Graco 257100 Water Pump User Manual
Contents
1. Motor Leads Control Board Wiring Diagrams Digital Display Potentiometer TA D Pressure Transducer Black MD rl 2 NY yny Is Prime Fill Tool Reed switch Green Ground 3A0246C Blue Green Ground l ti15686a 35 Wiring Diagrams 220 240 VAC Units Thermal Switch Digital Display Potentiometer TA D Pressure Transducer UE i Black S O _ ng uu Z Motor Control Prime Fill Tool Leads Board Reed switch Al 0000 LEFT Black Blue s JE Blue Green Ground 36 3A0246C 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 Sound data for2. 3 Remove trigger stop 420 with hex wrench ti15862a ti15811a 3A0246C Inline Valve 5 Tap rear of inline valve with a plastic mallet and punch to push needle assembly 404b out through front of housing 401 ti15809a Installation 1 Guide threaded end of needle assembly 404b into front of housing 401 ti15804a 401 2 Install bracket 413 and locknut 414 loosely on threaded end of needle 404b Squeeze trigger to pull needle assembly into housing 401 3 Squeeze trigger while installing o ring 404a and housing seat 404c Torque housing seat to 26 32 ft lb 35 43 Nem 404a 404c 4 Adjust needle before using inline valve t15805Xa 27 Inline Valve Needle Adjustment 1 Engage inline valve 135 with safety latch Hold inline valve with nozzle straight up 2 Hold your finger against trigger 410 with light pres sure 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 The fluid flow should stop immediately Engage safety latch and try to trigger inline valve No fluid should flow If the inline valve fails either test relieve pressure disconnect hose and readjust needle 5 Install trigger stop 420 when needle has been properly adjusted ti15862a
3. 404 404a 404b 404c 4067 408 408a 408b 408c 410 411 413 414 416 32 Part 15Y164 179733 15Y204 24F263 104444 257590 103338 24F269 257580 257790 197058 107110 177538 Description HOUSING fluid SEAL sleeve FLUID tube KIT inline valve needle and seat PACKING o ring NEEDLE gun assembly HOUSING seat 188 orifice PACKING o ring KIT sanitary clamp CLAMP 1 in sanitary SLEEVE oval CABLE TRIGGER w magnet HOUSING valve w overmold BRACKET stem LOCKNUT STUD trigger Qty aes Ss Ss PO SH PD HS IAA AAA LI Ref 417 420 423 424 425 425a 425b 426 427 428 431 437 439 Part 15Y526 15Y200 256228 15Y201 24F260 108284 15X949 15X950 15X951 15Y263 16C346 16C952 ti15796a Description NUT lock m4 sst FASTENER pan head 6 32 x 188 sst CONTROL board transmitter NUT battery wedged KIT battery cap CAP PLUG battery PACKING o ring BATTERY CR123A lithium 3 volt PAD foam isolator PAD foam isolator FASTENER self tapping 6 32x 5 sst ADAPTER 3 8 nptf x 1 00 rad seal PIN clevis fastener T Repair Kit 24F262 is a 10 pack Qty 1 1 00 N sa a a 3A0246C Box Slide Parts 24F463 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 BASE hinge assembly LID sli
4. displacement PUMP displacement 15Y925 FITTING 5 8 JIC 1 2 NPT 114666 SCREW cap socket head 106115 WASHER lock hi collar 16D622 SHIELD assy painted 193031 NUT retaining 15D033 GROMMET transducer 258843 CONTROL board drywall feed 258889 CONTROL board drywall 240V 100016 WASHER lock 116171 BUSHING strain relief 112746 NUT lock nylon thin pattern 107129 BOLT round head 260215 SCREW hex HD 24F259 KIT repair display 115522 SCREW mach PNH 116252 SCREW 10 taptite phil CONTROL board receiver 15X508 LABEL brand smartcontrol LCD PAD foam 15X507 LABEL smartcontrol SEAL extruded w adhesive COVER control 16D642 GASKET 15D036 GASKET control box 15X617 PANEL control 15C979 SWITCH rocker 15D527 SWITCH rocker 240V 243222 TRANSDUCER flow control 118444 SCREW mach slot hex wash HD 3A0246C ore See ae se ose AW VO A A RAH m A ARH HP HH NY HAH HH aH SB A OD HH Pha Ref 41 42 43 46 46a 46b 46c 48 50 54 55 56 58 61 70 71 72 72a 72b 72C 74 75 78 79 80 81 83 84 87 88 92 94 98 99 101 102 104 105 108 109 110 181 182 183 T 257600 Repair Kit is available with control board only 257601 Repair Kit is available with control board only Part 15H066 15H065 15D528 15D530 15D529 116167 120059 287943 120223 116969 15T629 111457 15G935 256219 15C973 114391 123128 15X122 24B339
5. 2 Remove Power Module see page 7 3 Disconnect material hose 79 from pump 18a RA da SEL LZ ti15624a OL 5 Remove four screws 33b and display cover 33k 2 ti15786a 6 Disconnect display from motor control board 24 and remove display 14 7 Remove bottom two screws 61 control panel 37 ti15795a Disconnect Prime Tool Fill Recirculate reed switch connector E from motor control board 24 J AA LA ZZZ BA e KO 24 BU a da Q lt BUS 224 ti13572a 9 Disconnect potentiometer connector C from motor control board 24 10 Disconnect black power lead G from motor control board to filter board Disconnect blue power lead B from motor control board to filter board 11 Remove ground screw 58 from motor control board heat sink assembly ti15846a 3A0246C 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 13 Disconnect transducer connector from motor control board 24 1115845a 16 Remove six outer screws two inner screws and remove control board 24 from heat sink ti12999a 14 Disconnect three motor connectors from motor con trol board to motor e ti15844a 3A0246C 15 Motor Control Board Installation 120V
6. Install pump pin 7b Verify retaining spring is in groove of connecting rod ti13093a NOTE Pin should be installed from the top side of the pump Make sure to control the pump pin when installing so that it does not fall into the pump module 3A0246C 3 Push pump up until pump threads engage SS t15924a 4 Screw in pump until threads are flush with drive housing opening ti15621a 5 Align pump outlet to right side so that hose can be reassembled EZ GL T_T ti15923a 6 Screw jam nut up toward drive housing 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 Nem ti15925a 3A0246C Pump 7 Replace pump rod shield 48 and torque two screws 40 to 30 34 in lb ATA 18a al ti15616a 7 9 Replace Power Module see page 7 Motor Motor Removal AA 1 Perform Pressure Relief Procedure see page 4 2 Remove Power Module see page 7 3 Disconnect material hose 79 from pump 18a Jl ti15616a 4 Remove four screws 40 and lift motor shroud 98 off of motor 6 A ti15624a J gt IO 5 Disconnect three wire harnesses see Wiring Diagrams pages 34 36 6 Remove two screws 5b from underneath motor base plate Lift and remove motor pump assembly from pump module B Wie IEN A ju 4 R l Z x 5b 2 gt ni e ti
7. 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call 1 800 690 2894 to identify the nearest distributor 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 Original instructions This manual contains English MM 3A0246 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2010 Graco Inc is registered to ISO 9001 www graco com Revised 02 2011
8. wire extension cords Ensure ground prongs are intact on power and extension cords Do not expose to rain Store indoors SKIN INJECTION HAZARD High pressure fluid from dispensing device hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment E e Engage trigger lock when not dispensing Do not point dispensing device at anyone or at any part of the body Do not put your hand over the fluid outlet Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop dispensing and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and ZX explosion moi e Do not dispense flammable or combustible materials near an open flame or sources of ignition such as cigarettes motors and electrical equipment Material or solvent flowing through the equipment is able to result in static electricity Static electricity creates a risk of fire or explosion in the presence of material or solvent fumes All parts of the system including the pump hose assembly dispenser and objects in and around th
9. 11734a 10 7 Loosen four screws 19 on bearing housing 9 and remove from gear housing 2 PY 8 Remove three screws 5c on motor 8a Remove motor from gear housing A A KC lt e Cem ls GA Ne PE 8a RE Sy 3 ti11735a Installation 1 Apply brown lithium grease supplied with motor repair kit 8 to gear cluster 17a and inside of motor cavity ti15629a 2 Align orientation tab on gear housing with slot on motor and slide gears into motor 3 Replace three screws 5c on motor 8a Torque to 200 220 in lb 8 AR 4 RU n i L KON amp y ee Sa s O Sh R 5c A ti11735a 3A0246C 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 5 Replace motor pump assembly into pump module Replace and torque two screws 5b underneath motor base plate to 200 220 in lb 4 ti11734a 6 Reconnect three wire harnesses see Wiring Diagrams pages 34 36 3A0246C Motor 7 Replace motor shroud 98 and torque four screws 40 to 30 34 in lb 9 Replace Power Module see page 7 11 Motor Control Board Motor Control Board Removal ma 120V Models 1 Perform Pressure Relief Procedure see page 4 Wait 5 minutes before servicing 2 Remove Power Module see page 7 3 Disconnect material hose 79 from pump 18a 4 Rem
10. 24E960 24A382 15C972 15Y934 121112 190451 16C350 118484 15X902 110637 16C993 258644 198650 16D004 16D640 16D624 16C681 16E335 15U014 16D653 15Y118 116876 119228 257905 195551 242001 287121 Parts Description CORD power Model 257047 CORD power Model 262289 CORD power CE CORD power UK CORD power global KNOB potentiometer SWITCH rocker KIT repair coil COIL SCREW machine flat head NUT lock SHIELD pump rod PACKING o ring CONNECTOR electrical POTENTIOMETR assembly GASKET SCREW grounding SCREW mach pan head 10 24X4 MANIFOLD fluid VALVE prime heavy duty KIT handle HANDLE valve prime BASE valve heavy duty PIN grooved FITTING 5 8 JIC 3 4 NPT SCREW cap socket head UNION adapter HOSE coupled FITTING connector LABEL euro SCREW mach panhead GROMMET motor lead KIT reed switch includes reed switch and sealant SPACER shaft LABEL drywall dump valve indent GASKET control SHIELD base painted LABEL no weight amp no step LABEL graco LABEL cap LABEL drywall warning label LABEL Made in the USA WASHER flat SCREW mach flat hd CONTROL board CLIP retaining CORD SET adapter Europe CORD SET adapter Italy Denmark Switzerland AMS Ss A m oe Nm m m m m m m m m sss m m So AP AH A Aaa a ap A E Paris Inline Valve Parts 24F538 Ref 401 402 403
11. 5642a Description CLIP drain line SCREW hex HD flanged FRAME painted TMAX MODULE power ETL listed MODULE power CE listed MODULE power UK CE listed MODULE power 120V MODULE power CE Cord HOPPER assembly LABEL brand drywall us hopper WASHER wave spring PLUG expanding CLAMP quick release HANDLE TMAX NUT hex flanged PIN locking 1 4 in WASHER flat FITTING hopper adapter CLAMP hose KIT control box slide Parts Qty A POY H YD AH N Parts Pump Module Parts 102 99 15 VCA di 40 gt a SALA SZ x 40 N he 8 Pa 4 n DS 2 ko al 39 74 ti15643a 33h 33j 33m 30 3A0246C Pump Module Parts List Ref 3 4 5 5a 5b 5c 5d 6 7 7a 7b 7c 8 8a 8b 8c 9 10 Part Description 15G700 BOX control 15D431 BOX control CE and UK 277657 GUIDE base 24E959 KIT housing drive HOUSING drive 120981 SCREW mach hex washer HD 15C753 SCREW mach hex wash HD 116192 WASHER thrust 100023 WASHER flat 287720 KIT rod connecting ROD connecting 15F856 PIN pump 119778 SPRING retaining 24D362 KIT motor electric MOTOR electric 15V577 FAN motor 122347 RING retaining external 240724 HOUSING bearing 113817 BUMPER 287290 KIT gear combination GEAR combo 114699 WASHER thrust 114672 WASHER thrust 24E957 KIT pump
12. 87 from motor control board 24 4 Install o ring 50 and transducer 39 in manifold 70 Torque to 35 45 ft lb 47 61 Nem Install grom met onto transducer 39 and transducer into control box 3 ti15792a ti15793a 3 3A0246C 21 Pressure Transducer 2 Connect transducer connector E and reed switch 5 Connect display connector A to motor control connector to control board 24 board 24 ti12999a 3 Install control box 3 and control panel 37 with four 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 ti15795a 4 Connect potentiometer connector D and reed switch connector 87 to control board 24 ti15786a ti15792a 22 3A0246C Flow Control Adjust Potentiometer Removal mo 1 Perform Pressure Relief Procedure see page 4 Wait 5 minutes before servicing 2 Remove four screws 33b and cover 33k 33k a 33b 3 Remove bottom two screws 61 and remove control panel 37 ti15795a 4 Disconnect potentiometer connector D from motor control board 24 ti7258a 3A0246C Flow Control Adjust Potentiometer 6 Remove gasket 56 nut spacer 88 and potenti ometer 55 from control panel 37 ti15794a 56 37 Installation 1 Install gasket 56 nut spacer 88 and pot
13. Models 1 Use acetone or equivalent cleaner to thoroughly remove thermal paste from pockets on heat sink ti14693a Linn 3 Replace two inner screws and washers to control board and torque to 17 in lb x ti15926a 4 Replace six outer screws to control board and torque to 11 in lb ti14697a NOTE SW1 position setting does not matter 16 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 l F I Assemble gasket 94 to heat sink assembly ti15852a ti15911a 7 Assemble two screws 83 to hold motor control board heat sink assembly to power module frame Torque to 35 45 in lb ti15845a Assemble ground screw 58 to heat sink Torque to 30 34 in lb ti15846a Assemble control box enclosure 3 to power mod ule and tighten two screws 61 Torque to 30 35 in Ib 61 go DM a t15912a 3A0246C Motor Control Board 10 Connect black power lead J on motor control 15 Replace control panel 37 and tighten bottom two board to ON OFF switch screws 61 Torque to 30 35 in lb ti15795a 16 Connect display connector to motor control board 11 Connect white power cord conductor D to motor 24 control board 24 ti13569a ti15851a 3 O 17 Assemble d
14. NTY 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
15. Removal Installation 1 Remove hopper plug 117 if installed A 2 Replace power 153 module and insert pump outlet into hopper inlet 1 Perform Pressure Relief Procedure see page 4 Unplug power cord 2 Release hopper adapter clamp 158 158 u 3 Pull rod clamp up and tighten knob 112 on front of pump module 3 Loosen rod clamp knob 112 on front of pump mod ule and push rod down ti11675a 4 Lift and pull power module 153 off of unit NOTE Power module weighs approximately 85 Ib 3A0246C 7 Pump Pump Removal AA 1 Perform Pressure Relief Procedure see page 4 2 Remove Power Module see page 7 3 Disconnect material hose 79 from pump 18a a TE a 4 Loosen two screws 40 and remove pump rod shield 48 ti15619a 5 Turn flow control knob to a very low setting and turn prime valve handle to TOOL FILL position JOG mode will appear in display Use ON OFF switch or turn control knob OFF to stop pump when pin is visible ti15620a 6 Use screwdriver to press pin 7b out of pump ti15617a NOTE Pin should be removed by pressing the pin out through the bottom side of the pump Make sure to control the pump pin when removing so that it does not fall into the pump module 7 Use hammer to loosen pump retaining nut 22 Installation 1 Extend pump piston rod 1 5 in ti7171a 2
16. Repair gt GRACO 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 in this manual dB READ ALL WARNINGS AND INSTRUCTIONS Save these instructions Maximum Working Pressure 2500 psi 17 2 MPa 172 bar Model 257100 120V NA ETL Listed Model 258906 240V Euro Multicord Model 258907 110V UK CE Model 262288 120V NA Model 262300 240V Euro CE Cord Agency Approvals FEl CE O 257100 4 A w 258906 4 4 258907 A 262288 A w 262300 4 w HOO3 PROVEN QUALITY LEADING TECHNOLOGY 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 sec tion may appear throughout the body of this manual where applicable ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power cord before servicing equipment Use only grounded electrical outlets Use only 3
17. Replacing the Battery Removal 1 Unscrew battery cap 425a from housing 411 Remove battery and discard Installation 1 Install battery 426 in housing 411 and screw in battery cap 425a NOTE Make sure o ring 425b is in place when installing the battery cap 425a 28 Box Slide Control Use Brake Assembly Repair Kit 24F261 Removal 1 Remove set screw from brake knob 518b ti15865a Installation 1 Thread brake knob 518b onto assembly 2 Apply label 518a 3 Torque set screw to 15 20 in lb 3A0246C Parts Ref Part 111 120211 112 15C799 113 104430 114 15C797 115 101566 116 100004 117 15D306 118 121458 119 100333 126 16C298 127 257133 128 223756 129 24D166 135 24F538 137 24E958 138 122267 139 150287 141 162449 146 16C794 3A0246C 160 Description RING retaining e ring ROD clamp PIN cotter BRACKET swivel NUT lock SCREW cap hex HD PLUG adapter hopper texture TIE lanyard SCREW cap hex HD FILTER hopper HOSE cpld 1 2 in mxf 50 ft HOSE cpld 1 4 in x 15 ft SWIVEL Z complete VALVE inline assembly KIT drain hose WHEEL foam COUPLING FITTING nipple reducing SPACER 75 OD X 4 ID X 625 154 155 156 157 158 160 161 162 163 170 171 180 Part 278204 112785 15R633 257047 258890 258893 262289 262299 289668 16D307 116038 121308 234188 15R639 112958 121313 156306 15R609 102905 24F463 ti1
18. de control BATTERY CR123A lithium 3 volt KIT battery cap CAP PLUG battery PACKING o ring PACKING o ring NUT battery cap CONTROL board transmitter SCREW tapping pnhd SWITCH dual in line reed Q lt ANI m AMA st ss T Ref 511 512 513 514 515 518 518a 518b 518c 519 520 Part 16D937 16D760 16D765 24E473 122665 24F261 16E022 121591 16D763 15X950 15X951 ti15834a Description WASHER 12id x 380d x 04 thk PIN trigger SPRING trigger torsion TRIGGER magnet assembly SCREW fhcs 4 20 x 50 KIT box slide control brake LABEL drywall round KNOB 25 dia shaft w setscrew BRAKE slide control PAD foam isolator PAD foam isolator Parts 9 lt AAA AG AASAMNNNN 33 Wiring Diagrams Wiring Diagrams 100 120 VAC NA Units Thermal Switch Digital Display Potentiometer Pressure Transducer Black sp Control Tr Board Prime Fill Tool Reed switch Motor A Sensor Leads gt Motor Leads O OQO 20A 15A Switch Green Ground Green Ground ti14889a z 3A0246C 100 120 VAC UK Thermal Switch
19. drywall feed pump Technical Data Unit 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 7 Ipm varies depending on material 150 ft of 1 2 in hose plus 15 ft of 1 4 in hose 1 2 in NPT female swivel 40 to 55 in 102 cm to 140 cm with handle 22 in 56 cm 31 in 79 cm 196 Ib 89 kg Buna N aluminum brass polyethylene neoprene stainless steel nickel plated carbon steel fluoroelastomer nickel plated iron wool felt tungsten carbide PTFE nylon zinc plated carbon steel paper PVC UHMWPE leather rubber Sound pressure level 80 0 dB A Sound power level t 94 7 dB A Measured while dispensing at 1 m t Measured per ISO 3744 Technical Data Pump Maximum working pressure 2500 psi 172 bar 17 2 MPa Fluid outlet size 1 2 npt f 3A0246C 37 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 Grac
20. e work area shall be properly grounded to protect against static discharge and sparks Use Graco conductive or grounded high pressure airless material hoses Verify that all containers and collection systems are grounded to prevent static discharge Connect to a grounded outlet and use grounded extensions cords Do not use a 3 to 2 adapter Do not use a material or a solvent containing halogenated hydrocarbons Keep work area well ventilated Keep a good supply of fresh air moving through the area Keep pump assembly in a well ventilated area Do not smoke in the work area Do not operate light switches engines or similar spark producing products in the work area Keep area clean and free of material or solvent containers rags and other flammable materials Know the contents of the materials and solvents being dispensed Read all Material Safety Data Sheets MSDS and container labels provided with the materials and solvents Follow the material and solvents manufacturer s safety instructions Fire extinguisher equipment shall be present and working Drywall feed pump generates sparks When flammable liquid is used in or near the drywall feed pump or for flushing or cleaning keep unit at least 20 feet 6 m away from explosive vapors 3A0246C Warning K7 MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts e Keep clear of moving parts Do not operate equipment with protective guards o
21. entiome ter 55 on control panel 37 Torque nut to 30 35 in Ib 3 25 4 0 Nem ti15794a 2 Install control knob 42 Check control knob align ment to potentiometer shaft Turn shaft fully clock wise and attach knob in full ON position with a hex wrench Make sure set screw is tightened flat against potentiometer shaft 56 ti13338a 3 Connect potentiometer connector D to motor con trol board 24 23 Flow Control Adjust Potentiometer 4 Replace control panel 37 and tighten bottom two 6 Install cover 33k with four screws 33b Torque to screws 61 Torque to 30 35 in lb 30 35 in lb Make sure tabs on noise shield are routed inside the control box when assembling 61 i er ti15795a 5 Connect display connector A to motor control board 24 ti15786a 24 3A0246C Prime Tool Fil Recirculation Reed Switch Prime Tool Fill Recirculation Reed Switch Removal Mo A 1 Perform Pressure Relief Procedure see page 4 Wait 5 minutes before servicing 2 Remove four screws 33b and remove display cover 33k ti15786a 3 Remove bottom two screws 61 and remove control panel 37 ti15795a 4 Unplug reed switch 87 from control board A OR ti13572a 5 Unscrew reed switch 87 from control panel 37 N ti13573a 3A0246C Installation 1 Apply thread sealant to end of reed switch 87 Hand tighten reed switch un
22. hold motor control board heat sink assembly to power module frame ti15845a Assemble ground screw 58 to heat sink Torque to 30 34 in lb ti15846a Assemble control box enclosure 3 to power mod ule using two top screws 61 Torque to 30 35 in lb Connect blue B and black G power leads from motor control board 24 to filter board 3A0246C Motor Control Board 11 Connect potentiometer connector C to motor con 15 Assemble display cover 33k Spring tabs on noise trol board 24 shield need to be assembled to the inside of the control box enclosure Torque screws to 30 35 in lb ti15786a 12 Connect Prime Tool Fill Recirculate reed switch con nector E to motor control board 24 7SIic R KZ DN 16 Replace motor shroud 98 and torque four screws L 40 to 30 34 in lb 24 E ZA ti13572a 13 Replace control panel 37 and tighten bottom two screws 61 Torque to 30 35 in lb Fon L 0 RZE o tj O ti15624a 17 Reconnect material hose 79 to pump 18a 14 Connect display connector to motor control board 24 ti13569a 18 Replace Power Module see page 7 3A0246C 19 Prime Valve Handle Prime Valve Handle Removal AO A 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 pi
23. isplay cover 33k Spring tabs on noise shield need to be assembled to the inside of the control box enclosure Torque screws 33b to 12 Connect 15 20A switch connector X to motor con 30 35 in lb trol board 24 LG U 18 Remove four screws 40 and lift motor shroud 98 off of motor ti15786a ti15850a 13 Connect potentiometer connector C to motor con trol board 24 ti15791a 14 Connect Prime Tool Fill Recirculate reed switch con nector E to motor control board 24 ti13572a 20 Replace Power Module see page 7 3A0246C 17 Motor Control Board 110 UK and 240V Models 1 Use acetone or equivalent cleaner to thoroughly remove thermal paste from pockets on heat sink Sa K s k Ulm 5 e ti14695a 2 Apply new thermal paste into both pockets of heat sink US ti14693a 3 Replace two inner screws and washers to control board and torque to 17 in lb ti15926a 4 Replace six outer screws to control board and torque to 11 in lb o ti14697a NOTE SW1 position setting does not matter 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 F Nel ti15852a 18 6 7 10 Assemble gasket 94 to heat sink assembly ti15911a Assemble two screws 83 to
24. n 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 20 4 Clear out any material that is lodged in valve 71 or manifold 70 Installation 1 Tighten prime valve 71 into manifold 70 Use thread sealant on housing threads and torque to 190 to 210 in lb 2 Install prime valve base 72b Pin in base must align with hole in manifold 70 3 Orient hole in prime valve stem 71 vertically 4 Place prime valve handle 72a over prime valve base 72b with handle in apply mode Align hole in handle 72a w hole in prime valve stem 71 5 Use hammer to tap prime valve handle pin 72c back into place ti15633a 3A0246C Pressure Transducer Pressure Transducer Removal 5 Remove four screws 61 and control box 3 Allow control panel 37 to hang down freely 1 Perform Pressure Relief Procedure see page 4 Wait 5 minutes before servicing 2 2 Remove four screws 33b and cover 33k Ly 33k Af e 33b ti15786a 3 Disconnect transducer connector E from motor 7 Remove transducer 39 and o ring 50 from mani control board 24 fold 70 Remove grommet 23 from transducer and save for reuse m SS 24 R 23 39 gt 50 ti12999a ti15788a Installation 4 Disconnect potentiometer connector D and reed switch connector
25. o 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 WARRA
26. olvents e Many other fluids may contain chemicals that can react with aluminum Contact your material supplier for compatibility PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury hearing loss inhalation of toxic fumes and burns This equipment includes but is not limited to e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 3A0246C 3 Pressure Relief Procedure Pressure Relief Procedure AA 3 Turn prime valve handle to PRESSURE RELIEF N position 1 Turn flow control knob to fully counterclockwise to OFF position ti15614a 4 Display will read when all pressure is relieved 4 3A0246C Drive and Bearing Housing Do not drop gear cluster 17a when removing drive housing 5a Gear cluster may stay engaged in motor front end bell or drive housing Removal 1 Perform Pressure Relief Procedure page 4 2 Remove Power Module see page 7 3 Remove Pump page 8 4 Remove four screws 40 and lift motor shroud 98 off of motor SEE Z ti15624a 5 Disconnect three wire harnesses see Wiring Diagrams pages 34 36 3A0246C 8 Drive and Bearing Housing Remove two screws 5b f
27. ove four screws 40 and lift motor shroud 98 off of motor A DC ti15786a u 12 6 Disconnect display connector A from motor control board 24 and remove display ti13569a 7 Remove bottom two screws 61 and remove control panel 37 ti15795a 8 Disconnect Prime Tool Fill Recirculate reed switch connector E from motor control board 24 ti13572a 9 Disconnect potentiometer connector C from motor control board 24 ti15791a 10 Disconnect 15 20A switch connector X from motor control board 24 ti15850a 3A0246C Motor Control Board 11 Disconnect white power cord conductor D from 16 Disconnect three motor connectors from motor con motor control board 24 trol board to motor ti15851a S D ti15847a 17 Remove two screws 83 holding motor control 12 Disconnect black power lead J on motor control board heat sink assembly to power module frame board 24 from ON OFF switch Remove motor control board heat sink assembly lt 13 Remove ground screw 58 from motor control board heat sink assembly 18 Remove six outer screws two inner screws and NI remove control board 24 from heat sink ti15844a 15 Disconnect transducer connector from motor control board 24 ti12999a 3A0246C 13 Motor Control Board 110 UK and 240V Models 1 Perform Pressure Relief Procedure see page 4 Wait 5 minutes before servicing
28. r covers removed e 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 e Always wear appropriate gloves eye protection and a respirator or mask when dispensing e Do not operate or dispense near children Keep children away from equipment at all times e Do not overreach or stand on an unstable support Keep effective footing and balance at all times e Stay alert and watch what you are doing e Do not leave the unit energized or under pressure while unattended When the unit is not in use turn off the unit and follow the Pressure Relief Procedure for turning off the unit e Do not operate the unit when fatigued or under the influence of drugs or alcohol e Do not kink or over bend the hose e Do not expose the hose to temperatures or to pressures in excess of those specified by Graco e Do not use the hose as a strength member to pull or lift the equipment PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture Failure to follow this warning can result in death serious injury or property damage e Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such s
29. rom underneath motor base plate Lift and remove motor pump assembly from power module ti11734a Loosen four screws 19 on pump housing and remove bearing housing 9 from motor Remove three screws 5c on motor 8a Remove motor 8a from drive housing 5a ti11735a 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 ti15629a 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 y gt R 4 N A AI z SO gt gt La Z A LA ZA AO f 6h E 5c gt ti11735a 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 J FX _5a 5 Replace motor pump assembly into pump module Replace and tighten two screws 5b underneath motor base plate Torque to 200 220 in lb 7 J LE Lb y SH p 1 K gt Sa f ga NA pZ 5b ti11734a 6 Reconnect three wire harnesses see Wiring Diagrams pages 34 36 7 Replace motor shroud 98 and tighten four screws 40 Torque to 30 34 in lb 407 i Aa ti15624a 8 Replace Pump page 8 9 Replace Power Module see page 7 3A0246C Power Module Power Module
30. til it is tight against control panel 37 ti13574a Add thread sealant and tighten jam nut against threaded bus ti13576a Bo Connect reed switch 87 to control board 24 ti13572a Replace control panel 37 and tighten bottom two screws 61 Torque to 30 35 in lb ti15795a Replace display cover 33k and torque four screws 33b to 30 35 in Ib 2 7 t15786a 33k RA NOTE Make sure noise shield tabs are routed to the inside of the control box when assembling 25 Digital Display Digital Display Removal Installation 1 Plug display board connector A into motor control A board 24 1 Turn off unit Wait 5 minutes before servicing 2 Remove four screws 33b and remove display cover 33k 2 Replace display cover 33k and torque four screws ti15786a 33b to 30 35 in lb 33b 3 Unplug display board connector from motor control board 24 JK IS r ti15786a 33b NOTE Make sure noise shield tabs are routed to the inside of the control box when assembling 26 3A0246C Inline Valve Changing the Needle Removal mo A NOTE Needle 404b housing seat 404c and o ring 404a must be replaced together They are included in repair kit 24F263 1 Perform Pressure Relief Procedure see page 4 2 Squeeze trigger while unscrewing housing seat 404c and o ring 404a snai
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