Graco 307760E PT 2000 PRESSURE ROLLER SYSTEM Owner's Manual

INSTRUCTIONS-PARTS LIST
307-760
Rev E
SUPERSEDES C
This manual contains IMPORTANT
WARNINGS and INSTRUCTIONS
READ AND RETAINFOR REFERENCE
PT2000 Pressure Roller System
17.5 bar l2EOpsil MAXIMUM WORKING PRESSURE
GRACo INC. P.O. Box I441 MINNEAPOLIS. MN 55440-1444
@COPYRIGHT 1988, GRACO INC.
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TABLE
6F CONTENTS TERMS
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Terms
.;.
2
Warnings
..2
PTZOOO Pressure Roller System Description
3
setup.
.4
startup
.5
Operation
5
Maintenance
Flushing
6
7
Installing b Removing a Roller Cover
Cleaning the Roller Diffuser
7
Troubleshooting Chart
8
Repair
Roller Valve
9
Fuse
10
ONlOFF Switch
10
Rectifier
10
Power SupplyCord
..lo
Pressure Switch
.11
Outlet Valve
.11
Inlet Valve
.11
Diaphragm
12
Suction Tube
12
Priming Valve8 Tube
12
Motor, Connecting RodEt Bearing
13
Parts Drawing b Lists
14
Accessories
.17
Technical Data
Back Cover
Back Cover
Warranty
Be sure you read and understand eachof these terms
before reading the rest of the manual.
WARNING: Alerts user to avoid or correct conditions
which could cause bodily injury.
CAUTION: Alerts user to avoid or correct conditions
which could cause damage to or destruction of the
equipment.
NOTE: Gives additional explanationof a procedure or
helpful hints.
Be sure all operatorsof this equipment read, understand,
in this manual!
and follow the warnings and instructions
GENERAL SAFETY
Use extreme care
flushing weteror solvent into your ey&
tive eyewear.
Wear protec-
Be sure the area in which you are working is well ventilated, to avoid a buildup of harmful paintfumes.
To reduce the risk of electric shock, do not expose the
system to rain. Always store the system indoors. not
Do
operate the pump with the pump base cover removed.
. .
EQUIPMENT MISUSE HAZARD
This system is designedto be u
MAXIMUM WORKING PRESSURE. Use only componenta or accessories which are designedfor use with
the PT2Mx) System.
Any misuseof this equipment, suchas modifying parts,
using incompatible paintor solvent, or using worn or
damaged parts, can cause the equipment
to rupture and
result in serious bodily injury, fire, explosion and property damage.
ELECTRICAL GROUNDING
Uectrical groundingla 8888
electric shockor other serious bodily injuryfrom static
sparking. Read andfollow the grounding inatructiona
on
page 4 of this manual.
Never alter or modify any part of this equipment; doing
so could cause it to overpressurize ormalfunction.
EXTENSION MISUSEHAZARD
THIS IS NOT AN AIRLESS GUN EXTENSIONifor example, pole gun). Do not attempt t o modify the extension or roller frame, or
to use parts which are not designed for use with this system. Use the extension only with
the roller frame provided
with this system.
AVOID POWER LINES
Avoid contacting any
Contact with power lines couldcause extremely serious
bodily injury, including burns or electrocution.
Improper use of the extension, roller'frame,,.hose or
roller valve can result
in component ruptureor explosion
and muse serious bodily injury.
Check all parts of the system regularly and repair or
replace anyworn or dameged parts immediately.
HAZARD OF USING FLU
HALOGENATED HYDROCARBO
Never use 1.1.1-trichloroethane, methylene chloride,
other halogenated hydrocarbon solvents orfluids containing such solventsin this equipment. Such usecould
result in a serious chemical reaction,with the possibiljty
of explosion, which could cause death, seriousbodily Injury and/or substantial property damage.
Consult yourfluid suppliers to ensure that the fluids being
used are compatiblewith aluminum and zlnc parts.
pT2ooo PRESSURE
ROLLER SYSTEM DESCRIPTION
SUCTIONTUBE
PRIMINQTUBE
INLETVALVE
PAINT STRAINER
POWER SUPPLYCORD
ADD PLUQ ACCORDINQ
TO LOCALCODE
7.6 m 126 ftl HOSE
SPRINQ GUARD
46Oto~mm11ato~In.l
TELESCOPINQ EXTENSION
Motor
The motor drives the connecting rod which moves the
diaphragm.
Pressure Switch
The pessure switch at the pump outlet turns the motor
on and off to control paintpressure.
Diaphragm
The diaphragm is the heart Of the pump. Driven the
connecting rod and motor, the movement of the
diaphragm draws paint from the suction tube and
through t o the outlet valve.
Priming Valve
The priming valve assists in priming the pump during
startup. Turning the primingvalve counterclockwise
causes the paint to drain directly back into the pail
through the primingtube. Turning theknob clockwise
causes the paint to Row through the fluid outlet valve
and to the hose, roller valve and extension.
12 rnm Ill2 In.) NAP
L
Inlet Valve
As the diaphragm draws paint from the suction tube,
the paintpasses through the inletvalve which opens to
allow
paint the
into
pump.
Outlet Hose
The hose hasswivel-type couplingsfor easy assembly.
A larger diameter outlet hose and chemical-resistant
and
h o w ere available. see ACCESSOR~ESon page 17.
Roller Valve
The roller valve controls Paint
flow to the roller bv bigBering it on and off.
SUCTIONTUBE
PRIMINGTUBE
INLETVALVE
TIGHTEN SNUGLY
WITH LIGHT WRENCH
PAINTSTRAINER
POWER SUPPLYCORD
INSTAUA PLUD
ACCDRDINQTDLDCALCODE
7.8 m 126 ftl HOSE
USE TWO WR
TO TIGHTEN
SPRINQ QUARD
USE TWO WRENCH
46Oto&!Omm118to38ln.)
TELESCOPING EXTENSION
HAND TIGHTEN ONLY
PTFE
12 mm I l l 2 In.)
ROLLER
COVER
HAND TIGHTEN ONLY
TO AVOID CRACKING
ROLLER COVER
SETUP
CAUTION
To avoid premature wearof pressure q t c h , never
use more than 7.6 m ( 2 5 f t ) of 114 in. ID outlet
hose. When longeroutlet hose is needed, use 318
in. ID hose et a maximum of 30 m (100 f t ) long.
Never use 1/4 in. ID and 3/8in. ID hose together.
See ACCESSORIES, page 17, for ordering optional hoses.
1. Remove all parts from the boxes and assemble
them as shown in Fig 1, following any special notes
on the drawing.
2. Prepare the paint according to the manufacturer's
recommendations. Remove any skinthat may have
formed on the top of the paint. If necessary, thin
the paint.
3. Be sure the electrical service is properly rated for
your sprayer andthat the outlet youuse is properly
grounded. Install an appropriate plugon the power
code.
supply cord, accordingto your local electrical
Do not use an adapter. All extension cords must
have three wires. Use the chart at the right for
selecting the appropriate wire gaugefor the extension cord.
. "- "-
..~,
WARNING
Never remove the third (grounding) pin'of the
power supply cord plug.Be surethe outlet is properly grounded. In the event of an electricalshort
circuit, grounding reduces the risk of an electric
shock by providingan escape wire for the electric
current.
Inspect the power supply cord and extension cord
before each use. Be sure they are in good condition and have undamaged three-pin plugs. Replace
immediately if either cord shows signsof wear or
damage.
I. Loosen the locknut on the telescoping extension
and adjust the extension to the desired length.
Firmlv. tiahten
the locknut.
Extension Cord Chart
Cord Length
mnan
Ifeatl Crow
Extension Cord
Sactonal Araa
I
I
STARTUP
WARNING
To reduce the risk of serious bodily injury, including
injury from moving parts or electric shock, always
follow this procedure whenever you shut off the
system, when checking or servicing anypart of the
system, and whenever you stop painting.
1
1. Turn the ON/OFFswitch to OFF.
2. Unplug the power supplycord.
3. Trigger the roller valveto relieve pressure.
If you suspect that pressure is notfully relieved
after following the stepsabove, open the priming
valve 2 turns counterclockwise.
. Place the
2.
3.
4.
5.
suction tubein the pailof paint.
Plug in the sprayer;
Open the priming valve 2 turns counterclockwise.
Turn the ONIOFF switch ON.
You can see the paint being drawninto the suction
tube V i the tube is clean). As soon as you see paint
flow through the priming tube, close the priming
valve. This usually takes less than 30 seconds.
h
CAUTION
Failure to completely close the priming valve after
the system is primed will cause the valve to erode,
greatly shortening the valve life.
NOTE:
If your system is hard to prime, first try to
force feed the suction tube. Hold the suction
tube in a vertical positionend pour paintinto
it. Turn on the system.
If the system doesnot
prime within one minute, shut it off. Heavy
viscosity paint may need to be thinned. Be
sure to follow the paint manufacturer's
recommendations on thinning.
6. When the outlet hose and extensiontube are fully
primed, the motor will run when there is paint demand, but appears to shut itselfoff when thereis no
paint demand.
NOTE: An occasional start end stop of the motor
when the rollervalve is nottriggered is nonnal.
OPERATION
the system to rain. Ahnrays store the system indoors.
2. Experiment with triggering and rolling the paint until
you determine just how often you need to trigger
the roller valveto keep an evenflow of paint to the
roller.
3. To adjust the extension tube length, loosen the
locknut and extend or retract the tube.
If retracting,
some paint in the tube will be pushed out to the
roller. Roll this excess paint onto the wall, or completely retractthe tube, drainthe excess paint into a
pail, then adjust the tube length. Tighten
the
locknut securely.
4. Whenever you stop painting, turn the ONIOFF
switch to OFF and trigger the roller valve. Then
elevate the roller end of the tube to prevent paint
fro'm drainingout the roller end.
5. Flush the system thorougMy and immediately after
each use to keep it in good working order.See page 6.
~c
Always allow cold equipment to warm to room
system. Always
storeusing
the
temperature
before
to system
prevent indoors.
damaging the
CAUTION
Do not use lacquer or lacquer thinnerin the suc-
tion and outlet hoses supplied with this system.
These fluids quickly destroy the hose material. Use
the optional chemical-resistant hoses.
See ACCESSORIES, page 17, for ordering optional hoses.
1. With the system fully primed, trigger the roller valve
briefly until paint comes to the roller.
307-760
6
MAINTENANCE
CAUTION
~
Thorough flushing and proper maintenance are
essential to keep your system working properly1
Improper flushing or maintenance may prevant
the
system from working the next time you
need it,
and may resultin costly damage to the system.
ALWAYS flush your system thoroughly and immediately after eachuse.
ALWAYS fully extend the telescoping extension
when flushingto clean it thoroughly.
ALWAYS drain all water out of the roller valve and
extension end leavethe system filed with mineral
spiii to prevent corrosion.
Fluahlng (Latex Paint Only)
1. Turn the ON/OFF switch to OFF.
2. Fully extend the telescoping extension.
3. Trigger the roller valve and roll out the excess paint
from the roller onto 8 wall or newspaper. Remove
the roller cover and diffuser, and soakin a pail of
warm soapy water.
4. Place the suction tubein the pail of warm soapy water.
Hold the roller frame overthe paint pail, turn onthe
erstem and trigger the roller vaiva to drain and save
the paintin the hcses. Release the 8iggerandshut the
pump off just as soon as all paint 13 drained, to avoid
contaminating the paint with the flushing water.
5. Now hold the roller frame over the flushing pail.
Turn on the pump and trigger the roller valve. Cir-
culate the solutionfor three to five minutes(five to
ten minutes if it is cold).Pump the extensionin and
out a few times to clean it, then leave it extended.
Then open the priming valve for a few seconds to
clean the priming tube.Close the valve.
6. Raise the suction tubeabove the water endrun the
pump for a few seconds to drain the flushingsolution. Shut off the pump.
7. Wash off all external partsof the hoses, extension,
roller frame, roller valve and pump.
8. Using clean, clear watar, flush again, changing
water es often as necessary, until the system is
thoroughly cleaned.
9. Finally, flush the system with clean mineral spirits
for just a few seconds. Open the primingvalve and
turn off the pump. Soma mineralspirits must be left'
in the system to prevent corrosion. Retract the extension before storingit.
CAUTION
tension, roller valve and roller frame, your final
10. Clean the roller cover thomughlv by rinsing it inside
and out. Clean the d i i as explained on page 3.
11. Oil the needle in the roller valve and trigger
the valve
a few times to distribute the oil.See Detail A, Fig 3.
Rushing (011-based Paint Only)
NOTE:
Fig 3.
8
307-760
Follow the instructions above, except. use
mineral spirits. Do not heat the mineral
spirits.
Installingand Removing a Roller Cover (See Fig 4)
1. To install a cover, hold the diffuserand unscrewthe
retainer nut. Slide the cover over the diffuser
assembly and reimal1 the nut. Be careful not to
overtighten thenut.
2. To remove s cover, hold the cover and unscrewthe
retainer nut. Slidethe cover and diffuser assembly
off the roller frame, and press on the end
of the diffusw assembly to separate it from the m e r .
Cleaning the Roller Diffuser (See Fig 51
1. For water base paint (latex), vigorougly shake the
diffuser in a pail of hot soapy water to remove undried paint. For oil-base paint, use mineral spirits.
Use a soft brass bristle brushto remove dried paint.
2. To clear an obstruction in the frame, or for more
thorough cleaning, remove the screw. Be sure to
reinstall it after cleaning.
r
NUT
GREASE LIGHTLY WITH
PETROLEUM JELLY
3. D i m b l e if further cleaning is needed.
a. Remove the two screws. Pull off the outside
end cap. Disassemble all parts and clean
thoroughly in water or mineral spirits.
b. Installthe inside end capon the frame. Lightly
grease the O-ring with petroleum jelly. Slide the
diffusers onto the roller frame. Twist and press
the last diffuser to snap the pieces together.
c. Install the outside end cap and two
the screws.
Holding the inside end cap, press
on the screws
and rotate the diffusers to seat the screws.
Tighten the screws evenly into the inside end
and the difnap. Be sure there is no binding that
users move freely.
r
INSIDEEND CAP
WARNING
To reduce therisk of serious W i l y injury, including
injuty from moving parts or electric shock, always
follow this procedure whenever you shut off the
system, when checking or servicing any part of the
system, and whenever you atop painting.
1. Turn the ON/OFF switch to.OFF.
2. Unplug the power supply
cord.
3. Trigger the roller valveto relieve pressure.
If you suspect that pressure is not fulh relieved
efter following the steps above, open the priming
valve.two turns counterclockwise.
CAUTION
Thoroughly flush the system after each usat o
reduce down time and costly repair bills.
TROUBLESHOOTING CHART
PROBLEM
CAUSE
SOLUTION
Pump will notprime, or takes long
tlme to prime
Clogged suction tube strainer
Paint too thick
Clean.
Thin; try pouring paint into suction
tube; use 318 in. ID hoseif
necessary.
Pour paint into suction tube end try
to prime system. If it doesn't prime
in one minute, replacethe outlet
spring. See Outlet Valve, page 11.
Depress valve gently andpour in
about 1 teaspoon mineral spirits.
Try to prime pump. Replace valveif
necessary. Sea Inlet Valve, page 10.
Outlet valve springworn or damaged
Inlet valve stuck ordamagd
Loose inlet hose nut
Tiahten.
Pump will notstart
Power cord unplugged
ONlOFF switch turned off
Damaged motor
Fuse burned out
Plug in.
Turn on.
Replace. See page 13.
Replace. See page 10. If it burns
out again soon, return the system
to an authorized repair agency for
reper.
Low or no paint flow
Clogged roller cover, diffuser, roller
frame, roller valve or hose
Using more than7.6 m ( 2 5 ftl of
114 in. ID hose.
Loose inlet hose nut
Worn or damaged priming valve
Priming valve is open
Paint too thick
Damaged pressureswitch
Worn inlet andlor outlet
valve
Clean thoroughly after each use.
See Flushing on page 6.
Use up to 30 m (100 ftl of 3/8 in.
ID hose. See CAUTION, page 17.
Tighten.
Replace. Sea page 12.
Close.
Thin according to manufacturer's
recommendations.
Replace. See page 11.
Replace. See page 11.
Worn or damaged pressureswitch
Worn or damagedinlet valve
Worn or damaged priming valve
Worn roller valve packings or needle
Replace. See page 11.
Replace. sea page 11.
Replace. See page 12.
Repair. See page 9.
Pump runs after roller valve trigger
is released
3TE:
8
If you are not able to dete ne the cause of the problem, or the p
chart, return the system In authorized service agency for rep1
307-7130
Roller Valve
WARNING
Always follow the Pmasure Relief Procedure
Warning on page 8 before attemptingany repair.
NOTE:
Order repair kit no. 218-960 to repair this
roller valve.
1. Tap out the pin(A) from the trigger
(Dl and slidethe
trigger off of the valve. See Fig 6.
2. Remove the cap (Cl. Use a 1/2 in. socket wrench
to
screw thefluid housing (D) out of the valve. See Fig
6.
3. Pull the needle(K)out with needle nose pliers.
4. Tap the seat(GI out of the roller valve IN). See Fig
6.
5. Remove the ball (F)and spring (El from the valve
handle. See Fig 6.
6. Turn the nylon
screw (L),intothe packing. Insert the
needle (K)through thetop ofthe housing (D) and
push the packing outof the fluid housing. See Fig 7.
7. Clean all parts .thoroughly. Use a cotton-tipped
swab or pipe cleanerto clean small orifices..
8. Grease the needle (K)and packing (H). Insert the
tapered endof the n'eedle into the back (flat1side of
the packing; See Fig 8.
9. Guide the tapered end of the needle into the
assembly tool (MI and pressthe lipsof the packing
over the end of the tool. See Fig 8.
10. Grease the free end of the needle. Guide the tool
(M) into the fluid housing until the needle protrudes
through the top of the housing.. Lightly tap thetool
end until you "hear" the packing bottom in the
housing. Remove the tool with pliers. See Fig 8.
11. Grease the seat (GI and dace it on thefluid housino
so the seat which is formed on the
inside diamet&
faces out. See Fig 9.
12. Install the spring
(E) in the spring cavity of the valve
handle, then install the ball
(Fl so it is centered on
the spring. See Fig 6.
13. Place the O-ring (Jl around the fluid housing.
Pushing lightly \niith your fingers, start the threads
of the housing into the valve handle. Torque the
housing to 1.7-2.2 N.m (1520 in-lb). See Fig 6.
14. Push on the needle until you feelsome resistance.
15. Grease the cap (C) and place it on the end of the
needle. See Fig 6.
16. Slide the triggerIB) into place. Install thepin (AI in
the trigger. See Fig 6.
1.7-2.2N.m
I16201n-lbl
"
..
Fig 7
LIPS FACE OUT
OF HOUSING ID1
TAPERED END
Fig 8
SEAT MUST
FACE BALL
r C A u T I o1
N
Never attempt to remove the adapter fittings from
crack the
either
endbodv.
of the valve body(Nl. Doing so could
307-760
9
WARNING
should be performed only by
qualified repair personnel with an electrical background, using the propertwb. Failure to do the procedures correctly can result in electric shock,
or other
serious injury and damageto the pump.
72-
317
WARNING
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including
injury from moving parts or electric shock, always
follow this procedure whenever you shut off the
system, when checking or servicing any part of the
system, and whenever you stop painting.
1. Turn the ON/OFF switch
to OFF.
2. Unplug the power supply cord.
3. Trigger the roller valveto relieve pressure.
Ifyou suspect that pressure is not fully relieved
after following the stepsabove, open the priming
valve two turns counterclockwise.
NOTE:
.. .
. :.
,.
For all electrical repair, follow the Pressure
Relief Procedure Warning
above, and then
remove the base plate(42). screws (33)and
bumpers (43). Reinstall these parts, making
sure all wires are tucked in neatly, before
checking or operating the system.
Fuse (See Fig10)
1. Pull theold fuse out of the fuse holder( 6 5 ) and install a new fuse(67).Be sureyou installonly a 3AG.
1 amp fuse.
Rectifier (See Fig 111
1. Disconnect the four leads fromthexectifier.
2. Remove the screw (33)and rectifier (39).
3. Install a new rectifierso the positive terminal( + 1 is
closest to the fuse holder(65) and then install the
screw (33).
4. Connect the blue lead
to an unmarked terminal, and
the pressure switch lead to the other unmarkedterminal. Connectthe black motor leadto the negative
( ) terminal, and the red motor leadto the positive
( + ) terminal.
ONlOFF Switch (See Fig 10 8 11)
1. Disconnect thetwo leads from the ON/OFF switch
terminals. See Fig 11.
2. Remove the boot136) and pull the switch(34)Out Of
the base. See Fig 10.
3. Install the new switch, aligning the tab the
in base
with the slot in theswitch. See Fig 10. Then install
the boot.
4. Connect a pressure switch lead to the power-out
terminal, and a jumper wire leadto the power-in terminal of the new ON/OFF switch.
-
WARNING
To maintain groundingcontinuity in.your system,
and reduce the riskof electric shock, be sure the
green ground wire from the power supply
cord is
properly connectedto the grounding screw(831 as
instructedin Step 4. above. Also be surethe screw
(25) is tightly screwed into the base. See Fig 10
and 11..
10
307-780
.Fig 10
MOTOR LEAD
JUMPERWIRE
' J ' "
VELLOWIOREEN
E3
Fig 11
Power Supply Cord (See Fig 11)
1. Disconnect the power supply cord leads from the
terminal strip (71) by loosening the three screws on
the cordside of the strip. See Fig 11.
2. Loosen the screw in the side of the strain relief
bushing (38)and pull out the cord.
3. Strip approximately 6 mm(1/4 in.) of insulation off
each endof the new cord. Install the new cord and
connect the leadsto the terminalstrip as shown in
Fig 11, being sure that each color lead is across
from a like-colored lead.
4. Install an appropriate, three-pin plug on the other
end of the power supply cord.
Pressure Switch (See Fig 11, 12 8 13)
1. Disconnect the pressure switch leads from the
ON/OFF switch and from the redfier.
2. Remove the screws (24)and front cover (23). See
Fig 13.
3. Unscrew the retainer(14)and removethe pressure
switch 112)and'o-ring (13).
4. Grease and install a new O-ring (13)in the pump
housing (9).
5. Slide the retainer (14)over the pressure switch and
screw the retainer into the pump housing. Torque
the retainer to 6.2-7.4N m ( 5 6 6 5 in-lb).
6. Guide the pressure switch leads through the base.
Connect a lead to the power-out side of the
ON/OFF switch (34)and a lead to an unmarkedter(39).
minal on the rectifier
LUBRICATE
7. Reinstall the front cover plste.
ImRlh.CAUT'oN-l
To avoid damaging the pressure switch, do not
drop it, and do not press on the center of the
Outlet Valve (See Fig 12)
1. Remove the outlet hose (64)and unscrewthe outlet
fitting (2a)and remove the gasket (2b).
2. Tip the pump forwardto remove the ball(2d).
3. Use a 1/4.in. square socket wrench extensionto
screw out the seat @e).
4. Use a pointed tool, such ss a dentist's pick, to
remove the seal (2f).
5. Thoroughly clean all parts and dry.
6. Tip the pump back. Install a new seal (2f) making
sure it lays flat.
7. Install the seat (24and torque it to 13.516 N m
(1W140in-lbl.
8. Drop in the bal, making very sure it stays there/
CAUTION
9. Check the ball stop pin in the outlet fitting(2a)for
wear or damage, and replace the
fitting if necessary.
Place a new gasket ( 2 b ) around thefitting. The last
coil on one end of the spring(2c) is turned in.Place
this end on the ball stop pin.
Screw the fitting into
the pump housing, torquing to 32-34 N.m
C.30-300 in-lbl.
Inlet Valve (See Fig 13)
1. Unscrew the suction hose(44)from the inlet valve
(3). Screw the inlet valve outof the pump housing
(91. Remove the gasket (41;replace it if it is worn
damaged.
2. Screw the new valve into the pump housing,
torquing to 53-55 N m (470-490in-lb).
NOTE: To torque the inlet
valve, have someonefirmly hold the pump housing(9).
Fig 13
307-760 11
Diaphragm (See Fig 14)
CAUTION
Replace the diaphragm whenever you remove the
pump housing(9) or after each 100 hours of use,
whichever comes first. During use, small grooves
are formed in the diaphragm which cannot be
realigned properly. Reusing a diaphragm may
cause leaking which will result in costly damage to
the pump.
1. Remove the screws (15),and lockwashers (16).Tip
the pump housing (9) beck, being careful not to
damage the wires. Remove the screws (24)and
front cover plate (23).
2. Check the diaphragm guide(1 1) in the bottom of the
pump housing (9) for signs of wear or damage, and
replace it if necessary. When replacing the guide,
clean the pump housing thoroughly, then press the
into the housing, using only
new guide, flat side
your fingers. Be sure it is installed evenly.
3. Screw the diaphragm(17)out of the connectingrod
assembly (181.
4. Using a soft brass or nylon bristlebrush, clean the
top of the connectingrod and housing. Taking care
not to damage the diaphragm grooves, gently clean
the bonom of the pump housing(91.
5. Check the rod, motor bearing and eccentric
for any
sign of paint. If there is any paint or damage, clean
as explained
or 'replacethe connecting rod assembly
later.
6. Screw the new diaphragm(17)into the connecting
rod just untilit bottoms out. Then turn it 114 to 112
turn (2.7-3.6N.m I6-8 in-IbH.
first.
Fig 14
CAUTION
Never turn the diaphragm more than 112 turn
when torquing it, as that will prevent the
diaphragm from working properly.
7. Apply thread lubricantto the screws 115)and install
them with the lockwashers in the pump housing.
Torque the 'screws a few Newton-meter (inchpounds) a t a time, oppositely and evenly,to 9.8 N m
( 8 5 in-lbl.
8. Spin the motor shaft
(D) to be sure it turns freely.
9. Reinstall the front cover (23)and screws (241.
Priming Valve b Tube (See Fig 15)
NOTE: Each new primingvalve kit includes a priming
tube and fmings.
1. Unscrew the nut on the handle (E) of the priming
valve (loa), then unscrew the stem of the handle.
2. Screw the priming valve (loa) out of the pump
housing (9).
3. Wrap the threads of the primingvalve with PTFE
tape as shown in Fig 15, then screw it snugly into
the pump housing. The valve handle should be
parallel with the angled edgeof the housing to avoid
interference with the inlet or outlet valves.
4. Slide the nut (10d) and ferrule (1Ocl onto the tube
11Oe1, than install thetube support (lob1 in the end
of the tube. Screw thenut onto the primingvalve,
which will saat the ferrule.
5. Screw the stem of the handle (E) onto the-priming
valve until it bottoms, then back it out two turns.
Screw the nut hand tight onto the priming valve,
then tighten the stem into the valve.
12
307-780
Fig 16
Suction Tuba (See Fig 15)
1. Unscrew the nut (45) from thefluid inlet valve housing (1). Remove the hose clamp (47).Slit the suction hose to free the nipple146).
2. With the nipple (46)inserted through thenut (45).
dampen the new hose (44) with warm water and
press the hose over the nipple. Screw thenut onto
the inlet valve housing, then press the hose further
onto the nipple, leaving about a 118 in. (3 mm) gap
between thenut and hose end.
3. Install hose clamp(47)and tighten snugly.
4. Remove the filter housing (48)and strainer(491 from
the old suction hose and install them on the new
hose. Dampen the hose with warm water to ease
assembly.
Connectlng Rod andBearlng (See Fig 16)
1. Remove the screws (24) and front cover plate (23).
Remove the screws (15) and lockwashers (16) and
tip the pump housing(91 out of the way. Unscrew
the diaphragm (17) and discard.
CAUTION
Replace the diaphragm (171whenever you remove
the pump housing(9). During use, small grooves
are formed in the diaphragm which cannot be
realigned properly. Reusing a diaphragm may
cause leaking which will result in costly damage to
the pump.
2. Remove the motor screws (20) end lockwashers
(21). Lift the motor (30)slightly. Holding the connecting rod, pull the motoraway from the housing
(22).
3. Inspect the bearing (18b) in the connecting rod
(18d. If it looks worn or any rollers are broken,
replace the bearing endrod assembly (18). Inspect
if the ecthe motor eccentric, and replace the motor
centric is worn.
4. Use your fingersto pack high-quality bearing
grease
thoroughly in between the bearing rollers.
CAUTION
3
3
\2
Thorough greasing of the bearingis essential to extend the life of the bearing and the motor eccentric.
5. Using a soft brass or nylon bristle brush, clean the
top of the connecting rod
and housing. Taking care
not to damage the diaphragm grooves, gently clean
the bottom of the pump housing (9).
6. Install the connecting rod
(18) in the connectingrod
housing (22).Screw a new diaphragm (17) into the
rod justuntil it bottoms. Turn thediaphragm 114 to
1/2 turn more (2.7-3.6 N m (6-8 in-lbl). Do not turn
more than 112 turn, or the diaphragm will not function properly.
7. Align the motor with the pinsin the connectingrod
through
housing (22). guiding the motor eccentric
the connecting rod bearing (18b). Spin the motor
shaft to be sure it moves freely.
8. Loosely install thelockwashers (21) and screws(20)
to hold the motor. Spin the motor shaft
again. Now
alternately tighten the screws with a 9/64 in. hex
key wrench. Spin the motor shaft again.
CAUTION
Spinning the motor shaft while^ assembling the
pump ensures that parts are properly aligned. If
they sre not, and you start the pump, senous
damage could result to the motor, bearing, and
connecting rod. If you feel bindingor resistance,
disassemble the parts; checkingthespin often, until you determine thecause of the binding.
9. Position the pump housing (9) on the sprayer.
Lubricate the screws (15) and install them and the
lockwashers (16) loosely. Torque the screws a few
inch-pounds ( N d a t a time, oppositelyand evenly,
to 85 in-lb (9.8 N d
10. Reinstall thefront cover plate (23)and screws(24).
Motor (See Fig 16)
1. Remove the screws (24) and front cover plate (23).
2. Remove the screws (33). bumpers (43)and bottom
cover plate (42). Disconnect the motor leads from
the positive and negative rectifier terminals.
See Fig
11, page 12.
3. Remove the motor screws (20) and lockwashers
(21). Lift the motor (30) slightly. Holding the connecting rod, pull the motoraway from the housing
(22).
4. Inspect the bearing (18b) in the connecting rod
(18a). If it looks worn or any rollers are broken,
replace the bearing and rod assembly118) as instructed to the left.
5. Use yourfingers to pack high-quality bearing
grease
thoroughly in between the bearing rollers.
6. Feed the motor leads through the rubber grommet
(89).
Align the motor
with the pinsin the connecting
rod housing (221, guiding the motor eccentric
through the connecting rod bearing (18b). Spin the
motor shaft to be sure it moves freely.
7. Loosely install the lockwashers(21)and screws(20).
Spin the motor shaft again. Alternately
tighten the
8crewa with a 9/64 in. hex key wrench. Spin the
motor shaft again. See the CAUTION in step 8 of
Connecting Rod and Bearing.
8. Connect the redmotor lead to tha positive( + 1 terminal and the black motor lead
to the negative ( - 1
terminal of the rectifier(39).Refer to Fig 11.
9. Reinstall the front cover plate (23)end screws (241.
~~
PARTS DRAWING
1
PARTS DRAWING
Detail A
r3
Ref No. 66
Roller Flame
Includes items 5584%
5
5
1
SEE PARTS DETAIL ABOVE
307-760
16
PARTS LIST
PRESSURE ROLLER SYSTEM
Model
Series D
Includes items 2-85
220-240.
REF PART DESCRIPTION
NO. NO.
2
2a
2b
2c
2d
2e
2f
ZQ-952
180-451
107-521
101-956
218-968
180-455
OUTLET VALVE ASSEMBLY
Consists of items 2a-2f
.FITTING, outlet
.GASKET
.SPRING
.BALL
.HOUSING, seat, valve
.SEAL, washer
INLET VALVE
GASKET
HOUSING, pump
PRIMING VALVEKIT
GUIDE, diaphragm
SWITCH, pressure
O-RING
RETAINER
CAPSCREW, socket head;
5/16-18x 1-118 long
LOCKWASHER, spring, 5 / 1 6
DIAPHRAGM
CONNECTING RODEt BEARING
CAPSCREW, socket head;
No. 8-32 x 5/8'
LOCKWASHER, spring, 0.169"
HOUSING, conn rod; Always order
two of Ref No. 27 when replacing
housing
COVER, front
SCREW, mach. filh, No. 8-32~1.75"
CAPSCREW, hex head;
"~
~"
3
4
9
10
11
12
13
14
15
'220-930
183419
16
17
18
104608
775-619
218-981
108237
21
22
1W 7 9
181-147
23
24
25
181-166
1082%
102-313
26
100-028 LOCKWASHER, internal, shakeproof;
20
27
28
29
30
3oa
31
32
33
34
35
36
37
181-146
*218-973
181-152
218-974
108195
181-209
108-225
QN
1
1
1
1
1
1
1
1 46
1
1
1
1
1
1
1
QN
REF PART DESCRIPTION
NO. NO.
38
39
40
41
42
43
44
45
A7
48
49
52
53
54
55
55a
106-013
108"
w1m
181-167
181-574
108-220
181-231
181-159
1R1-1M
."
108-231
181-163
181-164
178342
"181-613
181-214
218-935
1
BUSHING, strain relief
1
RECTIFIER, bridge
5 in.
WIRE, jumper (not shown1
1
TERMINAL. around
1
COVER, base4
BUMPER
1
TUBE, suction
1
NUT, coupling
1
NIPPLE, hose
2
CLAMP, hose
1
HOUSING, filter
1
FILTER
2
CLAMP, hose
1
LABEL, Warning
1
LABEL, designation, lefl: hand
FRAME. roller
Includes items55a-559
1
1
.DIFFUSER, roller
1
.O-RING, raainer
1
.NUT, retainer
1
.FRAME, roller
1
.SETSCREW
1
VALVE, roller
1
COVER, roller, 112" nap
5EXTENSION, adjustable, 0.454.9 m
1
118-36") long
HOSE, fluid, nitrile rubber; 6 mm
(1/4") ID; cpld 3/8 npsmlf); 7.6 m
125') lono
1
~
~~~
~
~~~
.
~~~~~
55c
55d
55e
218-934
108186
275644
218-582
101-983
218-954
107-590
21~n
1
1
4
64
108356
114-20x 1 . 7 5
2
1 Id"
2
67 '108-419
FUSE, electrical, 3AG. 1 amp
68
108-223 SCREW, thd forming, pnh;
108-213 PiG, dowel
108230 SCREW. mach. hex washer head:
~
self tapping; 1 i 4 - 1 4 I"
181-215 LABEL, designation, front
181-575 MOTOR, electric
Includes item 3oa
F.R
AI~
596-421 .~.T_.
...M...I.N._
181-573 BASE, pump
181-182 HANDLE
108-224 SCREW, thd forming, pnh;
No. 8 x 7 W
105679 SWITCH, toggle
181-213 LABEL, designation, right hand
105659 TOGGLE. boot
181-626 CORD, power supply
ROLLER VALVE REPAIR KIT 218-960
Includes items A through F
Individual parts not sold separately.
See page 9 for instructions.
4
4
1 .
1
4
2
2
1
1
4
1
1
5
1
1
1
1
55b
60
.
.
181-218
70 100-072
71
108-421
72
104-038
69
78
82
83
84
f i 117"
~
..". -...
Nn
I-
GROMMET, rubber
NUT, hex, MSCR; No. 6-32 UNC9B
STRIP, terminal
SCREW. mach. Dnh:
No. 6 - 3 h x
102-799 TERMINAL (for ground wire)
103-181 LOCKWASHER, No. 6
103-584 SCREW, mach. bdgh; No. 6-32 UNC
0.w
2ax1/4"
158223. WASHER, special
*Recommended "tool box'spare parts.
'*Extra Warning labels available
at nocharge.
See "How To Order ReplacementPartd'on page 17.
1
1
1
1
3
1
2
1
1
1
1
3 In. ROLLER FRAME 8 DIFFUSER 220234
Same as 9 in. version but shorter. Must order cover
CAUTION
To avoid premature wearof the pressure switch,
never use morethan 7.6 m (25 f t ) of 6 mm (1/4 in.)
ID outlet hose. When longeroutlet hose is needed,
use 9 mm (318 in.) ID hose at a maximum of30 m
(100 f t ) long. Never use 6 mm (114 in.) ID and
9 mm (3/8 in.) ID hose together.
separately.
3 In. ROLLER COVER 1W-402
112 in. (12 mml nap, for semi-rough to smooth surfaces.
9 In. ROLLER COVERS
107-590 12mm (112in.) nap, forsemi-rough tosmooth
SlIrfFlCF?S
..-107-591 19 mm (314 in.) nap, for semi-rough surfaces
107-692 32 mm (1-1/4 in.) nap, .for rough surfaces
Do not use lacquer or lacquer thinnerin the suction and outlet hoses supplied with this system.
These fluids quickly destroy thehose material. Use
the optional chemical-resistant hoses.
"
CHEMICAL-RESISTANT SUCTION 8 OUTLET
HOSES
For usewith lacquer and lacquer thinners.
2E-142 Outlet Hose; Nylon; 9 mm (318')ID; cpld 3/8
npsm(fbe1; 7.6 m (25'1; 21 bar I3mpsi) MAX.
,
IMUM WORKING PRESSURE
219-095 Suction Hose; Nylon
LARGER DIAMETER OUTLET HOSE
Use this hose when using more than7.6 m ( 2 5 f t ) of
outlet hose. Not intended for use with lacquer or lacquer
thinners.
22ooo9 Outlet Hose; 9 mm (3/8') ID; cpld 3/8
npsm(fbe1; 15m EO'); 17.5barl250psilMAXIMUM WORKING PRESSURE
NIPPLE 1o&p8
Needed to couple two lengths of hose 220-009.
318 npsm(mbe1
"
ADJUSTABLE EXTENSION TUBES
218-775 0.450.9 m (1836 in.)
218-776 0.9-1.8 m (3-6f t l
218-777 1 .&3.7 m (6-12 f t )
218-778 2.4-4.8 m (8-16 f t )
SPRAY WAND pd-236
4050 psi (2W bart MAXIMUM WORKING PRESSURE
Creates,soft spray when used
with the PTXKX).
TWO ACCESSORY ADAPTER220-232
l(xM psi I 7 0 bart MAXIMUM WORKING PRESSURE
Adapts pumpoutlet of PT2ooo to use two accessory applicators simultaneously.
FLUSH ADAPTER220231
Allows youto use the city water supply to quickly flush
the PT2ooo.
ADAPTER FllTlNG 2
2
0
S
5wll Dsi 1350 bad MAXIMUM WORKING PRESSURE
Couples roller frame directlyto roller valve.
SERVICE INFORMATION
HOW TO ORDER REPLACEMENT PARTS
1. To be sure you receive the correct replacement parts, Listed below by the assembly changed are OLD, NRN,
ADDED and DELETED parts.
kit or accessories, always give all of the information
requested in the chart below.
ASSEMBLY PART
'REF PART .
..
2. Check the partslist to identify the correct part
number;
CHANGED STATUS NO. NO. NAME
do not use the ref. n a when ordering.
220-240
OLD
218978 Fitting
System
NEW
3. Order all parts from your near& Graco distributor.
2a 220-952 Fitting
to Series D OLD
220-931 Valve
'
~~
I
1I
6 digit
p.m r
.
NUMBER
""
II a n II
I
I
1
I
PARTDESCRIPTION
I
II
~~~~~
3 220-930 Valve
4 183-419 Gasket
DELETED (1) 33 108-224 Screw
NEW
ADDED
OLD
NEW
183-301 Terminal
41 181-167 Terminal
OLD
104-188 Fuse
NEW
67 108.419
Fuse
ADDED
78 102-799 Terminal
I
INTERCHANGEABILITY NOTE: NEW parts replace
OLD parts listed directly above them. ADDED parts are
not interchangeable with OLD parts.
307-760
17
TECHNICAL DATA
Maximum Operating Pressure: 17.5 bar l w ) psi)
Power Requirements: 50Hz. 220/240Vac. 1
Phase, 0.5 amp
Pump Output: 3.8 liter (1 gallon) in 5
minutes
Power Supply Cord: No. 16 AWG, 3 wire, 6'
(1.7 m) long
Weight: 6.1 Kg (13.5 Ib)
THE GRACO WARRANTY AND DISCLAIMERS
WARRANTY
Oram warrant8 ell equipment manufacturedby it end bearing its name to be free from dsfeas inmaterial and WorCmanShip on thedate of sele
bv an atdhotized Gram dmibutor to the original purchaser foruse. As purchaser's sole e
rm
& for breach of this warranty. Grawwill, for a
perbd of rwelve month from the date of sale. m i r or replace anypan of the equipment p m defectivs. This warranty applies on@ when the
equipmem ia installed, operated end maintained in acmrdanut
with Gram's witten recommendations.
Thii warnntv does not mvar, end Graw shall not be liable for, any maifunnion. damage orwear caused byfaun-+ installation. misepplicetbn,
abrasion. cormion, inadequate or impmper maintenance, negligence, eccldent.
tampring, or subsmudon of non-Gram wmponempaw. Nor
sbll Gram be liable fw malfunction, damage w w a r mused bythe inwmpatlbilii with Gram equipmentof aructum, accessories, equip
nmnt or matedab not eupplied by Gram, or the impmpr dwign. manufacture, installation, operation or maintensnce of mctum. accs*rriies,equipmant u materials not supplisd by Graw.
Thib
wanantv b mdfioned upon the prepaidm m of dw equipment claimedto be defectivs for examinationby Graw to wdfy the claimed
dele*. If the claimed defect ia veritied, Graw w i U W i r or replace free of charge any defecthaparts. The equipment will be retumed'to the
otiginal purchsser tranaponatbn prspaid.
If inspenion of the equipment dws not disclose any defect in materialor wodmanship, rapairs will be
msde at e rsssoMMe charge,which charges may include thethe cmm of paw. labar and
transporntion.
EQUIPMENT NOT COVERED BY QRACO WARRANTY
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESSFOR A PARTICULAR PURPOSE, WITH RESPECT TO ACCESSORIES, EQUIPMENT, MATERIALS, OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured byGrew (such as elec(ric mmr, mitches, hose, etc.), are s
u
mto mS warnntv, If any, of th6ir manufacturer. Graco wi!J pmvide purchaserwith maonable aglhrmnce in making any claim for breach of these warnmiss.
Factow Branchar:Atlanta. Dallas. Detroit. Los Angeles. West Caldwall lN.J.1 .
Subsldlay and Affiliate Companla8:Canada; England: Switzerland; France; Germany; Hong Kong; Japan
GRACO INC. P. 0. Box 1441 MINNEAPOLIS, MN 55440'1444
PRINTED IN U S A . Jn-760 1 4 8 Revuad 487

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