Graco ti11608a, Repair Manual

Page 1: ... not available in all countries IMPORTANT SAFETY INSTRUCTIONS Read all warnings and instructions Save these instructions Contact Graco Customer Service or your local Graco distributor to obtain a manual in your language Model VAC Country 262019 253958 120 North America 254968 254969 256391 240 Europe Europe multicord 254998 262024 256392 240 Asia Australia 256481 253961 110 UK Related Manuals 3108...

Page 2: ...fold Replacement 23 Power Cord Replacement 24 Motor Replacement 25 Wiring Diagram 26 Technical Data 27 Graco Standard Warranty 29 Graco Information 30 Manual Conventions Note WARNING 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 ...

Page 3: ...he 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 under stood or when in doubt as to whether the product is properly grounded Do not modify th...

Page 4: ... container labels provided with the paints and solvents Follow the paint and solvents manufacturer s safety instructions Fire extinguisher equipment shall be present and working Sprayer generates sparks When flammable liquid is used in or near the sprayer or for flushing or cleaning keep sprayer at least 20 feet 6 m away from explosive vapors SKIN INJECTION HAZARD Do not aim the gun at or spray an...

Page 5: ...ectrical outlets Use only 3 wire extension cords Ensure ground prongs are intact on sprayer and extension cords Do not expose to rain Store indoors 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...

Page 6: ...a R K A M N P F J H E U B A B U E H V F K J T T D D Item English A Pressure Control B ON OFF switch D Power Cord E Fluid Outlet F Prime Valve H Pump J Suction Hose K Drain Hose M Fluid Hose N Gun P Tip R Guard S Trigger Safety Lock T Model Serial Tag U Filter V Platform ...

Page 7: ... 240V 3 wire 16 AWG 1 0 mm2 minimum 300 ft 90 m maximum length Spray gun ground through connection to a properly grounded fluid hose and pump Fluid supply container follow local code Solvent and Oil based fluids follow local code Use only conductive metal pails placed on a grounded sur face such as concrete Do not place the pail on a non conductive surface such as paper or cardboard which interrup...

Page 8: ...as 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 4 Engage trigger safety lock on gun if unit is being shut down or left unattended WARNING Follow this Pressure Relief Procedure whenever you are instructed to relieve pressure stop spraying chec...

Page 9: ...e 4 WARNING 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 WARNING To reduce risk of serious injury including electric shock Do not touch moving or electric parts with fingers or tools while testing repair Unplug sprayer when power is not required for testing Install all covers gaskets ...

Page 10: ...filter Refer to gun instruction manual 309639 Basic Mechanical 1 Pump frozen or hardened paint Thaw sprayer if water or water based paint has frozen in sprayer Place sprayer in warm area to thaw Do not start sprayer until thawed com pletely If paint hardened dried in sprayer replace pump packings See page 14 Dis placement Pump Replacement 2 Displacement pump connecting rod pin Pin must be complete...

Page 11: ...inals Securely recon nect leads 6 Motor thermal switch Yellow motor leads must have continuity through thermal switch Replace motor See page 27 Motor Replace ment 7 Brush cap missing or loose brush lead connections Install brush cap or replace brushes if leads are damaged See page 19 Motor Brush Replacement 8 Brush length which must be 1 4 in 6mm minimum NOTE Brushes do not wear at the same rate o...

Page 12: ...nsion cord See page 7 Grounding and Electric Requirements 8 Leads from motor to circuit board for damaged or loose wire con nectors Inspect wiring insulation and terminals for signs of over heating Be sure male terminal pins are centered and firmly connected to female terminals Replace any loose terminals or damaged wiring Securely reconnect terminals 9 Worn motor brushes which must be 1 4 in 6 mm...

Page 13: ...lacement 2 Connecting rod assembly for damage Replace connecting rod assembly See page 14 Displacement Pump Replacement 3 Gears or drive housing Inspect drive housing assembly and gears for damage and replace if necessary See page 16 Drive Housing Replacement Motor is hot and runs intermittently 1 Be sure ambient temperature where sprayer is located is not more than 115 F 46 C and sprayer is not l...

Page 14: ... and remove the high pressure hose 14 4 Cycle pump until pin 32 is in position to be removed 5 Disconnect power cord from outlet 6 Using a flat screwdriver push retaining spring C up Push out pump pin 32 7 Using a hammer loosen pump jam nut 11 Unscrew and remove pump 9 WARNING Read Injection Hazard Warning page 3 Moving Parts Hazard Warning page 4 and Pressure Relief Procedure page 8 44 30 ti6104a...

Page 15: ... 7 Screw jam nut 11 up onto pump 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 ft lb 102 N m 8 Install suction tube 35 and high pressure hose 14 Tighten nuts A and B 9 Fill packing nut with Graco TSL until fluid flows onto top of seal 10 Rotate cover 44 Tighten screws 30 WARNING If pump pin works loose parts could break off due to ...

Page 16: ...grease to gears and needle bearing surfaces Install thrust bearing 4 and gears 2 and 3 in front endbell housing 2 Push drive housing into front endbell housing Insert gear crank 3 through hole in connecting rod 7 3 Install four screws 6 4 Install cover 32 with two screws 30 5 Install pump 9 Displacement Pump Replace ment page 14 WARNING Read Injection Hazard Warning page 3 and page 8 CAUTION Do no...

Page 17: ...rts If motor does not spin freely armature is shorted Replace motor page 27 Armature Brushes and Motor Wiring Open Circuit Test Continuity 1 Connect red and black motor leads with test lead Turn motor fan by hand at about two revolutions per second 2 If uneven or no resistance check for missing brush caps broken brush springs brush leads and worn brushes Repair as needed page 19 3 If still uneven ...

Page 18: ... shroud 29 3 Remove spring clip 101 on back of motor 4 Pull off fan 100 Installation 1 Slide new fan 100 in place on back of motor Be sure blades of fan face motor as shown 2 Install spring clip 101 3 Replace shroud 29 and two screws 30 WARNING Read Electric Shock Warning page 3 and Pressure Relief Procedure page 8 101 100 30 29 ti5769a ...

Page 19: ... Orient each cap with the 2 projections on either side of the brush lead You will hear a snap when cap is securely in place 3 Using a wire stripper strip off wire insulation approx imately 1 4 inch 6 mm from the end of each yellow wire C to the motor 4 Insert stripped end into end of a butt splice E on new brush assembly 5 Use a crimping tool to squeeze the ends of the butt splice E tightly around...

Page 20: ...ws 30 securing control board to housing 2 are located on the front and one on the back next to the power cord 6 Pull control board out slightly and then slide it back and off of frame 7 Remove grommet and wires from strain relief 8 Remove 2 power cord connectors from control board WARNING Read Electric Shock Warning page 3 and Pressure Relief Procedure page 8 30 33 30 ti6119a Make sure power cord ...

Page 21: ...40V blue and brown on control board 33 3 Carefully slide control board back into place on the side of the motor frame 4 Replace 3 screws 30 Torque to 30 35 in lbs 3 4 3 9 N m 5 Reattach motor connector B and pressure control assembly connector A 6 Install shroud 29 and two screws 30 Be sure power cord is routed between the blue high pressure hose to the manifold and the sprayer frame 33 ti6122a ti...

Page 22: ...wer cord from outlet 2 Remove two screws 30 and shroud 29 3 Remove fuse from control board 4 Remove spare fuse from motor Installation 1 Replace fuse on control board with spare fuse 2 Install shroud 29 and two screws 30 Replaceable Fuse ti9134b Spare Fuse included n 110V and 120 models only ...

Page 23: ...ng faces toward motor 2 Apply loctite to pressure control assembly threads 16 3 Screw pressure control assembly 16 into manifold and torque to 150 in lbs 17 0 N m 4 Wrap wires around knob and feed through slot in grommet 21 5 Insert grommet 21 in hole K in housing Secure wires to manifold housing with tape 22 6 Reconnect pressure switch connector A to control board 33 7 Install shroud 29 and two s...

Page 24: ... to disconnect Manifold from housing Installation 1 Position manifold on sprayer frame 2 Replace screws 6 and torque to 150 in lbs 17 N m 3 If removed install pressure control assembly See Pressure Control Assembly Replacement page 23 4 Feed pressure switch wires through hole in housing K 5 Insert grommet 21 in hole K in housing Secure wires to manifold housing with tape 22 6 Reconnect pressure sw...

Page 25: ...w barbed fitting 20 from manifold Installation 1 Screw barbed fitting 20 into manifold 2 Push drain line 40 onto barbed fitting 20 If you are only replacing the manifold and will be reusing the existing barbed fitting 20 and drain line 40 you will need to use a sharp knife to cut the remaining drain line material off the end of the barbed fitting 20 To make the drain line more pliable and easier t...

Page 26: ...31 Installation 1 Follow Control Board Replacement installation instructions steps 1 4 page 20 2 Reconnect green ground wire G to green ground ing screw 31 on frame Be sure terminal on ground faces UP or wires could get caught in shroud 3 Reattach motor connector B and pressure control switch connect A 4 Install shroud 29 and two screws 30 WARNING Read Electric Shock Warning page 3 and Pressure Re...

Page 27: ...n frame 45 with four screws 6 2 Install manifold 15 with two screws 6 Manifold Replacement page 24 3 Install control board 33 with three screws 30 Connect all leads to board See Control Board Replacement page 20 and Wiring Diagram page 28 4 Connect ground wire G to motor with green ground screw 31 5 Install Drive Housing Drive Housing Replace ment page 16 6 Install pump 9 Displacement Pump Replace...

Page 28: ...l Assembly Power Plug White Green Black from Motor 2 x Yellow ON OFF Switch ti5643a Capacitor Replaceable Fuse Black Power Plug Blue Green Brown ON OFF Switch Pressure Control Assembly Red from Motor 2 x Yellow Capacitor ti5857a Replaceable Fuse 120V Model 240V Model ...

Page 29: ... Maximum tip size 0 020 Fluid outlet npsm 1 4 in Dimensions Stand Length 15 75 in 40 0 cm Width 14 0 in 36 0 cm Height 17 in 43 0 cm Weight 30 lb 13 6 kg Dimensions Hi Boy Length 22 0 in 55 9 cm Width 20 5 in 52 1 cm Height 38 8 in 98 6 cm Weight 58 0 lb 25 9 kg Dimensions ProStep Length 20 0 in 50 8 cm Width 15 5 in 39 4 cm Height 19 25 in 48 9 cm Weight 40 0 lb 18 1 kg Wetted parts zinc and nick...

Page 30: ...aid 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...