Magnum 232735, Repair And Parts Manual

Page 1: ...For information about your material request MSDS from distributor or retailer Important Safety Instructions Read all warnings and instructions in this manual Save these instructions See page 3 for model and series information including dispense rate recommended hose length guns and maximum working pressure ti4309a ti6878a ti6877a ti6879a MAGNUM XR5 MODEL 232740 MAGNUM dx MODEL 232735 MAGNUM XR7 MO...

Page 2: ...blem Motor Does Not Operate 15 General Problem Circuit Breaker is Tripping 17 General Problem Erratic Motor Operation 18 General Problem Low or Fluctuating Output 19 General Problem No Output 21 General Problem Excessive Pressure Build Up 21 List of Kits 22 Motor Diagnostics 24 Control Board Diagnostics 25 Pump Diagnostics 25 Pump Service 25 Parts 26 dx Sprayer Model 232735 26 XR5 Sprayer Model 23...

Page 3: ...OSHA requirements for the use of flammable and combustible materials Model Name Model No Series Dispense Rate gpm lpm Hose Length and Diameter Gun Model Maximum Working Pressure PSI MPa bar Magnum dx 232735 B 0 24 gpm 0 91 lpm 25 ft 7 6 m 3 16 in SG1 EF 2800 19 193 Magnum XR5 232740 E 0 27 gpm 1 02 lpm 25 ft 7 6 m 1 4 in SG1 EF 3000 21 207 Magnum XR7 232745 D 0 34 gpm 2 17 lpm 50 ft 15 2 m 1 4 in ...

Page 4: ...he fluid distributor or retailer Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn lights on or off when flammable fumes are present Ground all equipment in work area See Grounding instructions If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a fi...

Page 5: ... or alcohol PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property damage TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious inju...

Page 6: ...on 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 Do not place the pail on a nonconductive surface such as paper or cardboard which interrupts grounding continuity Grounding the metal pail connect a ground wire to the pail by clamping...

Page 7: ...Installation 309226M 7 Notes ...

Page 8: ...ects fluid to drain tube Automatically relieves system pressure in overpressure situations K Fluid inlet connection and inlet valve Suction tube connection to pump and inlet valve L Inlet screen Prevents debris from entering pump M Paint hose Transports high pressure fluid from pump to spray gun N Cord wrap bracket Stows electrical cord XR5 model only P Airless spray gun Dispenses pumped fluid Q T...

Page 9: ...le with bolt holes in frame 2 Run bolts through holes with heads pointing toward each other and hand tighten wingnuts NOTE For space saving configuration loosen but do not remove wingnuts Fold handle forward over sprayer shroud Sprayers 0 TI A W X K W W K X Magnum XR7 Magnum XR9 Magnum dx Magnum XR5 K D B Spray Guns Q R S T Q R S U T 9562A V V 9561A ...

Page 10: ...gger lock See Trigger Lock page 10 or your gun operation manual If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after following the steps above VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually then loosen completely Clear hose or tip obstruction Trigger Lock Always engage the trigger lock when you stop sprayi...

Page 11: ...g electric shock Do not touch moving or electric pars with fingers or tools while testing repair Unplug sprayer when power is not required for test ing Install all covers gaskets screws and washers before you operate sprayer Flammable materials spilled on hot bare motor could cause fire or explosion To reduce risk of burns fire or explosion do not operate sprayer with cover removed CAUTION Do not ...

Page 12: ...uit breaker or replace fuse Extension cord is damaged Replace extension cord See Grounding and Electric Require ments page 6 Sprayer electric cord is damaged Check for broken insulation or wires Replace electric cord if damaged Paint is frozen or hardened in pump See Motor Does Not Operate page 15 Pump does not prime Spray Prime Drain Valve J is in SPRAY position Turn Spray Prime Drain Valve to PR...

Page 13: ...prayer pressure increases Spray tip is clogged Unclog spray tip See Operation Man ual 309225 InstaClean fluid filter is clogged XR models only Clean or replace InstaClean fluid fil ter E Spray gun fluid filter is clogged or installed backward Clean or replace gun fluid filter V Spray pattern is inconsistent or is leaving stripes Pressure is set too low Turn Pressure Control Knob C clockwise to inc...

Page 14: ... are plugged in on same circuit Free up circuit unplug things or use a less busy circuit Sprayer electrical cord is damaged Check broken insulation or wires Replace electrical cord if damaged Fan pattern varies dramatically while spraying OR Sprayer does not turn on promptly when resuming spraying Pressure control switch is worn and causing excessive pressure variation Replace pressure control kno...

Page 15: ...r until completely thawed or you may damage the motor control board and or drivetrain 1 Turn OFF power switch 2 Place sprayer in warm area for several hours 3 Plug in and turn on sprayer 4 Slowly increase pressure until motor starts If paint hardened in sprayer 1 Replace pump packings 2 Remove all residue from valves Pump Service page 25 Motor is damaged Remove gear and try to rotate motor shaft b...

Page 16: ...r shorts using armature tester growler or perform spin test Motor Diagnostic page 24 If shorts are evident replace motor using Motor Kit page 22 Control board damaged CAUTION Do not perform control board diagnostics until you have determined the armature is good A bad armature can burn out a good control board See Control Board Diagnostics page 25 Replace control board if damaged using Control Boa...

Page 17: ...cific Problem Cause Solution General Problem Circuit Breaker is Tripping Specific Problem Cause Solution Building circuit breaker opens as soon as sprayer is turned on Sprayer electrical wiring is pinched or insulation is damaged Repair or replace any damaged wiring or terminals Securely reconnect wires Wires between pressure control switch and control board are pinched Motor armature is shorting ...

Page 18: ...rol board wire at power switch 3 Check resistance of switch with ohmmeter 4 Reading must be infinity with power switch OFF 5 Reading must be zero with power switch ON 6 Replace power switch if damaged Also see Basic Electrical Problems and Sprayer Wiring Problems page 16 Specific Problem Cause Solution General Problem Erratic Motor Operation Specific Problem Cause Solution Sprayer quits after runn...

Page 19: ...ord is too long or not heavy enough gauge Replace extension cord Grounding and Electrical Requirements page 6 Leads from motor or pressure switch to control board are damaged loose pinched or overheated Be sure terminals are centered and firmly connected Inspect for pinched wiring and wiring insulation and terminals for signs of overheating Replace any loose terminals or damaged wiring Securely re...

Page 20: ...ay Drain Valve Kit page 22 Spray pattern has variations pressure fluctuates excessively or motor runs very slowly Leads from motor or pressure switch to control board are damaged loose or overheated Be sure terminals are centered and firmly connected Inspect wiring insulation and terminals for signs of overheating Replace any loose terminals or damaged wiring Securely reconnect terminals Pressure ...

Page 21: ...d or dry out and retry Replace if necessary using Pressure Control Switch Kit page 22 General Problem Excessive Pressure Build Up Specific Problem Cause Solution Prime Spray Valve actuates automatically relieving pressure through drain tube Pressure control switch is worn Replace pressure control switch using Pressure Control Switch Kit page 22 Water or paint entered pressure control switch or sho...

Page 22: ...64 XR5 Series C D E XR7 and XR9 Series B C D Front cover 3 8 in bronze bearing 119276 XR5 and XR7 Fuse 12 5 Amp 119277 XR9 Fuse 16 Amp 243082 All models Inlet Strainer or inlet of suction tube 245080 dx Motor repair 243236 XR5 Series A and B XR7 and XR9 Series A Motor drive housing 10 mm ball bearing motor casting includes fan shroud and brace 245063 XR5 Series C All XR7 and XR9 Series B and C Mot...

Page 23: ...ter nate Style page 28 37 Use with Pump Inlet Valve Module 243093 only 197607 XR5 Suction Tube Inlet valve with integral hose barb no elbow Use with Pump Inlet Valve Module 245070 only 195883 XR7 and XR9 Series A Suction Tube inlet valve with 1 2 in NPT bottom port Alternate Style page 28 37 Use with Pump Inlet Valve Module 243093 only 197608 XR7 and XR9 Series B Suction Tube inlet valve with inte...

Page 24: ...ace 5 Remove four screws and front cover 6 Remove yoke and guide rods 7 Remove gear Armature Short Circuit Spin Test XR models only Quickly turn motor fan by hand There should not be electrical shorts and fan should coast two or three revolutions before stopping If fan does not spin freely armature is shorted Replace motor using Motor Kit page 22 Armature Brushes and Motor Wiring Open Circuit Test...

Page 25: ...tch Kit page 22 If motor does not run replace control board repeat test Control Board Kit page 22 Pump Diagnostics When pump packings wear paint begins to leak down outside of pump Replace pump packings at the first sign of leaking or additional damage to drive train could occur Use Pump Repair Kit page 22 Pump Service If sprayer continues to cycle motor and pump run when the spray gun trigger is ...

Page 26: ...els 2 dowel pins and 2 bushings 1 44 245149 KIT gear includes 2 gears and connecting rod 1 50 245078 KIT pump repair 1 51 245079 KIT control board 1 52 245080 KIT motor repair 1 53 245076 KIT outlet valve 1 54 245077 KIT inlet valve includes 54a 1 54a C38312 O RING 55 116295 CLAMP spring 0 88 in diameter 1 56 115478 SCREW machine pan head 2 57 196594 CORD power 1 58 243954 HOSE paint DuraFlex 3 16...

Page 27: ...Parts 309226M 27 Parts dx Sprayer Model 232735 42 44 50 57 59 58 1 56 72 71 70 73 60 12 5 1 56 60 4 61 7 63 51 52 63 23 54 54a 55 62 5 12 2 3 13 4 53 30 32 38 13 64 31 ti5469b ...

Page 28: ...r 1 61 115642 BUSHING strain relief Series A B C D 1 62 243237 COVER with label Series A and B 1 245064 COVER with label Series C D E 1 63 195110 CORD power Series A B C D 1 118900 CORD power Series E 1 65 115478 SCREW torx slt pan hd 1 4 in 8 66 115499 SWITCH rocker Series A B C D 1 118899 SWITCH rocker Series E 1 67 195431 LEG left Series A B and C 1 15D922 LEG left Series D E 1 68 195430 LEG ri...

Page 29: ...Series A B C D 54 58 1 65 76 74 81 72 69 68 67 65 70 52 73 51 62 66 52 61 47 46 13 75 90 36 20 2 19 18 43 44 45 88 48 114 114 127 17 25 63 75 59 94 95 137 112 ti5468b 1 Apply light coat of lithium based grease 1 Alternate Config 25 20 71 93 72 40 138 ...

Page 30: ...es E 1 65 76 74 81 72 69 68 67 65 70 52 73 62 13 75 90 36 20 2 19 18 43 44 45 88 127 17 25 75 59 94 95 137 Apply light coat of lithium based grease 1 Alternate Config 25 20 71 93 72 40 66 47 51 54 58 46 52 52 48 114 114 112 148 142 141 140 63 143 ti6881b ...

Page 31: ...Parts 309226M 31 Notes ...

Page 32: ... pan hd 1 4 in 8 66 115499 SWITCH rocker Series A B C 1 118899 SWITCH rocker Series D 1 67 195433 LEG right Series A B 1 15D923 LEG right Series C D 1 68 195434 LEG left Series A B 1 15D924 LEG left Series C D 1 69 195436 FRAME cart 1 70 195435 HANDLE cart 1 71 15D650 RACK hose 1 72 115097 SCREW curved head 2 73 115480 KNOB t handle 1 74 197285 AXLE 1 75 195367 SPACER 2 76 115095 WHEEL 9 in 2 77 1...

Page 33: ...6 61 62 79 67 68 79 77 76 75 74 80 72 65 72 47 51 73 113 70 1 65 13 54 58 46 71 86 85 20 87 88 89 52 69 36 52 81 43 44 45 19 18 52 84 102 48 125 125 25 17 40 150 ti5467b Alternate Config 84 20 26 94 88 2 127 95 96 149 126 1 Apply light coat of lithium based grease 1 ...

Page 34: ...68 79 77 76 75 74 80 72 65 72 73 113 70 1 65 13 71 86 85 20 87 88 89 69 36 52 81 43 44 45 19 18 84 102 25 17 20 26 Alternate Config 94 88 2 127 95 96 149 1 Apply light coat of lithium based grease 1 40 85 66 47 51 54 58 46 52 52 48 125 125 126 150 153 152 151 154 ti6882b ...

Page 35: ...Parts 309226M 35 Notes ...

Page 36: ...478 SCREW torx slt pan hd 1 4 in 8 66 115499 SWITCH rocker Series A B C 1 118899 SWITCH rocker Series D 1 67 195433 LEG right Series A B 1 15D923 LEG right Series C D 1 68 195434 LEG left Series A B 1 15D924 LEG left Series C D 1 69 195439 FRAME cart 1 70 195438 HANDLE cart 1 71 15D650 RACK hose 1 72 115097 SCREW curved head 2 73 115480 KNOB t handle 1 74 195366 AXLE 1 75 195367 SPACER 2 76 115094...

Page 37: ...7 76 75 74 79 72 71 112 69 65 72 73 112 70 71 63 66 61 62 47 51 1 13 54 58 46 86 20 83 87 88 52 36 52 80 40 19 85 52 2 65 78 78 84 48 124 124 101 17 127 43 44 45 148 ti5466c Alternate Config 85 20 26 94 88 18 25 95 96 147 123 1 Apply light coat of lithium based grease 1 ...

Page 38: ...8 77 76 75 74 79 72 71 112 69 65 72 73 112 70 71 66 62 47 51 1 13 54 58 46 83 87 88 52 36 52 80 40 19 52 2 65 78 78 48 124 124 101 17 127 94 88 18 25 95 96 147 123 1 Apply light coat of lithium based grease 1 43 44 45 148 86 85 20 84 26 153 152 151 154 63 ti6883c ...

Page 39: ...cm Height with folded handle is 26 in 66 cm Power cord 16 AWG 3 wire 6 ft 1 8 m 16 AWG 3 wire 10 ft 3 05 m Fluid inlet fitting 3 4 in internal thread standard garden hose thread Fluid outlet fitting 1 4 NPSM external thread Inlet screen on suction tube Early models 14 mesh 1300 micron Later models 35 mesh 450 micron Wetted parts pump hose stainless steel brass ultra high molecular weight polyethyl...

Page 40: ... 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 MERCH...