Graco 3A7936A, Control and Pump Kits for SaniSpray HP™ 65 Portable Hopper Sprayer, Repair Instructions

Repair Kit Instructions

Control and Pump Kits for SaniSpray

HP

™

65 Portable Hopper Sprayer

3A7936A

EN

Use these instructions when replacing the control board or pump components for the

SaniSpray HP 65 Portable Hopper Sprayer.

Important Safety Instructions

Read all warnings and instructions in this manual and in Operations manual before using the equipment. Be familiar with the controls and the proper usage of the equipment. Save all instructions.

Includes:

Control Board Replacement, page 8

Pump Cartridge Replacement, page 10

Pump Inlet Valve Replacement, page 11

Prime Valve and Knob Replacement, page 11

Pressure Control Replacement, page 13

25T416, 25T417

25T418

25T403

25T415

25T402

WARNING

ELECTRIC SHOCK HAZARD: To avoid serious injury, turn off and disconnect power cord before servicing the equipment.

Pressure Relief Procedure

Before servicing the sprayer, pump pressure must be relieved.

WARNING

SKIN INJECTION HAZARD: This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection or splashing fluid, follow the Pressure Relief

Procedure whenever sprayer is stopped and before sprayer is cleaned or checked, and before equipment is serviced.

1.

Turn ON/OFF switch to the OFF position.

2.

Engage the trigger lock. Always engage the trigger lock when sprayer is stopped to prevent the gun from being triggered accidentally.

3.

Turn Pressure Control Knob to the lowest setting.

4.

Put drain tube into a pail and turn

Prime/Spray Valve to PRIME position to relieve pressure.

5.

Hold a metal part of the Spray Gun firmly to a grounded metal pail. Point Spray Gun into pail. Disengage the Trigger Lock and trigger the Spray Gun to relieve pressure.

6.

Engage the trigger lock.

7.

If you suspect the spray tip or hose is clogged or that pressure had not been fully relieved: a.

VERY SLOWLY loosen the spray tip guard retaining nut or the airless hose end coupling to relieve pressure gradually.

b.

Loosen the nut or coupling completely c.

Clear airless hose or spray tip obstruction.

Use only genuine Graco replacement parts.

The use of non-Graco replacement parts may void warranty .

Parts - SaniSpray HP 65 (Quick Repair)

1

Torque to 110-120 in-lb

(12.5-13.6 N•m)

2

Torque to 30-36 in-lb

(3.4-4.0 N•m)

2 3A7936A

Parts List - SaniSpray HP 65 (Quick Repair)

Ref. Sprayer Model Part Description Qty.

1

7

8

26

31†

32

36

56 

25R972, 25R962 25R921  KIT, motor, drive, HP65, 120V, includes 56

25R946 25T291 KIT, motor, drive, 230V, CEE, includes 56

25R948, 25R954 25T292  KIT, motor, drive, 230V, multi, includes 56

All

All

25R920

25R922

KIT, pump

KIT, enclosure

All

25R792

25R923 KIT, hopper

25R874 GUN, SaniSpray, HP, NA

25R946, 25R948 25T289

25R954, 25R962 25T290

GUN, SaniSpray, HP, EU

GUN, SaniSpray, HP, AP

All

All

All

LP617 TIP, LP617

LP619 † TIP, LP619

LP621

112133

TIP, LP621

SCREEN, hopper

25T410

222385

17F690

KIT, warning labels, cord

CARD, medical alert (not shown)

English, Spanish, French

Dutch, German, Italian

1

1

1

1

1

1

1

1

60 

98

99*

101

118

144

146

147

149

All

All

All

All

25R948, 25R954

17A134 English, Chinese, Korean

17R476 English, Spanish, Portuguese (Brazil)

26A997 English, Indonesian, Hindi

26A998 English, Chinese, Japanese

25T282

25R872

25C828

195551

EXTENSION, 15 in. (not shown)

TIPSEAL, 5-pack (not shown)

HOSE, 1/8 in. x 4-1/2 ft.

PLUG, retaining

1

25R962

25R954

244285 CORDSET, Japan (not shown)

17N232 CORDSET, India (not shown)

25R948, 25R954 242001

25R954 242005

CORDSET, EU Schuko

CORDSET, ANZ

157

158

25R948

25R948

287121

17J242

CORDSET, Italy, Denmark, Switzerland

CORDSET, UK (not shown)

1

1

 Motor/Drive Kit 25R921 does not include cordset adapter for Japan. Cordset adapter must be ordered separate (see Ref. 144). Control Kit 25T292 does not include cordset adapter.

Cordset adapter must be ordered separate (see Ref. 146-158).

* Two extra TipSeals (polymer spray tip seals) are included with the sprayer. For disinfectant applications, use TipSeal (polymer spray tip seal) instead of the OneSeal (metal seal) that is included with the replacement spray tips.

† SaniSpray HP Gun includes LP619 Spray Tip.

 Replacement safety labels, tags, and cards are available at no cost.

1

1

1

1

1

1

1

1

3A7936A 3

Parts - SaniSpray HP 65 (Extended Repair)

1

Torque to 110-120 in-lb

(12.5-13.6 N•m)

2

Torque to 30-36 in-lb

(3.4-4.0 N•m)

5

4

Ref. Sprayer Model Part Description

3

25R792, 25R962 17J173

25R946 17J175

25R948, 25R954 17L301

25R792, 25R962 25T416

CORD, power, USA

CORD, power, EU Schuko

CORD, power, Multicord

BOARD, control, 100-120V, includes 15a

15 25R946, 25R948,

25R954

25T417

25R792, 25R962 119276

BOARD, control, 220-240V, includes 15a

FUSE, 12.5A slow blow, 100-120V

15a

39

25R946, 25R948,

25R954

All

129882

17K336

FUSE, 6.3A slow blow, 220-240V

TUBE, drain, assembly

56  All 25T410 KIT, warning labels, cord

 Replacement safety labels, tags, and cards are available at no cost.

Qty.

1

1

1

1

1

3A7936A

Parts - SaniSpray HP 65 (Pump Repair)

1

Torque to 140-160 in-lb

(16-18 N•m)

2

Torque to 270-330 in-lb

(30-37 N•m)

3

Torque to 30-35 ft-lb

(40-48 N•m)

4

Torque to 220-250 in-lb

(25-28 N•m)

Ref. Sprayer Model

6

8

25

28

All

All

All

All

Part

25T403

25T415

25T418

25T402

Description

KIT, inlet valve assembly

KIT, prime valve

KIT, pump cartridge

KIT, control, pressure

3A7936A

Qty.

1

1

1

1

5

6

Motor Shield

Removal/Installation

Disassembly

1.

Perform Pressure Relief Procedure , page 1.

2.

Disconnect power cord.

Remove Motor Shield

3.

Remove two machine screws and motor shield (8).

Install Motor Shield

1.

Install motor shield (8) using the two screws removed earlier. Make sure the motor shield slides into the switch bracket.

Be careful not to pinch cable when installing the motor shield.

Pump Removal/

Installation

Remove Pump

1.

Perform

Pressure Relief Procedure , page 1.

2.

Disconnect power cord.

3.

Remove the hopper.

4.

Remove airless hose, if attached.

5.

Re-position sprayer to access the easy access door.

Open Easy Access Door

6.

Pull tabs on sides of the easy access door towards you while pushing the entire door away from the inlet end of the pump.

7.

Now lift the easy access door so it swivels out of the way.

1

2

3 ti27463a

3A7936A

8.

Slide pump assembly off the mounting pins.

2.

Move pump displacement rod up or down until cap is level with the opening in the yoke.

Install Pump

1.

Slide pump assembly onto the mounting pins.

ti27037a

Close Easy Access Door

3.

Swing easy access door closed and push down to latch into pump.

1

2

3A7936A

3 ti27478a

NOTE: Door must be fully closed and latched before sprayer will operate.

4.

Install hopper and the hoses removed earlier.

5.

Perform Assembly Verification , page 13.

7

8

Control Board

Replacement

Refer to Wiring Diagrams

, pages 14 and 15.

Note color and location of all wires connected to the control board before you start the control board replacement.

Removal

1.

Perform Pressure Relief Procedure , page 1.

2.

Disconnect power cord.

3.

Remove Motor Shield , page 6.

4.

Disconnect pressure switch and motor connector from control board (15).

5.

Disconnect ON/OFF switch and power cord (3) connectors from control board (15) leads.

6.

Remove screw securing control board (15) to drive housing.

Installation

1.

Carefully slide new control board (15) into place on the side of the driving housing.

Secure the screw and torque. See

Parts -

SaniSpray HP 65 (Extended Repair) , page 4.

3A7936A

2.

Reconnect ON/OFF Switch and power cord (3) connectors to the control board

(15) leads.

3.

Reattach pressure switch and motor connector to control board (15).

Fuse Replacement

If fuse is blown, check for:

• Pinched or shorted wires

• A defective motor

• A locked or frozen pump

1.

Perform Pressure Relief Procedure , page 1.

2.

Disconnect power cord.

3.

Remove Motor Shield , page 6.

4.

Remove fuse (15a) from control board

(15).

5.

Install new fuse (15a) on control board

(15).

6.

Install Motor Shield , page 6.

7.

Perform Assembly Verification , page 13.

4.

Install Motor Shield , page 6.

5.

Perform Assembly Verification , page 13.

3A7936A 9

Pump Cartridge

Replacement

Disassembly

1.

Remove Hopper and Pump from sprayer.

See

Remove Pump , page 6.

2.

Insert hex end of pump into hex tool in the sprayer frame and turn counterclockwise to loosen assembly.

Assembly

1.

On the new pump cartridge, remove protective cap from the end of the piston rod.

NOTICE

Be careful not to lose the packing spring that is installed on the pump rod. Operation without the packing spring will cause early pump failure.

2.

While holding the pump body upside down, start threading the new packing assembly in by hand.

3.

Remove entire packing assembly from pump housing including the packing spring.

ti26954a

3.

Insert hex end of pump into hex tool in the sprayer frame and tighten. Recommended torque is 300 in-lb (35 N•m).

4.

Install Pump onto sprayer, see page 7.

5.

Perform Assembly Verification , page 13.

10 3A7936A

Pump Inlet Valve

Replacement

See Parts - SaniSpray HP 65 (Pump Repair) , page 5, for pump assembly diagram.

Disassembly

1.

Perform

Pressure Relief Procedure , page 1.

2.

Disconnect power cord.

3.

Remove the hopper.

4.

Remove inlet valve fitting (6) from pump housing and discard. Make certain inlet ball

(6b), spring (6c), and ball guide (6d) are removed from pump housing.

5.

Clean all dried residue from around pump inlet sealing area in pump housing.

Assembly

1.

Assemble ball guide (6d), spring (6c), and ball (6b) into pump housing (1).

a.

The ball guide (6d) is keyed for proper alignment.

b.

Make certain the bump on the ball guide (6d) is aligned with the slot in the pump housing. Slide ball guide

(6d) into pump housing.

c.

Install spring (6c) over ball stop pin in the ball guide (6d).

d.

Install ball (6b) into ball guide (6d).

2.

Make certain o-ring (6a) is installed on inlet valve housing (6).

3.

Thread new inlet valve housing into pump

housing and torque. See Parts -

SaniSpray HP 65 (Pump Repair) , page 5,

for torque.

4.

Use a pencil or similar object to push on the ball (6b) through the inlet valve intake to make sure the ball moves freely.

5.

Re-install the hopper.

6.

Perform Assembly Verification , page 13.

Prime Valve and Knob

Replacement

1.

Perform Pressure Relief Procedure , page 1.

2.

Disconnect power cord.

3.

Turn knob (8a) up to SPRAY position.

4.

Remove pin (8c) with pin punch and hammer.

5.

Remove knob (8a) and base (8b).

3A7936A 11

6.

Remove valve stem assembly (8) from pump housing. Make certain gasket (X) and seat (Z) do not stay in pump housing.

9.

Rotate valve stem with a pin punch until hole is horizontal.

Assembly

7.

Apply sealant (provided in kit) to valve threads. Install valve stem assembly in pump manifold and torque. See

Parts -

SaniSpray HP 65 (Pump Repair) , page 5,

for torque.

8.

Install base (8b) on valve, aligning pin (E) in base (8b) with hole on pump housing.

10. Install knob (8a) over base (8b).

11. Place knob in SPRAY position.

12. Insert end of pin punch through hole in knob (8a), to make sure knob and valve stem are aligned.

13. Apply small amount of grease to pin. Install pin (8c) through hole in knob (8a). Tap pin through knob with hammer. End of pin will be flush with knob when correctly installed.

12

14. Perform Assembly Verification , page 13.

3A7936A

Pressure Control

Replacement

See Parts - SaniSpray HP 65 (Pump Repair) , page 5, for pump assembly diagram.

Disassembly

1.

Remove Pump from sprayer, see page 6.

2.

Remove wire shield (28f).

• Unsnap the wire shield.

• Remove retaining screw from pump housing.

• Note wire routing, wires on new pressure control will be routed the same way.

• Save wire shield.

3.

Remove the two screws (28d) from electrical connector bracket (28e). Save the screws.

4.

Turn Pressure Control Knob fully counterclockwise to expose the wrench flats. Remove pressure control (28a) with wire and electrical connector bracket

(28e). Verify the o-ring (28c) has been removed from the pump housing.

Assembly

1.

Examine pressure control (28a) to verify the o-ring (28c) is on the pressure control.

If o-ring is not installed on pressure control, install o-ring.

2.

Apply one or two drops of thread locking adhesive (included in kit) to threads of pressure control (28a). Assemble pressure control (28a) into pump housing and

torque. See Parts - SaniSpray HP 65

(Pump Repair) , page 5, for torque.

3.

Route wire from pressure control (28a) with electrical connector bracket (28e) along pump housing to mounting location.

4.

Secure electrical connector bracket (28e) to pump housing with two screws removed earlier and torque. See

Parts - SaniSpray

HP 65 (Pump Repair) , page 5, for torque.

5.

Install wire shield (28f).

• Make certain wire is under wire shield

(28f).

• Snap the wire shield around the pump housing.

• Install retaining screw for wire shield into pump housing.

6.

Turn Pressure Control Knob clockwise as far as it will go. Apply pressure control label

(28b) to knob. To position label correctly, see note below:

NOTE: When properly positioned, the function indicator (fi) and (+) position symbol on the pressure control label (28b) are aligned.

7.

Install Pump onto sprayer, see page 7.

8.

Perform Assembly Verification , page 13.

Assembly Verification

After assembly is complete, perform the following steps to verify proper operation. If sprayer fails one of the steps, repeat sprayer repair procedures.

• Rotate Prime/Spray Valve to make sure it rotates forward to the spray position and down to the prime pump position.

• Fill cup assembly with water and verify sprayer primes and sprays. Follow setup instructions in sprayer operation manual for proper priming and spraying procedure.

3A7936A 13

Wiring Diagrams

Wiring Diagrams

100-120V

M

14 ti27233a

3A7936A

220-240V

Wiring Diagrams

M ti27485a

3A7936A 15

Graco Information

For the latest information about Graco products, visit www.graco.com

.

For patent information, see www.graco.com/patents .

TO PLACE AN ORDER, contact your Graco distributor or call distributor.

1-800-690-2894 to identify the nearest

??

??

www.graco.com/techsupport

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 3A7936

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2020, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision A, July 2020