Graco TEXSPRAY 1030 User's Manual

Repair

TexSpray 1030 t FC

German Patent No. P 43 18 679.3--09

309662J

- For portable spray application of architectural paints and coatings -

0.9 to 3.0 gpm (3.4 to 11.4 lpm) Flow Rate

750 psi (5.1 MPa, 51 bar) Maximum Working Pressure

500 psi (3.4 MPa, 34 bar) Recommended Maximum Working Pressure

Model 234113, Series A

TexSpray 1030 FC sprayer, 235490 TexSpray gun and 50 ft (15 m) air and fluid hose set

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

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309663

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308274

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CONTENTS

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Description . . . . . . . . . . . . . . . . . .

Maintenance

Troubleshooting

Repair

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6

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10

2

5

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data

Dimensions

Warranty

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20

26

27

27

28

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440- 1441

Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001 ti3005b

Specifications

This equipment is not intended for use with flammable or combustible materials used in places such as cabinet shops or other “factory” or fixed locations. If you intend to use this equipment in this type of application, you must comply with NFPA 33 and OSHA requirements for the use of flammable and combustible materials.

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

Warnings

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

2 309662

The following are general Warnings related to the safe setup, use, maintenance and repair of this equipment.

Additional, more specific warnings may be found throughout the text of this manual where applicable.

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:

D Use equipment only in well ventilated area.

D Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop clothes (potential static arc).

D

Sprayer generates sparks. When flammable liquid is used in or near sprayer or for flushing or cleaning, keep sprayer at least 20 ft (6 m) away from explosive vapors.

D Do not clean with materials having flash points lower than 70_F (21_C). Use water--based materials or mineral spirits type material only. For complete information about your fluid, request the

MSDS from the fluid distributor or retailer.

D

Keep work area free of debris, including solvent, rags and gasoline.

D Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

D

Ground equipment and conductive objects in work area. Read Grounding instructions.

D If there is static sparking or you feel a shock, stop operating immediately. Do not use equipment until you identify and correct the problem.

SKIN INJECTION 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.

D Do not point gun at anyone or any part of the body.

D Do not put your hand over the spray tip.

D Do not stop or deflect leaks with your hand, body, glove, or rag.

D

Engage trigger lock when not spraying.

D Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking or servicing equipment.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in this equipment. Such use could result in a serious chemical reaction, with the possibility of explosion, which could cause death, serious injury and/or substantial property damage.

309662 3

INSTRUCTIONS

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

D

Read all instruction manuals, tags, and labels before operating the equipment.

D

Use equipment only for its intended purpose. Call your Graco distributor for information.

D Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. This gun has a 150 psi (10 bar) maximum fluid working pressure at a 125 psi (9

bar) maximum incoming air pressure. Read Technical Data in all equipment manuals.

D Do not alter or modify equipment.

D Check equipment daily. Repair or replace worn or damaged parts immediately.

D Do not lift pressurized equipment.

D Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 180_F (82_C) or below --40_F (--40_C).

D

Do not use hoses to pull equipment.

D Keep children and animals away from work area.

D

Comply with all applicable safety regulations.

D Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in this equipment, which contains aluminum and/or zinc parts. Such use could result in a serious chemical reaction, with the possibility of explosion, which could cause death, serious injury and/or substantial property damage.

D

Wear eye and ear protection when operating this equipment. Keep body parts away from front of gun. See Sound Data in TECHNICAL DATA.

TOXIC FLUID HAZARD

Toxic fluid or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

D Read MSDS’s to know the specific hazards of the fluids you are using.

D Store hazardous fluid in approved containers and dispose of it according to all 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:

D

Protective eye wear.

D Clothing and respirator as recommended by the fluid and solvent manufacturer.

D Gloves.

D Hearing protection.

4 309662

Component Description

Flow and Air Control

Fig. 1. The flow control (A) has a shut off and pressure relief feature to soft start each time the gun is triggered, instead of a blast of unatomized material. The flow control has three modes:

Prime Valve

Fig. 1. The prime valve (C) relieves system pressure and stops the pump when the gun trigger is released.

TexSpray Gun, 235490

D LOW/MED/HIGH: Triggering the gun sends an air signal to the flow control that closes the prime valve and starts the pump which fills the material hose.

When the gun trigger is released, the prime valve opens and relieves the system pressure into the supply container. When the gun is triggered the automatic pressure relief, special TexSpray hoses and pump design eliminate blasts of material and spray pulsing to ensure consistent atomization.

D OFF: Puts the sprayer in neutral/relieve pressure -neither the pump nor the gun will operate and there is no material pressure in the pump, hose or gun.

WARNING

INSTRUCTIONS

EQUIPMENT MISUSE HAZARD

The TexSpray Gun 235490 is for use only with the GM 1030 TexSpray 234113 which is designed so the fluid pressure of the gun will not exceed the working pressure rating of the components. The maximum fluid working pressure of the GM 1030 TexSpray is 750 psi

(5.1 MPa, 51 bar), but the recommended maximum is 500 psi (3.4 MPa, 34 bar).

D PRIME: The prime valve remains open so material circulates through the pump and back to the supply container through the drain hose.

The air control (B) increases or decreases the air pressure to the sprayer from the air supply.

OFF

PRIME

LOW/MED/HIGH

Fig. 2. Air flow is controlled at the gun. During priming, turn the gun air control valve (D) in fully to prevent air from mixing with the fluid, which allows you to check and adjust the fluid flow accurately. (When this valve is closed the air exits the rear of the gun.) During operation, open the air control valve to introduce air at the correct volume for the desired spray pattern. The gun also has a trigger bail (E) to reduce operator fatigue when spraying large surfaces.

D

B

Fig. 1

A C

159

Black

TI3010A

TI3101A

158

Blue

E

Fig. 2

TexSpray Hoses

01808

CAUTION

Use Graco hoses designed for this sprayer. Using other hoses will damage the flow control.

309662 5

Component Description

Compressor Requirements

NOTE: This sprayer requires an external air compressor.

CAUTION

Install an air filter on external air compressor to reduce contamination to spray system.

After first 20 hours of operation and each 100

hours thereafter: Change oil.

Weekly: Remove engine air filter cover and clean element. In very dusty environments, check filter daily.

Replace element as needed. Replacement elements can be purchased from your local HONDA dealer.

Air compressor range: 10 scfm to 35 scfm, 30 to 140 psi (0.2--0.97 MPa, 2 to 9.7 bar)

Spark plug: Use only a (NGK) BP6ES or BPR6ES plug. Gap plug to 0.025 to 0.030 in. (0.7 to 0.8 mm).

Always use a spark plug wrench.

6 months: Clean Air Flow Sensor as follows:

Material

Elastomerics

(textured)

Simulated

Accoustical

Splatter Coat and

Knockdown

Air Requirements* Minimum

Compressor

Size*

30 scfm at 90 psi

(0.84 m 3 /min at

0.63 MPa, 6.3 bar)

15 HP

20 scfm at 60 psi

(0.56 m 3 /min at

0.42 MPa, 4.2 bar)

15 scfm at 40 psi

(0.42 m 3 /min at

0.28 MPa, 2.8 bar)

5.5 HP

8 HP

Orange Peel 20 scfm at 60 psi

(0.56 m 3 /min at

0.42 MPa, 4.2 bar)

8 HP

* Material, temperature and volume affect cfm needed to properly atomize material.

1. Fig. 3. Loosen adapter (A). Pull down quick release (C) and swing out flow sensor regulator.

Disconnect connector (B).

2. Remove inlet fitting (D), retainer ring (E), piston (F) and spring (G) from flow sensor regulator (H).

CAUTION

Do not scratch or nick piston (F) or inside of flow sensor regulator (H).

3. Clean all parts (D, E, F, G). Clean inside of (H) with a pipe cleaner.

4. Assemble all parts and install flow sensor regulator.

Maintenance

CAUTION

D For detailed engine maintenance and specifications, refer to separate HONDA engine manual.

D Close black fuel shutoff lever whenever you are transporting sprayer to prevent fuel from flooding engine.

D Keep sprayer upright and level when operating it and when transporting it. This prevents crankcase oil from leaking into combustion chamber, which makes startup very difficult.

Daily: Check engine oil level and fill as needed.

Daily: Check and fill gas tank.

Daily: Check sprayer air filter, clean and replace element as needed.

6 309662

D E

Fig. 3

A

Flow

Sensor Regulator

F G

C

B

H

Flow

Sensor Regulator ti4366a

Troubleshooting

WARNING

To reduce risk of injury due to sprayer starting unexpectedly, shut off engine before performing checks or service.

Check everything in chart before disassembling sprayer.

PROBLEM

Engine does not start

Engine operates, but displacement pump does not

CAUSE

Engine switch not ON

Out of gas

Spark plug cable disconnected or spark plug damaged

Oil seepage into combustion chamber

Oil level low

Flow control set to OFF

Air compressor not on or insufficient air flow from compressor

Air pressure set to low

Sprayer engine RPM too low

Clutch connector into back of circuit board is loose.

Air filter dirty

Air flow sensor dirty or damaged

Air transducer failed

Fluid transducer failed

Clutch not engaging

Displacement pump rod seized by dry coating

SOLUTION

Turn engine switch ON

Fill gas tank

Connect spark plug cable or replace spark plug

Remove spark plug. Pull starter rope 3 or

4 times. Clean and install spark plug. Try to start. Keep sprayer upright and do not overfill engine crankcase to avoid oil seepage.

Add oil to engine crankcase

Set flow control to PRIME mode or LOW/

MED/HIGH while triggering gun

Start air compressor

Increase SCFM or compressor size.

Check air passages and tips for obstructions.

Check air filter element for clogs.

Check display for air pressure. System requires a minimum of 40 psi (0.28 MPa,

2.8 bar) to operate. Increase pressure by adjusting air control knob.

Increase engine speed

Check and ensure a tight connection.

Clean or replace filter element.

Check air filter.

Clean air flow sensor (see page 4) or replace as needed.

Check display for correct air pressure reading. Replace circuit board as needed.

Check connection at circuit board.

Replace fluid transducer.

Worn or damaged clutch. See page 18.

Fluid transducer failure. Air transducer failure.

Service pump. See page 10.

309662 7

Troubleshooting (Continued)

PROBLEM

Engine operates, but displacement pump does not

Engine operates, displacement pump operates, but no

Low fluid delivery

Loss of air control or volume at gun

Displacement pump output low on upstroke

CAUSE SOLUTION

Connecting rod worn or damaged

Drive housing worn or damaged

Replace connecting rod. See page 14.

Replace drive housing. See page 15.

Pinion assembly worn or damaged Service pinion assembly. See page 16.

Flow control is set to PRIME

Fluid system over--pressurized

Set flow control to LOW/MED/HIGH while triggering gun.

Spraying material is too thick or the material hose is too long. Use a less course material or a shorter hose.

Gun nozzle/disk is clogged

Material flowing out drain line

Check and clean nozzle/disk as needed.

Switch to a larger nozzle/disk.

Check for air leaks to dump valve.

Check dump valve for wear, replace as needed.

Air flow sensor dirty or damaged.

Pump is packed out

Siphon hose strainer is clogged.

Engine RPM too low

Flow control set too low

Hose too long or material too coarse

Material flowing out drain line

Disassemble and clean pump (see page

8), hose(s) and gun.

Clean or remove strainer

Increase engine speed. See Startup, procedure in operator manual.

Increase flow control to MED or HIGH

Change to a shorter hose or less coarse material.

Gun nozzle/disk is clogged

Pump is packed out

Check drain line for a constant flow of material when sprayer is operating in

LOW/MED/HIGH mode.

Check for air leaks to prime valve.

Check dump valve for wear, replace as needed.

Check and clean nozzle/disk as needed.

Switch to a larger nozzle/disk.

Disassemble and clean pump (see page

8), hose(s) and gun.

Gun air passages clogged with material

After releasing gun trigger, make sure system is fully depressurized before triggering gun again. This helps prevent material backing into gun passages.

Clean or replace element Air filter dirty

Air flow sensor dirty or damaged Check air filter.


Piston ball (220) not seating Clean piston area. See page 12.

Piston packings worn or damaged Replace packings. See page 12.

Replace or install gasket Siphon hose coupling gasket (1e) worn or missing.

Pump cylinder o-ring (205) worn or missing

Replace o-ring

8 309662

Troubleshooting (Continued)

PROBLEM

Displacement pump output low on downstroke or both strokes

Material leaks into wet-cup

Material leaks into wet-cup

Intermittent material flow out of gun

(

Heavy or poorly atomized material when gun is first triggered

(lack of soft start) )

Pump does not shut off after gun trigger is released

Premature prime valve failures

CAUSE

Siphon hose strainer is clogged

Piston packings worn or damaged

Intake valve ball (216) not seating properly

Clutch (9) worn or damaged

Air leak at pump foot valve or siphon tube elbow

SOLUTION

Clean strainer

Replace packings. See page 12.

Clean and service intake valve. See page 12.

Replace clutch. See page 18.

Be sure foot valve is tight each day.

Be sure seal in elbow is in place and is not worn or damaged.

Loose wet-cup (202) Tighten wet-cup enough to stop leakage

Throat packings worn or damaged Replace packings. See page 12.

Displacement rod (201) worn or damaged

Replace displacement rod. See page 12.

Material supply is low or empty

Air control on gun is set too high.

Hose too long or material too coarse

Fluid pressure was not allowed to fully self relieve after releasing gun trigger

Gun was not fully triggered immediately when squeezed, causing gun air passages to clog with material.

Refill and prime pump. See Startup procedure in operator manual. Check material supply often to prevent running pump dry.

Reduce the air flow through the gun by turning the air control knob on the back of the gun.

Change to a shorter hose or less coarse material.

Wait longer between releasing gun trigger and re--triggering.

Air valve failure


Air leaks in the system after the air flow sensor

Air leaks in gun


Pump does not shut off after gun trigger is released.

Always squeeze trigger fully to prevent just air from turning on, which starts pump and pressurizes hoses. Disassemble and clean gun.

Check and replace as needed

Check air filter.


Check and tighten all connections between the air flow sensor and the gun.

Check gun for excessive air leaks and repair.

See manual 309661

Check air filter.


Read “Pump does not shut off after gun trigger is released” and fix appropriate problem.

Repair or replace Prime Valve.

See page 19.

309662 9

Removal

WARNING


1. Fig. 4. Flush sprayer. Remove suction hose elbow

(150a), pump outlet hose (A) and drain hose (64).

A

63

159 158

150a

27

Displacement Pump Repair

85

3

22

2. Fig. 5. Start engine. Jog flow control between

PRIME and OFF until connecting rod stops near bottom of stroke. Shut off engine.

3. Loosen two quick disconnect screws (27).

4. Pry retaining spring (37) up on connecting rod (128). Push pin (38) out with a screwdriver.

5. Fig. 6. Remove cover (C) to control housing (54) by removing four screws (12). Detach pressure transducer cord (63, Fig. 4) from control board (9) at port (D). Remove pressure transducer cord from control box.

6. Fig. 4. Remove air hoses (158) and (159) from prime valve manifold (85). Note correct air hose connection to ports on air cylinder (22). Use 5/16 inch wrench to hold ring on hose fitting while removing hose from fitting.

7. Support weight of pump (3) and remove two quick disconnect screws (27).

8. Unscrew assembled dump valve manifold (85) and air cylinder (22) from pump (3).

TI3021B

64

D

Fig. 4

WARNING

MOVING PARTS HAZARD

To reduce risk of amputating fingers, keep fingers away from connecting rod and pin while jogging engine.

9

3

Fig. 5

1

2

3

38

23

37

128

27 1

38

201

128

61

Torque to 20 ft--lb (27 N.m)

Back of pump

Cutaway view shows how pin (38) goes through connecting rod

3

2

Fig. 6

12

C

0407

Repair

See page 12 for pump repair instructions.

ti3007b

54

10 309662

Displacement Pump Repair

Installation

1. Fig. 4. Screw assembled dump valve manifold (85) and air cylinder (22) into pump (3).

2. Fig. 5. Pull piston rod (201) out of pump (3) 2 to 3 inches (50 to 75 mm).

WARNING

MOVING PARTS HAZARD

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. Make sure pin and retaining spring are properly installed.

3. Lift pump (3) into position and push in pin (38). Be sure retaining spring (37) snaps down over end of pin.

4. Support weight of pump (3) and fasten two quick disconnect screws (27). Torque screws to 20 ft-lb

(27 N.m).

5. Fig. 4. Reattach air hoses (158) and (159) to prime valve manifold (85). Ensure air hoses are attached to the correct port on air cylinder (22).

6. Fig. 6. Route the pressure transducer cord (63,

Fig. 4) to the control box and attach to port (D) on control board (9). Assemble cover (C) to control housing (54) using four screws (12).

309662 11

Pump Repair

WARNING


Disassemble Pump

1. See Displacement Pump Repair on page 10 to remove pump.

2. Use a hammer on tabs of lug nut (214) to loosen foot valve housing.

3. Fig. 7. Disassemble pump, but do not disassemble piston rod (201) from piston housing (206) unless either needs to be replaced. These two parts are joined with high-strength (red) Loctiter. Joint must be heated to disassemble.

Clean and Inspect All Parts

1. Clean all traces of sealant from all parts with a compatible solvent.

2. Inspect all part for nicks and scratches. Replace worn or damaged parts as they cause packings to wear more quickly and may result in poor pump performance.

Repair Kit

Packing Repair Kit 235186 is available. Replace all parts in kit for best results.

Parts included in kit are marked with an asterisk in text and drawings. For example, 208*.

Assemble Pump

1. Fig. 7. If piston rod (201) and piston housing (206), were disassembled, clean threads thoroughly.

Apply Loctite primer and then red Loctite to threads and torque to 80 to 100 ft-lb (110 to

135 N.m). Allow to dry at least 1 hour.

2. Assemble onto piston seat (213): washer (212); u-cup seal (218*) with lips toward ring; female gland (211*) and then alternate white (210*) and purple packings (219*), all with lips facing up; male gland (209*).

3. Install nut (208*) on piston seat (213). Hand tighten nut firmly.

4. Install ball (220*) in piston housing (206).

5. Apply blue Loctite to piston seat (213) threads and screw assembly onto rod, hand tight.

TIP: Draw a line across male gland, nut and piston housing for an alignment reference before tightening piston and nut.

6. Place piston seat (213) in a vise. Hold packing nut

(208) steady with one wrench and use a torque wrench to tighten rod assembly to 90--125 ft-lb

(122--170 N.m). Make sure reference line made in step 5 is aligned.

7. Grease throat of intake housing (227). Assemble into throat: male gland (204*), flat side first; alternate white packings (225*) and purple packings

(203*) and then female gland, all with lips facing down. Install packing nut (202) and hand tighten, firmly.

8. Grease piston packings and inside throat packings.

9. Grease new o-rings (205*) and install on cylinder

(221). Slide cylinder into bottom of intake housing

(227) until you hear it snap.

10. Guide piston rod assembly into cylinder so piston rod flats are aligned with opening in front of pump.

Push down until you hear another snap. Turn pump over and push assembly in completely.

11. Align rod hole to front of pump with a screw driver.

12. Grease o-ring (223*), install on plug (224), install plug and screws (222) loosely. Torque screws to

50--70 in--lb (5.6--8 N.m) in a crosswise pattern.

13. Install ball (216*) and ball guide (217) into foot valve. Place pump assembly on foot valve and push into place.

14. Screw on lug nut (214). Tighten lug nut securely with a hammer.

TIP: Lug nut must be tight or pump will not prime.

Draw a line between intake housing and lug nut for an alignment reference during operation.

12 309662

Pump Repair

1

2

3

5

6

7

8

9

10

Grease inside of throat before installing packings

Lips of v-packings in throat must face down

Grease inside of packings after installing

Torque piston housing to piston seat

(213) to 90--125 ft--lb (122--170

N.m) without changing alignment of packing nut

Lips of v-packings on piston must face up

Grease outside of packings after installing

Lips of u-cup seal on piston must face down

If piston seat and rod were separated, apply Loctite primer, then red Loctite, and torque to

80--100 ft--lb (110--135 N.m)

Tighten with hammer

2 3

1

202

227

*226

*203

*204

5 206

6 7

8

*209

*210

*211

*218

212

221

215

Fig. 7

225* 2 3

201

9

205*

220*

207*

208*

219*

6 7

TI3015A

214

217

205*

10

216*

TI3015A

309662 13

Removal

Bearing Housing & Connecting Rod

WARNING


4. Align connecting rod with crank (A) and carefully align locating pins (D) in drive housing (20) with holes in bearing housing (23). Push bearing housing onto drive housing or tap it into place with a plastic mallet.

5. Install four screws (48) and lockwashers (49) on bearing housing (23). Torque screws evenly to 25 ft-lb (34 N.m).

1. Fig. 8. Perform steps 1--8 of Displacement Pump,

Removal, page 10.

6. Do steps 2 -- 5 of Displacement Pump, Installa-

tion, page 10.

2. Remove four screws (40) and front cover (21).

3. Remove four screws (48) and lockwashers (49) from bearing housing (23).

4. Pull connecting rod assembly (22) and lightly tap lower rear of bearing housing (23) with a plastic mallet to loosen it from drive housing (20). Pull bearing housing and connecting rod assembly off drive housing.

3 48,49

23

1

B

1

C

22

A 20

40

5. Inspect crank (A) for excessive wear and replace drive housing, if necessary, page 15.

Installation

1. Evenly lubricate inside of bronze bearing (E) in bearing housing (23) with high-quality motor oil.

Liberally pack top roller bearing (B), lower bearing

(C) inside connecting rod assembly (22) with bearing grease.

2. Assemble connecting rod (22) and bearing housing

(23).

3. Clean mating surfaces of bearing housing (23) and drive housing (20).

CAUTION

Do not use bearing housing screws (48) to align or seat bearing housing with drive housing. Align these parts with locating pins (D), to avoid premature bearing wear.

85b

Fig. 8

21

4

3

4

1

2

Liberally pack with bearing grease

(20d), supplied

Lubricate with high quality motor oil

Torque to

25 ft--lb (34 N.m)

See page 10 to remove pump

1f

86

D

E

2

TI3021A

14 309662

19

91

8g

8h

1

40

A

84

56

39

93

36

59

36

58

Drive Housing

WARNING


2

8

84

92

1. Fig. 9. Disconnect siphon hose elbow (150a), drain hose (64) and material hose (not shown) from pump outlet. Disconnect cables. Remove screws

(21) and front cover (19).

2. Remove four screws (40) and lockwashers (56) from bearing housing (39).

3. Lightly tap back of bearing housing (39) with a plastic mallet. Pull pump, bearing housing and connecting rod away from drive housing (8) as one assembly.

21

1

2

Torque to

25 ft--lb

(34 N.m)

Apply remaining grease to these areas

150a

Fig. 9

TI3023A

64

4. Remove bearing housing screws (93) and lockwasher (36) and pinion housing screws (59) and lockwashers (36).

5. Lightly tap around drive housing (8) to loosen drive housing. Pull drive housing straight off pinion housing (58). Be prepared to support combination gear (91), which may also come out.

6. Liberally apply bearing grease (supplied with combination gear) to combination gear (91) and to areas called out by note 2.

7. Place bronze colored washer (8g) and then silvercolored washer (8g) on shaft protruding from big bearing of drive housing (8). Align gears and push new drive housing straight onto pinion housing and locating pins (A).

8. Reassemble sprayer. Or, go to next section in this manual if further service is needed.

309662 15

Pinion Assembly/Rotor/Field/Shaft/Clutch

Removal

WARNING


6. Fig. 12. Remove retaining ring (58e).

7. Tap pinion shaft (58d) out with plastic mallet.

If pinion assembly (58) is not removed from clutch housing (88), do 1. through 4. Otherwise, start at 5.

1. Remove drive housing (8); page 15.

2. Disconnect field cable from flow control.

3. Fig. 10. Remove five screws (99) and lockwashers (43) and pinion assembly (58).

99

43

58

58e

58d

8703B

Fig. 12

99

Fig. 10

43

8700A

4. Fig. 11. Place pinion assembly (58) on bench with rotor side up.

5. Remove four screws (95) and lockwashers (43).

Install two screws in threaded holes (E) in rotor.

Alternately tighten screws until rotor comes off.

95

43

E

8. Fig.13. Use an impact wrench or wedge something between armature (89) and clutch housing to hold engine shaft during removal.

9. Remove four screws (2) and lockwashers (43).

10. Remove armature (89).

89

43

2

8704A

8701B

Fig. 13

Fig. 11

16 309662

Pinion Assembly/Rotor/Field/Shaft/Clutch

Installation

1. Fig. 14. Lay two stacks of two dimes on smooth bench surface.

2. Lay armature (89) on two stacks of dimes.

6. Fig. 12. Tap pinion shaft (58d) in with plastic mallet.

3. Press center of clutch down on bench surface.

4a

0.12 ±.01 in. (3.0 ±.25 mm)

7. Install retaining ring (58e) with beveled side facing field.

8. Fig. 11. Place pinion assembly (58) on bench with rotor side up.

8705A

9. Apply locktite to screws. Install four screws (2) and lockwashers (43). Alternately torque screws to 125 in-lb until rotor is secure. Use threaded holes to hold rotor.

Fig. 14

4. Install armature (89) on engine drive shaft.

10. Fig. 10. Install pinion assembly (58) with five screws (99) and lockwashers (43).

5. Install four screws (2) and lockwashers (43) with torque of 125 in-lb.

11. Connect field cable to flow control.

Collar

Removal

1. Fig. 15. Loosen two screws (2) on collar (86),

2. Push screwdriver into slot in collar (86) and remove collar.

1

2

Face of clutch housing

1.812 ±.010 in. (46.02 ±.25 mm)

3 Torque to 125 ±.10 in-lb (14 ±1.1 N¡m)

4 Chamfer this side

1 88

Installation

1. Fig.15. Install engine shaft key (90).

2. Tap collar (86) on engine shaft (A) with plastic mallet.

2

86

3. Press collar (86) onto engine shaft (A). Maintain dimension shown note 2 in Fig. 15. Chamfer must face engine.

Check dimension: Place rigid, straight steel bar (B) across face of clutch housing (88). Use accurate measuring device to measure distance between bar and face of collar. Adjust collar as necessary.

Torque two screws (16) to 125 ±10 in-lb (14 ±1.1

N¡m).

90

Fig. 15

A

B 4

2

3

03483

309662 17

Clutch Housing

Removal

1. Fig. 16. Remove four capscrews (42) and lockwashers (29) which hold clutch housing (88) to engine.

2. Remove screw (101) from under mounting plate (D).

3. Remove engine key (90).

4. Pull off clutch housing (88).

Installation

1. Fig. 16. Push on clutch housing (88).

2. Install four capscrews (42) and lockwashers (29) and secure clutch housing (88) to engine. Torque to 200 in-lb (22.6 NSm).

3. Install capscrew (101) from beneath mounting plate (D). Torque to 26 ft-lb (35.2 NSm).

Fig. 16

90

101

D

88

29

42

8708A

18 309662

Engine

Removal

1. Remove Pinion Assembly/Rotor/Field/Pinion/

Clutch, Clamp and Clutch Housing, as instructed on pages 16, 17, and 18.

2. Fig. 17. Disconnect all necessary wiring.

3. Fig. 18. Remove two locknuts (18) and screws (17) from base of engine.

4. Lift engine carefully and place on work bench.

NOTE: All service to the engine must be performed by an authorized HONDA dealer.

Installation

1. Lift engine carefully and place on cart.

2. Fig. 18. Install two screws (17) in base of engine and secure with locknuts (18). Torque to 200 in-lb

(22.6 NSm).

3. Fig. 17. Connect all necessary wiring.

4. Install Pinion Assembly/Rotor/Field/Pinion/

Clutch, Clamp and Clutch Housing, as instructed on pages 16 and 17 and 18.

SPRAYER WIRING DIAGRAM

6 Wires

Red, Yellow, Green,

Blue, White, Black

Flow control

Transducer

2X Red

2X Black

Flow sensor regulator

TI3110A Fig. 17

Air valve

70

71

Fig. 18

8710A

309662 19

C

13

60

TI4365a

100

122

104

BOTTOM VIEW

24

117

34

72 1

35

164

81

32

24

A

Page 22

17

25

61

Parts - Sprayer

DETAIL A

52

95

43

94 59

36

58, page 21

Ref 8h

Ref 8g

91

92

8, page 21

75 1

14

123

1

128

38

37

56

99

43 88

90

43

2

29,

42

84

89

158

1

62

159

36

87

43

2 83, page

23

93

85

86

185

27

101

33

39

40

112

19

21

80

3, page 20

64

18

130

162 ti4365c

26

102

16

153

152

51

118

119 140 105

73

150

1 Danger and warning labels, tags, and cards are free.

20 309662

Ref No. Part No.

45

46

47

49

50

51

52

53

38

39

40

41

42

43

44

63b

64

66

68

69

70

54

55

56

58

59

60

61

62

63a

15B558

15B684

106115

245399

101864

240997

102478

194125

287130

15C238

235738

117741

111831

109466

15B671

72Y 194126

73 188509

75Y 290228

183210

287129

114666

15C088

108842

105510

117740

111457

164856

234231*

15B680

234232

104811

112827

115244

30

31

32

33

34

35

36

37

22

23

23

24

25

26

27

28**

29

17

18

19

21

9

12**

13

14

16

6

7

8

3

4

1

2

111836

114263

104172

237686

112798

224442

187111

15c004

100214

111834

157785

114530

245162

113084

192014

104008

183169

187604

108803

235706

157705

116354

15B560

287128

234234

116252

15B935

183350

193682

110837

110838

241308

114818

Parts - Sprayer

Description Qty

SLEEVE, cart

SCREW, hex, socket head

PUMP, texture, 3 gpm

UNION, swivel

BUSHING, strain relief

SPACER, bolt

KIT, repair, drive housing

KIT, control board

SCREW, #8 taptite phil

WIRE, jumper

WASHER

PLUG, tube

SCREW, flange, hex

NUT, lock

COVER, drive

SCREW, self--tap, filhd

CYLINDER, air

FITTING, connector, male (for 1030fc)

FITTING, connector, male (for 1030)

CLAMP, grounding assy

SCREW, thread forming, hex hd

KIT, repair, suction, (55 gal)

SCREW, quick disc

LABEL, crtl box cover

WASHER, lock

NIPPLE, pipe, hex

UNION, swivel

ENGINE, gas, 5.5 hp, Honda

FRAME, cart

RIVET, blind

PLATE, indicator

WASHER, lock, spring

SPRING, retaining

PIN, str, hdls

HOUSING, bearing

SCREW, cap, socket hd

ADAPTER, dump valve

SCREW, cap, hex hd

WASHER, lock, spring (hi--collar)

KNOB, switch

PACKING, o--ring

FITTING, nipple, reducing

KIT, dump valve, repair

PLATE, control box

KIT, flow sensor

CAP, hub

BUTTON, snap

NUT, regulator

HOUSING, control

PANEL, control

WASHER, lock spring (hi--collar)

KIT, repair, pinion housing

SCREW, cap, sch

CONDUCTOR, ground

STRAP, tie, wire

LABEL, danger, English 1

TRANSDUCER, pressure, (for 1030fc) 1

1

1

4

1

1

1

4

PLUG, manifold, (for 1030)

HOSE, drain, 12 ft

SCREW, mach, phillips

SCREW, cap, skt, button hd

NUT, lock, hex

SWITCH, rotary

LABEL, warning

CLIP, spring

LABEL, caution

1

2

1

2

1

1

1

2

1

2

2

1

1

1

1

1

1

4

15

1

4

1

1

1

1

6

1

2

1

1

1

1

2

1

1

1

4

1

1

1

1

1

4

2

2

1

2

1

4

2

1

1

1

1

1

2

6

80

81

82

83

84

Ref No. Part No.

76**

79

15C003

114151

. . . . . . . . . . . . . . . . . . .

79 112698

. . . . . . . . . . . . . . . . . . . .

15C002

114687

111832

287127

114672

Description

LABEL, display LCD

FITTING, elbow, male, swivel (for 1030fc,

5/32 in. tubing)

FITTING, elbow, male, swivel (for 1030,

1/4 in. tubing)

Qty

1

1

1

LABEL, identification

CLIP, retainer

SCREW, cap, sch

KIT, dump valve (see pg 23)

WASHER, thrust

3

1

1

1

2

15B766

193680

193510

193531

183401

241440

114699

114686

122

123

124

128

130

138

111482

108068

115522

241279

116891

112774

140

144

235490

15C005

145Y 189246

146** 15B668

148

150

151

188634

235737

15B683

152

153

117780

110980

101682

100020

100644

114678

113802

114984

111483

206994

108795

245245

198723

198720

114331

104

105

112

117

118

119

120

94†

95

96

99

100

101

102

85

86

91

92

93

87

88

89†

90

MANIFOLD, dump valve

COLLAR, shaft

HUB, armature

HOUSING, clutch

ARMATURE, clutch, 5 in

KEY, parallel

GEAR, combination

WASHER, thrust

SCREW, cap, socket hd

ROTOR, clutch, 5

SCREW, cap, sch

WASHER, lock

SCREW, cap, sch

BUSHING, strain relief

SCREW, hex hd, flanged

SCREW, tapping, phillips pan hd

CLAMP, cable

FLUID, TSL 8 oz bottle

SCREW, mach, pnh

HANDLE, cart

CLIP, axle

WHEEL, semi pneumatic, 12 in.

SCREW, mach, pnh, sems

RIVET, snap

PIN, spring straight

SCREW, mach, pnh

ROD, connecting

WASHER

SCREW, mach

GUN, texture (see manual 308274)

LABEL, flow control

LABEL, warning

LABEL, instruction

LABEL, outlet

HOSE SET, 1/2” air x 3/4” fluid

VALVE, air

FITTING, tee male branch

CLAMP, hose

154

155

156

157

158

159

160

Y

117781

C27076

15C190

115492

15C173

15C174

102040

SCREW, machine, pnh

NUT

PLATE, retaining

SCREW, mach, slot hex wash hd

HOSE, 5/32” blue tubing

HOSE, 5/32“ black tubing

NUT, lock. hex

*

**

†

162 15C040

163** 246606

164

185

15C283

111340

LABEL, instruction

KIT, digital display

TUBE, nylon

GASKET

Kit 234231 contains: seat, sst tip, and o--rings

Kit 246606 contains items:12, 28, 76 and 146

Kit 241113 contains items:89 and 94

Danger and warning labels, tags, and cards are free.

1

1

2

1

2

2

2

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

2

2

4

9

2

2

6

4

1

2

1

1

1

2

3

5

1

4

1

1

2

1

1

1

1

1

1

309662 21

Parts - Flow Control

See page 21 for parts description and page 20 for location on sprayer.

171

172

C

170

169

168

174

167

160

162

138

160

145

1

54

46

176

Kit 248327

173

157

138

6

163 28 53 55 50

66

9

49

146 148

120

151

70

7

155

154

4

76

44

124

12

Ref

No.

Part No.

138† 112774

157† 115492

160† 102040

162† 15D885

167† 15D864

168† 155494

169† 155665

170† 155699

171† C20483

172† 106148

Description

SCREW, mach

Qty

9

SCREW, mach, slot hex wash hd 2

NUT, hex, 1/4--20

LABEL, instructions

BRACKET, 1030FC, air filter

UNION, swivel, 90 degree

UNION, adapter

ELBOW, street

2

1

1

1

1

1

NIPPLE, hex, 3/8 npt

FILTER, air, 3/8 npt

1

1

173† 15D863

174† 119251

176† 106151

180‡ 156823

181‡ 162453

182‡

SPACER, standoff, 1030FC, filter

SCREW, self--tap, filhd, 8--32

VALVE, drain, auto

UNION, swivel

ADAPTER

FLOW SWITCH

† Included in Kit 248327 which may be ordered separately

2

2

1

1

1

1

‡ Included in Kit 248328 which may be ordered separately

69

144

1 Danger and warning labels, tags, and cards are free .

B

ti4366b

Flow

Sensor Regulator

C

ti4366a

22 309662

180

A

181 182

Parts - Dump Manifold

See page 21 for parts description and page 20 for location on sprayer.

159 (black)

158 (blue)

79n

3 41n

30

23n

22n

68n

63a

63bn

45n

96n

82n

2

1 47n

Detail A

TI3122A 3

3

31 85n

TI3008e

1

2

Prime Valve Repair Kit 234231 Installation

1. Replace all parts shown for (47).

2. Apply blue LockTite to threads of screw (68).

3. Detail A. Hold piston assembly of air cylinder (22) with 3/16 in. hex driver and torque screw (68) to 40 to 50 in-lb.

4. Detail C. Place valve seat (b) with rounded end out toward screw head. Place dark color o--ring (c), carbide seat (d) either side up, and white o--ring (e).

Torque screw (82) to 40 to 50 in-lb.

smaller ID bore and OD orientation groove (if present) toward air cylinder assembly.

n

Parts included in kit 287127.

Detail B

TI10245e b

Detail C

TI10246e c e d

309662 23

Parts - Displacement Pump

Model 235166, Series A

Includes items 201227

202

228

201

Ref

No.

Part No.

Description Qty

201 188437 PISTON ROD

202 187068 PACKING NUT

203 188560* V-PACKING, poly

204 187939* GLAND, male

205 188557* O-RING

206 187934 PISTON HOUSING

207 188559* O-RING, fluoroelastomer

208 188434* NUT

209 188432* GLAND, male


211 188433* GLAND, female

212 188627 BACKUP WASHER, nylon

213 235165 PISTON SEAT

214 187929 LUG NUT

215 235963 INTAKE HOUSING

216 102973* BALL, intake, 1.25 in. Dia.

217 187064 BALL GUIDE 1

218 188558* U-CUP SEAL, poly/fluoroelastomer1


220 102972* BALL, piston; 0.875 in. Dia.

221

225

226

227

228

232

187066

187071*

187070*

187933

183210

235962

CYLINDER

V-PACKING, poly

GLAND, female

HOUSING, outlet

PIN

SEAL, foot valve

1

1

1

1

1

3

3

1

1

1

1

1

1

1

1

2

1

1

2

1

2

1

1

1

* Included in Repair Kit 235186, purchased separately. Kit includes pressure drain valve u-cup packing, 111829.

*226

*225

*204

227

*205

221

*205

*210

203*

206

208*

207*

209*

213

217

216*

232

215

219*

211*

218*

212

220*

214

TI3020A

24 309662

Parts - Pinion and Drive Housing Repair Kits

Ref No. 58 and 8

Pinion Housing Repair Kit Ref No. 8: Drive Housing Repair Kit

Ref

No.

Part No.

Description Qty

Ref

No.

Part No.

Description Qty

KIT, repair, drive housing

WASHER

WASHER

LABEL, caution

1

1

1

1

58 245399 KIT, repair, pinion housing

58b 105489

58d* 241114

PIN

PINION SHAFT

58e 112770 RETAINING RING, large

*Must be ordered separately.

58e

58d

58b

1

2

1

1

8

8g

8h

8p

59 (Ref)

36 (Ref)

58

8h

8g

287128

194173

116192

290228

84 (Ref) 8

8p

17 (Ref)

81 (Ref)

1

91 (Ref)

92 (Ref)

TI0177B

1 Pinion housing assembly (58) includes clutch field and connector

309662 25

Accessories

USE ONLY GENUINE GRACO PARTS AND ACCESSORIES

Air And Material Hose Kit

Max. Working Pressure

Fluid: 750 psi (5.18 MPa, 51.7 bar)

Air: 300 psi (2.07 MPa, 20.7 bar)

235737

50 ft (15.2 m) hoses to supplement 50 ft (15.2 m) hose kit supplied with sprayer. Use up to three more hose kits. DO NOT use this kit at sprayer outlet as it does not have a spring guard on material hose.

26 309662

Technical Data

Honda GX160 Engine

Power Rating @ 3600 rpm

ANSI . . . . . . . . . . . . . . . . . . . . . . . . .

DIN 6270/DIN 6271

NA

NB

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Working Pressure

Cycles/gallon (liter)

Maximum Delivery

Fuel Tank Capacity

. . . . . . . . . . . . .

5.5 Horsepower

2.9 Kw--4.0 Ps

3.6 Kw--4.9 Ps

. . . . . . . . . . . . . .

1000 psi

(7.0 MPa, 70 bar)

Pump Inlet Size

Fluid Outlet Size

. . . . . . . . . . . . . . . . . . . . . . . .

42 (11)

3 gpm (11 liter/min)

. . . . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

Wetted Parts

Displacement Pump

0.95 gallon (3.7 liter)

2 inch quick disconnect

3/4 npsm(f)

. . . .

Nickle-plated carbon steel,

Stainless steel, Chrome-plated stainless steel,

Poly, Tungsten carbide, fluoroelastomer

Sound Data

Sprayer:

Sound Pressure Level

Sound Power Level

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

*Measured readings at 1 m, normal load.

97dB(A)*

105dB(A)*

Gun:

Sound Pressure Level

Sound Power Level

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

96dB(A)**

104dB(A)**

**Measured while spraying simulated acoustical texture under typical conditions as specified by material manufacturer.

Dimensions

Weight (dry, without packaging)

Height

. . .

. . . . . . . . . . . . . . . . . . . . . . . . .

Length

Width

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

150 pound (68 kg)

32 inch (813 mm)

30 inch (762 mm)

23 inch (584 mm)

309662 27

Graco Warranty and Disclaimers

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 procedures concernées.

TO PLACE AN ORDER, contact your Graco distributor or call 1--800--690--2894 to identify the nearest distributor.

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

This manual contains English. MM309662

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440- 1441 www.graco.com

Written in USA 12/2002, Rev 01/2008

28 309662

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