Graco 824191B Nova, NovaPro, SuperNovaPro Repair Owner's Manual

REPAIR

KEEP FOR REFERENCE.

Read this and all related manuals for important warnings and instructions.

INSTRUCTIONS

NOVA / NOVApro / SuperNOVApro

Airless Paint Sprayers

3000 psi (210 bar, 21 MPa ) Maximum Working Pressure

120 VAC

NOVA

Type

NOVApro

SuperNOVApro

Series Stand Lo-Boy Hi-Boy

B 824920

B

B

A

824940

824941

824932

824942

824191

Rev. B

Related Manuals

. . . . . . . 309070

. . . . . . . 824190

. . . . . . . 309054

. . . . . . . 824192

824920

9546A

. . . . . . . 309053

. . . . . . . 309055

Table of Contents

Component Function and Identification

Grounding

. . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Repair Information . . . . . . . . . . . . . . . . . . . . . .

5

4

Spin Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . .

10

10

On/Off Switch Replacement

Pressure Control Repair

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

12

13

Drive Housing Replacement . . . . . . . . . . . . . . . . . . . . 15

Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Displacement Pump Replacement

Technical Data

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

18

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Sherwin–Williams Standard Warranty . . . . . . . . . . . . 19

Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

The SHERWIN–WILLIAMS COMPANY, CLEVELAND, OHIO 44115

COPYRIGHT 1999, GRACO INC.

WARNING

Fire and explosion hazard: Solvent and paint fumes can ignite or explode.

To help prevent a fire and explosion:

Use only in an extremely well ventilated area.

Eliminate all ignition sources; such as pilot lights, cigarettes and static arcs from plastic drop cloths. Do not plug or unplug power cords or turn lights on or off in spray area.

Ground Sprayer, object being sprayed, paint and solvent pails.

Hold gun firmly to side of grounded pail when triggering into pail.

Use only conductive airless paint hose.

Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use could result in a chemical reaction, with the possibility of explosion.

Fluid injection and high pressure hazard: High pressure spray or leaks can inject fluid into the body.

To help prevent injection, always:

Engage trigger safety latch when not spraying.

Keep clear of nozzle and leaks.

Never spray without a tip guard.

Do PRESSURE RELIEF if you stop spraying or begin servicing sprayer.

Do not use components rated less than sprayer Maximum

Working Pressure

Never allow children to use this unit.

If high pressure fluid pierces your skin, the injury might look like

“just a cut”. But it is a serious wound! Get immediate medical attention.

MISE EN GARDE

Risque d’incendie et d’explosion imminent pendant la pulvérisation ou le rinçage à pression de fluides inflammables dans une zone à mauvaise circulation d’air et en présence de gaz inflammables pouvant s’allumer par une flamme nue ou des étincelles.

Pour éviter les risques d’incendie et d’explosion:

Manipuler les fluides à l’air libre ou dans une zone extrêmement bien aérée.

Ne jamais utiliser de trichloroéthane 1,1,1, de chlorure de méthylène, d’autres solvants à base d’hydrocarbures halogénés, ni de produits contenant de tels solvants dans un équipement sous pression en aluminium. Cela pourrait provoquer une réaction chimique avec risque d’explosion.

Retirer, éteindre ou déboucher toute source d’inflammation, recouvrir tout interrupteur mural avec du ruban adhésif. Ne pas fumer dans la zone de pulvérisation.

Ne jamais remplir le réservoir d’essence lorsque le moteur est chaud ou en marche.

Mettre à la terre le pulvérisateur, l’objet à pulvériser ainsi que les seaux de peinture et de solvants.

Tenir le pistolet fermement contre la paroi d’un seau mis à la terre lorsqu’on pulvérise dans le seau.

N’utiliser qu’un flexible pour peinture pulvérisée sans air.

Ne jamais mettre en marche un moteur dans une zone fermée.

L’injection de fluide constitue une lésion grave! Si un fluide haute

pression perce la peau, la blessure peut paraître comme une

«simple coupure». Mais il s’agit bien d’une lésion grave! Consulter immédiatement un médecin.

Pour éviter les risques d’injection, toujours:

Bloquer le loquet de sécurité de la gâchette à la fin de la pulvérisation.

Pointer le pistolet loin de soi-même et toute autre personne à proximité

Décharger la pression avant de vérifier ou réparer une fuite.

Décharger la pression après la mise hors tension du pulvérisateur ou

à la fin de la pulvérisation.

Ne pas utiliser de composants dont la pression nominale est inférieure

à la pression maximale de service du système.

Ne jamais permettre aux enfants d’utiliser cet appareil. En cas de blessure pour avoir utilisé cet appareil, consulter immédiatement un médecin.

2 824191

ADVERTÊNCIA

Poderá ocorrer incêndio e explosão quando for pulverizado ou injetado líquido inflamável numa área onde houver má circulação de ar; vapores inflamáveis poderão incendiar-se a partir de uma chama ou fagulhas a descoberto.

Para ajudar a evitar incêndio e explosão:

Utilize no exterior ou numa área muito bem ventilada.

Não utilize 1,1,1–tricloroetano, cloreto de metileno, outros solventes de hidrocarbonetos halogenados ou líquidos contendo tais solventes em equipamento de alumínio pressurizado. Tal utilização poderá resultar numa reação química, com possibilidade de explosão.

Retire, elimine ou desligue todas as fontes de ignição; coloque fita adesiva na tomada da parede. Não fume na área de pulverização.

Nunca abasteça o depósito de combustível com o motor em funcionamento ou quente.

Ponha em contato com a terra o pulverizador, o objeto a ser pulverizado, e os baldes de tinta e de solventes.

Segure a pistola firmemente de encontro ao lado de um balde em contato com a terra, quando estiver descarregando para dentro do mesmo.

Utilize somente tubos flexíveis condutores para pintura a alta pressão.

Nunca faça funcionar o motor numa área fechada.

A injeção de líquido é um ferimento grave! Se o líquido a alta pres-

são penetrar na sua pele, o ferimento poderá parecer “simplesmente um corte”. Mas é um ferimento grave! Procure o médico imediatamente.

Para ajudar a evitar injeção de líquido, faça sempre o seguinte:

Engate o trinco de segurança do gatilho quando não estiver pulverizando.

Sempre aponte a pistola para longe de você mesmo(a) ou de outras pessoas.

Alivie a pressão antes de verificar ou reparar qualquer vazamento.

Alivie a pressão quando desligar o pulverizador ou parar de pulverizar.

Não utilize componentes classificados para uma pressão nominal inferior à pressão máxima de trabalho dos sistemas.

Nunca permita que crianças utilizem esta unidade. Se sofrer algum ferimento durante a utilização deste equipamento, procure o médico imediatamente.

ADVERTENCIA

Pueden ocurrir incendios y explosiones cuando se pulveriza fluido inflamable o cuando se lava con este tipo de fluido en un área donde la circulación de aire es deficiente y los vapores inflamables se pueden encender al contacto con el fuego o chispas.

Para prevenir incendios y explosiones:

Use en espacios abiertos o en un área muy bien ventilada.

No utilice nunca tricloretano–1,1,1, cloruro de metileno, u otros disolventes a base de hidrocarburos halógenos o fluidos que contengan tales disolventes en un equipo a presión de aluminio. El uso de estas sustancias puede provocar una intensa reacción química, con riesgos de explosión.

Retire, apague o desconecte todas las fuentes de ignición; asegure el interruptor de la pared con cinta. No fume en el área de pulverización.

Nunca llene el estanque de combustible mientras el motor esté en marcha o caliente.

Ponga a tierra el pulverizador, el objeto que recibe el chorro pulverizado, las cubetas de pintura y disolvente.

Sostenga firmemente la pistola a un lado de la cubeta puesta a tierra cuando dispare dentro de ella.

Use solamente mangueras para pintura conductora sin aire.

Nunca haga andar el motor dentro de un área cerrada.

¡ La inyección de fluido en la piel es una lesión seria! Si fluido de

alta presión le penetra la piel, la lesión podría parecer “sólo un corte”. ¡Es una lesión seria! Consulte de inmediato al médico.

Para prevenir la inyección en la piel, siempre:

Enganche el seguro del gatillo cuando no use el pulverizador.

No apunte la pistola ni a sí mismo ni a los demás.

Alivie la presión antes de inspeccionar o reparar cualquier filtración.

Alivie la presión cuando apague el pulverizador o deje de usarlo.

No use componentes cuya capacidad nominal sea inferior a la presión máxima de operación del sistema.

No permita que niños usen esta unidad. Si se lesiona usando este equipo, sométase de inmediato a tratamiento médico.

Component Identification and Function

R P S

K

F

U

V

T

J

A

H

B

D

N

Fig. 1

M

E G

8050A

A Motor

B Drive Assembly

D Displacement Pump

DC motor, permanent magnet, totally enclosed, fan cooled

Transfers power from DC motor to displacement pump

E Fluid Outlet

F Prime Valve

Transfers fluid to be sprayed from source through spray gun

Spray gun is connected here

G Fluid Filter Final filter of fluid to spray gun

H Pressure Adjusting Knob Controls fluid outlet pressure

J Pressure Control

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

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

K ON/OFF Switch

M 50 ft (15 m) Main Hose

N Spray Gun

P RAC 5 Switch Tip

R HandTite Tip Guard

S Thumb Lock Safety

T Power Cord Rack

Power switch that controls main power to sprayer

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 inhibits accidental triggering of spray gun

Holds wrapped power cord for storage

U Suction Hose

V Drain Tube

Transfers fluid to be sprayed from source to pump

Fluid outlet used to drain and prime the sprayer

824191 3

General Repair Information

Pressure Relief Procedure

1.

Keep all screws, nuts, washers, gaskets, and

electrical fittings removed during repair procedures. These parts are not normally provided with replacement assemblies.

WARNING

INJECTION HAZARD

System pressure must be manually relieved to prevent system from starting or spraying accidentally. Fluid under high pressure can be injected through skin and cause serious injury. To reduce risk of injury from injection, splashing fluid, or moving parts, follow Pres-

sure Relief Procedure whenever you: are instructed to relieve pressure, stop spraying, check or service any system equipment, or install or clean spray tip.

WARNING

ELECTRIC SHOCK HAZARD

MOVING PARTS HAZARD

To reduce risk of serious injury, including electric shock, do not touch moving or electrical parts with fingers or tools while testing repair. Shut off and unplug sprayer when inspection is complete. Install all covers, gaskets, screws and washers before operating sprayer.

2.

Test repair after problem is corrected.

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.

3.

If sprayer does not operate properly, review repair procedure to verify procedure was done correctly. If necessary, see Troubleshooting Guide, pages 5 – 9, for other possible solutions.

WARNING

HOT SURFACES HAZARD

EXPLOSION HAZARD

Motor and drive housing may be very hot during operation and could burn skin if touched.

Flammable materials spilled on hot, bare motor could cause fire or explosion.

Have motor shroud in place during operation to reduce risk of burns, fire or explosion.

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 directs cooling air around motor to prevent overheating. It can also reduce risk of burns, fire or explosion; see preceding WARNING.

4 824191

Grounding

WARNING

Improper installation or alteration of grounding plug results in risk of electric shock, fire or explosion that could cause serious injury or death.

1. All models require a 60 Hz, 15A circuit with a

120 Vac grounding receptacle. See Fig. 2.

2. Do not alter ground prong or use adapter.

Grounding Plug Grounded

Outlets

Fig. 2

3. A 12 AWG, 3-wire with grounding prong, 300 ft

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

Troubleshooting

Relieve pressure ; page 4.

MOTOR WON’T OPERATE

TYPE OF PROBLEM WHAT TO CHECK

If check is OK, go to next check

Basic Fluid Pressure

Problems

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

2. Spray tip or fluid filter may be clogged.

WHAT TO DO

When check is not OK refer to this column

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

Basic Mechanical

Problems

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

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. 10.

3. Motor (1). Remove drive housing assembly

(10). See page 15. Try to rotate fan by hand.

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

2. Electrical supply. Meter must read

85–130 Vac.

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

4. Sprayer power supply cord (79). Inspect for damage such as broken insulation or wires.

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

1. 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 17 ( Displacement Pump Replace-

ment).

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

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

16.

1. See Motor Control Board Diagnostics , page 13.

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

3. Replace extension cord.

4. Replace power supply cord.

824191 5

Troubleshooting

MOTOR WON’T OPERATE (Continued)

TYPE OF PROBLEM

Basic Electrical Problems

(continued)

Refer to wiring diagram on page 12 to identify test points (TP).

WHAT TO CHECK

If check is OK, go to next check

1 .

That motor leads are securely fastened and properly mated.

2. For loose motor brush lead connections and terminals. See page 10.

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

See page 10.

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

4. For broken or misaligned motor brush springs.

Rolled portion of spring must rest squarely on top of brush. See page 10.

5. Motor brushes may be binding in brush holders.

See page 10.

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

See page 10.

7. Motor armature for shorts using armature tester

(growler) or perform spin test. See page 10.

1. Power supply cord (79). Connect volt meter between TP1 (neutral) and TP2 (L2, 120 V ac).

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

Unplug sprayer.

2. ON/OFF switch (23). Connect volt meter between L1 and L2 terminal on ON/OFF switch.

Plug in sprayer and turn ON. Meter must read

85–130 Vac.

3. Motor thermal cutoff switch. Turn sprayer OFF.

Check for continuity between TO1 and TO2 with ohmmeter.

4. All terminals for damage or loose fit.

WHAT TO DO

When check is not OK refer to this column

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

Clean circuit board terminals. Securely reconnect leads.

2. Tighten terminal screws. Replace brushes if leads are damaged. See page 10.

3. Replace brushes. See page 10.

4. Replace spring if broken. Realign spring with brush. See page 10.

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

6. Remove motor and have motor shop resurface commutator if possible. See page 16.

7. Replace motor. See page 16.

1. Replace power supply cord.

2. Replace ON/OFF switch. See page 12.

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. Replace damaged terminals and reconnect securely.

6 824191

Troubleshooting

LOW OR FLUCTUATING OUTPUT

TYPE OF PROBLEM WHAT TO CHECK

Low Output

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 Warn-

ing, then replace tip. See your separate gun or tip manual.

2. Service pump. See page 17.

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

3. Filter clogged.

4. Prime valve leaking.

5. Suction hose connections.

3. Relieve pressure. Check and clean filter.

4. Relieve pressure. Repair prime valve.

5. Tighten any loose connections.

6. Electrical supply with volt meter.

Meter must read 85–130 Vac. Low voltages reduce sprayer performance.

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.

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.

9. For loose motor brush leads and terminals. See page 10.

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

minimum. See page 10.

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

12.Motor brushes for binding in brush holders. See page 10.

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

7. Replace with a correct, grounded extension cord.

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. Tighten terminal screws. Replace brushes if leads are damaged. See page 10.

10. Replace brushes. See page 10.

11. Replace spring if broken. Realign spring with brush. See page 10.

13.Low stall pressure.

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. Do either or both: a. Turn pressure control knob fully clockwise. Make sure pressure control knob is properly installed to allow full clockwise position.

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

10.

b. Try a new transducer.

14.Replace motor. See page 16.

824191 7

Troubleshooting

LOW OR FLUCTUATING OUTPUT

TYPE OF PROBLEM

Motor runs but pump does not stroke

WHAT TO CHECK

If check is OK, go to next check

Motor runs and pump strokes 1. Paint supply.

2. Intake strainer clogged.

3. Suction tube or fittings loose.

4. To see if intake valve ball and piston ball are seating properly. See page 17.

5. Leaking around throat packing nut which may indicate worn or damaged packings. See page 17.

6. Pump rod damage.

1. Displacement pump pin (9a) (damaged or missing), page 17.

2. Connecting rod assembly (9) for damage, page 15.

3. Gears or drive housing, page 15.

WHAT TO DO

When check is not OK refer to this column

1. Refill and reprime pump.

2. Remove and clean, then reinstall.

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

4. Remove intake valve and clean. Check balls and seats for nicks; replace if necessary, page 17. Strain paint before using to remove particles that could clog pump.

5. Replace packings, page 17. Also check piston valve seat for hardened paint or nicks and replace if necessary. T ighten packing nut/wet-cup.

6. Repair pump, page 17.

1. Replace pump pin if missing. Be sure retainer spring (9b) is fully in groove all around connecting rod, page 17.

2. Replace connecting rod assembly, page 15.

3. Inspect drive housing assembly and gears for damage and replace if necessary, page 15.

8 824191

Troubleshooting

MOTOR IS HOT AND RUNS INTERMITTENTLY

TYPE OF PROBLEM

Motor is hot and runs intermittently.

WHAT TO CHECK

If check is OK, go to next check

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

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

WHAT TO DO

When check is not OK refer to this column

1. Decrease pressure setting or increase tip size.

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

ELECTRICAL SHORT

TYPE OF PROBLEM

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

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.

WHAT TO CHECK

If check is OK, go to next check

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

See page 16.

WHAT TO DO

When check is not OK refer to this column

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

2. For missing inspection plate gasket (see page

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

3. Motor armature for shorts. Use an armature tester (growler) or perform spin test. See page

10. Inspect windings for burns.

2. Correct faulty conditions.

3. Replace motor. See page 16.

4. Motor control board (35) by performing motor control board diagnostics on page 13. If diagnostics indicate, substitute with a good board.

4. Replace with a new pressure control board

(35). See page 13.

.

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

Sprayer quits after sprayer operates for 5 to 10 minutes.

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 on page 5.

2. ON/OFF switch (23) See page 12. 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.

3. For damaged or pinched wires in pressure control. See page 13.

1. Basic Electrical Problems on page 5.

1. Perform necessary procedures.

2. Replace ON/OFF switch. See page 12.

3. Replace damaged parts. See page 13.

1. Perform necessary procedures.

2. Electrical supply with volt meter.

Meter must read 85–130 Vac.

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

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

3. Loosen packing nut. Check for leaking around throat. Replace pump packings, if necessary. See page 17.

824191 9

1.

Setup

Electric Shock Hazard; page 4.

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; page 10.

Relieve pressure ; page 4.

3. If still uneven or no resistance, replace motor; page 16.

2. Remove drive housing; page 15.

3. Fig. 3. Remove pressure control cover (39).

Disconnect motor leads (F) and (G).

4. Fig. 4. Remove motor shroud (74) and inspection covers (A).

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 16.

39

Fig. 3

F

G

9578A

Motor Brush Removal

Motor Brush Replacement

74

Replace brushes worn to less than 1/2 in. Brushes wear differently on each side of motor, check both sides. Brush Repair Kit 236967 is available. Spring clip, 112766, may be purchased separately.

1. Read General Repair Information; page 4.

2.

Relieve pressure ; page 4.

3. Fig. 4. Remove motor shroud (74) and two inspection covers (A).

(Continued on page 11)

Fig. 4

A

7703B

10 824191

Motor Brush Replacement

4. Fig. 5. Push in spring clip (A) to release hook (B) from brush holder (C). Pull out spring clip (A).

5. Fig. 5. Pull brush lead (D) out of terminal (E).

Remove brush (F).

F

1 Motor lead; do not disconnect

2 Minimum 0.5” (12.5 mm)

3 Included in Brush Repair Kit

2

F

1

3 A

B

C

E

Fig. 5

D

03881

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.

Motor Brush Installation

CAUTION

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

1. Fig. 6. Install new brush (F) with lead into brush holder (C).

2. Fig. 5. Slide brush lead (D) into terminal (E).

3. Fig. 6. Install spring clip (A). Push down to set hook (B) into brush holder (C).

1

B

C

Fig. 6

E

03881

4. Repeat for other side.

5. Test brushes.

a. Remove pump (13); Displacement Pump

Replacement, page 17.

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

Plug in sprayer.

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

CAUTION

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

6. Install brush inspection covers and gaskets.

7. Break in brushes.

a. Operate sprayer 1 hour with no load.

b. Install pump (13); Displacement Pump Re-

placement, page 17.

824191 11

Removal

1.

On/Off Switch Replacement

Installation

Relieve pressure ; page 4.

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

(24) and toggle boot (25).

2. Fig. 7. Remove four screws (18) and pressure control cover (39).

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

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

Remove ON/OFF switch (23).

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

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

25

24

A

35

37

23

18

52

D E

39

Fig. 7

Power

Plug

Ref 29

ON/OFF

Switch

Ref 23

TP1

Black

Green

White from Motor

Black (–)

Wiring Diagram

Ref 60

Red (+)

L2 L1

Ref 34

Yellow

Potentiometer

Ref 26

Pressure

Transducer

Ref 52

9580A

9535A

12 824191

Removal

Refer to Fig. 7.

1.

Pressure Control Repair

Motor Control Board

Relieve pressure ; page 4.

Installation

1. Clean pad on rear of motor control board. Apply small amount of thermal compound 073019 to pad.

2. Fig. 7. Install motor control board (35) with five screws (36).

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

3. Disconnect at motor control board (35):

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

Lead (D) from potentiometer.

Lead (E) from transducer.

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

3. Connect to motor control board (35):

Lead (E) to transducer.

Lead (D) to potentiometer.

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

4. Bundle and tie all loose wires.

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

Motor Control Board Diagnostics

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

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).

See Fig. 7.

2. Turn ON/OFF switch ON.

3. Observe LED operation and reference following table:

4.

Relieve pressure and unplug sprayer before servicing control board ; page 4.

LED

BLINKS

Once

Two times repeatedly

Three times repeatedly

SPRAYER OPERATION

Sprayer runs

Sprayer shuts down and LED continues to blink two times repeatedly

Sprayer shuts down and LED continues to blink three times repeatedly

Four times repeatedly

Five times repeatedly

Sprayer shuts down and LED continues to blink four times repeatedly

Sprayer shuts down and LED continues to blink five times repeatedly

INDICATES

Normal operation

Run away pressure. Pressure greater than 4500 psi

(310 bar, 31 MPa).

Pressure transducer is faulty or missing

Line voltage is too high

WHAT TO DO

Do nothing

Replace motor control board.

See preceding Motor control board removal procedure.

Check transducer connection.

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

Check for voltage supply problems

Too much current Check for locked rotor, worn motor brushes, or shorted wiring or motor. Repair or replace failed parts.

824191 13

Pressure Control Repair

Pressure Control Transducer

Removal

Refer to Fig. 7.

1.

Relieve pressure ; page 4.

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

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

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

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

6. 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).

Pressure Adjust Potentiometer

Removal

Refer to Fig. 7.

1.

Relieve pressure ; page 4.

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

3. Disconnect all leads from motor control board (35).

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

5. 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. Turn potentiometer fully clockwise.

b. 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).

14 824191

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

1.

Relieve pressure ; page 4.

2. Remove pump (13); Displacement Pump

Replacement, page 17.

3. Fig. 8. Tip sprayer up. Remove screw (74c) and remove shroud (74).

4. Remove two front screws (22).

5. Remove two back screws (22).

6. 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. 8. Tip sprayer up. Install shroud (74) with screw (74c).

5. Install pump (13); Displacement Pump

Replacement, page 17.

6. Instal new access cover (10a) with two screws

(10b).

74

1

22

7

A

Fig. 8

74c

10

10a

9581A

10b

22

74c

9582A

824191 15

Disassembly

1.

Motor Replacement

6. Remove strain relief (37, page 12, 13, 14).

Relieve pressure ; page 4.

2. Remove pump (13); Displacement Pump

Replacement, page 17.

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.

3. Remove drive housing (10); Drive Housing

Replacement, page 15.

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

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

7. Remove three screws (22) behind board and remove control housing (21).

8. 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, page 12, 13, 14).

4. Install board (35) with five screws (36). Connect all leads to board (35).

5. Install drive housing (10); Drive Housing

Replacement, page 15.

6. Install pump (13); Displacement Pump

Replacement, page 17.

1

1

35

36

18

39

1

22

22

7699B

Fig. 9

1 Liberally apply grease

16 824191

Displacement Pump Replacement

See manual 309053 for pump repair instructions.

See manual 309057 or 309058 for sprayer part number references.

Removal

1. Flush pump (13).

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

2.

Relieve pressure ; page 4.

5. Fig. 11. Remove suction tube (78) and hose (19).

6. Loosen pump jam nut (12). Unscrew pump.

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

19

10b

12

10a

78

Fig. 10

9a

9573A

Fig. 11

9574A

WARNING

If pin works loose, parts could break off due to force of pumping action. Parts could project through the air and result in serious injury or property damage.

Installation

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. 11. Install suction tube (78) and hose (19).

6. Fig. 13. 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).

CAUTION

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

1. Fig. 12. Extend pump piston rod fully. Apply grease to top of pump rod at (A) or inside connecting rod.

Fig. 13 9576A

7. Fig. 14. Fill packing nut with Throat Seal Liquid

(TSL) until fluid flows onto top of seal.

A

10b 10a

9575A

Fig. 12

2. Fig. 10. Install pump pin (9a). Verify retainer spring

(9b) is in groove of pump pin.

Fig. 14

9577A

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

824191 17

Technical Data

Model

NOVA

NOVApro

SuperNOVApro

(120V)

∅ , A, Hz

1, 15, 60

1, 15, 60

1, 15, 60

Generator

Minimum

W

3000

3400

3750

Motor HP

(W)

1/2 (373)

5/8 (466)

3/4 (560)

Cycles per gallon (liter)

680 (180)

680 (180)

680 (180)

Maximum

Delivery gpm

(lpm)

0.38 (1.25)

0.46 (1.74)

0.54 (2.09)

Maximum

Tip size

0.019

0.021

0.023

Fluid Outlet npsm

1/4 in.

1/4 in

1/4 in

Basic Sprayer Wetted Parts: zinc-plated carbon steel, polyurethane, polyethylene, stainless steel,

UHMWPE, aluminum, stainless steel, tungsten carbide

PTFE

NOTE: Delrin and PTFE

, Delrin , chrome plating, leather, V-Max

Dimensions

Model

Stand

Lo–Boy

Hi-Boy

NOVA

39 (18)

N/A

N/A

Weight lb (kg)

NOVApro SuperNOVApro

N/A

N/A

59 (27)

43 (20)

61 (28)

66 (30)

Height: in. (cm)

21 (53.3)

21 (53.3)

Handle down:

29.5 (74.9)

Handle up:

39.5 (100.3)

Length: in. (cm)

15 (38.1)

26 (66.0)

21 (53.3)

Width: in. (cm)

14 (35.6)

20.5 (52.1)

20.5 (52.1)

18 824191

Sherwin-Williams 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 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 of structures, accessories, equipment or materials not supplied by Graco.

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

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT

NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

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

A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD

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

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

FOR GRACO CANADA CUSTOMERS

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

ADDITIONAL WARRANTY COVERAGE

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

Program”.

824191 19

Phone Number

TO PLACE AN ORDER OR FOR SERVICE , contact your Graco distributor, or call 1–800–690–2894 to identify the nearest distributor.

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.

The SHERWIN–WILLIAMS COMPANY, 101 PROSPECT AVENUE, CLEVELAND, OHIO 44115

PRINTED IN U.S.A. 824191 5/2001

20 824191