Graco 332162A - RentalPro 210 Electric Airless Sprayer Lo-Boy Repair/Parts Owner's Manual

Repair/Parts

332162A

RentalPro 210 Electric Airless Sprayer, Lo-Boy

- For portable spray applications of architectural paints and coatings -

Model 262906

3300 psi (22.7 MPa, 227 bar) Maximum Working Pressure

Important Safety Instructions

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

332161

312830

English

312831

Français

312832

Español

309250

EN

309541 ti20399a

2

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risks. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

Grounding Instructions

WARNING

GROUNDING

This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This product is equipped with a cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

• Improper installation of the grounding plug is able to result in a risk of electric shock.

• When repair or replacement of the cord or plug is required, do not connect the grounding wire to either flat blade terminal.

• The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire.

• Check with a qualified electrician or serviceman when the grounding instructions are not completely understood, or when in doubt as to whether the product is properly grounded.

• Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a qualified electrician.

• This product is for use on a nominal 120V circuit and has a grounding plug similar to the plug illustrated in the figure below.

120V US

• Only connect the product to an outlet having the same configuration as the plug.

• Do not use an adapter with this product.

Extension Cords:

• Use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle that accepts the plug on the product.

• Make sure your extension cord is not damaged. If an extension cord is necessary, use 12 AWG

(2.5 mm

2

) minimum to carry the current that the product draws.

• An undersized cord results in a drop in line voltage and loss of power and overheating.

332162A

332162A

Warnings

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:

• Do not spray flammable or combustible materials near an open flame or sources of ignition such as cigarettes, motors, and electrical equipment.

• Paint 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 paint or solvent fumes. All parts of the spray system, including the pump, hose assembly, spray gun, and objects in and around the spray area shall be properly grounded to protect against static discharge and sparks. Use Graco conductive or grounded high-pressure airless paint sprayer hoses.

• Verify that all containers and collection systems are grounded to prevent static discharge. Do not use pail liners unless they are antistatic or conductive.

• Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2 adapter.

• Do not use a paint or a solvent containing halogenated hydrocarbons.

• Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area. Keep pump assembly in a well ventilated area. Do not spray pump assembly.

• Do not smoke in the spray area.

• Do not operate light switches, engines, or similar spark producing products in the spray area.

• Keep area clean and free of paint or solvent containers, rags, and other flammable materials.

• Know the contents of the paints and solvents being sprayed. Read all Material Safety Data Sheets (MSDS) and container labels provided with the paints and solvents. Follow the paint and solvents manufacturer’s safety instructions.

• Fire extinguisher equipment shall be present and working.

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

SKIN INJECTION HAZARD

High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that injection occurs, get immediate surgical treatment.

• Do not aim the gun at, or spray any person or animal.

• Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with any part of the body.

• Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.

• Use Graco nozzle tips.

• Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while spraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing the nozzle tip to clean.

• 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.

• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.

• This system is capable of producing 3300 psi (22.7 MPa, 227 bar). Use Graco replacement parts or accessories that are rated a minimum of 3300 psi (22.7 MPa, 227 bar).

• Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.

• Verify that all connections are secure before operating the unit.

• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.

3

Warnings

4

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Always wear appropriate gloves, eye protection, and a respirator or mask when painting.

• Do not operate or spray near children. Keep children away from equipment at all times.

• Do not overreach or stand on an unstable support. Keep effective footing and balance at all times.

• Stay alert and watch what you are doing.

• Do not 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 operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not kink or over-bend the hose.

• Do not expose the hose to temperatures or to pressures in excess of those specified by Graco.

• Do not use the hose as a strength member to pull or lift the equipment.

• Do not spray with a hose shorter than 25 feet.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

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.

• Connect only to 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

• Wait five minutes after disconnecting power cord before servicing large capacitor units.

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.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

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.

TOXIC FLUID OR FUMES HAZARD

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

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective 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.

332162A

Component Identification

Component Identification

T

C

B

A

F

A Pressure Control

B ON/OFF switch

C Hour Meter

D Power Cord

E Fluid Outlet

F Prime Valve

H Pump

E

S

R

P

D

K J

J Suction Hose

K Drain Hose

M Fluid Hose

N Gun

P Tip

R Guard

S Trigger Safety Lock

T Serial Number ID Label

H

N

M

332162A 5

6

Pressure Relief Procedure

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

3.

Turn prime valve down. If you suspect spray tip or hose is clogged or pressure is not fully relieved,

VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure. Then loosen completely.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1.

Turn pressure control to lowest pressure.

ti20406a

4.

Turn power switch OFF, if unit is being shut down or will be left unattended.

ti5316a

/.

ti20417a

2.

Hold gun against side of grounded metal flushing pail. Trigger gun to relieve pressure.

/&&

332162A

Grounding

Grounding

The equipment must be grounded to reduce the risk of static sparking. Static sparking can cause fumes to ignite or explode. Grounding provides an escape wire for the electric current.

Air and fluid hoses: use only electrically conductive hoses with a maximum of 500 ft. (150 m) combined hose length to ensure grounding continuity. Check electrical resistance of hoses. If total resistance to ground exceeds 29 megohms, replace hose immediately.

Spray gun: ground through connection to a properly grounded fluid hose and pump.

Fluid supply container: follow local code.

Object being sprayed: follow local code.

The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Extension Cords

• If an extension cord is necessary, use a 3-wire, 12

AWG (2.5 mm

2

) minimum.

• Use an extension cord with an undamaged ground contact.

ground

120 volt plug

Pails

Solvent and oil/based fluids: follow local code. Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

Do not place pail on a nonconductive surface such as paper or cardboard which interrupts grounding continuity.

TIA ti5850a

Grounding a metal pail: connect a ground wire to the pail by clamping one end to pail and other end to a true earth ground such as a water pipe.

Do not modify plug! If it will not fit in outlet, have grounded outlet installed by a qualified electrician.

Do not use an adapter.

ti5851a

To maintain grounding continuity when flushing or relieving pressure: hold metal part of spray gun firmly to side of a grounded metal pail. Then trigger gun.

ti4297a

Power Requirements

100-120V units require 100-120 VAC, 60 Hz, 11A,

1 phase.

TIAB

332162A 7

8

General Repair Information

General Repair Information

Flammable materials spilled on hot, bare, motor could cause fire or explosion. To reduce risk of burns, fire or explosion, do not operate sprayer with cover removed.

To reduce risk of serious injury, including electric shock:

• Do not touch moving or electric parts with fingers or tools while testing repair.

• Unplug sprayer when power is not required for testing.

• Install all covers, gaskets, screws and washers before you operate sprayer.

• Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures.

These parts usually are not provided with replacement kits.

• Test repairs after problems are corrected.

• If sprayer does not operate properly, review repair procedure to verify you did it correctly. See Troubleshooting

, page 9.

• Overspray may build up in the air passages.

Remove any overspray and residue from air passages and openings in the enclosures whenever you service sprayer.

• Do not operate the sprayer without the motor shroud in place. Replace if damaged. Motor shroud directs cooling air around motor to prevent overheating and insulates the control board from accidental electric shock.

NOTICE

• Do not run sprayer dry for more than 30 seconds.

Doing so could damage pump packings.

• Protect the internal drive parts of this sprayer from water. Openings in the cover allow for air cooling of the mechanical parts and electronics inside. If water gets in these openings, the sprayer could malfunction or be permanently damaged.

• Prevent pump corrosion and damage from freezing.

Never leave water or water-base paint in sprayer when its not in use in cold weather. Freezing fluids can seriously damage sprayer. Store sprayer with

Pump Armor to protect sprayer during storage.

332162A

Troubleshooting

Troubleshooting

Problem

What To Check

(If check is OK, go to next check)

What To Do

(When check is not OK, refer to this column)

Motor Won’t Operate

Basic Fluid Pressure

Basic Mechanical

1.

Pressure control knob setting.

Motor will not run if set at minimum (fully counter-clockwise).

2.

Spray tip or fluid filter may be clogged.

Slowly increase pressure setting to see if motor starts.

Relieve pressure

, page 6. Then clear clog or

clean gun filter. Refer to gun instruction manual.

1.

Pump frozen or hardened paint Thaw sprayer if water or water-based paint has frozen in sprayer. Place sprayer in warm area to thaw. Do not start sprayer until thawed completely. If paint hardened (dried) in sprayer,

replace pump packings. See page 13,

Displacement Pump Replacement .

2.

Displacement pump connecting rod pin. Pin must be completely pushed into connecting rod and retaining spring must be firmly in groove or pump pin.

Push pin into place and secure with spring

retainer. See page 13,

Displacement Pump

Replacement .

3.

Motor. Remove drive housing

assembly. See page 15,

Drive

Housing Replacement . Try to rotate fan by hand.

Replace motor if fan won’t turn. See page 27,

Motor Replacement .

332162A 9

Troubleshooting

Problem

What To Check


What To Do


Basic Electrical

See Wiring Diagram , page

28.

1.

Electric supply. ON/OFF switch in OFF position. Meter must read

100-130 Vac.

Turn ON/OFF switch to ON position. Reset building circuit breaker, replace building fuses.

Try another outlet.

2.

Extension cord. Check extension cord continuity with volt meter.

Replace extension cord.

3.

Sprayer power supply cord.

Inspect for damage such as broken insulation or wires.

Replace power supply cord. See page 26,

Power Cord Replacement .

4.

Fuse. Check replaceable fuse on control board (next to ON/OFF switch).

Replace fuse after completing motor inspection.

See page 21,

Fuse Replacement .

5.

Motor leads are securely fastened and properly connected to control board.

Replace loose terminals; crimp to leads. Be sure terminals are firmly connected.

Clean circuit board terminals. Securely reconnect leads.

6.

Motor thermal switch. Yellow motor leads must have continuity through thermal switch.

Replace motor. See page 27,

Motor Replacement .

7.

Brush cap missing or loose brush lead connections.

Install brush cap or replace brushes if leads are

damaged. See page 18,

Motor Brush

Replacement .

8.

Brush length which must be greater than 1/4 in. (6mm).

NOTE: Brushes do not wear at the same rate on both sides of motor. Check both brushes.

Replace brushes. See page 18,

Motor Brush

Replacement .

9.

Motor armature commutator for burn spots, gouges and extreme roughness.

Remove motor and have motor shop resurface

commutator if possible. See page 18,

Motor

Replacement .

10. Motor armature for shorts using armature tester (growler) or per-

form spin test, page 16.


Motor Replacement .

11. Pressure control not plugged in to control board.

Insert pressure control connector into control board.

10 332162A

Problem

Low Output

Troubleshooting

What To Check


What To Do


1.

Worn spray tip.

2.

Verify pump does not continue to stroke when gun trigger is released.

Service pump. See page 13,

Displacement

Pump Replacement .

3.

Drain valve leaking.


, page 6. Replace tip. Refer

to gun instruction manual, 311861.

4.

Suction tube connections.


, page 6. Then repair drain

valve. See page 24,

Manifold Replacement .

Tighten any loose connections. Check o-ring on suction tube.

5.

Electric supply with volt meter.

Meter must read 100-130 Vac.

Low voltages reduce sprayer performance.

Reset building circuit breaker; replace building fuse. Repair electrical outlet or try another outlet.

6.

Extension cord size and length.

Replace with a correct, grounded extension

cord. See page 7 , Grounding and Electric

Requirements.

7.

Leads from motor to circuit board for damaged or loose wire connectors. Inspect wiring insulation and terminals for signs of overheating.

Be sure male terminal pins are centered and firmly connected to female terminals. Replace any loose terminals or damaged wiring.

Securely reconnect terminals.

8.

Worn motor brushes which must be greater than 1/4 in. (6 mm).

Replace brushes. See page 18.

Motor Brush

Replacement .

9.

Motor brushes binding in brush holders.

Clean brush holders. Remove carbon dust by using compressed air to blow out brush dust.

10. Low stall pressure. Turn pressure control knob fully clockwise.

Replace pressure control assembly. See page

22,

Pressure Control Assembly Replacement .

11. Motor armature for shorts by using an armature tester

(growler) or perform spin test,

page 16.


Motor

Replacement .

332162A 11

Troubleshooting

Problem

What To Check


What To Do


Motor runs and pump strokes

1.

Prime Valve Open.

2.

Paint supply.

3.

Intake strainer clogged.

4.

Suction tube leaking air.

Close prime valve.

Refill and reprime pump.

Remove and clean, then reinstall.

Tighten nut. Check o-ring on tube.

5.

Intake valve ball and piston ball are seating properly.

See Pump Manual 309250. Strain paint before using to remove particles that could clog pump.

6.

Leaking around throat packing nut which may indicate worn or damaged packings.

See Pump Manual 309250.

Motor runs but pump does not stroke

Motor is hot and runs intermittently

7.

1.

Pump rod damaged.

Displacement pump pin damaged or missing.

See Pump Manual 309250.

Replace pump pin if missing. Be sure retaining spring is fully in groove all around connecting

rod. See page 13,

Displacement Pump

Replacement .

Replace connecting rod assembly. See page

13,

Displacement Pump Replacement .

2.

Connecting rod assembly for damage.

3.

Gears or drive housing.

1.

Be sure ambient temperature where sprayer is located is not more than 115°F (46°C) and sprayer is not located in direct sun.

Inspect drive housing assembly and gears for damage and replace if necessary. See page

15,

Drive Housing Replacement .

Move sprayer to shaded, cooler area if possible.

2.

Motor has burned windings indicated by removing positive (red) brush and seeing burned adjacent commutator bars.


Motor

Replacement .

3.

Tightness of pump packing nut.

Overtightening tightens packings on rod, restricts pump action and damages packings.

Loosen packing nut. Check for leaking around throat. Replace pump packings if necessary.

See pump manual 309250.

Hour Meter hours and SVC are alternately flashing

Indicates 40 hours of motor run time

Replace pump packings. See manual 309541 for hour meter reset instructions.

12 332162A

Displacement Pump Replacement

Displacement Pump Replacement

See manual 309250 for pump repair instructions.

See manual 309541 for hour meter reset instructions.

Removal

4.

Cycle pump until pin (37) is in position to be removed.

5.

Disconnect power cord from outlet.

6.

Push up retaining spring (C). Push out pump pin (37).

C

1.


, page 6.

2.

Loosen two screws (26) and remove pump rod cover

(57).

ti20451a

37

7.

Loosen pump jam nut (41). Unscrew and remove pump (63).

26

41

63 ti20449a

57

3.

Loosen nut (62) and remove suction tube (70).

Loosen nut (B) and remove coupled hose (53).

53 ti20450a

B

70

62 ti20452a

332162A 13

Displacement Pump Replacement

Installation

1.

Extend pump piston rod fully. Apply grease to top of pump rod (D). Install jam nut (41) on pump threads.

6.

Align pump outlet (E) to back.

29

D

41 ti20453a

2.

Install pump rod (D) into connecting rod (29).

41

E ti20455a

7.

Screw jam nut (41) up onto pump until nut stops.

Tighten jam nut by hand, then tap 1/8 to 1/4 turn with a 20 oz (maximum) hammer to approximately

75 ft-lb (102 N•m).

.

8.

Install suction tube adapter (70) and coupled hose

(53). Tighten nuts (62) and (B).

If pump pin works loose, parts could break off due to force of pumping action, project through the air, and result in serious injury or property damage. To avoid, ensure the retainer spring is installed properly.

3.

Install pump pin (37). Verify retainer spring (29a) is in groove over pump pin.

29a

37

29

70

B

53

62 ti20450a

9.

Install pump rod cover (57) with screws (26).

26 ti9144a

4.

Push pump (63) up until pump threads engage.

57 ti20449a

10. Fill packing nut with Graco TSL until fluid flows onto top of seal. ti20454a

5.

Screw in pump until threads are flush with top of drive housing opening. ti6111a ti20456a

14 332162A

Drive Housing Replacement

Drive Housing Replacement

Installation

1.

Apply a liberal coat of grease to gears and needle bearing surfaces. Install thrust bearing (43) and gears (42) and (34) in motor front end bell.

Removal

1.


, page 6.

2.

Remove pump (63). Displacement Pump

Replacement

, page 13.

3.

Disconnect power cord from outlet.

34

43 35

Needle

Bearing Surfaces

34

43

48

67

26

42 ti20459a

2.

Push drive housing (35) into motor front end bell.

Insert gear crank (34) through hole in connecting rod (29).

44

34

29

4.

Remove two screws (26) and cover (67).

5.

Remove screw (48) and four screws (44).

ti20457a

6.

Pull drive housing (35) out of motor front end bell.

7.

Remove gear cluster (34) and (42) and thrust bearing (43) from drive housing.

35

44

67

26

NOTE: Do not drop gear cluster (34) and (42) when removing drive housing (35). Gear cluster may stay engaged in motor front end bell or drive housing.

ti20462a

3.

Install four screws (44) and screw (48).

4.

Install cover (67) with two screws (26).

5.

Install pump (63). Displacement Pump Replacement

, page 13.

332162A 15

Spin Test

Spin Test

See Wiring Diagram

, page 28.

To check armature, motor winding and brush electrical continuity:

1.


, page 6. Disconnect power cord

from outlet.

2.

Remove two screws (26) and front cover (67).

45

35

48

67

Armature, Brushes, and Motor Wiring Open

Circuit Test (Continuity)

1.

Connect red and black motor leads with test lead.

Turn motor fan by hand at about two revolutions per second.

2.

If uneven or no resistance, check for missing brush caps, broken brush springs, brush leads, and worn brushes. Repair as needed.

3.

If still uneven or no resistance, replace motor, page 27.

D ti20461a

26

3.

Remove screw (48) and shroud (45).

4.

Remove drive housing (35), page 15.

5.

Disconnect motor connector (D).

Armature Short Circuit Test

Quickly turn motor fan by hand. If motor coasts two or three revolutions before complete stop, there are no electrical shorts. If motor does not spin freely, armature

is shorted. Replace motor, page 27.

D ti9135a

4.

Connect motor connector (D).

5.

Install drive housing, page 15.

6.

Install shroud (45) with screw (48).

7.

Install front cover (67) with two screws (26).

16 332162A

Fan Replacement

Fan Replacement

Removal

1.



from outlet.

2.


3.


4.

Remove retaining ring (68b) on back of motor.

5.

Pull off fan (68a).

Installation

1.

Slide new fan (68a) on back of motor. Be sure fan blades face motor.

2.

Install retaining ring (68b).

3.


4.


67

26

48

45

68a

68b ti20458a

332162A 17

Motor Brush Replacement

Motor Brush Replacement


, page 28.

Removal

Replace brushes worn to less than 1/4 in. (6 mm).

Brushes wear differently on each side of motor, check both sides.

3.

Strip approximately 1/4 inch (6 mm) of insulation from end of each yellow wire (C) from motor.

4.

Insert stripped end into end of a butt splice (E) on new brush assembly.

5.

Crimp ends of butt splice (E) around each wire. Pull gently on each wire to be sure wire does not pull out of butt splice.

6.

Wrap new tie wrap around motor and wires only. Trim off excess. Be sure pressure hose is not caught in tie wrap.

7.

Connect motor connector (D) to control board (59).

D

1.



from outlet.

2.


3.


4.

Disconnect motor connector (D) from control board (59).

5.

Cut tie wrap (F).

6.

Locate two yellow wires (C). Cut each yellow wire at the center.

7.

Pry off two brush caps (A). Remove brushes (B) from motor.

8.

Discard old brush assembly.

9.

Rotate fan by hand and blow compressed air into top brush holder to remove brush dust.

NOTE: Place end of a shop vacuum hose over lower brush holder. Turn on shop vacuum when you blow compressed air into top brush holder.

A

A

59

+

Red

C

B

B

D

Bl a ck

F

D

E

Installation

NOTE: Use all new parts included in brush kit. Do not reuse old parts if new replacement parts are provided.

1.

Install new brushes (B) in motor with wires facing toward front of motor. Install positive (red) brush lead in top of motor and negative (black) brush lead in side of motor.

2.

Push each cap (A) into place over brush. Orient each cap with the two projections on either side of the brush lead. You will hear a snap when cap is securely in place.

ti9133a

8.


9.


18 332162A

Control Board Replacement

Control Board Replacement


, page 28.

6.

Pull control board out slightly and then slide control board back and off of frame.

NOTE: Make sure power cord is free and not wrapped around cord wrap.

.

7.

Remove grommet and wires from strain relief.

NOTE: Ground wire remains attached to sprayer with grounding screw.

Removal

1.



from outlet.

2.



3.

Disconnect pressure control assembly connector

(A) from control board (59).

59

Strain

Relief

D ti6122a

Grommet

8.

Remove two power cord connectors (C) from control board.

59

A ti9132b

4.

Disconnect motor connector (D) from control board (59).

5.

Remove three screws (26) securing control board to housing (two are located on the front and one on the back next to the power cord).

ti9132b

C

59 ti10180a

26

332162A 19

Control Board Replacement

Installation

1.

Push grommet and power cord wires into strain relief in control board (59).

4.

Slide control board into place on side of motor front end bell.

59

2.

59

Grommet ti6122a

Connect power cord connectors (C) to terminals indicated on control board (59).

Strain

Relief ti10185a

26

5.

Replace three screws (26). Torque to 30-35 in-lb

(3.4-3.9 N.m).

D ti9132b

C

3.

Route power cord (32) between coupled hose (53) to filter manifold and sprayer frame.

53

59

A ti9132b

6.

Connect motor connector (D) and pressure control assembly connector (A).

7.


8.


Bottom View of Sprayer ti10762a

32

20 332162A

Fuse Replacement

Fuse Replacement

If the fuse is blown, check for:

• Pinched or shorted wires

• A defective motor (see Spin Test

, page 16).

• A locked or frozen pump

Correct defective condition before replacing fuse.

Removal

1.



from outlet.

2.



3.

Remove fuse from control board.

Installation

1.

Install Fuse 119277 on control board.

2.


3.


Repl

a

ce

a

ble Fuse

ti9134b

332162A 21

Pressure Control Assembly Replacement

Pressure Control Assembly Replacement


, page 28.

5.

Pull wires through hole (K).

6.

Turn pressure control knob (36) counter clockwise as far as you can to access flats on either side of pressure control.

7.

Loosen and unscrew pressure control.

36

Removal

1.



from outlet.

2.


3.


45

35

48

67 ti20461a

26

4.

Disconnect pressure switch connector (A) from control board (59). Pull bushing (49) from hole (K).

ti10173a

NOTE: If you plan to reuse pressure control, be careful not to damage or tangle wires when unscrewing pressure control.

8.

Remove pressure control.

A

59 ti10168a

K 49

22 332162A

Pressure Control Assembly Replacement

Installation

A

59 ti10168a

K 49 B 13 o-ring

1.

Inspect pressure control before installation to verify o-ring is installed.

2.

Align pressure control wire cap (13) on fluid manifold so opening faces toward motor.

3.

Apply thread sealant to pressure control knob (B) threads.

4.

Screw pressure control threads (B) into manifold and torque to 150 in-lb (17.0 N.m).

NOTE: Be careful when tightening pressure control knob that wires are not pinched between pressure control and fluid manifold.

5.

Tuck wires into pressure control wire cap (13) and route wires toward cap opening.

6.

Insert bushing (49) in hole (K). Feed wires through housing bushing (49).

7.

Connect pressure switch connector (A) to control board (59).

8.

Install shroud (45) with screw (48). Install front cover

(67) with two screws (26).

332162A 23

Drain Valve Replacement

Drain Valve Replacement

Removal

1.



from outlet.

2.

Remove pin (51) from drain valve handle (39).

3.

Pull drain valve handle and valve base (40) from drain valve (38).

4.

Unscrew drain valve from manifold (43).

5.

Remove valve seat (38b) and seat gasket (38a) from inside of manifold or end of drain valve.

Installation

1.

Install new seat gasket (38a) and valve seat (38b) on end of drain valve.

2.

Screw drain valve (38) into manifold (43). Torque to

120 to 130 in-lb.

3.

Push valve base (40) over drain valve (38) and then valve drain handle (39) over valve base.

4.

Install pin (51) in drain valve handle. If necessary, use a hammer to tap pin in place completely.

38b

38

51

40

39

38a

43 ti10170a

24 332162A

Drain Line Replacement

Drain Line Replacement

Removal

1.

Cut drain line (58) from barbed fitting (33).

2.

Unscrew barbed fitting from manifold (43).

NOTE: To reuse existing barbed fitting (51) and drain line (58), cut and remove remaining drain line material from end of barbed fitting.

Installation

1.

Screw barbed fitting (51) into manifold (43).

2.

Push drain line (58) onto barbed fitting.

NOTE: To make drain line more pliable and easier to install over barbed fitting, heat end of drain line

(58) with a hair dryer or place end in hot water a few seconds.

ti10169a

33

58

43

332162A 25

Power Cord Replacement

Power Cord Replacement


, page 28.

Removal

1.

Remove control board, Control Board Replacement,

page 19.

2.

Remove green ground screw (52) and disconnect green ground wire (G) from frame.

Installation

1.

Connect green ground wire (G) to frame with green ground screw (52). Be sure green ground wire terminal faces up or wires could get caught in shroud.

2.

Install control board, Control Board Replacement,

page 6.

G ti9137b

52

26 332162A

Motor Replacement

Motor Replacement


, page 28.

NOTE: Do not drop gear cluster (34) and (26) when removing drive housing (35). Gear cluster may stay engaged in motor front end bell or drive housing.

Removal

1.



from outlet.

2.

Remove pump, Displacement Pump

Replacement

, page 13.

3.

Remove drive housing, Drive Housing

Replacement

, page 15.

4.

Remove control board, Control Board

Replacement

, page 19.

5.

Disconnect hour meter leads.

6.

Remove two screws (44) and manifold (43).

7.

Remove green ground screw (52) and ground wire

(G) from motor end bell.

8.

Remove four screws (44) and motor (68) from frame

(20). Remove cover (46).

Installation

1.

Install cover (46) on motor (68). Install motor on frame (20) with four screws (44).

2.

Connect green ground wire (G) to frame with green ground screw (52). Be sure green ground wire terminal faces up or wires could get caught in shroud.

(See illustration, page 25.)

3.

Install manifold (43) with two screws (44).

4.

Connect hour meter leads.

5.

Install control board, Control Board Replacement ,

page 19.

6.

Install drive housing. Drive Housing Replacement ,

page 15.

7.

Install pump. Displacement Pump Replacement ,

page 13.

46

68

1

52

G

20

43

44

44

26

59

26

1 Liberally apply grease ti20460a

332162A 27

Wiring Diagram

Wiring Diagram from Mo

t

or

2 x Yellow

Pressure

Con

t

rol

Assembly

Red (+)

Bl

a

ck (-)

Repl

a

ce

a

ble Fuse

ON/OFF

Sw

it

ch

C

a

p

a

c

it

or

Power

Plug

ti 11493a

Wh

it

e

Bl

a

ck

Green

(

+

)

(

-

)

Hour Me

t

er

28 332162A

Parts

Parts

85 45

83

4

6

5

31 55

54

68b

68a

79

49

68

8

46

82

75

77

7

42

34

43

35

2

3

53

50

47

69

62

71

65

48

44

29

57

26

41

37

63

67

26

78

70

61

64

1

73

74 ti20463a

332162A 29

Parts

Parts List

Ref.

Part Description

34

35

37

41

8

26

29

31

6

7

4

5

1

2

3

246250 FRAME, cart, lo

287488 HANDLE, assy, lo cart

109032 SCREW, mach, pnh

195766 WHEEL, semi pneumatic

15B999 CLIP, retaining

104811 CAP, hub

120091 SCREW, 1/4-20 x 2

16U457 SPACER, standoff

117501 SCREW, mach, slot hex wash HD

287053 ROD, connecting

246013 METER, hour

287054 GEAR, crankshaft

255168 HOUSING, drive

196762 PIN, straight

195150 NUT, jam, pump

46

47

48

49

42

43

44

45

249194 GEAR, reducer (first stage)

180131 BEARING, thrust

117493 SCREW, mach, hex washer HD

16U501 SHIELD, motor, machined

15J651 COVER, 210/190ES

115099 WASHER, garden hose


115756 BUSHING, universal

50

53

162453 FITTING, (1/4 npsm x 1/4 npt)

287003 HOSE, cpld

54 Y 195833 LABEL, warning, ENG/FRE/SPA

55 Y 15K359 LABEL, warning

Qty.

1

1

1

1

6

1

1

1

1

1

2

1

1

1

1

1

1

1

4

7

2

4

2

2

1

1

4

Ref.


57

60

61

62

63

64

65

67

68

15B589 COVER, pump rod

117559 O-RING

195400 CLIP, spring

15E813 NUT, jam

246428 PUMP, displacement, st

195697 STRAINER

116295 CLAMP, tube

15E630 COVER

249040 MOTOR, electric, 120V, 390

(includes 68a, 68b)

68a 249043 FAN (includes 68b)

68b 119653 RING, retaining o-ring

69

70

71

73

15B652 WASHER, suction

197607 TUBE, suction

15R237 ADAPTER, inlet

243012 GUN, spray, SG3, (unpack)

74

75

77

78

240794 HOSE, cpld, 1/4 in. x 50 ft

15B870 CUP, suction/drain

122667 SCREW, drill, hex washer head

15R247 LABEL, front, 210

82 121092 CLIP, spring

83 Y 332165 GUIDE, quick tips guide 210

85 15Y118 LABEL, Made in the USA

Y Warning labels and guide are available free of charge.

Qty.

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

2

1

1

30 332162A

Parts Drawing

Parts Drawing

59

95

52

32 ref

11

36

13

53 ti20464a

24

51

39

40

38

44

33

66

50

32

58

66

56

Parts List

Ref.

Part

11

13

24

26

32

33

36

38

39

40

44

50

Description

15A464 LABEL, control

15E794 CAP, wire, control, pressure

15E295 MANIFOLD, control, pressure 390

117501 SCREW, mach, slot hex wash HD

15J370 CORD, power

M70809 FITTING, barbed, hose

249005 CONTROL, pressure, 120V

235014 VALVE, drain

187625 HANDLE, valve, drain

224807 BASE, valve


162453 FITTING, (1/4 npsm x 1/4 npt)

Qty.

1

1

7

1

1

1

1

1

6

1

1

2

Ref.


51

52

53

111600 PIN, grooved

115498 SCREW, mach, slot hex wash hd

287003 HOSE, cpld

56

58

244035 DEFLECTOR, barbed

15R392 TUBE, drain

59

66

249052 CONTROL, board

115489 CLAMP, drain tube

95 Y 189930 LABEL, caution

Qty.

1

2

1

1

1

1

1

1

Y Warning labels are available free of charge.

332162A 31

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by

Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED

TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

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.

This manual contains English. MM 332162

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

Copyright 2008, Graco Inc. is registered to I.S. EN ISO 9001 www.graco.com

Revision A - November 2012

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