Repair Airless Sprayer 309477F US Patent 6,752,067 Europe Patent 1 208 287 - For portable spray applications of architectural paints and coatings (Specifications, page 3) Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.
Contents Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Conventions Manual Conventions WARNING Hazard Symbol WARNING: a potentially hazardous situation which, if not avoided, could result in death or serious injury. Warnings in the instructions usually include a symbol indicating the hazard. Read the general Warnings section for additional safety information. CAUTION CAUTION: a potentially hazardous situation which, if not avoided, may result in property damage or destruction of equipment. Note Additional helpful information.
Warnings Warnings The following are general related to the safe setup, grounding, use, maintenance, and repair of this equipment. Additional, more specific warnings may be found throughout the text of this manual, where applicable. WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: • Use equipment only in well ventilated area.
WARNING WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. • Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. • Check equipment daily. Repair or replace worn or damaged parts immediately.
Pressure Relief Procedure Pressure Relief Procedure To help prevent injuries, follow this procedure when you stop spraying and before you service or clean the sprayer, remove parts or repair leaks. 3. Turn Prime/Spray valve to PRIME. Trigger gun to relieve pressure in hose. 1. Turn OFF power switch. to2012a ti2018a ti2011 dx model 4. Engage trigger safety. XR9 model 2. Unplug sprayer. ti2048a Leave Prime/Spray valve in PRIME position until you are ready to spray again.
Grounding and Electrical Requirements Grounding and Electrical Requirements This sprayer requires 220-240 VAC, 50/60 Hz, 10A circuit with a grounding receptacle. Do not use an outlet that is not grounded. Spray gun: ground through connection to a properly grounded fluid hose and pump. Fluid supply container: follow local code. Solvent pails used when flushing: follow local code. Use only conductive metal pails, placed on a grounded surface such as concrete.
General Repair Information General Repair Information • WARNING Page 4. • Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts are not normally provided with replacement assemblies. • Test repair after problem is corrected. • If sprayer does not operate properly, review repair procedure to verify you did it correctly. See Basic Troubleshooting, page 9 and Advanced Troubleshooting, page 11. • 8 Overspray may build up in the air passages.
Basic Troubleshooting Basic Troubleshooting The following troubleshooting guidelines are included here as preemptive measures against Advanced Troubleshooting, page 11. Problem Cause Power switch is on and sprayer Pressure is set at zero pressure is plugged in, but motor does not run and pump does not Motor control is damaged cycle Electrical outlet is not providing power Pump does not prime Spray gun stopped spraying Solution Turn pressure control knob counterclockwise to increase pressure setting.
Basic Troubleshooting Problem Cause Spray pattern is inconsistent or Pressure is set too low is leaving stripes Pressure is set at maximum but cannot achieve a good spray pattern Solution Turn pressure control knob clockwise to increase pressure. Spray tip is worn beyond capability of sprayer Replace spray tip. Spray tip is too big for sprayer Select smaller spray tip. Spray tip is worn beyond capability of sprayer Replace spray tip.
Advanced Troubleshooting Advanced Troubleshooting WARNING Page 4. General Problem: Motor Does Not Operate Specific Problem Cause Solution Power switch is on and sprayer See Basic Troubleshooting, is plugged in; pump does not page 9 cycle Basic mechanical problems Paint is frozen or hardened in pump Unplug sprayer from electrical outlet. If paint is frozen in sprayer: • Do NOT try to start sprayer until completely thawed or you may damage the motor, control board, and/or drivetrain. 1.
Advanced Troubleshooting Specific Problem Basic electrical problems Sprayer Wiring Problems NOTE: Remove enclosure mounting screws and pull enclosure away from drive housing. Take care not to pull on leads from electrical cord and power switch. 12 Cause Solution Motor overheated Allow motor to cool for 30 minutes. Retry. Electrical outlet is damaged Reset building circuit breaker or replace building fuse. Try another outlet. Check electric supply with volt meter. Meter must read 200-260V AC.
Advanced Troubleshooting Specific Problem Cause Sprayer Wiring Problems (cont.) Motor thermal overload cutoff switch damaged. Thermal Overload, page 7. Terminals are damaged or loose Solution 1. Unplug sprayer electrical cord. 2. Remove motor harness from control card 3. Check for continuity between yellow leads or motor harness. 4. If thermal relief switch is open (no continuity) allow motor to cool. 5. If switch remains open after motor cools, replace motor using Motor Kit, page 18. 6.
Advanced Troubleshooting Specific Problem Cause Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on. NOTE: Remove enclosure mounting screws and pull enclosure away from drive housing. Take care not to pull on leads from electrical cord and power switch. Solution Sprayer electrical cord is damaged 1. Unplug sprayer electrical cord. 2. Disconnect black electrical cord wire at power switch 3. Unplug in-line connection white cord wire. 4.
Advanced Troubleshooting General Problem: Low or Fluctuating Output Specific Problem Pump cycles, but output is low or surging Cause Solution See Basic Troubleshooting, page 9. Worn or obstructed pump valves Check for worn pump valves as follows: Prime/Spray valve is leaking Check Prime/Spray valve for debris trapped on seat and for worn parts. Torque to 21 N•m (185 in-lb). Replace if parts are worn using Prime/Spray Drain Valve Kit, page 18. 1. Prime sprayer with paint. 2.
Advanced Troubleshooting Specific Problem Cause Solution See Control Board Diagnostics, page 19. If Control board is damaged. damaged replace control board using Control CAUTION: Do not perform control board diagnostics until Board Kit, page 18. you have determined the armature is good. A bad motor can burn out a good control board.
Advanced Troubleshooting General Problem: No Output Specific Problem Cause Solution Power switch is on and sprayer See Basic Troubleshooting, is plugged in but pump does page 9. not cycle Motor runs but pump does not cycle Gear and/or yoke are damaged Replace gear and yoke using Gear/Yoke Repair (XR9 only) Kit, page 18. Motor does not run Water or paint entered pressure control switch or shorted control board Clean out and/or dry out and retry.
List of Kits List of Kits Kit Number 235014 243082 243090 245077 245070 15A473 15D883 15A475 245076 243094 244035 246286 245677 245665 243231 287770 245062 245064 245667 287784 245595 287785 245078 245646 245053 Models/Series All All XR9 dx XR9 dx, XR9 Series A XR9 Series B, C All dx XR9 All All dx XR9 XR9 Series A, B XR9 Series C XR9 XR9 XR9 Series A, B XR9 Series C XR9 Series A, B XR9 Series C dx dx XR9 Kit Description Prime/Spray Drain Valve Inlet Strainer (or inlet of suction tube) Pump Repair (pump
Motor Diagnostics Motor Diagnostics Check for electrical continuity in motor armature, windings and brush as follows: If Motor Diagnostics reveal a damaged motor or if motor brushes are shorter than 6.4 mm (1/4 in.) or if the motor shaft cannot turn, replace the motor using Motor Kit, page 18. 4. Remove fan brace. WARNING 0 MPa/bar/PSI Page 4. 5. Remove four screws and front cover. 6. Remove yoke and guide rods (XR9 model only). 7. Remove gear.
Control Board Diagnostics Control Board Diagnostics Check for motor problems before replacing control board. A damaged motor may burn out a good control card Check for a damaged control board or pressure control switch as follows: screwdriver, press tab on right side connector to release. WARNING 7. Attach harness from a control board you know is functioning correctly to control board. Page 4, 6. Pressure control switch does not have to be installed in pump. 1. Relieve pressure. 2.
Parts Parts dx Pressure Roller/Spray System Model 232736, 232737, 232738 Ref No. 2 3 5 12 13 15 16 18 19 23 30 31 32 38 41 42 43 44 50 51 52 53 54 55 56 57 Part No.
Parts dx Pressure Roller/Spray System Model 232736, 232737, 232738 1 42 Apply light coat of lithium-based grease 43 44 30, 32, 38 53 1 50 31 64 13 63 54 23 57 52 51 12 55 63 70 61 71 72 5 7 73 58 41 13 19 63 59 61 3 56 18 15 2 69 76 16 75 WL E ti2083a 22 309477F
Parts Pressure Roller Assembly Model 245589 b e a d f c 75a 75b 75c 75d 75e 75f 15A586 245999 246277 15B065 186678 197106 309477F TUBE, extension CAP, end, roller CAP, end, roller CORE, roller BRUSH, roller, 9 in. x 1/2 in.
Parts Parts XR9 Spray System Model 232751, 232752, 232753 Ref No. 1 2 13 17 18 19 20 25 26 36 40 43 44 45 46 47 48 51 52 54 57 58 59 60 61 62 63 65 66 67 68 69 70 24 Part No.
Parts XR9 Spray System Model 232751, 232752, 232753 9 (Series A, B) 63 60 1 Apply light coat of lithium-based grease 59 71 61 51 52 57 47 66 112 124 151 52 70 48 62 65 73 147 71 72 124 149 46 152 54 58 80 123 52 127 72 112 13 2 69 75 17 1 65 1 74 40 67 79 36 43, 44, 45 87 18 19 101 25 20 68 86 26 77 84 78 76 87 95 94 83 85 96 ti2084 309477F 25
Parts XR9 Spray System Model 232751, 232752, 232753 (Series C) WL D 26 309477F
Parts XR9 Spray System Labels Ref No. 149 Qty Part No.
Technical Data Technical Data Working pressure range Electric motor Operating horsepower Maximum delivery (with tip) Paint hose Maximum tip hole size Weight, sprayer only Weight, sprayer, hose & gun Dimensions: Length Width Height dx Roller/Spray System 0 - 207 bar, 21 MPa (0 - 3,000 psi) 3.5 AMP (open frame, universal) 3/8 0.91 lpm (0.24 gpm) 7.6 m (25 ft) x 1/4 in. 0.38 mm (0.015 in.) 6 kg (13 lb) 7.8 kg (17 lb) XR9 Sprayer 0 - 207 bar, 21 MPa (0 - 3,000 psi) 4.5 AMP (permanent magnet DC) 7/8 1.
Graco Warranty Graco 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.
All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. MM 309477F Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441 www.graco.
