Graco 3A0246B Drywall Feed Pump Repair Owner's Manual

Repair
Drywall Feed Pump
3A0246B
ENG
U.S. Patents Pending: 61/315,288; 61/315/322; 61/316,013; 61/316,010
- For water-based materials only - Not for use in explosive atmospheres - Not for use with quick-set materials READ ALL WARNINGS AND INSTRUCTIONS
Read all warnings and instructions in this manual.
Save these instructions.
Maximum Working Pressure 2500 psi (17.2 MPa, 172 bar)
Model 257100: 120V NA ETL Listed
Model 258906: 240V Euro Multicord
Model 258907: 110V UK, CE
Model 262288: 120V NA
Model 262300: 240V Euro CE Cord
Agency Approvals:
257100
258906
258907
262288
262300
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ti14873a
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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 symbols refer to procedure-specific risks. When these symbols appear
in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. 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 power and extension cords.
• Do not expose to rain. Store indoors.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, 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.
• Engage trigger lock when not dispensing.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing
equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and
explosion:
• Do not dispense flammable or combustible materials near an open flame or sources of ignition such as cigarettes,
motors, and electrical equipment.
• Material or solvent flowing through the equipment is able to result in static electricity. Static electricity creates a
risk of fire or explosion in the presence of material or solvent fumes. All parts of the system, including the pump,
hose assembly, dispenser, and objects in and around the work area shall be properly grounded to protect against
static discharge and sparks. Use Graco conductive or grounded high-pressure airless material hoses.
• Verify that all containers and collection systems are grounded to prevent static discharge.
• Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2 adapter.
• Do not use a material or a solvent containing halogenated hydrocarbons.
• Keep work area well-ventilated. Keep a good supply of fresh air moving through the area. Keep pump assembly in
a well ventilated area.
• Do not smoke in the work area.
• Do not operate light switches, engines, or similar spark producing products in the work area.
• Keep area clean and free of material or solvent containers, rags, and other flammable materials.
• Know the contents of the materials and solvents being dispensed. Read all Material Safety Data Sheets (MSDS)
and container labels provided with the materials and solvents. Follow the material and solvents manufacturer’s
safety instructions.
• Fire extinguisher equipment shall be present and working.
• Drywall feed pump generates sparks. When flammable liquid is used in or near the drywall feed pump or for
flushing or cleaning, keep unit at least 20 feet (6 m) away from explosive vapors.
2
3A0246B
Warning
WARNING
WARNING
MOVING PARTS HAZARD
Moving parts can pinch, cut 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 and disconnect all power sources.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•
•
•
•
•
Always wear appropriate gloves, eye protection, and a respirator or mask when dispensing.
•
•
•
•
Do not operate the unit when fatigued or under the influence of drugs or alcohol.
Do not operate or dispense 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 leave the unit energized or under pressure while unattended. When the unit is not in use, turn off the unit and
follow the Pressure Relief Procedure for turning off the unit.
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.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and
equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such
solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.
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, hearing loss, inhalation of toxic fumes, and burns. This
equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
3A0246B
3
Pressure Relief Procedure
Pressure Relief Procedure
3. Turn prime valve handle to PRESSURE RELIEF
position.
1. Turn flow control knob to fully counterclockwise to
OFF position.
bar/psi
ti15614a
4. Display will read “----” when all pressure is relieved.
ti8793a
2. Place deflector in hopper or suitable container.
ti14876a
4
3A0246B
Drive and Bearing Housing
Drive and Bearing Housing
NOTICE
Do not drop gear cluster (17a) when removing drive
housing (5a). Gear cluster may stay engaged in motor
front end bell or drive housing.
6. Remove two screws (5b) from underneath motor
base plate. Lift and remove motor/pump assembly
from power module.
Removal
5b
ti11734a
1. Perform Pressure Relief Procedure, page 4.
7. Loosen four screws (19) on pump housing, and
remove bearing housing (9) from motor.
2. Remove Power Module, see page 7.
3. Remove Pump, page 8.
4. Remove four screws (40) and lift motor shroud (98)
off of motor.
9
ti15630a
19
40
98
8. Remove three screws (5c) on motor (8a). Remove
motor (8a) from drive housing (5a).
8a
5a
5c
ti15624a
5. Disconnect three wire harnesses (see Wiring
Diagrams, pages 34-36).
3A0246B
ti11735a
5
Drive and Bearing Housing
Installation
1. Apply brown lithium grease supplied with drive
housing kit (5) to gear cluster (17a) and inside of
motor cavity.
5. Replace motor/pump assembly into pump module.
Replace and tighten two screws (5b) underneath
motor base plate. Torque to 200 - 220 in-lb.
5a
5b
ti15629a
17a
2. Align orientation tab on gear housing with slot on
motor and slide gears into motor.
3. Replace and tighten three screws (5c) on motor
(8a). Torque to 200-220 in-lb.
5c
ti11734a
6. Reconnect three wire harnesses (see Wiring
Diagrams, pages 34-36).
7. Replace motor shroud (98) and tighten four screws
(40). Torque to 30-34 in-lb.
40
98
8a
ti11735a
4. Attach bearing housing (9) to gear housing (5a)
(slowly turn motor fan by hand to align gear into
pump connecting rod). Torque four bearing housing
screws (19) to 25-30 ft-lb.
5a
ti15624a
8. Replace Pump, page 8.
9
9. Replace Power Module, see page 7.
ti15630a
19
6
3A0246B
Power Module
Power Module
Removal
Installation
1. Remove hopper plug (117) if installed.
2. Replace power (153) module and insert pump outlet
into hopper inlet.
1. Perform Pressure Relief Procedure, see page 4.
Unplug power cord.
153
2. Release hopper adapter clamp (158).
ti15625a
158
3. Pull rod clamp up and tighten knob (112) on front of
pump module.
ti15684a
112
3. Loosen rod clamp knob (112) on front of pump module and push rod down.
112
ti11678a
4. Fasten hopper adapter clamp (158).
ti11675a
4. Lift and pull power module (153) off of unit.
NOTE: Power module weighs approximately 85 lb.
158
153
ti15683a
ti15623a
5. Install hopper plug (117) if needed.
117
3A0246B
ti15623a
7
Pump
Pump
Removal
7. Use hammer to loosen pump retaining nut (22).
22
1. Perform Pressure Relief Procedure, see page 4.
ti15615a
2. Remove Power Module, see page 7.
8. Unscrew and remove pump (18a) from module.
3. Disconnect material hose (79) from pump (18a).
79
18a
18a
ti15618a
ti15616a
4. Loosen two screws (40) and remove pump rod
shield (48).
Installation
1. Extend pump piston rod 1.5 in.
40
48
1.5 in.
ti15619a
5. Turn flow control knob to a very low setting and turn
prime valve handle to TOOL FILL position (JOG
mode will appear in display). Use ON/OFF switch or
turn control knob OFF to stop pump when pin is
visible.
ti7171a
2. Install pump pin (7b). Verify retaining spring is in
groove of connecting rod.
7b
ti15620a
6. Use screwdriver to press pin (7b) out of pump.
7b
ti13093a
ti15617a
NOTE: Pin should be installed from the top side of the
pump. Make sure to control the pump pin when installing
so that it does not fall into the pump module.
NOTE: Pin should be removed by pressing the pin
out through the bottom side of the pump. Make sure
to control the pump pin when removing so that it
does not fall into the pump module.
8
3A0246B
Pump
3. Push pump up until pump threads engage.
7. Replace pump rod shield (48) and torque two
screws (40) to 30 - 34 in-lb.
40
48
ti15924a
4. Screw in pump until threads are flush with drive
housing opening.
ti15619a
8. Reconnect material hose (79) to pump (18a).
79
18a
ti15616a
9. Replace Power Module, see page 7.
ti15621a
5. Align pump outlet to right side so that hose can be
reassembled.
ti15923a
6. Screw jam nut up toward drive housing 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 N•m).
ti15925a
3A0246B
9
Motor
Motor
Removal
7. Loosen four screws (19) on bearing housing (9),
and remove from gear housing.
5a
9
1. Perform Pressure Relief Procedure, see page 4.
ti15630a
2. Remove Power Module, see page 7.
19
3. Disconnect material hose (79) from pump (18a).
8. Remove three screws (5c) on motor (8a). Remove
motor from gear housing.
79
5c
18a
ti15616a
4. Remove four screws (40) and lift motor shroud (98)
off of motor.
8a
ti11735a
40
Installation
98
1. Apply brown lithium grease supplied with motor
repair kit (8) to gear cluster (17a) and inside of
motor cavity.
ti15624a
5. Disconnect three wire harnesses (see Wiring
Diagrams, pages 34-36).
6. Remove two screws (5b) from underneath motor
base plate. Lift and remove motor/pump assembly
from pump module.
ti15629a
17a
2. Align orientation tab on gear housing with slot on
motor and slide gears into motor.
3. Replace three screws (5c) on motor (8a). Torque to
200-220 in-lb.
5a
5c
5b
ti11734a
8a
ti11735a
10
3A0246B
Motor
4. Attach bearing housing (9) to gear housing (5a)
(slowly turn motor fan by hand to align gear into
pump connecting rod). Torque four bearing housing
screws (19) to 25-30 ft-lb.
7. Replace motor shroud (98) and torque four screws
(40) to 30 - 34 in-lb.
40
5a
98
9
ti15630a
19
5. Replace motor/pump assembly into pump module.
Replace and torque two screws (5b) underneath
motor base plate to 200 - 220 in-lb.
ti15624a
8. Reconnect material hose (79) to pump (18a).
79
5b
18a
ti15616a
ti11734a
9. Replace Power Module, see page 7.
6. Reconnect three wire harnesses (see Wiring
Diagrams, pages 34-36).
3A0246B
11
Motor Control Board
Motor Control Board
Removal
6. Disconnect display connector (A) from motor control
board (24) and remove display.
ti13569a
120V Models:
24
1. Perform Pressure Relief Procedure, see page 4.
Wait 5 minutes before servicing.
2. Remove Power Module, see page 7.
A
7. Remove bottom two screws (61) and remove control
panel (37).
3. Disconnect material hose (79) from pump (18a).
37
79
61
18a
ti15616a
4. Remove four screws (40) and lift motor shroud (98)
off of motor.
ti15795a
8. Disconnect Prime/Tool Fill/Recirculate reed switch
connector (E) from motor control board (24).
24
40
98
E
ti13572a
9. Disconnect potentiometer connector (C) from motor
control board (24).
24
ti15624a
ti15791a
C
5. Remove four screws (33b) and display cover (33k).
10. Disconnect 15/20A switch connector (X) from motor
control board (24).
33k
24
X
33b
ti15786a
ti15850a
12
3A0246B
Motor Control Board
11. Disconnect white power cord conductor (D) from
motor control board (24).
16. Disconnect three motor connectors from motor control board to motor.
24
ti15851a
D
ti15847a
12. Disconnect black power lead (J) on motor control
board (24) from ON/OFF switch.
17. Remove two screws (83) holding motor control
board /heat sink assembly to power module frame.
Remove motor control board/heat sink assembly.
J
83
ti15849a
13. Remove ground screw (58) from motor control
board/heat sink assembly.
58
ti15845a
18. Remove six outer screws, two inner screws, and
remove control board (24) from heat sink.
24
ti15846a
14. Remove two top screws (61) and control box (3).
ti15844a
61
3
ti15912a
15. Disconnect transducer connector from motor control
board (24).
ti12999a
24
3A0246B
13
Motor Control Board
110 UK and 240V Models:
7. Remove bottom two screws (61) control panel (37).
1. Perform Pressure Relief Procedure, see page 4.
Wait 5 minutes before servicing.
2. Remove Power Module, see page 7.
37
3. Disconnect material hose (79) from pump (18a).
61
79
ti15795a
8. Disconnect Prime/Tool Fill/Recirculate reed switch
connector (E) from motor control board (24).
18a
ti15616a
24
4. Remove four screws (40) and lift motor shroud (98)
off of motor.
ti13572a
E
40
98
9. Disconnect potentiometer connector (C) from motor
control board (24).
24
ti15791a
ti15624a
C
5. Remove four screws (33b) and display cover (33k).
33k
10. Disconnect black power lead (G) from motor control
board to filter board. Disconnect blue power lead (B)
from motor control board to filter board.
G
33b
ti15786a
B
6. Disconnect display from motor control board (24)
and remove display.
ti15848a
11. Remove ground screw (58) from motor control
board/heat sink assembly.
58
24
ti13569a
14
ti15846a
3A0246B
Motor Control Board
12. Remove top two screws (61) and control box (3).
15. Remove two screws (83) holding motor control
board / heat sink assembly to power module frame.
Remove motor control board/heat sink assembly.
61
3
83
ti15912a
13. Disconnect transducer connector from motor control
board (24).
ti15845a
16. Remove six outer screws, two inner screws, and
remove control board (24) from heat sink.
24
ti12999a
24
14. Disconnect three motor connectors from motor control board to motor.
ti15844a
ti15847a
3A0246B
15
Motor Control Board
Installation
120V Models:
1. Use acetone or equivalent cleaner to thoroughly
remove thermal paste from pockets on heat sink.
5. Connect motor control board lead connectors (F) to
leads from motor. Insert grommet in heat sink baffle.
Use zip tie or electrical tape (Z) to hold grommet
together on grommet end on the motor side of the
heat sink.
Z
F
ti14695a
2. Apply new thermal paste into both pockets of heat
sink.
ti15852a
6. Assemble gasket (94) to heat sink assembly.
94
ti14693a
ti15911a
3. Replace two inner screws and washers to control
board and torque to 17 in-lb.
7. Assemble two screws (83) to hold motor control
board/ heat sink assembly to power module frame.
Torque to 35-45 in-lb.
83
ti15926a
4. Replace six outer screws to control board and
torque to 11 in-lb.
ti15845a
8. Assemble ground screw (58) to heat sink. Torque to
30-34 in-lb.
58
ti14697a
ti15846a
NOTE: SW1 position setting does not matter.
9. Assemble control box enclosure (3) to power module and tighten two screws (61). Torque to 30-35
in-lb.
61
3
ti15912a
16
3A0246B
Motor Control Board
10. Connect black power lead (J) on motor control
board to ON/OFF switch.
15. Replace control panel (37) and tighten bottom two
screws (61). Torque to 30-35 in-lb.
J
37
61
ti15849a
11. Connect white power cord conductor (D) to motor
control board (24).
ti15795a
16. Connect display connector to motor control board
(24).
ti13569a
24
ti15851a
24
D
12. Connect 15/20A switch connector (X) to motor control board (24).
17. Assemble display cover (33k). Spring tabs on noise
shield need to be assembled to the inside of the
control box enclosure. Torque screws (33b) to
30-35 in-lb.
33k
24
X
33b
ti15786a
ti15850a
13. Connect potentiometer connector (C) to motor control board (24).
24
18. Remove four screws (40) and lift motor shroud (98)
off of motor.
40
98
ti15791a
C
14. Connect Prime/Tool Fill/Recirculate reed switch connector (E) to motor control board (24).
ti15624a
19. Disconnect material hose (79) from pump (18a).
24
79
E
18a
ti13572a
ti15616a
20. Replace Power Module, see page 7.
3A0246B
17
Motor Control Board
110 UK and 240V Models:
6. Assemble gasket (94) to heat sink assembly.
1. Use acetone or equivalent cleaner to thoroughly
remove thermal paste from pockets on heat sink.
94
ti15911a
ti14695a
2. Apply new thermal paste into both pockets of heat
sink.
7. Assemble two screws (83) to hold motor control
board/ heat sink assembly to power module frame.
Torque to 35-45 in-lb.
83
ti14693a
3. Replace two inner screws and washers to control
board and torque to 17 in-lb.
ti15845a
8. Assemble ground screw (58) to heat sink. Torque to
30-34 in-lb.
58
ti15926a
4. Replace six outer screws to control board and
torque to 11 in-lb.
ti15846a
9. Assemble control box enclosure (3) to power module using two top screws (61). Torque to 30-35 in-lb.
61
3
ti14697a
NOTE: SW1 position setting does not matter.
5. Connect motor control board lead connectors (F) to
leads from motor. Insert grommet in heat sink baffle.
Use zip tie or electrical tape (Z) to hold grommet
together on grommet end on the motor side of the
heat sink.
ti15912a
10. Connect blue (B) and black (G) power leads from
motor control board (24) to filter board.
G
Z
F
B
ti15848a
ti15852a
18
3A0246B
Motor Control Board
11. Connect potentiometer connector (C) to motor control board (24).
24
15. Assemble display cover (33k). Spring tabs on noise
shield need to be assembled to the inside of the
control box enclosure. Torque screws to 30-35 in-lb.
33k
ti15791a
C
ti15786a
12. Connect Prime/Tool Fill/Recirculate reed switch connector (E) to motor control board (24).
16. Replace motor shroud (98) and torque four screws
(40) to 30 - 34 in-lb.
24
40
98
E
ti13572a
13. Replace control panel (37) and tighten bottom two
screws (61). Torque to 30-35 in-lb.
ti15624a
37
17. Reconnect material hose (79) to pump (18a).
ti15795a
79
61
14. Connect display connector to motor control board
(24).
18a
ti15616a
18. Replace Power Module, see page 7.
ti13569a
24
3A0246B
19
Prime Valve Handle
Prime Valve Handle
Removal
4. Clear out any material that is lodged in valve (71) or
manifold (70).
Installation
1. Perform Pressure Relief Procedure, see page 4.
Wait 5 minutes before servicing.
2. Use 3/32 in. punch and hammer to tap out handle
pin (72c) (pliers may be required to pull out handle
pin). Pull off handle (72a) and base (72b).
3. Use crescent wrench to unscrew prime valve (71).
NOTE: Make sure that the seat and gasket are
removed from the manifold.
1. Tighten prime valve (71) into manifold (70). Use
thread sealant on housing threads and torque to
190 to 210 in-lb.
2. Install prime valve base (72b). Pin in base must
align with hole in manifold (70).
3. Orient hole in prime valve stem (71) vertically.
4. Place prime valve handle (72a) over prime valve
base (72b) with handle in “apply” mode. Align hole
in handle (72a) w/hole in prime valve stem (71).
5. Use hammer to tap prime valve handle pin (72c)
back into place.
71
72c
70
72a
72b
ti15633a
20
3A0246B
Pressure Transducer
Pressure Transducer
Removal
5. Remove four screws (61) and control box (3). Allow
control panel (37) to hang down freely.
3
37
1. Perform Pressure Relief Procedure, see page 4.
Wait 5 minutes before servicing.
61
ti15797a
61
2. Remove four screws (33b) and cover (33k).
ti15795a
6. Remove grommet (23) from control box (3).
23
33k
33b
ti15786a
ti15785a
3. Disconnect transducer connector (E) from motor
control board (24).
3
7. Remove transducer (39) and o-ring (50) from manifold (70). Remove grommet (23) from transducer
and save for reuse.
70
24
E
23
39
50
ti12999a
ti15788a
4. Disconnect potentiometer connector (D) and reed
switch connector (87) from motor control board (24).
24
D
Installation
1. Install o-ring (50) and transducer (39) in manifold
(70). Torque to 35-45 ft-lb (47-61 N•m). Install grommet onto transducer (39) and transducer into control
box (3).
70
23
87
39
50
ti15792a
ti15793a
ti15783a
3A0246B
3
21
Pressure Transducer
2. Connect transducer connector (E) and reed switch
connector to control board (24).
24
5. Connect display connector (A) to motor control
board (24).
E
24
ti12999a
ti13569a
A
3. Install control box (3) and control panel (37) with
four screws (61). Torque to 30 - 35 in-lb.
3
6. Install cover (33k) with four screws (33b). Torque to
30-35 in-lb. Make sure tabs on noise shield are
routed inside the control box when assembling.
37
61
61
ti15797a
ti15795a
4. Connect potentiometer connector (D) and reed
switch connector (87) to control board (24).
24
33k
D
ti15786a
33b
87
ti15792a
22
3A0246B
Flow Control Adjust Potentiometer
Flow Control Adjust
Potentiometer
6. Remove gasket (56), nut, spacer (88) and potentiometer (55) from control panel (37).
Removal
55
ti15794a
88
37
56
1. Perform Pressure Relief Procedure, see page 4.
Wait 5 minutes before servicing.
2. Remove four screws (33b) and cover (33k).
Installation
1. Install gasket (56), nut, spacer (88) and potentiometer (55) on control panel (37). Torque nut to 30-35
in-lb (3.25-4.0 N•m).
55
ti15786a
33k
33b
3. Remove bottom two screws (61) and remove control
panel (37).
37
61
ti15794a
88
37
56
2. Install control knob (42): Check control knob alignment to potentiometer shaft. Turn shaft fully clockwise and attach knob in full ON position with a hex
wrench. Make sure set screw is tightened flat
against potentiometer shaft.
42
ti15795a
4. Disconnect potentiometer connector (D) from motor
control board (24).
24
ti13338a
3. Connect potentiometer connector (D) to motor control board (24).
24
ti15791a
D
5. Use hex wrench to remove control knob (42).
D
42
ti15791a
ti7258a
3A0246B
23
Flow Control Adjust Potentiometer
4. Replace control panel (37) and tighten bottom two
screws (61). Torque to 30-35 in-lb.
6. Install cover (33k) with four screws (33b). Torque to
30-35 in-lb. Make sure tabs on noise shield are
routed inside the control box when assembling.
37
33k
61
ti15795a
5. Connect display connector (A) to motor control
board (24).
33b
ti15786a
24
ti13569a
A
24
3A0246B
Prime/Tool Fill/Recirculation Reed Switch
Prime/Tool Fill/Recirculation Reed Switch
Removal
Installation
1. Apply thread sealant to end of reed switch (87).
Hand-tighten reed switch until it is tight against
control panel (37).
1. Perform Pressure Relief Procedure, see page 4.
Wait 5 minutes before servicing.
37
2. Remove four screws (33b) and remove display
cover (33k).
87
ti13574a
2. Add thread sealant and tighten jam nut against
threaded bus.
33k
ti13576a
ti15786a
33b
3. Connect reed switch (87) to control board (24).
3. Remove bottom two screws (61) and remove control
panel (37).
24
37
ti13572a
61
87
4. Replace control panel (37) and tighten bottom two
screws (61). Torque to 30-35 in-lb.
ti15795a
4. Unplug reed switch (87) from control board.
37
61
87
ti13572a
5. Unscrew reed switch (87) from control panel (37).
ti15795a
5. Replace display cover (33k) and torque four screws
(33b) to 30-35 in-lb.
37
33k
87
ti13573a
ti15786a
33b
NOTE: Make sure noise shield tabs are routed to the
inside of the control box when assembling.
3A0246B
25
Digital Display
Digital Display
Removal
Installation
1. Plug display board connector (A) into motor control
board (24).
1. Turn off unit. Wait 5 minutes before servicing.
2. Remove four screws (33b) and remove display
cover (33k).
24
ti13569a
A
33k
ti15786a
2. Replace display cover (33k) and torque four screws
(33b) to 30-35 in-lb.
33b
3. Unplug display board connector from motor control
board (24).
33k
ti15786a
33b
24
ti13569a
NOTE: Make sure noise shield tabs are routed to the
inside of the control box when assembling.
A
26
3A0246B
Inline Valve
Inline Valve
Changing the Needle
5. Tap rear of inline valve with a plastic mallet and
punch to push needle assembly (404b) out through
front of housing (401).
Removal
ti15809a
NOTE: Needle (404b), housing/seat (404c), and o-ring
(404a) must be replaced together. They are included in
repair kit 24F263.
401
404b
Installation
1. Perform Pressure Relief Procedure, see page 4.
2. Squeeze trigger while unscrewing housing/seat
(404c) and o-ring (404a).
404c
1. Guide threaded end of needle assembly (404b) into
front of housing (401).
404a
ti15804a
ti15810a
404b
ti15626a
3. Remove trigger stop (420) with hex wrench.
420
401
404b
2. Install bracket (413) and locknut (414) loosely on
threaded end of needle (404b). Squeeze trigger to
pull needle assembly into housing (401).
413
ti15806a
414
ti15862a
4. Remove locknut (414) and bracket (413).
3. Squeeze trigger while installing o-ring (404a) and
housing/seat (404c). Torque housing/seat to 26-32
ft-lb (35-43 N•m).
404c
ti15811a
413
404a
414
t15805Xa
ti15626a
404b
4. Adjust needle before using inline valve.
3A0246B
27
Inline Valve
Needle Adjustment
Box Slide Control
1. Engage inline valve (135) with safety latch. Hold
inline valve with nozzle straight up.
Use Brake Assembly Repair Kit 24F261
2. Hold your finger against trigger (410) with light pressure. Use a 5/16 open-ended wrench to turn locknut
(414) clockwise until you feel trigger lift slightly.
3. Turn locknut (414) 3/4 turn counter-clockwise.
4. Connect fluid hose. Prime the system. Trigger inline
valve (135) and release it. The fluid flow should stop
immediately. Engage safety latch and try to trigger
inline valve. No fluid should flow. If the inline valve
fails either test, relieve pressure, disconnect hose
and readjust needle.
Removal
1. Remove set screw from brake knob (518b).
518a
518b
ti15863a
2. Unthread brake knob (518b) from assembly.
5. Install trigger stop (420) when needle has been
properly adjusted.
518b
ti15862a
Replacing the Battery
ti15865a
Removal
1. Unscrew battery cap (425a) from housing (411).
Remove battery and discard.
411
Installation
1. Thread brake knob (518b) onto assembly
2. Apply label (518a).
426
3. Torque set screw to 15-20 in-lb.
425a
ti15812a
Installation
1. Install battery (426) in housing (411) and screw in
battery cap (425a).
NOTE: Make sure o-ring (425b) is in place when
installing the battery cap (425a).
28
3A0246B
Parts
Parts
155
154
162
148
147
160
146
161
117
118
119
152
116
155
114
113
154
115
112
126
157
171
170
158
163
156
138
153
111
127
141
128
139
137
129
135
ti15642a
180
Ref.
111
112
113
114
115
116
117
118
119
126
127
128
129
135
137
138
139
141
146
Part
120211
15C799
104430
15C797
101566
100004
15D306
121458
100333
16C298
257133
223756
24D166
24F538
24E958
122267
150287
162449
16C794
3A0246B
Description
RING, retaining, e-ring
ROD, clamp
PIN, cotter
BRACKET, swivel
NUT, lock
SCREW, cap, hex HD
PLUG, adapter, hopper, texture
TIE, lanyard
SCREW, cap, hex HD
FILTER, hopper
HOSE, cpld, 1/2 in. mxf 50 ft
HOSE, cpld, 1/4 in. x 15 ft
SWIVEL, Z, complete
VALVE, inline, assembly
KIT, drain, hose
WHEEL, foam
COUPLING
FITTING, nipple, reducing
SPACER, .75 OD X .4 ID X .625
Qty.
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
Ref.
147
148
152
153
154
155
156
157
158
160
161
162
163
170
171
180
Part
278204
112785
15R633
257047
258890
258893
262289
262299
289668
16D307
116038
121308
234188
15R639
112958
121313
156306
15R609
102905
24F463
Description
CLIP, drain line
SCREW, hex HD, flanged
FRAME, painted, TMAX
MODULE, power, ETL listed
MODULE, power, CE listed
MODULE, power, UK CE listed
MODULE, power, 120V
MODULE, power, CE Cord
HOPPER, assembly
LABEL, brand, drywall us, hopper
WASHER, wave spring
PLUG, expanding
CLAMP, quick release
HANDLE, TMAX
NUT, hex, flanged
PIN, locking, 1/4 in.
WASHER, flat
FITTING, hopper, adapter
CLAMP, hose
KIT, control, box slide
Qty.
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
2
2
1
1
1
29
Parts
Pump Module Parts
102
99
21
105
8c
40
8b
40
8a
101
48
104
17a
98
17c
17b
84
79
18b
5d
75
5a
25
5c
50
70
24
18a
7c
92
7b
78
80
7a
20
58
72c
94
22
19
3
72a
29
9
46c
108
83
61
23
94
39 74
87
79 71 72b
ti15643a
88
81
36
61
46b
33h
32
4
6
28
5b
10
54
46a
43
182 181
27
41
183
55
33b
37
38
33d
56
42
109
33e
110
33k
33a
33c
3 ref
30
33j 33m
3A0246B
Parts
Pump Module Parts List
Ref.
3
4
5
5a
5b
5c
5d
6
7
7a
7b
7c
8
8a
8b
8c
9
10
17
17a
17b
17c
18
18a
18b
19
20
21
22
23
24
25
27
28
29
32
33
33a
33b
33c
33d
33e
33h
33j
33k
33m
36
37
38
39
40
Part
15G700
15D431
277657
24E959
120981
15C753
116192
100023
287720
15F856
119778
24D362
15V577
122347
240724
113817
287290
114699
114672
24E957
15Y925
114666
106115
16D622
193031
15D033
258843†
258889*
100016
116171
112746
107129
260215
24F259
115522
116252
15X508
15X507
15Y893
16D642
15D036
15X617
15C979
15D527
243222
118444
3A0246B
Description
Qty.
BOX, control
1
BOX, control, CE and UK
1
GUIDE, base
4
KIT, housing, drive
1
HOUSING, drive
1
SCREW, mach, hex washer HD
2
SCREW, mach, hex wash HD
3
WASHER, thrust
1
WASHER, flat
4
KIT, rod, connecting
1
ROD, connecting
1
PIN, pump
1
SPRING, retaining
1
KIT, motor, electric
1
MOTOR, electric
1
FAN, motor
1
RING, retaining, external
1
HOUSING, bearing
1
BUMPER
2
KIT, gear, combination
1
GEAR, combo
1
WASHER, thrust
1
WASHER, thrust
2
KIT, pump, displacement
1
PUMP, displacement
1
FITTING, 5/8 JIC / 1/2 NPT
1
SCREW, cap, socket head
4
WASHER, lock (hi-collar)
4
SHIELD, assy, painted
1
NUT, retaining
1
GROMMET, transducer
1
CONTROL, board, drywall feed
1
CONTROL, board, drywall (240V)
1
WASHER, lock
4
BUSHING, strain relief
1
NUT, lock, nylon, thin pattern
4
BOLT, round head
4
SCREW, hex HD
2
KIT, repair, display
1
SCREW, mach, PNH
3
SCREW, #10, taptite phil
4
CONTROL, board, receiver
1
LABEL, brand, smartcontrol LCD
1
PAD, foam
1
LABEL, smartcontrol
1
SEAL, extruded w/adhesive
1
COVER, control
1
GASKET
1
GASKET, control box
1
PANEL, control
1
SWITCH, rocker
1
SWITCH, rocker (240V)
1
TRANSDUCER, flow control
1
SCREW, mach, slot hex wash HD
10
Ref.
41
Part
15H066
15H065
15D528
15D530
15D529
116167
120059
287943
42
43
46
46a
46b
46c
48
50
54
55
56
58
61
70
71
72
72a
72b
72c
74
75
78
79
80
81
83
84
87
120223
116969
15T629
111457
15G935
256219
15C973
114391
123128
15X122
24B339
24E960
258894
24A382
15C972
15Y934
121112
190451
16C350
118484
15X902
110637
16C993
258644
88
92
94
98
99
101
102
104
105
108
109
110
181
182
183
198650
16D004
16D640
16D624
16C681
16E335
15U014
16D653
15Y118
116876
119228
257905
195551
242001
287121
Description
Qty.
CORD, power (Model 257047)
1
CORD, power (Model 262289)
1
CORD, power, CE
1
CORD, power, UK
1
CORD, power, global
1
KNOB, potentiometer
1
SWITCH, rocker
1
KIT, repair, coil
1
COIL
1
SCREW, machine, flat head
1
NUT, lock
1
SHIELD, pump rod
1
PACKING, o-ring
1
CONNECTOR, electrical
1
POTENTIOMETR, assembly
1
GASKET
1
SCREW, grounding
1
SCREW, mach, pan head, 10-24X4 4
MANIFOLD, fluid
1
VALVE, prime, heavy duty
1
KIT, handle
1
HANDLE, valve, prime
1
BASE, valve, heavy duty
1
PIN, grooved
1
FITTING, 5/8 JIC / 3/4 NPT
1
SCREW, cap, socket head
4
UNION, adapter
1
HOSE, coupled
1
FITTING, connector
1
LABEL, euro
1
SCREW, mach, panhead
2
GROMMET, motor lead
1
KIT, reed switch (includes reed
1
switch and sealant)
SPACER, shaft
1
LABEL, drywall dump valve indent
1
GASKET, control
2
SHIELD, base, painted
1
LABEL, no weight & no step
1
LABEL, graco
1
LABEL, cap
1
LABEL, drywall warning label
1
LABEL, Made in the USA
1
WASHER, flat
2
SCREW, mach, flat hd
4
CONTROL, board
1
CLIP, retaining
1
CORD SET, adapter, Europe
1
CORD SET, adapter, Italy,
1
Denmark, Switzerland
† 257600 Repair Kit is available with control board only.
* 257601 Repair Kit is available with control board only.
31
Parts
Inline Valve Parts 24F538
411
431
425b
425a
427
428
423
411
426
406
427
437
424
403
402
431
401
411
408c
439
410
408b
414
413
416
417
404b
404a
420
ti15796a
404c
406
408a
Ref.
401
402
403
404
404a
404b
404c
406†
408
408a
408b
408c
410
411
413
414
416
32
Part
15Y164
179733
15Y204
24F263
104444
257585
257590
103338
24F269
15Y171
257580
257790
197058
107110
177538
Description
HOUSING, fluid
SEAL, sleeve
FLUID, tube
KIT, inline valve needle and seat
PACKING, o-ring
NEEDLE, gun, assembly
HOUSING, seat, .188 orifice
PACKING, o-ring
KIT, sanitary clamp
CLAMP, 1 in. sanitary
SLEEVE, oval
CABLE
TRIGGER, w/magnet
HOUSING, valve w/ overmold
BRACKET, stem
LOCKNUT
STUD, trigger
Qty.
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
1
Ref.
417
420
Part
Description
Qty.
15Y526 NUT, lock, m4 sst
1
15Y200 FASTENER, pan head, 6-32 x .188
1
sst
423 256228 CONTROL, board, transmitter
1
424 15Y201 NUT, battery, wedged
1
425 24F260 KIT, battery cap
1
425a 15Y203 CAP PLUG, battery
1
425b 108284 PACKING, o-ring
1
426 15X949 BATTERY, CR123A, lithium, 3 volt
1
427 15X950 PAD, foam, isolator
2
428 15X951 PAD, foam, isolator
1
431 15Y263 FASTENER, self tapping, 6-32x.5
8
sst
437 16C346 ADAPTER, 3/8 nptf x 1.00 rad seal
1
439 16C952 PIN, clevis, fastener
1
† Repair Kit 24F262 is a 10-pack.
3A0246B
Parts
Box Slide Parts 24F463
502
503
505b
505a
514
512
513
514
519
512
520
513
508
507
506
510
509
511
518a
518b
501
ti15834a
515
518c
Ref.
501
502
503
505
505a
505b
506
507
508
509
510
Part
258993
16D718
15X949
24F260
15Y203
108284
C20272
16D761
256228
101855
16D933
3A0246B
Description
Qty.
BASE, hinge assembly
1
LID, slide control
1
BATTERY, CR123A, lithium, 3 volt
1
KIT, battery cap
1
CAP PLUG, battery
1
PACKING, o-ring
1
PACKING, o-ring
1
NUT, battery cap
1
CONTROL, board, transmitter
1
SCREW, tapping, pnhd
2
SWITCH, dual in-line reed
1
Ref.
511
512
513
514
515
518
518a
518b
518c
519
520
Part
16D937
16D760
16D765
24E473
122665
24F261
16E022
121591
16D763
15X950
15X951
Description
WASHER, .12id x.38od x.04 thk
PIN, trigger
SPRING, trigger torsion
TRIGGER, magnet assembly
SCREW, fhcs, 4-20 x .50
KIT, box slide control brake
LABEL, drywall, round
KNOB, .25 dia. shaft, w/setscrew
BRAKE, slide control
PAD, foam, isolator
PAD, foam, isolator
Qty.
2
2
2
2
4
1
1
1
1
1
1
33
Wiring Diagrams
Wiring Diagrams
100-120 VAC NA Units
Thermal
Switch
Digital Display
Potentiometer
Motor
Pressure
Transducer
Black
Control
Board
Motor
Leads
Prime/Fill Tool
Reed switch
Motor
Sensor
Leads
20A/15A
Switch
Green/Ground
Black
ON/OFF
Switch
White
Black
Green/Ground
ti14889a
34
3A0246B
Wiring Diagrams
100-120 VAC UK
Thermal
Switch
Digital Display
Potentiometer
Motor
Pressure
Transducer
Black
Control
Board
Motor
Leads
Prime/Fill Tool
Reed switch
Motor
Sensor
Leads
Black
Blue
Blue
Green/Ground
Brown
Blue
Brown
Green/Ground
ti15686a
3A0246B
35
Wiring Diagrams
220-240 VAC Units
Thermal
Switch
Digital Display
Potentiometer
Motor
Pressure
Transducer
Black
Prime/Fill Tool
Reed switch
Control
Board
Motor
Leads
Motor
Sensor
Leads
Black
Blue
Blue
Green/Ground
Brown
Brown
Blue
ti15685a
36
3A0246B
Technical Data (Unit)
Technical Data (Unit)
Power requirements:
Models 257100, 262288
Models 258906, 262300
Model 258907
Motor HP (W)
Maximum fluid working pressure
Hopper capacity
Maximum delivery with texture
material
Maximum hose length
Fluid outlet size
Dimensions
Length
Width
Height
Weight (with hoses and applicator)
Wetted parts
100-120 VAC, 60 Hz, 15/20A
220-240 VAC, 50 Hz, 10A
100-120 VAC, 50/60 Hz, 15A
2.5 (1864)
2500 psi (17.2 MPa, 172 bar)
25 gallons (95 liters)
Up to 1.5 gpm (5.7 lpm) - varies depending on material
150 ft of 1/2 in. hose plus 15 ft of 1/4 in. hose
1/2 in. NPT female swivel
40 to 55 in. (102 cm to 140 cm) with handle
22 in. (56 cm)
31 in. (79 cm)
196 lb (89 kg)
Buna-N, aluminum, brass, polyethylene, neoprene, stainless steel,
nickel-plated carbon steel, fluoroelastomer, nickel-plated iron, wool
felt, tungsten carbide, PTFE, nylon, zinc-plated carbon steel, paper,
PVC, UHMWPE, leather, rubber
Sound data for drywall feed pump
Sound pressure level *
Sound power level †
* Measured while dispensing at 1 m
† Measured per ISO-3744
80.0 dB(A)
94.7 dB(A)
Technical Data (Pump)
Maximum working pressure
Fluid outlet size
3A0246B
2500 psi (172 bar, 17.2 MPa)
1/2 npt(f)
37
Notes
Notes
38
3A0246B
Notes
Notes
3A0246B
39
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.
Original instructions. This manual contains English. MM 3A0246
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2010, Graco Inc. is registered to ISO 9001
www.graco.com
Revised 01/2011

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