Repair and Parts

Parts

230E Airless Paint Sprayer

309860B

Model 246737

3000 psi (20.7 MPa, 207 bar) Maximum Working Pressure

Read warnings and instructions.

Related Manuals

309859 – Operation

309646 – Tool Tips

309060 – Pump Repair

TI3477A

GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441

Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001

FIRE AND EXPLOSION HAZARD

A Fire and explosion hazard exists any time you spray or flush flammable fluids.

To help prevent fire or explosion when spraying flammable fluids

Do not use plastic drop cloths when spraying or flushing flammable fluids.

Avoid all ignition sources, such as pilot lights, cigarettes, and plastic drop cloths (static arc hazard). Do not plug in or unplug power cords or turn lights on or off in spray area.

Tape wall switches to prevent them from being turned off or on.

Do not smoke in spray area.

Use only Graco airless paint hoses.

Use outdoors or in a well-ventilated area.

FLUID INJECTION HAZARD

If high-pressure fluid pierces skin, the injury might look like “just a cut” but is a serious wound. Get immediate medical attention.

To help prevent injection

Always lock gun trigger safety latch when not spraying.

Always shut off power and relieve pressure when you stop spraying and before you service or clean sprayer, remove parts, or repair leaks. See

Pressure Relief Procedure , page 5.

Do not allow children to use this equipment.

Keep clear of tip and/or roller frame. Never point at yourself or anyone else.

pressure

EQUIPMENT MISUSE HAZARD

Misuse can cause the equipment to rupture or malfunction and result in serious injury.

To help prevent injury

Do not modify or use parts not designed for this equipment.

Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in this or any other pressurized aluminum equipment.

Such use could result in a chemical reaction, with the possibility of explosion.

TOXIC FLUID HAZARD

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

To help prevent injury or death from toxic fluids

Know specific hazards of fluid you are using; store hazardous fluid in approved container; dispose of hazardous fluid according to all local, state, and national guidelines.

Always wear protective eyewear, gloves, clothing, and respirator as recommended by fluid and solvent manufacturer.

PINCH HAZARD

Do not touch moving parts with fingers or tools while testing or repairing. Shut off and unplug sprayer when inspection is complete. Install all covers, gaskets, screws and washers before operating sprayer.

FLUID SPLASHBACK HAZARD

To avoid splashing fluid when spraying into pail, always aim at inside wall of pail.

Make sure gun is assembled with correct gasket for fluid being sprayed.

PRESSURIZED EQUIPMENT HAZARD

This sprayer is capable of producing up to 3000 psi (20.7 MPa, 207 bar) maximum working pressure. To avoid component rupture and injury, do not operate sprayer with components rated less than pressure of sprayer.

Sprayer is equipped with a pressure drain that automatically relieves overpressure in the event of a fault condition. This automatic pressure relief may cause splashing of fluid. Correct fault before you resume spraying.

NOTE: Inadequate flushing and/or dried paint in drain system may prevent proper overpressure relief.

SHOCK HAZARD

Failure to observe the following electrical hazards could result in serious injury, including burns or electrocution.

To help prevent harmful electric shock

Use only grounded electrical outlets.

Only use 3-wire extension cords.

Make sure ground prongs are intact on sprayer and extension cords.

Keep electrical connections and inside of shroud dry.

Avoid contact with power lines.

Only use Graco airless paint hoses.

Unplug sprayer before servicing.

ALCOHOL AND DRUG HAZARD

Do not operate equipment under the influence of alcohol or while taking medication that impairs your senses or reactions.

2 309860

Component Identification and Function

A

J

H T

B

R P S

K

F

E

D

U

V

TI3508A

N

M G

A Motor

B Drive Assembly

D Displacement Pump

E Fluid Outlet

DC motor, permanent magnet, fan cooled

Transfers power from DC motor to displacement pump

Transfers fluid to be sprayed from source through spray gun

Spray gun is connected here

F Prime Valve Used to prime and drain sprayer (also relieves fluid outlet pressure) when open

G Fluid Filter Final filter of fluid to spray gun

H Pressure Adjusting Knob Controls fluid outlet pressure

J Pressure Control Controls motor speed to maintain fluid outlet pressure at displacement pump outlet. Works with pressure adjusting knob.

Power switch that controls main power to sprayer K ON/OFF Switch

M 50 ft (15 m) Main Hose

N SG3 Spray Gun

P

R

S

413 Tip

Reversible Tip Guard

Gun Safety Lock

T Hour Meter

1/4 in. ID, grounded, nylon hose with spring guards on both ends

High pressure spray gun with gun safety latch

Uses high pressure fluid to clear tip clogs without removing tip from spray gun

Tip guard reduces risk of injection injury

Gun safety latch prevents accidental triggering of spray gun

U

V

Suction Hose

Drain Tube

Every 40 hours flashes, indicating it is time to change pump throat packings, and inspect filter and ball checks.

Transfers fluid to be sprayed from source to pump

Fluid outlet used to drain and prime the sprayer

309860 3

Maintenance

Daily:

1.

Inspect, clean and replace as needed

Manifold filter, gun filter and inlet stainer.

Wet cup for leakage, tighten if needed.

Hour meter. Will flash after every 40 hours of operation. When flashing, change throat packings, check filter, inspect ball checks.

Gun trigger safety.

Tip wear, replace if necessary.

Electric cord and plug.

2.

Fill throat packing nut with Graco TSL to prevent premature packing wear.

Do this each time you spray.

Weekly:

Check tightness of wet cup.

Inspect all high pressure paint hoses.

Annually:

Schedule maintenance check at an authorized Graco repair center.

Approximate Fill Level

4 309860

General Repair Information

Pressure Relief Procedure

WARNING

1.

Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts are not normally provided with replacement assemblies.

Page 2

WARNING

Page 2

1. Lock gun safety latch.

2. Turn ON/OFF switch to OFF.

3. Unplug power supply cord.

4.

Unlock gun safety latch. Hold metal part of gun firmly to grounded metal pail. Trigger gun to relieve pressure.

5. Lock gun safety latch.

6. Open pressure drain valve. Leave pressure drain valve open until ready to spray again.

If suspected that spray tip or hose is completely clogged, or that pressure has not been fully relieved after following steps above , VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or hose obstruction.

2.

Test repair after problem is corrected.

3.

If sprayer does not operate properly , review repair procedure to verify procedure was done correctly. If necessary, see Troubleshooting Guide, pages 6 – 10, for other possible solutions.

WARNING

Page 2

CAUTION

To reduce risk of pressure control malfunction:

Use needle nose pliers to disconnect wire. Never pull on wire, pull on connector.

Mate wire connectors properly. Center flat blade of insulated male connector in female connector.

Route wires carefully to avoid interference with other connections of pressure control. Do not pinch wires between cover and control box.

CAUTION

Do not run sprayer dry for more than 30 seconds to avoid damaging pump packings.

4.

Install motor shroud before operation of sprayer and replace if damaged. Motor shroud prevents overheating, and protects operator from possible electrical shock by touching terminals of capacitor.

It can also reduce risk of burns, fire or explosion; see preceding WARNING .

309860 5

Grounding

Page 2

WARNING grounded outlets

1.

100–120 Vac models require a 50/60 Hz, 15A circuit with a grounding receptacle. See Fig. 1.

2.

Do not alter ground prong or use adapter.

Fig. 1 grounding prong

3.

120 Vac: A 12 AWG, 3 wires with grounding prong,

300 ft (90 m) extension cord may be used. Long lengths reduce sprayer performance.

Troubleshooting

WARNING

Page 2

MOTOR WON’T OPERATE

TYPE OF PROBLEM

Basic Fluid Pressure

Problems

WHAT TO CHECK

If check is OK, go to next check

WHAT TO DO

When check is not OK refer to this column

1. Pressure control knob setting. Motor will not run if at minimum setting (fully counterclockwise).

1. Slowly increase pressure setting to see if motor starts.

2. Spray tip or fluid filter may be clogged.

2. Relieve pressure and clear clog or clean filter; refer to separate gun or tip instruction manual.

Basic Mechanical

Problems

1. Pressure control knob setting.

1. Motor stops running when pressure setting is reached.

2. Pump (13) for frozen or hardened paint.

2. 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. ( Displacement Pump Replacement, page 20.)

2. Displacement pump connecting rod pin (9a).

Pin must be completely pushed into connecting rod (9) and retaining spring (9b) must be firmly in groove of pump pin. See Fig. 8.

2. Push pin into place and secure with spring retainer.

6

3. Motor (1). Remove drive housing assembly

(10). See page 18. Try to rotate fan by hand.

3. Replace motor (1) if fan won’t turn. See page

19.

Basic Electrical Problems 1. Motor control board. Board shuts down and displays error code.

1. Motor Control Board Diagnostics, page 15.

2. Electrical supply. Meter must read 85–130 Vac for 100–120 Vac models.

2. Reset building circuit breaker; replace building fuse. Try another outlet.

3. Extension cord. Check extension cord continuity with volt meter.

3. Replace extension cord.

4. Sprayer power supply cord (29). Inspect for damage such as broken insulation or wires.

4. Replace power supply cord.

309860

Troubleshooting

MOTOR WON’T OPERATE (Continued)

TYPE OF PROBLEM

Basic Electrical Problems

(continued)

WHAT TO CHECK

If check is OK, go to next check

WHAT TO DO

When check is not OK refer to this column

5.

That motor leads are securely fastened and properly mated.

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

Clean circuit board terminals. Securely reconnect leads.

6. For loose motor brush lead connections and terminals. See page 11.

6. Tighten terminal screws. Replace brushes if leads are damaged. See page 11.

7. Brush length which must be 1/2 in. minimum.

See page 11.

7. Replace brushes. See page 11.

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

8. For broken or misaligned motor brush springs.

Rolled portion of spring must rest squarely on top of brush. See page 11.

8. Replace spring if broken. Realign spring with brush. See page 11.

9. Motor brushes may be binding in brush holders.

See page 11.

9. Clean brush holders. Remove carbon with small cleaning brush. Align brush leads with slot in brush holder to assure free vertical brush movement.

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

See page 11.

10.Remove motor and have motor shop resurface commutator if possible, page 19.

11. Motor armature for shorts using armature tester

(growler) or perform spin test. See page 11.

11. Replace motor, page 19.

Refer to wiring diagram on page 26, to identify test points (TP).

1. Power supply cord (29). Connect volt meter between TP1 (neutral) and TP2 (L2, 120 Vac).

Plug in sprayer. Meter must read 85–130 Vac for

100–120 Vac models.

Unplug sprayer2

1. Replace power supply cord.

2. ON/OFF switch (23). Connect volt meter between L1 or L and L2 or N terminal on ON/OFF switch. Plug in sprayer and turn ON.

Meter must read 85–130 Vac for 100–120 Vac models.

2. Replace ON/OFF switch, page14.

3. Motor thermal cutoff switch. Turn sprayer OFF.

Check for continuity between TO1 and TO2 with ohmmeter.

3. If thermal switch is open (no continuity), allow motor to cool. If switch remains open after motor cools, replace motor. If thermal switch closes after motor cools, correct cause of overheating.

4. All terminals for damage or loose fit.

4. Replace damaged terminals and reconnect securely.

309860 7

Troubleshooting

LOW OR FLUCTUATING OUTPUT

TYPE OF PROBLEM

Low Output

WHAT TO CHECK

If check is OK, go to next check

1. For worn spray tip.

WHAT TO DO

When check is not OK refer to this column

1. Follow Pressure Relief Procedure, then replace tip. See your separate gun or tip manual.

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

2. Service pump, page 20.

3. Filter clogged (If optional filter is installed).

3. Relieve pressure. Check and clean filter.

4. Prime valve leaking.

5. Suction hose connections.

4. Relieve pressure. Repair prime valve.

5. Tighten any loose connections.

6. Electrical supply with volt meter.

Meter must read 85–130 Vac for 100–120 Vac models. Low voltages reduce sprayer performance.

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

7. Extension cord size and length; must be at least

12 gauge wire and no longer than 300 ft. Longer cord lengths reduce sprayer performance.

7. Replace with a correct, grounded extension cord.

8. Leads from motor to pressure control circuit board (35) for damaged or loose wires or connectors. Inspect wiring insulation and terminals for signs of overheating.

8. Be sure male terminal blades are centered and firmly connected to female terminals.

Replace any loose terminal or damaged wiring. Securely reconnect terminals.

9. For loose motor brush leads and terminals, page 11.

9. Tighten terminal screws. Replace brushes if leads are damaged, page 11.

10.For worn motor brushes which must be 1/2 in.

minimum, page 11.

10. Replace brushes, page 11.

11. For broken and misaligned motor brush springs. Rolled portion of spring must rest squarely on top of brush.

11. Replace spring if broken. Realign spring with brush, page 11.

12.Motor brushes for binding in brush holders, page 11.

12.Clean brush holders, remove carbon dust with small cleaning brush. Align brush lead with slot in brush holder to assure free vertical brush movement.

13.Low stall pressure.

13. Do either or both: a.

Turn pressure control knob fully clockwise. Make sure pressure control knob is properly installed to allow full clockwise position.

b.

Try a new transducer.

14.Motor armature for shorts by using an armature tester (growler) or perform spin test, page 11.

14.Replace motor, page 19.

8 309860

Troubleshooting

LOW OR FLUCTUATING OUTPUT

TYPE OF PROBLEM WHAT TO CHECK

If check is OK, go to next check

Motor runs and pump strokes 1. Paint supply.

2. Intake strainer clogged.

WHAT TO DO

When check is not OK refer to this column

1. Refill and reprime pump.

2. Remove and clean, then reinstall.

3. Suction tube or fittings loose.

3. Tighten; use thread sealant or sealing tape on threads if necessary.

4. To see if intake valve ball and piston ball are seating properly, page 20.

4. Remove intake valve and clean. Check balls and seats for nicks; replace if necessary, page 20. Strain paint before using to remove particles that could clog pump.

5. Leaking around throat packing nut which may indicate worn or damaged packings, page 20.

5. Replace packings, page 20. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten packing nut/wet-cup.

6. Pump rod damage.

6. Repair pump, page 20.

7.Capacitor failure. Visually inspect capacitor near terminals. Ensure that orange safety relief plug is intact.

7. Replace capacitor.

Motor runs but pump does not stroke

1. Displacement pump pin (9a) (damaged or missing), page 20.

1. Replace pump pin if missing. Be sure retainer spring (9b) is fully in groove all around connecting rod, page 20.

2. Connecting rod assembly (9) for damage, page 18.

2. Replace connecting rod assembly, page 18.

3. Gears or drive housing, page 18.

3. Inspect drive housing assembly and gears for damage and replace if necessary, page 18.

309860 9

Troubleshooting

MOTOR IS HOT AND RUNS INTERMITTENTLY

TYPE OF 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 is hot and runs intermittently.

1. Determine if sprayer was operated at high pressure with small tips, which causes low motor RPM and excessive heat build up.

1. Decrease pressure setting or increase tip size.

2. Be sure ambient temperature where sprayer is located is no more than 90 F and sprayer is not located in direct sun.

2. Move sprayer to shaded, cooler area if possible.

ELECTRICAL SHORT

TYPE OF PROBLEM WHAT TO CHECK

If check is OK, go to next check

WHAT TO DO

When check is not OK refer to this column

Building circuit breaker opens as soon as sprayer switch is turned on.

1. All electrical wiring for damaged insulation, and all terminals for loose fit or damage. Also wires between pressure control and motor. See page

19.

1. Repair or replace any damaged wiring or terminals. Securely reconnect all wires.

CAUTION

Any short in any part of the motor power circuit will cause the control circuit to inhibit sprayer operation. Correctly diagnose and repair all shorts before checking and replacing control board.

2. For missing inspection plate gasket (see page

19), bent terminal forks or other metal to metal contact points which could cause a short.

2. Correct faulty conditions.

3. Motor armature for shorts. Use an armature tester (growler) or perform spin test, page 11. Inspect windings for burns.

3. Replace motor, page 19.

4. Motor control board (35) by performing motor control board diagnostics, page 15. If diagnostics indicate, substitute with a good board.

4. Replace with a new pressure control board

(35), page 15.

Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on.

CAUTION: Do not perform this check until motor armature is determined to be good. A bad motor armature can burn out a good board.

1. Basic Electrical Problems, page 6.

1. Perform necessary procedures.

2. ON/OFF switch (23), page 14. Be sure sprayer is unplugged!

Disconnect wires from switch.

Check switch with ohmmeter. Reading must be infinity with ON/OFF switch OFF, and zero with switch ON.

2. Replace ON/OFF switch, page 14

3. For damaged or pinched wires in pressure control, page 15.

3. Replace damaged parts, page 15.

Sprayer quits after sprayer operates for 5 to 10 minutes.

1. Basic Electrical Problems, page 6.

1. Perform necessary procedures.

2. Electrical supply with volt meter.

Meter must read 85–130 Vac for 100–120 Vac models.

2. If voltage is too high, do not operate sprayer until corrected.

3. Tightness of pump packing nut. Over tightening tightens packings on rod, restricts pump action, and damages packings.

3. Loosen packing nut. Check for leaking around throat. Replace pump packings, if necessary, page 20.

.

10 309860

Setup

WARNING

Page 2

Spin Test

Armature, Brushes, and Motor Wiring Open

Circuit Test (Continuity)

1.

Connect red and black motor leads together with test lead. Turn motor fan by hand at about two revolutions per second.

To check armature, motor winding and brush electrical continuity:

2.

If uneven or no resistance, check for: broken brush springs, brush leads, motor leads; loose brush terminal screws, motor lead terminals; worn brushes. Repair as needed.

WARNING 3.

If still uneven or no resistance, replace motor, page 19.

Page 2

1.

Remove drive housing, page 18.

2.

Fig. 2. Remove pressure control cover (39). Disconnect motor leads (F) and (G).

3.

Fig. 3. Remove motor shroud (74).

Armature Short Circuit Test

Quickly turn motor fan by hand. If no electrical shorts, motor coasts two or three revolutions before complete stop. If motor does not spin freely, armature is shorted. Replace motor, page 19.

39

Fig. 2

F

G

9578A

Motor Brush Removal

Motor Brush Replacement

Replace brushes worn to less than 1/2 in. Check both sides. Brush Repair Kit 245545.

3.

Fig. 4. Remove screw (C) and discard brush (B) for motor with capacitor attached. Remove brush lead from control box for motor without capacitor attached.

(Continued on page 12)

1.

Read General Repair Information, page 5.

74

WARNING

Page 2

1.

Fig. 3. Remove four screws (22) and motor shroud (74).

2.

Pry off two brush caps (A). Tag locations of red (+) and black (–) motor leads.

Fig. 3

22 A

309860

TI0053

11

Motor Brush Replacement

4.

Fig. 4. Insert brush (B). Push clip (A) until it snaps into place and secures brush.

6.

Inspect commutator for excessive pitting, burning or gouging. A black color on commutator is normal.

Have commutator resurfaced by a motor repair shop if brushes wear too fast.

CAUTION

When installing brushes, follow all steps carefully to avoid damaging parts.

7.

Test brushes.

5.

Fig. 4. Install red (+) and black (–) motor leads according to tags. Install brush lead end with screw (C) to motor-mounted capacitor or route lead into control box and connect to board.

A a.

Remove pump (13); Displacement Pump

Replacement, page 20.

b.

With sprayer OFF, turn pressure control knob fully counterclockwise to minimum pressure.

Plug in sprayer.

C c.

Turn sprayer ON. Slowly increase pressure until motor is at full speed.

8.

Break in brushes.

B a.

Operate sprayer 1 hour with no load.

b.

Install pump (13), Displacement Pump Replacement, page 20.

Fig. 4

TI0053

12 309860

Hour Meter Replacement

1.

Unplug sprayer.

The sprayer is equipped with a SenDEC Hour Meter.

Every 40 hours it will flash, signaling the need to change throat packings, check filter and inspect ball checks.

2.

Unplug wire leads from hour meter (133).

To replace the meter:

Assembly

Disassembly

1.

Plug new hour meter (133) in to wire leads.

WARNING

2.

Attach 2–sided tape (134) to top of meter.

Page 2

3.

Reposition meter under sprayer. Push it firmly into place making sure the 2–sided tape is adhering tightly.

134

133

Fig. 5 ti3555a

309860 13

Removal

On/Off Switch Replacement

WARNING

Installation

1.

Install new ON/OFF switch (23). Install locking ring

(24) and toggle boot (25).

2.

Connect two wires (A) to ON/OFF switch.

Page 2

3.

Install pressure control cover (39) with four screws (18).

1.

Fig. 6. Remove four screws (18) and pressure control cover (39).

2.

Disconnect two wires (A) from ON/OFF switch (23).

3.

Remove toggle boot (25) and locking ring (24).

Remove ON/OFF switch (23).

29

25

24

32

Ref 1

27

33

26

23

134

21

30

133

131

36

34

35

37

39

18

130

132 Ref 45

22

28

52

51

Fig. 6

TI3523a

14 309860

Pressure Control Repair

Motor Control Board Diagnostics

Note: Keep a new transducer on hand to use for test.

WARNING

CAUTION

Do not allow sprayer to develop fluid pressure without transducer installed. Leave drain valve open if test transducer is used.

1.

Remove four screws (18) and cover (39).

2.

Turn ON/OFF switch ON.

3.

Observe LED operation and reference following table:

Page 2

LED

BLINKS

Once

Once and stays ON

Two times repeatedly

Three times repeatedly

Four times repeatedly

Five times repeatedly

Six times repeatedly

SPRAYER OPERATION INDICATES WHAT TO DO

Sprayer runs

Sprayer shuts down and LED continues to blink two times repeatedly

Sprayer shuts down and LED continues to blink three times repeatedly

Normal operation

Sprayer shuts down and LED stays ON Motor open circuit or bad control board

Run away pressure. Pressure greater than 4500 psi

(310 bar, 31 MPa).

Pressure transducer is faulty or missing

Replace motor control board.

See following Motor Control

Board procedure.

Check transducer connection.

Open drain valve. Substitute new transducer for transducer in sprayer. If sprayer runs, replace transducer.

Line voltage is too high

Do nothing

Check motor brushes and armature. If OK, replace motor control board.

Sprayer shuts down and LED continues to blink four times repeatedly

Sprayer shuts down and LED continues to blink five times repeatedly

Sprayer shuts down and LED continues to blink six times repeatedly

Too much current

Motor thermal switch open circuit

Check for voltage supply problems

Check for locked rotor, shorted wiring or motor. Repair or replace failed parts.

Check for binding in pump or drive. Check for bad motor.

309860 15

Removal

Refer to Fig. 6.

Pressure Control Repair

Motor Control Board

Installation

4.

Fig. 6. Install motor control board (35) with five screws (36).

WARNING

5.

Connect to motor control board (35):

Page 2

Lead (E) to transducer.

1.

Remove four screws (18) and cover (39).

2.

Disconnect at motor control board (35):

Four motor leads: two yellow, black (–) and red (+).

Two line voltage leads.

Lead (D) from potentiometer.

Lead (E) from transducer.

3.

Remove five screws (36) and circuit board (35).

Lead (D) to potentiometer.

Two line voltage leads.

Four motor leads: two yellow, black (–) and red (+).

6.

Install cover (39) with four screws (18).

16 309860

Pressure Control Repair

Pressure Control Transducer

Removal

Refer to Fig. 6.

WARNING

Pressure Adjust Potentiometer

Removal

Refer to Fig. 6.

WARNING

Page 2

Page 2

1.

Remove four screws (18) and cover (39).

2.

Disconnect lead (E) from motor control board (35).

3.

Remove two screws (22) and filter housing (45).

4.

Thread transducer lead plastic connector down through transducer grommet (28).

5.

Remove pressure control transducer (52) and packing o-ring (51) from filter housing.

Installation

1.

Install packing o-ring (51) and pressure control transducer (52) in filter housing (45). Torque to

30–35 ft-lb.

2.

Thread transducer lead plastic connector up through transducer grommet (28).

3.

Install filter housing (45) with two screws (22).

4.

Connect lead (E) to motor control board (35).

5.

Install cover (39) with four screws (18).

1.

Remove four screws (18) and cover (39).

2.

Disconnect all leads from motor control board (35).

3.

Remove five screws (36) and board (35).

4.

Remove potentiometer knob (27), sealing shaft nut

(33) and pressure adjust potentiometer (26).

Installation

1.

Install pressure adjust potentiometer (26), sealing shaft nut (33) and potentiometer knob (27).

a.

b.

Turn potentiometer fully clockwise.

Install knob at full clockwise position.

2.

Install board (35) with five screws (36).

3.

Connect all leads to motor control board (35).

4.

Install cover (39) with four screws (18).

309860 17

Drive Housing Replacement

CAUTION

Do not drop gear cluster (7) when removing drive housing (10). Gear cluster may stay engaged in motor front end bell or drive housing.

Disassembly

WARNING

Page 2

1.

Remove pump (13), Displacement Pump Replacement, page 20.

2.

Fig. 7. Remove two screws (22).Tip sprayer up.

Remove two screws (22) and remove shroud (74).

3.

Remove two front screws (22).

4.

Remove two back screws (22).

5.

Pull drive housing (10) off of motor (1).

Assembly

1.

Push drive housing (10) onto motor (1)

2.

Install two front screws (22).

3.

Install two back screws (22).

4.

Fig. 7. Install shroud (74) with two screw (22).Tip

sprayer up. Install two screws (22).

5.

Install pump (13) Displacement Pump

Replacement, page 17.

6.

Install new access cover (10a) with two screws

(10b).

74

1

22

7

A

10

10a

10b

22

22

74c

TI3521A Fig. 7

18 309860

Disassembly

Motor Replacement

5.

Remove strain relief (37) and motor fan (2), page

23.

WARNING

6.

Remove three screws (22) behind board and remove control housing (21), Fig. 6, page 14.

Page 2

1.

Remove pump (13), Displacement Pump

Replacement, page 20.

CAUTION

Do not drop gear cluster (7) when removing drive housing (10). Gear cluster may stay engaged in motor front end bell or drive housing.

2.

Remove drive housing (10), Drive Housing Replacement, page 18.

3.

Remove four screws (18) and cover (39), Fig. 6, page 14.

4.

Disconnect all leads from board (35). Remove five screws (36) and board.

7.

Remove four screws (22) and motor (1) from frame (63).

Assembly

1.

Install new motor (1) on frame (63) with four screws (22).

2.

Install control housing (21) with three screws (22).

3.

Install strain relief (37) and motor fan (2), page 23.

4.

Install board (35) with five screws (36), Fig. 6, page 14. Connect all leads to board (35).

5.

Install drive housing (10), Drive Housing Replacement, page 18.

6.

Install pump (13), Displacement Pump Replacement, page 20.

309860 19

Displacement Pump Replacement

1.

Flush pump (13).

WARNING

Removal

3.

Cycle pump until pump pin (9a) is in position to be removed. Remove pump pin (9a).

4.

Fig. 9. Remove suction tube (78) and hose (19).

5.

Loosen pump jam nut (12). Unscrew pump.

Page 2

2.

Fig. 8. Loosen two screws (10b) and rotate cover (10a).

10b

19

12

78 10a

9a

9573A

Fig. 9

TI1647A

T

Fig. 8

CAUTION

If the pump locknut loosens during operation, the threads of the drive housing will be damaged.

Installation

6.

Fig. 11. Screw jam nut (12) 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 +/–5 ft–lb (102 N m).

1.

Fig. 10. Extend pump piston rod fully. Apply grease to top of pump rod at (A) or inside connecting rod.

A

Fig. 11 TI0063

7.

Fig. 12. Fill packing nut with Graco TSL until fluid flows onto top of seal.

10b

10a

TI0062

Fig. 10

2.

Fig. 8. Install pump pin (9a). Verify retainer spring

(9b) is in groove of pump pin.

3.

Push pump up until pump threads engage.

4.

Screw in pump until threads are flush with drive housing opening. Align pump outlet to back.

5.

Fig. 9. Install suction tube (78) and hose (19).

Fig. 12 TI0061

8.

Fig. 8. rotate cover (10a); tighten screws (10b).

20 309860

Notes

309860 21

Parts List - Sprayer

3

7

9

1

2

242012*

115525

243219

243218

243221

9a 195175

9b 195512

10 243220

10a 195099

10b 115492

12 195150

13 243187

14 195497

19 241926

22 115495

31 195847

38 15C934

45 195157

47 104361

48 243080†

49 195139

53 111699

55 187615

56 235014

57 224807

58 111600

59 187625

62 162453

63 241867

67 108691

69 239998

70 110243

71 192027

72 111590

REF

NO.

PART NO.

DESCRIPTION

MOTOR, 120 vac

BLADE, fan motor

GEAR, combination

CRANK SHAFT

CONNECTING ROD includes 9a and 9b

PIN, pump

RETAINER, pin

DRIVE HOUSING includes 10a and 10b

COVER

SCREW

NUT, jam, pump

PUMP

HOOK, pail

HOSE, coupled, high pressure

SCREW, slot hd, hex, washer hd

ELBOW, 90 street

FITTING, adapter

HOUSING, filter

O-RING

FILTER, fluid, 60 mesh

CAP, filter

GASKET, seat, valve

VALVE, seat

ASSY, drain valve includes 53 and 55

ASSY, cam, drain valve

PIN, grooved

HANDLE, valve, drain

NIPPLE, 1/4 npt(m) x 1/4 npsm

FRAME, cart

PLUG, tubing

HANDLE, cart

RING, retaining

SLEEVE, cart

BUTTON, snap

QTY

1

1

1

1

1

1

1

1

1

1

1

1

1

13

2

1

1

1

1

1

1

1

1

6

1

2

2

2

1

2

1

1

1

2

REF

NO.

PART NO.

DESCRIPTION QTY

73

74

82 187190

83 109032

85 241920

86 276888

88 106062

89 101242

90 104811

92 206994

105 111483

106 103473

112 243105

112a

112b

183350

287159

74a 195159

74b 114531

74c 115843

78 198973

79 244240

114 196773

123 15C393

124 195711

125 15C392

126 195833

127 195805

128 115491

129 115979

WASHER

KIT, shroud, motor includes 74a, 74b, 74c, 126 and 127

BRACKET, shroud

SCREW, slot hd, hex, washer hd

SCREW, mach, pnhd, self-drill

TUBE, suction, intake

KIT, hose, drain, includes 85, and 86

STRAINER

SCREW, pan hd

DEFLECTOR, threaded

CLIP, spring

WHEEL, semi-pneumatic

RING, retaining, external

CAP, hub

FLUID, TSL, 8 oz

CLAMP, cable

STRAP, tie, wire

KIT, accessory, gun/hose

(includes 112a and 112b)

GUN, spray, SG3

HOSE, coupled, 1/4” x 50”

(hi–performance)

FILTER INSERT

LABEL

LABEL

LABEL, Identification

LABEL, WARNING

LABEL, DANGER

WIPER, rod

PLUG

Extra Danger and Warning tags and labels available free.

* Motor Brush Kit 236967 is available

† Other filters available: 243081, 100 mesh; 243226, 200 mesh

1

4

1

1

2

2

2

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

2

1

22 309860

Parts Drawing

88

89

90

53

55

56

57

59

58

31

38

79

Detail A

A

71

72

73

70

126

69

74

127

1

3

7

112

9

113

129

10

2

22

Ref 19

45

47

A

74a

9b

133

74b 74c

74b

Detail A

63

83

19

128

62

31 62

48

114

22

86

78

49

92

82

67

14

12

9a

13

10b

10a

22

Ref 79

85 ti3522a

309860 23

29

25

24

Parts Drawing

32

26

23

27

33

21

39

18

134

30

133

131

36

34

35

37

130

132

22

28

Ref 1

Ref 45

52

51 TI3523a

Parts List – Sprayer

REF

NO.

PART NO.

DESCRIPTION

18 115492

21 276539

22 115495

23 195429

24 15A435

25 195428

26 236352

27 116167

28 195423

29 241874

30 114421

32 15A356

33 112382

34 115498

SCREW, slot hd, hex, washer hd

HOUSING, control

SCREW, slot hd, hex, washer hd

SWITCH, toggle

RING, locking

BOOT, toggle

QTY

POTENTIOMETER, adjust, pressure 1

KNOB, potentiometer

GROMMET, transducer

CORD SET, power

BUSHING, strain relief

LABEL, control

NUT, shaft, sealing

SCREW, slot hd, hex, washer hd

1

1

1

1

1

1

5

1

1

4

1

1

1

REF

NO.

PART NO.

DESCRIPTION

35 241990

36 115494

37 115756

39 198935

51 111457

52 243222

60

130

131

132

133

134

195866

15B182

15B181

15B187

117472

15B953

BOARD, control

SCREW, 6–32 X 1/2, TAPTITE

BUSHING, strain relief

CONTROL, cover

O–RING

TRANSDUCER, pressure control includes 51

WIRE, jumper

WIRE, jumper

WIRE, jumper

CONNECTOR, wire

METER, hour

TAPE, foam

QTY

1

1

1

1

1

5

1

1

1

1

1

1

24 309860

Wiring Diagram

ON/OFF

Switch

Black

Green

Power

Plug

White

Black (–)

Red (+)

TI3515A

Yellow

Potentiometer

Pressure

Transducer

Hour Meter from Motor

309860 25

Technical Data

100–120V, ∅ ,

A, Hz

220–240V, ∅ ,

A, Hz

Generator

Minimum W

Motor HP

(W)

1, 15, 50/60 1, 10, 50/60 3000 7/8 (653)

Basic Sprayer Wetted Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . zinc-plated carbon steel, polyurethane, polyethylene, stainless steel, PTFE , Delrin , chrome plating, leather, V-Max UHMWPE, aluminum, stainless steel, tungsten carbide

NOTE: Delrin and PTFE

Cycles per gallon

(liter)

680 (180)

Maximum

Delivery gpm

(lpm)

0.38 (1.25)

Maximum

Tip size

Fluid Outlet npsm

0.019

1/4 in.

Dimensions

Weight lb (kg)

76.5 (28.55)

Height in. (cm)

32.0 (81.28)

Length in. (cm)

24.0 (60.96)

Width in. (cm)

22.0 (55.88)

26 309860

Notes

309860 27

Graco Standard Warranty

Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor 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 or 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.

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, gas engines, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

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

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

ADDITIONAL WARRANTY COVERAGE

Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty

Program”.

Graco Phone Number

TO PLACE AN ORDER , contact your Graco distributor, or call this number to identify the distributor closest to you:

1–800–690–2894 Toll Free

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

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

Sales Offices: Minneapolis, Detroit

International Offices: Belgium, Korea, Hong Kong, Japan

GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441 www.graco.com

PRINTED IN USA 309680 3/2003, Revised 8/03

28 309860