Graco Pro 230ES, Repair And Parts Manual

Page 1: ...EN Pro 230ES Model 262863 Pro 270ES Model 262864 3000 psi 20 7 MPa 207 bar Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual and in other manuals Save these instructions Related Manuals 3A2813 312830 312015 ti19332a 262863 ...

Page 2: ...shock When repair or replacement of the cord or plug is required do not connect the grounding wire to either flat blade terminal The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire Check with a qualified electrician or serviceman when the grounding instructions are not completely understood or when in doubt as to whether the product i...

Page 3: ...t containing halogenated hydrocarbons Keep spray area well ventilated Keep a good supply of fresh air moving through the area Keep pump assembly in a well ventilated area Do not spray pump assembly Do not smoke in the spray area Do not operate light switches engines or similar spark producing products in the spray area Keep area clean and free of paint or solvent containers rags and other flammabl...

Page 4: ... the maximum working pressure or temperature rating of the lowest rated system compo nent See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equip ment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave th...

Page 5: ...d or swal lowed Read MSDSs to know the specific hazards of the fluids you are using Store hazardous fluid in approved containers and dispose of it according to applicable guidelines RECOIL HAZARD Gun may recoil when triggered If you are not standing securely you could fall and be seriously injured PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help pre...

Page 6: ...Component Identification 6 3A2817A Component Identification Model 262863 shown ti19331a B H E G C F D J K Q R A S T ti9667a M ti16978a V SG2 SG3 W L X V ...

Page 7: ...to prime tube In SPRAY position pointing forward directs pressurized fluid to paint hose Automatically relieves system pressure in overpressure situations K Serial Tag below sprayer frame Sprayer model and serial number information L Inlet screen Prevents debris from entering pump M Paint hose Transports high pressure fluid from pump to spray gun Q Tip guard Reduces risk of fluid injection injury ...

Page 8: ...ed ground contact If an extension cord is necessary use a 3 wire 12 AWG 2 5 mm2 minimum Pails Solvent and oil based fluids follow local code Use only conductive metal pails placed on a grounded surface such as concrete Do not place pail on a nonconductive surface such as paper or cardboard which interrupts grounding continuity Grounding a metal pail connect a ground wire to the pail by clamping on...

Page 9: ...mpletely clogged or that pressure has not been fully relieved after follow ing these steps VERY SLOWLY loosen tip guard retain ing nut or hose end coupling to relieve pressure gradually then loosen completely Now clear tip or hose obstruction This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as skin injection splashing f...

Page 10: ...lled on hot bare motor could cause fire or explosion To reduce risk of burns fire or explosion do not operate sprayer with cover removed NOTICE 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 int...

Page 11: ...in must be completely pushed into connecting rod and retaining spring must be firmly in groove of pump pin See page 17 Displacement Pump Replacement Push pin into place and secure with spring retainer Motor Remove drive housing assembly See Drive Housing Replacement page 20 Replace motor if fan won t turn See Fan Replacement page 23 Motor control board Board shuts down and displays error code See ...

Page 12: ...lace spring if broken Realign spring with brush Motor brushes may be binding in brush holders Clean brush holders Remove car bon with small cleaning brush Align brush leads with slot in brush holder to assure free vertical brush move ment Motor armature commutator for burn spots gouges or extreme roughness Remove motor and have motor shop resurface commutator of pos sible See Motor Replacement pag...

Page 13: ...ilding fuse Repair electri cal outlet or try another outlet Extension cord size and length must be at least 12 gauge wire and no longer than 300 ft Longer cord lengths reduce sprayer perfor mance Replace with a correct grounded extension cord Leads from motor to pressure con trol circuit board for damaged or loose wires or connectors Inspect wiring insulation and terminals for signs of overheating...

Page 14: ...Tighten use thread sealant or seal ing tape on threads necessary See if intake valve ball and piston ball are seating properly See pump manual Remove intake valve and clean Check balls and seats for nicks replace if necessary Strain paint before using to remove particles that could clog pump See pump manual Leaking around throat packing nut which may indicate worn or dam aged packings See pump man...

Page 15: ... conditions Motor control board by performing control board diagnostics See page 17 If diagnostics indicate substitute with a good board CAUTION Do not perform this check until motor armature is deter mined to be good A bad motor armature can burn out a good board Replace with a new pressure con trol board See page 29 Building circuit breaker opens as soon as sprayer switch is turned on This probl...

Page 16: ...30 VAC for 120V models If voltage is too high do not operate sprayer until corrected Tightness of pump packing nut Over tightening tightens packings on rod restricts pump action and overloads motor Loosen packing nut Check for leak ing around throat Replace pump packings if necessary See pump manual Type of Problem What to Check if check is OK go to next What to DO When check is not OK refer to th...

Page 17: ...rews 12 Push cover 70 up and pull off sprayer 4 Remove suction tube 60 and hose 45 5 Cycle motor until pump pin 32 is in position to be removed 6 Disconnect power cord from outlet 7 Using a flat screwdriver push retaining spring 31 up Push out pump pin 32 8 Loosen pump jam nut 29 Unscrew and remove pump 41 ti19380a 12 70 ti19382a 45 60 ti19378a 32 ti6106b 32 31 ti19381a 29 41 ...

Page 18: ...e over pump pin 4 Push pump 41 up until pump threads engage 5 Screw in pump until threads are flush with top of drive housing opening 6 Align pump outlet to back If pump pin works loose parts could break off due to force of pumping action Parts could project through air and result in serious injury or property damage NOTICE If the pump jam nut loosens during operation the threads of the drive hous...

Page 19: ... to 1 4 turn with a 20 oz maximum hammer to approximately 75 ft lb 102 N m 8 Install suction tube 60 and high pressure hose 45 Tighten fittings 9 Fill packing nut with Graco TSL until fluid flows onto top of seal 10 Replace cover 70 over screws Push cover down into place Tighten screws 12 ti19382a 45 60 ti19376a ...

Page 20: ...surfaces 2 Install washers 8 10 on back of gear 40 Install gear in motor end bell Using grease for retention place washer 10 over bearing inside housing 42 3 Install washers 1 9 on back of gear 44 Install in motor endbell 4 Install thrust washer 25 on gear 44 5 Push drive housing 42 on motor endbell as you guide gear crank 44 through hole in connecting rod 43 6 Install screws 47 7 Install cover 22...

Page 21: ...Drive Housing Replacement 3A2817A 21 ti2570d 12 23 54 9 1 44 25 42 47 22 12 12 70 47 10 40 10 8 ...

Page 22: ...e pressure control cover 50 Disconnect connector F 5 Remove four screws 12 and motor shroud 23 and inspection covers Armature Short Circuit Test Quickly turn motor fan by hand If not shorted motor will coast two or three revolutions before complete stop If motor does not spin freely armature is shorted Replace motor page 33 Armature Brushes and Motor Wiring Open Circuit Test Continuity 1 Connect r...

Page 23: ... 2 Remove four screws 12 and shroud 23 3 Loosen tensioning screw 126 on fan 125 Pro 270ES only 4 Pull off fan 77 or 125 Installation 1 Slide new fan 125 in place on back of motor Be sure blades of fan face motor as shown 2 Tighten screw 126 3 Replace shroud 23 and four screws 12 125 126 23 12 Pro 270ES shown 77 ...

Page 24: ...air shop if brushes wear too fast Motor Brush Installation 1 Install new brush G with lead into brush holder D 2 Slide brush lead E onto terminal F 3 Install spring clip B Push down to set hook C into brush holder D 4 Repeat for other side 5 Test brushes a With sprayer OFF turn pressure control knob fully counter clockwise to minimum pressure Plug in sprayer b Turn sprayer ON Slowly increase press...

Page 25: ... pressure control cover 50 4 Disconnect two wires A from ON OFF switch 58 5 Remove toggle boot 30 and locking ring Remove ON OFF switch 58 Installation 1 Install new ON OFF switch 58 Install locking ring and toggle boot 30 2 Connect two wires A to ON OFF switch 58 3 Install pressure control cover 50 with four screws 12 ti2509b 11 37a 30 37 58 50 12 38 E D 6 49 47 19 20 A ...

Page 26: ...On Off Switch Replacement 26 3A2817A Pro 230ES Wiring Diagram ON OFF Switch Power Plug from Motor Black White Black Green 2 x Red Black Black Black ti2471b ...

Page 27: ...ening in control box housing 9 Disconnect black lead between control boards 10 Remove switch board from box Installation 1 Reconnect black lead between control and switch boards 2 Slide ON OFF switch board 30 through opening in control box housing and position switch board 3 Place toggle boot 58 over ON OFF switch Using a 5 8 in deep socket wrench tighten securely 4 Install switchboard mounting sc...

Page 28: ...On Off Switch Replacement 28 3A2817A Pro 270ES Wiring Diagram MOTOR ti7380a ...

Page 29: ... ON OFF Switch Power Cord Kit removal instructions page 27 4 Remove screw 127 from bottom of control box and screws 6 holding motor control 49 to back of con trol box 48 5 Remove motor shroud 23 and screws 12 6 Disconnect motor and thermistor connections 210 211 7 Disconnect pressure transducer lead J11 8 Disconnect potentiometer lead J12 from board 9 Remove grommet 5 from back of control box Slid...

Page 30: ...re transducer E 03 Three times repeatedly Sprayer shuts down and LED continues to blink three times repeatedly Pressure transducer is faulty or missing Check transducer connection Open drain valve Substitute new transducer for trans ducer in sprayer If sprayer runs replace transducer E 04 Four times repeatedly Sprayer shuts down and LED continues to blink four times repeatedly Power is applied Lin...

Page 31: ... 20 and slide grommet into slot in control box housing 48 3 Connect transducer lead J7 or J11 to motor control board 49 4 Install cover 50 with screws 12 Pressure Adjust Potentiometer Removal 1 Relieve pressure page 9 2 Unplug sprayer powercord 3 Remove screws 12 from cover 50 4 Disconnect potentiometer lead from motor control board 49 5 Remove potentiometer knob 11 nut 37a and pressure adjust pot...

Page 32: ...bout 1 second after turning on sprayer Pro 230ES displays model family for a few sec onds and then data point 1 is displayed 5 Push display button and next data point displays 6 Turn sprayer OFF and then ON to exit stored data mode Data Point Definition 1 Number of hours power switch has been ON with power applied Pro 230ES only Serial Number of sprayer Pro 270ES only 2 Number of hours motor has b...

Page 33: ... 8 Remove screws 47 and manifold 15 9 Remove screws 47 and motor 54 from frame 59 Installation 1 Install new motor 54 on frame 59 with screws 47 2 Install manifold 15 with screws 47 3 Install control housing 48 with screws 47 4 Install board 49 with screws 6 Connect all leads to board See wiring diagram page 26 5 Install drive housing see Drive Housing Replace ment page 20 6 Install pump see Displ...

Page 34: ...Motor Replacement 34 3A2817A 47 ti2569c 48 49 6 12 50 47 15 59 40 44 42 54 47 1 1 Liberally apply grease 1 ...

Page 35: ...tor 54 from frame 59 Installation 1 Install new motor 54 on frame 59 with screws 47 2 Install control housing 48 with screws 47 3 Install manifold 15 with screws 47 4 Connect motor leads See wiring diagram on page 28 5 Install drive housing see Drive Housing Replace ment page 20 6 Install pump see Displacement Pump Replace ment page 17 7 Replace front cover 22 and screws 12 Tighten screws securely...

Page 36: ...Motor Replacement 36 3A2817A ti7434b 12 23 54 48 22 12 59 47 47 15 12 49 50 ...

Page 37: ...0ES Model 262863 12 53 23 65 63 77 17 2 16 54 9 1 44 25 8 10 40 42 47 22 52 12 74 43 3 38 20 24 15 Ref 47 Ref 45 47 27 31 12 70 55 47 29 32 41 39 67 45 24 76 62 14 4 36 35 26 5 Ref 55 84 69 60 57 59 75 47 81 83 82 33 46 61 page 39 ...

Page 38: ...includes 8 10 1 41 255198 PUMP displacement 1 42 287055 HOUSING drive includes 12 47 1 43 287053 ROD connecting includes 31 32 1 44 287054 GEAR crankshaft includes 1 9 25 1 45 287003 HOSE cpld 1 46 247340 HOSE cpld 1 4 in x 50 ft 1 47 117493 SCREW mach hex washer hd 10 52 16P989 LABEL front Pro 230ES 1 53 16P990 LABEL side Pro 230ES 1 54 287015 MOTOR 120V includes 77 1 55 244240 HOSE drain include...

Page 39: ...ash hd 1 11 116167 KNOB potentiometer 1 12 117501 SCREW mach hex waher hd 4 19 15B118 BUSHING motor wire 1 30 195428 BOOT toggle 1 37 256219 POTENTIOMETER assembly 1 47 117493 SCREW mach hex washer hd 2 48 276868 BOX control 1 49 16T028 CONTROL board 120V 1 50 276882 COVER control 1 51 15K393 LABEL control 1 56 15B258 CORD power 1 58 195429 SWITCH toggle 1 Ref No Part No Description Qty ...

Page 40: ...Parts 40 3A2817A Wiring Diagram Pro 230ES ON OFF Switch Power Plug from Motor Black White Black Green 2 x Red Black Black Black ti2471 TP2 TP1 L1 2 x White L2 J7 J8 ...

Page 41: ... 262864 12 53 117 23 54 9 1 44 25 42 70 65 22 52 47 12 47 8 10 40 43 31 45 24 41 13 14 84 69 60 57 29 32 55 39 62 114 81 83 82 33 59 115 116 74 47 55 35 17 18 2 16 20 38 3 56 47 27 4 36 Ref 45 15 24 63 51 126 125 61 46 ti7679b page 43 ...

Page 42: ...isplacement ST 1 42 287899 HOUSING drive includes 12 47 1 43 287053 ROD connecting includes 31 32 1 44 248231 GEAR crankshaft includes 1 9 25 1 45 287003 HOSE cpld 1 46 247340 HOSE cpld 1 4 in x 50 ft 1 47 117493 SCREW mach hex washer hd 12 51 15K383 LABEL Smart Control 2 2 52 16P991 LABEL front Pro 270ES 1 53 16P992 LABEL side Pro 270ES 1 54 287807 MOTOR 120V includes 125 126 1 55 244240 HOSE dra...

Page 43: ...er hd 4 19 115498 SCREW mch slot hex wash hd 1 30 287911 BOARD filter 120V GFI 1 37 256219 POTENTIOMETER adjust pres sure includes 37a 1 37a 112382 NUT potentiometer 1 48 16T033 BOX AND CONTROL includes 11 30 37 49 58 1 49 16T030 KIT control board 120V 1 50 277229 COVER control 1 51 15K383 LABEL Smart Contol 2 1 56 253371 CORD power 1 58 195428 BOOT toggle 1 127 120165 SCREW mach phillips pan hd 1...

Page 44: ...Parts 44 3A2817A Wiring Diagram Pro 270ES MOTOR ti7380a 210 211 37 Pressure Transducer J11 J12 Black White Green Ground Black ...

Page 45: ...G 3 wire 10 ft 3 05 m Fluid inlet fitting 7 8 14 UNF external thread Fluid outlet fitting 1 4 NPSM external thread Inlet screen on suction tube 12 mesh 1675 micron Wetted parts pump hose zinc plated carbon steel nylon stainless steel PTFE acetal chrome plating leather UHMWPE aluminum carbide Wetted parts gun aluminum brass carbide nylon plated steel stainless steel UHMWPE zinc Generator requiremen...

Page 46: ...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 s...