5771a
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.
A
33
Installation
18
1. Position manifold on sprayer frame.
2. Replace screws (6) and torque to 150 in-lb
(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).
A
17
ProStep
Ref 14
6
13
23
24
25
26
ti12077a
20
40
6. Reconnect pressure switch connector (A) to control
board (33).
24
311737G
Drain Valve Replacement
Drain Valve Replacement
Installation
NOTE: Before installing new drain valve, be sure old
gasket (23a) and seat (23b) are not still inside manifold.
1. Thread drain valve (23) into manifold (15) opening.
Removal
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
2. Using a punch and hammer, tap pin (26) out of drain
handle (25).
3. Pull drain handle (25) and base (24) off drain valve
(23).
2. Hand tighten securely. Using a wrench, torque to
120 to 130 in-lbs.
3. Push base (24) over drain valve (23) and then drain
handle (25) over base (24).
4. Replace pin (26) in drain handle (25). If necessary,
use a hammer to tap it in place completely.
4. Using a wrench, loosen drain valve (23) and remove
it from manifold (15).
24
25
23
23a
23b
ti8384a
26
311737G
25
Drain Line Replacement
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.
Installation
1. Screw barbed fitting (20) into manifold.
2. Push drain line (40) onto barbed fitting (20).
Removal
To remove the drain line (40) from the manifold:
1. Cut drain line (40) from barbed fitting (20).
NOTE: 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.
2. Unscrew barbed fitting (20) from manifold.
NOTE: 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).
20
40
ti8333a
26
311737G
Power Cord Replacement
Power Cord Replacement
Installation
See Wiring Diagram, page 29.
1. Follow Control Board Replacement installation
instructions, steps 1-4, page 20.
2. Reconnect, green ground wire (G) to green grounding screw (31) on frame. Be sure terminal on ground
faces UP or wires could get caught in shroud.
Removal
1. Follow Control Board Replacement removal
instructions, steps 1-8, page 20.
3. Reconnect power cord connectors (C and D) to control board (33).
2. Disconnect power cord connectors (C and D) from
control board (33).
4. Reattach motor connector (B) and pressure control
switch connect (A).
3. Disconnect green ground wire (G) from sprayer by
loosening grounding screw (31).
5. Install shroud (29) and two screws (30) (see illustration, page 17).
33
120V
240V
D
C
C
D
31
G
311737G
27
Motor Replacement
Motor Replacement
6. Remove ground wire (G) from motor endbell.
See Wiring Diagram, page 29.
7. Remove four screws (6) and motor (1) from frame
(45).
Installation
NOTICE
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.
1. Install new motor (1) on frame (45) with four screws
(6).
2. Install manifold (15) with two screws (6). Manifold
Replacement, page 24
1. Relieve pressure, page 8. Disconnect power cord
from outlet.
3. Install control board (33) with three screws (30).
Connect all leads to board. See Control Board
Replacement, page 20 and Wiring Diagram, page
29.
2. Remove pump (9). Displacement Pump Replacement, page 14.
4. Connect ground wire (G) to motor with green ground
screw (31).
3. Remove drive housing, Drive Housing Replacement, page 16.
5. Install Drive Housing. Drive Housing Replacement, page 16.
4. Remove Pressure (Fluid) Manifold, Manifold
Replacement, page 24.
6. Install pump (9). Displacement Pump Replacement, page 14.
5. Disconnect all leads from board (33) and remove
control board. Control Board Replacement, page
20.
7. Install shroud (29) with two screws (30) (see illustration, page 17).
Removal
34
31
1
33
3
30
1
2
1
6
6
45
ti5642b
28
1 Liberally apply grease
311737G
Wiring Diagram
Wiring Diagram
120V Model
from Motor
Red (+)
2 x Yellow
Black (-)
Replaceable Fuse
Pressure
Control
Assembly
ON/OFF
Switch
ti5643a
Black
Power
Plug
Capacitor
White
Green
ti5643a
240V Model
Capacitor
Pressure Control
Assembly
from Motor
Red (+)
2 x Yellow
Black (-)
Replaceable Fuse
ON/OFF
Switch
ti5857a
Blue
Brown
Power
Plug
Green
ti5857a
311737G
29
Technical Data
Technical Data
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). . . . . . . . . . . . . . . . . . . . . . . . . . . 680 (180)
Maximum delivery gpm (lpm)
253958, 253961, 254968, 254969, 256391, 262019,
826084 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.47 (1.8)
254998, 256392, 262024 . . . . . . . . . . . . . . . . . . . . . . 0.38 (1.4)
Maximum tip size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
253958, 253961, 254968, 254969, 256391, 262019,
826084 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.021
254998, 256392, 262024 . . . . . . . . . . . . . . . . . . . . . . 0.019
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 cm)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 lbs (13.6 kg)
Weight (with gauge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 lbs (14.0 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 lbs (25.9 kg)
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . zinc and nickel-plated carbon steel, nylon, stainless steel,
PTFE, Acetal, leather, UHMWPE, aluminum, tungsten
carbide
Noise level*
Sound power (IS0 3744)
100dBa*
Sound pressure (ISO 3744)
90 dBa*
*Measured 3 feet (1 meter) from equipment.
30
311737G
Notes
Notes
311737G
31
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
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 procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
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.
2ULJLQDOLQVWUXFWLRQV This manual contains English. MM 311737
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2004 Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised 01/2012