Repair Drywall Feed Pump 3A0246C ENG U.S. Patents Pending: 61/315,288; 61/315/322; 61/316,013; 61/316,010 - For water-based materials only - Not for use in explosive atmospheres - Not for use with quick-set materials READ ALL WARNINGS AND INSTRUCTIONS Read all warnings and instructions in this manual. Save these instructions. Maximum Working Pressure 2500 psi (17.
Warning Warning The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
Warning WARNING WARNING MOVING PARTS HAZARD Moving parts can pinch, cut or amputate fingers and other body parts. • Keep clear of moving parts. • Do not operate equipment with protective guards or covers removed. • Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources. EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury.
Pressure Relief Procedure Pressure Relief Procedure 3. Turn prime valve handle to PRESSURE RELIEF position. 1. Turn flow control knob to fully counterclockwise to OFF position. bar/psi ti15614a 4. Display will read “----” when all pressure is relieved. ti8793a 2. Place deflector in hopper or suitable container.
Drive and Bearing Housing Drive and Bearing Housing NOTICE Do not drop gear cluster (17a) when removing drive housing (5a). Gear cluster may stay engaged in motor front end bell or drive housing. 6. Remove two screws (5b) from underneath motor base plate. Lift and remove motor/pump assembly from power module. Removal 5b ti11734a 1. Perform Pressure Relief Procedure, page 4. 7. Loosen four screws (19) on pump housing, and remove bearing housing (9) from motor. 2. Remove Power Module, see page 7. 3.
Drive and Bearing Housing Installation 1. Apply brown lithium grease supplied with drive housing kit (5) to gear cluster (17a) and inside of motor cavity. 5. Replace motor/pump assembly into pump module. Replace and tighten two screws (5b) underneath motor base plate. Torque to 200 - 220 in-lb. 5a 5b ti15629a 17a 2. Align orientation tab on gear housing with slot on motor and slide gears into motor. 3. Replace and tighten three screws (5c) on motor (8a). Torque to 200-220 in-lb. 5c ti11734a 6.
Power Module Power Module Removal Installation 1. Remove hopper plug (117) if installed. 2. Replace power (153) module and insert pump outlet into hopper inlet. 1. Perform Pressure Relief Procedure, see page 4. Unplug power cord. 153 2. Release hopper adapter clamp (158). ti15625a 158 3. Pull rod clamp up and tighten knob (112) on front of pump module. ti15684a 112 3. Loosen rod clamp knob (112) on front of pump module and push rod down. 112 ti11678a 4. Fasten hopper adapter clamp (158).
Pump Pump Removal 7. Use hammer to loosen pump retaining nut (22). 22 1. Perform Pressure Relief Procedure, see page 4. ti15615a 2. Remove Power Module, see page 7. 8. Unscrew and remove pump (18a) from module. 3. Disconnect material hose (79) from pump (18a). 79 18a 18a ti15618a ti15616a 4. Loosen two screws (40) and remove pump rod shield (48). Installation 1. Extend pump piston rod 1.5 in. 40 48 1.5 in. ti15619a 5.
Pump 3. Push pump up until pump threads engage. 7. Replace pump rod shield (48) and torque two screws (40) to 30 - 34 in-lb. 40 48 ti15924a 4. Screw in pump until threads are flush with drive housing opening. ti15619a 8. Reconnect material hose (79) to pump (18a). 79 18a ti15616a 9. Replace Power Module, see page 7. ti15621a 5. Align pump outlet to right side so that hose can be reassembled. ti15923a 6. Screw jam nut up toward drive housing until nut stops.
Motor Motor Removal 7. Loosen four screws (19) on bearing housing (9), and remove from gear housing. 5a 9 1. Perform Pressure Relief Procedure, see page 4. ti15630a 2. Remove Power Module, see page 7. 19 3. Disconnect material hose (79) from pump (18a). 8. Remove three screws (5c) on motor (8a). Remove motor from gear housing. 79 5c 18a ti15616a 4. Remove four screws (40) and lift motor shroud (98) off of motor. 8a ti11735a 40 Installation 98 1.
Motor 4. Attach bearing housing (9) to gear housing (5a) (slowly turn motor fan by hand to align gear into pump connecting rod). Torque four bearing housing screws (19) to 25-30 ft-lb. 7. Replace motor shroud (98) and torque four screws (40) to 30 - 34 in-lb. 40 5a 98 9 ti15630a 19 5. Replace motor/pump assembly into pump module. Replace and torque two screws (5b) underneath motor base plate to 200 - 220 in-lb. ti15624a 8. Reconnect material hose (79) to pump (18a). 79 5b 18a ti15616a ti11734a 9.
Motor Control Board Motor Control Board Removal 6. Disconnect display connector (A) from motor control board (24) and remove display. ti13569a 120V Models: 24 1. Perform Pressure Relief Procedure, see page 4. Wait 5 minutes before servicing. 2. Remove Power Module, see page 7. A 7. Remove bottom two screws (61) and remove control panel (37). 3. Disconnect material hose (79) from pump (18a). 37 79 61 18a ti15616a 4. Remove four screws (40) and lift motor shroud (98) off of motor. ti15795a 8.
Motor Control Board 11. Disconnect white power cord conductor (D) from motor control board (24). 16. Disconnect three motor connectors from motor control board to motor. 24 ti15851a D ti15847a 12. Disconnect black power lead (J) on motor control board (24) from ON/OFF switch. 17. Remove two screws (83) holding motor control board /heat sink assembly to power module frame. Remove motor control board/heat sink assembly. J 83 ti15849a 13.
Motor Control Board 110 UK and 240V Models: 7. Remove bottom two screws (61) control panel (37). 1. Perform Pressure Relief Procedure, see page 4. Wait 5 minutes before servicing. 2. Remove Power Module, see page 7. 37 3. Disconnect material hose (79) from pump (18a). 61 79 ti15795a 8. Disconnect Prime/Tool Fill/Recirculate reed switch connector (E) from motor control board (24). 18a ti15616a 24 4. Remove four screws (40) and lift motor shroud (98) off of motor. ti13572a E 40 98 9.
Motor Control Board 12. Remove top two screws (61) and control box (3). 15. Remove two screws (83) holding motor control board / heat sink assembly to power module frame. Remove motor control board/heat sink assembly. 61 3 83 ti15912a 13. Disconnect transducer connector from motor control board (24). ti15845a 16. Remove six outer screws, two inner screws, and remove control board (24) from heat sink. 24 ti12999a 24 14. Disconnect three motor connectors from motor control board to motor.
Motor Control Board Installation 120V Models: 1. Use acetone or equivalent cleaner to thoroughly remove thermal paste from pockets on heat sink. 5. Connect motor control board lead connectors (F) to leads from motor. Insert grommet in heat sink baffle. Use zip tie or electrical tape (Z) to hold grommet together on grommet end on the motor side of the heat sink. Z F ti14695a 2. Apply new thermal paste into both pockets of heat sink. ti15852a 6. Assemble gasket (94) to heat sink assembly.
Motor Control Board 10. Connect black power lead (J) on motor control board to ON/OFF switch. 15. Replace control panel (37) and tighten bottom two screws (61). Torque to 30-35 in-lb. J 37 61 ti15849a 11. Connect white power cord conductor (D) to motor control board (24). ti15795a 16. Connect display connector to motor control board (24). ti13569a 24 ti15851a 24 D 12. Connect 15/20A switch connector (X) to motor control board (24). 17. Assemble display cover (33k).
Motor Control Board 110 UK and 240V Models: 6. Assemble gasket (94) to heat sink assembly. 1. Use acetone or equivalent cleaner to thoroughly remove thermal paste from pockets on heat sink. 94 ti15911a ti14695a 2. Apply new thermal paste into both pockets of heat sink. 7. Assemble two screws (83) to hold motor control board/ heat sink assembly to power module frame. Torque to 35-45 in-lb. 83 ti14693a 3. Replace two inner screws and washers to control board and torque to 17 in-lb. ti15845a 8.
Motor Control Board 11. Connect potentiometer connector (C) to motor control board (24). 24 15. Assemble display cover (33k). Spring tabs on noise shield need to be assembled to the inside of the control box enclosure. Torque screws to 30-35 in-lb. 33k ti15791a C ti15786a 12. Connect Prime/Tool Fill/Recirculate reed switch connector (E) to motor control board (24). 16. Replace motor shroud (98) and torque four screws (40) to 30 - 34 in-lb. 24 40 98 E ti13572a 13.
Prime Valve Handle Prime Valve Handle Removal 4. Clear out any material that is lodged in valve (71) or manifold (70). Installation 1. Perform Pressure Relief Procedure, see page 4. Wait 5 minutes before servicing. 2. Use 3/32 in. punch and hammer to tap out handle pin (72c) (pliers may be required to pull out handle pin). Pull off handle (72a) and base (72b). 3. Use crescent wrench to unscrew prime valve (71). NOTE: Make sure that the seat and gasket are removed from the manifold. 1.
Pressure Transducer Pressure Transducer Removal 5. Remove four screws (61) and control box (3). Allow control panel (37) to hang down freely. 3 37 1. Perform Pressure Relief Procedure, see page 4. Wait 5 minutes before servicing. 61 ti15797a 61 2. Remove four screws (33b) and cover (33k). ti15795a 6. Remove grommet (23) from control box (3). 23 33k 33b ti15786a ti15785a 3. Disconnect transducer connector (E) from motor control board (24). 3 7.
Pressure Transducer 2. Connect transducer connector (E) and reed switch connector to control board (24). 24 5. Connect display connector (A) to motor control board (24). E 24 ti12999a ti13569a A 3. Install control box (3) and control panel (37) with four screws (61). Torque to 30 - 35 in-lb. 3 6. Install cover (33k) with four screws (33b). Torque to 30-35 in-lb. Make sure tabs on noise shield are routed inside the control box when assembling. 37 61 61 ti15797a ti15795a 4.
Flow Control Adjust Potentiometer Flow Control Adjust Potentiometer 6. Remove gasket (56), nut, spacer (88) and potentiometer (55) from control panel (37). Removal 55 ti15794a 88 37 56 1. Perform Pressure Relief Procedure, see page 4. Wait 5 minutes before servicing. 2. Remove four screws (33b) and cover (33k). Installation 1. Install gasket (56), nut, spacer (88) and potentiometer (55) on control panel (37). Torque nut to 30-35 in-lb (3.25-4.0 N•m). 55 ti15786a 33k 33b 3.
Flow Control Adjust Potentiometer 4. Replace control panel (37) and tighten bottom two screws (61). Torque to 30-35 in-lb. 6. Install cover (33k) with four screws (33b). Torque to 30-35 in-lb. Make sure tabs on noise shield are routed inside the control box when assembling. 37 33k 61 ti15795a 5. Connect display connector (A) to motor control board (24).
Prime/Tool Fill/Recirculation Reed Switch Prime/Tool Fill/Recirculation Reed Switch Removal Installation 1. Apply thread sealant to end of reed switch (87). Hand-tighten reed switch until it is tight against control panel (37). 1. Perform Pressure Relief Procedure, see page 4. Wait 5 minutes before servicing. 37 2. Remove four screws (33b) and remove display cover (33k). 87 ti13574a 2. Add thread sealant and tighten jam nut against threaded bus. 33k ti13576a ti15786a 33b 3.
Digital Display Digital Display Removal Installation 1. Plug display board connector (A) into motor control board (24). 1. Turn off unit. Wait 5 minutes before servicing. 2. Remove four screws (33b) and remove display cover (33k). 24 ti13569a A 33k ti15786a 2. Replace display cover (33k) and torque four screws (33b) to 30-35 in-lb. 33b 3. Unplug display board connector from motor control board (24).
Inline Valve Inline Valve Changing the Needle 5. Tap rear of inline valve with a plastic mallet and punch to push needle assembly (404b) out through front of housing (401). Removal ti15809a NOTE: Needle (404b), housing/seat (404c), and o-ring (404a) must be replaced together. They are included in repair kit 24F263. 401 404b Installation 1. Perform Pressure Relief Procedure, see page 4. 2. Squeeze trigger while unscrewing housing/seat (404c) and o-ring (404a). 404c 1.
Inline Valve Needle Adjustment Box Slide Control 1. Engage inline valve (135) with safety latch. Hold inline valve with nozzle straight up. Use Brake Assembly Repair Kit 24F261 2. Hold your finger against trigger (410) with light pressure. Use a 5/16 open-ended wrench to turn locknut (414) clockwise until you feel trigger lift slightly. 3. Turn locknut (414) 3/4 turn counter-clockwise. 4. Connect fluid hose. Prime the system. Trigger inline valve (135) and release it.
Parts Parts 155 154 162 148 147 160 146 161 117 118 119 152 116 155 114 113 154 115 112 126 157 171 170 158 163 156 138 153 111 127 141 128 139 137 129 135 ti15642a 180 Ref.
Parts Pump Module Parts 102 99 21 105 8c 40 8b 40 8a 101 48 104 17a 98 17c 17b 84 79 18b 5d 75 5a 25 5c 50 70 24 18a 7c 92 7b 78 80 7a 20 58 72c 94 22 19 3 72a 29 9 46c 108 83 61 23 94 39 74 87 79 71 72b ti15643a 88 81 36 61 46b 33h 32 4 6 28 5b 10 54 46a 43 182 181 27 41 183 55 33b 37 38 33d 56 42 109 33e 110 33k 33a 33c 3 ref 30 33j 33m 3A0246C
Parts Pump Module Parts List Ref.
Parts Inline Valve Parts 24F538 411 431 425b 425a 427 428 423 411 426 406 427 437 424 403 402 431 401 411 408c 439 410 408b 414 413 416 417 404b 404a 420 ti15796a 404c 406 408a Ref.
Parts Box Slide Parts 24F463 502 503 505b 505a 514 512 513 514 519 512 520 513 508 507 506 510 509 511 518a 518b 501 ti15834a 515 518c Ref. 501 502 503 505 505a 505b 506 507 508 509 510 Part 258993 16D718 15X949 24F260 108284 C20272 16D761 256228 101855 16D933 3A0246C Description Qty.
Wiring Diagrams Wiring Diagrams 100-120 VAC NA Units Thermal Switch Digital Display Potentiometer Motor Pressure Transducer Black Control Board Motor Leads Prime/Fill Tool Reed switch Motor Sensor Leads 20A/15A Switch Green/Ground Black ON/OFF Switch White Black Green/Ground ti14889a 34 3A0246C
Wiring Diagrams 100-120 VAC UK Thermal Switch Digital Display Potentiometer Motor Pressure Transducer Black Control Board Motor Leads Prime/Fill Tool Reed switch Motor Sensor Leads Black Blue Blue Green/Ground Brown Blue Brown Green/Ground ti15686a 3A0246C 35
Wiring Diagrams 220-240 VAC Units Thermal Switch Digital Display Potentiometer Motor Pressure Transducer Black Prime/Fill Tool Reed switch Control Board Motor Leads Motor Sensor Leads Black Blue Blue Green/Ground Brown Brown Blue ti15685a 36 3A0246C
Technical Data (Unit) Technical Data (Unit) Power requirements: Models 257100, 262288 Models 258906, 262300 Model 258907 Motor HP (W) Maximum fluid working pressure Hopper capacity Maximum delivery with texture material Maximum hose length Fluid outlet size Dimensions Length Width Height Weight (with hoses and applicator) Wetted parts 100-120 VAC, 60 Hz, 15/20A 220-240 VAC, 50 Hz, 10A 100-120 VAC, 50/60 Hz, 15A 2.5 (1864) 2500 psi (17.2 MPa, 172 bar) 25 gallons (95 liters) Up to 1.5 gpm (5.
Notes Notes 38 3A0246C
Notes Notes 3A0246C 39
Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.