Graco Inc Texspray 235490 Users Manual 309662L 1030 FC, Repair

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2015-02-09

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ti3005c

Repair

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440- 1441

0.9 to 3.0 gpm (3.4 to 11.4 lpm) Flow Rate

750 psi (5.1 MPa, 51 bar) Maximum Working Pressure

500 psi (3.4 MPa, 34 bar) Recommended Maximum Working Pressure

Model 234113, Series C

TexSpray 1030 FC sprayer, 235490 TexSpray gun

and 50 ft (15 m) air and fluid hose set

309662L

‘

CONTENTS

Warnings 2..............................

Component Description 5..................

Maintenance 6...........................

Troubleshooting 7........................

Repair 10...............................

Parts 20.................................

Accessories 26...........................

Technical Data 27........................

Dimensions 27...........................

Warranty 28.............................

308274.......

309663.......

- For portable spray application of architectural paints and coatings -

TexSpray 1030tFC

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

German Patent No. P 43 18 679.3--09

2 309662

Specifications

This equipment is not intended for use with flammable or combustible materials used in places such as

cabinet shops or other “factory” or fixed locations. If you intend to use this equipment in this type of

application, you must comply with NFPA 33 and OSHA requirements for the use of flammable and

combustible materials.

Warnings

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious

injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to

or destruction of equipment if you do not follow the

instructions.

309662 3

The following are general Warnings related to the safe setup, 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:

DUse equipment only in well ventilated area.

DEliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic

drop clothes (potential static arc).

DSprayer generates sparks. When flammable liquid is used in or near sprayer or for flushing or

cleaning, keep sprayer at least 20 ft (6 m) away from explosive vapors.

DDo not clean with materials having flash points lower than 70_F(21_C). Use water--based materi-

als or mineral spirits type material only. For complete information about your fluid, request the

MSDS from the fluid distributor or retailer.

DKeep work area free of debris, including solvent, rags and gasoline.

DDo not plug or unplug power cords or turn lights on or off when flammable fumes are present.

DGround equipment and conductive objects in work area. Read Grounding instructions.

DIf there is static sparking or you feel a shock, stop operating immediately. Do not use equipment

until you identify and correct the problem.

SKIN INJECTION HAZARD

High pressure fluid from gun, 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.

DDo not point gun at anyone or any part of the body.

DDo not put your hand over the spray tip.

DDo not stop or deflect leaks with your hand, body, glove, or rag.

DEngage trigger lock when not spraying.

DFollow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

checking or servicing equipment.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or

fluids containing such solvents in this equipment. Such use could result in a serious chemical reaction,

with the possibility of explosion, which could cause death, serious injury and/or substantial property

damage.

4 309662

WARNING

INSTRUCTIONS

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

DRead all instruction manuals, tags, and labels before operating the equipment.

DUse equipment only for its intended purpose. Call your Graco distributor for information.

DDo not exceed the maximum working pressure or temperature rating of the lowest rated system

component. This gun has a 150 psi (10 bar) maximum fluid working pressure at a 125 psi (9

bar) maximum incoming air pressure. Read Technical Data in all equipment manuals.

DDo not alter or modify equipment.

DCheck equipment daily. Repair or replace worn or damaged parts immediately.

DDo not lift pressurized equipment.

DRoute the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not

expose Graco hoses to temperatures above 180_F(82_C) or below --40_F(--40_C).

DDo not use hoses to pull equipment.

DKeep children and animals away from work area.

DComply with all applicable safety regulations.

DDo not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or

fluids containing such solvents in this equipment, which contains aluminum and/or zinc parts. Such

use could result in a serious chemical reaction, with the possibility of explosion, which could cause

death, serious injury and/or substantial property damage.

DWear eye and ear protection when operating this equipment. Keep body parts away from front of

gun. See Sound Data in TECHNICAL DATA.

TOXIC FLUID HAZARD

Toxic fluid or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or

swallowed.

DRead MSDS’s to know the specific hazards of the fluids you are using.

DStore hazardous fluid in approved containers and dispose of it according to all applicable guide-

lines.

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, inhalation of toxic

fumes, burns, and hearing loss. This equipment includes, but is not limited to:

DProtective eye wear.

DClothing and respirator as recommended by the fluid and solvent manufacturer.

DGloves.

DHearing protection.

309662 5

Component Description

Flow and Air Control

Fig. 1. The flow control (A) has a shut off and pressure

relief feature to soft start each time the gun is trig-

gered, instead of a blast of unatomized material. The

flow control has three modes:

DLOW/MED/HIGH: Triggering the gun sends an air

signal to the flow control that closes the prime valve

and starts the pump which fills the material hose.

When the gun trigger is released, the prime valve

opens and relieves the system pressure into the

supply container. When the gun is triggered the

automatic pressure relief, special TexSpray hoses

and pump design eliminate blasts of material and

spray pulsing to ensure consistent atomization.

DOFF: Puts the sprayer in neutral/relieve pressure --

neither the pump nor the gun will operate and there

is no material pressure in the pump, hose or gun.

DPRIME: The prime valve remains open so material

circulates through the pump and back to the supply

container through the drain hose.

The air control (B) increases or decreases the air

pressure to the sprayer from the air supply.

Fig. 1

OFF

PRIME

LOW/MED/HIGH

AB C

TI3101b

158

Blue

159

Black

Prime Valve

Fig. 1. The prime valve (C) relieves system pressure

and stops the pump when the gun trigger is released.

TexSpray Gun, 235490

EQUIPMENT MISUSE HAZARD

The TexSpray Gun 235490 is for use

only with the GM 1030 TexSpray 234113

which is designed so the fluid pressure

of the gun will not exceed the working pressure

rating of the components. The maximum fluid work-

ing pressure of the GM 1030 TexSpray is 750 psi

(5.1 MPa, 51 bar), but the recommended maximum

is 500 psi (3.4 MPa, 34 bar).

WARNING

INSTRUCTIONS

Fig. 2. Air flow is controlled at the gun. During priming,

turn the gun air control valve (D) in fully to prevent air

from mixing with the fluid, which allows you to check

and adjust the fluid flow accurately. (When this valve is

closed the air exits the rear of the gun.) During opera-

tion, open the air control valve to introduce air at the

correct volume for the desired spray pattern. The gun

also has a trigger bail (E) to reduce operator fatigue

when spraying large surfaces.

01808

Fig. 2 E

TexSpray Hoses

CAUTION

Use Graco hoses designed for this sprayer. Using

other hoses will damage the flow control.

6 309662

Component Description

Compressor Requirements

NOTE: This sprayer requires an external air compres-

sor.

UTION

Install an air filter on external air compressor to

reduce contamination to spray system.

Air compressor range: 10 scfm to 35 scfm, 30 to 140

psi (0.2--0.97 MPa, 2 to 9.7 bar)

Material Air Requirements* Minimum

Compressor

Size*

Elastomerics

(textured)

30 scfm at 90 psi

(0.84 m3/min at

0.63 MPa, 6.3 bar)

15 HP

Simulated

Accoustical

20 scfm at 60 psi

(0.56 m3/min at

0.42 MPa, 4.2 bar)

5.5 HP

Splatter Coat

and

Knockdown

15 scfm at 40 psi

(0.42 m3/min at

0.28 MPa, 2.8 bar)

8HP

Orange Peel 20 scfm at 60 psi

(0.56 m3/min at

0.42 MPa, 4.2 bar)

8HP

* Material, temperature and volume affect cfm needed

to properly atomize material.

Maintenance

UTION

DFor detailed engine maintenance and specifica-

tions, refer to separate HONDA engine manual.

DClose black fuel shutoff lever whenever you are

transporting sprayer to prevent fuel from flooding

engine.

DKeep sprayer upright and level when operating it

and when transporting it. This prevents crankcase

oil from leaking into combustion chamber, which

makes startup very difficult.

Daily: Check engine oil level and fill as needed.

Daily: Check and fill gas tank.

Daily: Check sprayer air filter, clean and replace

element as needed.

After first 20 hours of operation and each 100

hours thereafter: Change oil.

Weekly: Remove engine air filter cover and clean

element. In very dusty environments, check filter daily.

Replace element as needed. Replacement elements

can be purchased from your local HONDA dealer.

Spark plug: Use only a (NGK) BP6ES or BPR6ES

plug. Gap plug to 0.025 to 0.030 in. (0.7 to 0.8 mm).

Always use a spark plug wrench.

6 months: Clean Air Flow Sensor as follows:

1. Fig. 3. Loosen adapter (A). Pull down quick re-

lease (C) and swing out flow sensor regulator.

Disconnect connector (B).

2. Remove inlet fitting (D), retainer ring (E), piston (F)

and spring (G) from flow sensor regulator (H).

UTION

Do not scratch or nick piston (F) or inside of flow

sensor regulator (H).

3. Clean all parts (D, E, F, G). Clean inside of (H)

with a pipe cleaner.

4. Assemble all parts and install flow sensor regula-

tor.

Flow

Sensor Regulator

ti4366a

Flow

Sensor Regulator

D E FG H

Fig. 3

309662 7

Troubleshooting

To reduce risk of injury due to sprayer starting

unexpectedly, shut off engine before performing

checks or service.

WARNING

Check everything in chart before disassembling sprayer.

PROBLEM CAUSE SOLUTION

Engine does not start Engine switch not ON Turn engine switch ON

Outofgas Fill gas tank

Spark plug cable disconnected or

spark plug damaged

Connect spark plug cable or replace

spark plug

Oil seepage into combustion

chamber

Remove spark plug. Pull starter rope 3 or

4 times. Clean and install spark plug. Try

to start. Keep sprayer upright and do not

overfill engine crankcase to avoid oil

seepage.

Oil level low Add oil to engine crankcase

Engine operates, but

displacement pump does not

Flow control set to OFF Set flow control to PRIME mode or LOW/

MED/HIGH while triggering gun

Air compressor not on or insufficient

air flow from compressor

Start air compressor

Increase SCFM or compressor size.

Check air passages and tips for obstruc-

tions.

Check air filter element for clogs.

Air pressure set to low Check display for air pressure. System

requires a minimum of 40 psi (0.28 MPa,

2.8 bar) to operate. Increase pressure by

adjusting air control knob.

Sprayer engine RPM too low Increase engine speed

Clutch connector into back of circuit

board is loose.

Check and ensure a tight connection.

Air filter dirty Clean or replace filter element.

Air flow sensor dirty or damaged Check air filter.

Clean air flow sensor (see page 4) or re-

place as needed.

Air transducer failed Check display for correct air pressure

reading. Replace circuit board as need-

ed.

Fluid transducer failed Check connection at circuit board.

Replace fluid transducer.

Clutch not engaging Worn or damaged clutch. See page 18.

Fluid transducer failure. Air transducer

failure.

Displacement pump rod seized by

dry coating

Service pump. See page 10.

8 309662

Troubleshooting (Continued)

PROBLEM CAUSE SOLUTION

Engine operates, but

Connecting rod worn or damaged Replace connecting rod. See page 14.

acement pump

oes not

(

Continued

)

Drive housing worn or damaged Replace drive housing. See page 15.

(

)

Pinion assembly worn or damaged Service pinion assembly. See page 16.

Engine operates, displace-

ment pump operates, but no

Flow control is set to PRIME Set flow control to LOW/MED/HIGH while

triggering gun.

mater

pressure at gun. Fluid system over--pressurized Spraying material is too thick or the mate-

rial hose is too long. Use a less course

material or a shorter hose.

Gun nozzle/disk is clogged Check and clean nozzle/disk as needed.

Switch to a larger nozzle/disk.

Material flowing out drain line Check for air leaks to dump valve.

Check dump valve for wear, replace as

needed.

Air flow sensor dirty or damaged.

Pump is packed out Disassemble and clean pump (see page

8), hose(s) and gun.

Low fluid delivery Siphon hose strainer is clogged. Clean or remove strainer

Engine RPM too low Increase engine speed. See Startup,

procedure in operator manual.

Flow control set too low Increase flow control to MED or HIGH

Hose too long or material too

coarse

Change to a shorter hose or less coarse

material.

Material flowing out drain line Check drain line for a constant flow of

material when sprayer is operating in

LOW/MED/HIGH mode.

Check for air leaks to prime valve.

Check dump valve for wear, replace as

needed.

Gun nozzle/disk is clogged Check and clean nozzle/disk as needed.

Switch to a larger nozzle/disk.

Pump is packed out Disassemble and clean pump (see page

8), hose(s) and gun.

Loss of air control or volume

at gun

Gun air passages clogged with

material

After releasing gun trigger, make sure

system is fully depressurized before trig-

gering gun again. This helps prevent

material backing into gun passages.

Air filter dirty Clean or replace element

Air flow sensor dirty or damaged Check air filter.

Clean air flow sensor (see page 4) or re-

place as needed.

Displacement pump output

Piston ball (220) not seating Clean piston area. See page 12.

ow on upstro

ePiston packings worn or damaged Replace packings. See page 12.

Siphon hose coupling gasket (1e)

worn or missing.

Replace or install gasket

Pump cylinder o-ring (205) worn or

missing

Replace o-ring

309662 9

Troubleshooting (Continued)

PROBLEM CAUSE SOLUTION

Displacement pump output

Siphon hose strainer is clogged Clean strainer

ow on

ownstro

eor

strokes Piston packings worn or damaged Replace packings. See page 12.

Material leaks into wet-cup Intake valve ball (216) not seating

properly

Clean and service intake valve. See

page 12.

Clutch (9) worn or damaged Replace clutch. See page 18.

Air leak at pump foot valve or

siphon tube elbow

Be sure foot valve is tight each day.

Be sure seal in elbow is in place and is

not worn or damaged.

Material leaks into wet-cup Loose wet-cup (202) Tighten wet-cup enough to stop leakage

Throat packings worn or damaged Replace packings. See page 12.

Displacement rod (201) worn or

damaged

Replace displacement rod. See page 12.

Intermittent material flow out

of gun

Material supply is low or empty Refill and prime pump. See Startup proce-

dure in operator manual. Check material

supply often to prevent running pump dry.

Air control on gun is set too high. Reduce the air flow through the gun by

turning the air control knob on the back of

the gun.

Hose too long or material too

coarse

Change to a shorter hose or less coarse

material.

Heavy or poorly atomized mate-

rial when gun is first triggered

(lack of soft start)

Fluid pressure was not allowed to

fully self relieve after releasing gun

trigger

Wait longer between releasing gun trigger

and re--triggering.

(

)

Gun was not fully triggered immedi-

ately when squeezed, causing gun

air passages to clog with material.

Always squeeze trigger fully to prevent

just air from turning on, which starts pump

and pressurizes hoses. Disassemble and

clean gun.

Air valve failure Check and replace as needed

Air flow sensor dirty or damaged Check air filter.

Clean air flow sensor (see page 4) or re-

place as needed.

Pump does not shut off after

gun trigger is released

Air leaks in the system after the air

flow sensor

Check and tighten all connections be-

tween the air flow sensor and the gun.

Air leaks in gun Check gun for excessive air leaks and re-

pair.

See manual 309661

Air flow sensor dirty or damaged Check air filter.

Clean air flow sensor (see page 4) or re-

place as needed.

Premature prime valve fail-

ures

Pump does not shut off after gun

trigger is released.

Read “Pump does not shut off after gun

trigger is released” and fix appropriate

problem.

Repair or replace Prime Valve.

See page 19.

10 309662

Displacement Pump Repair

Removal

To reduce risk of injury due to sprayer starting

unexpectedly, shut off engine before performing

checks or service.

WARNING

1. Fig. 4. Flush sprayer. Remove suction hose elbow

(150a), pump outlet hose (A) and drain hose (64).

Fig. 4

ti12869a

150a

159

158

MOVING PARTS HAZARD

To reduce risk of amputating fingers,

keep fingers away from connecting rod

and pin while jogging engine.

WARNING

0407

Torque to 20 ft--lb (27 N.m)

Fig. 5

128

201

128

Back of pump

Cutaway view shows how pin (38) goes

through connecting rod

2. Fig. 5. Start engine. Jog flow control between

PRIME and OFF until connecting rod stops near

bottom of stroke. Shut off engine.

3. Loosen two quick disconnect screws (27).

4. Pry retaining spring (37) up on connecting

rod (128). Push pin (38) out with a screwdriver.

5. Fig. 6. Remove cover (C) to control housing (54)

by removing four screws (12). Detach pressure

transducer cord (63, Fig. 4) from control board (9)

at port (D). Remove pressure transducer cord from

control box.

6. Fig. 4. Remove air hoses (158) and (159) from

prime valve manifold (85). Note correct air hose

connection to ports on air cylinder (22). Use 5/16

inch wrench to hold ring on hose fitting while

removing hose from fitting.

7. Support weight of pump (3) and remove two quick

disconnect screws (27).

8. Unscrew assembled dump valve manifold (85) and

air cylinder (22) from pump (3).

Fig. 6

ti3007b

Repair

See page 12 for pump repair instructions.

309662 11

Displacement Pump Repair

Installation

1. Fig. 4. Screw assembled dump valve manifold (85)

and air cylinder (22) into pump (3).

2. Fig. 5. Pull piston rod (201) out of pump (3) 2 to 3

inches (50 to 75 mm).

WARNING

MOVING PARTS HAZARD

If pin works loose, parts could break off

due to force of pumping action. Parts

could project through the air and result in

serious injury or property damage. Make sure pin

and retaining spring are properly installed.

3. Lift pump (3) into position and push in pin (38). Be

sure retaining spring (37) snaps down over end of

pin.

4. Support weight of pump (3) and fasten two quick

disconnect screws (27). Torque screws to 20 ft-lb

(27 N.m).

5. Fig. 4. Reattach air hoses (158) and (159) to prime

valve manifold (85). Ensure air hoses are attached

to the correct port on air cylinder (22).

6. Fig. 6. Route the pressure transducer cord (63,

Fig. 4) to the control box and attach to port (D) on

control board (9). Assemble cover (C) to control

housing (54) using four screws (12).

12 309662

Pump Repair

To reduce risk of injury due to sprayer starting

unexpectedly, shut off engine before performing

checks or service.

WARNING

Disassemble Pump

1. See Displacement Pump Repair on page 10 to

remove pump.

2. Use a hammer on tabs of lug nut (214) to loosen

foot valve housing.

3. Fig. 7. Disassemble pump, but do not disassemble

piston rod (201) from piston housing (206) unless

either needs to be replaced. These two parts are

joined with high-strength (red) Loctiter. Joint must

be heated to disassemble.

Clean and Inspect All Parts

1. Clean all traces of sealant from all parts with a

compatible solvent.

2. Inspect all part for nicks and scratches. Replace

worn or damaged parts as they cause packings to

wear more quickly and may result in poor pump

performance.

Repair Kit

Packing Repair Kit 235186 is available. Replace all

parts in kit for best results.

Parts included in kit are marked with an asterisk in text

and drawings. For example, 208*.

Assemble Pump

1. Fig. 7. If piston rod (201) and piston housing (206),

were disassembled, clean threads thoroughly.

Apply Loctite primer and then red Loctite to

threads and torque to 80 to 100 ft-lb (110 to

135 N.m). Allow to dry at least 1 hour.

2. Assemble onto piston seat (213): washer (212);

u-cup seal (218*) with lips toward ring; female

gland (211*) and then alternate white (210*) and

purple packings (219*), all with lips facing up; male

gland (209*).

3. Install nut (208*) on piston seat (213). Hand tight-

en nut firmly.

4. Install ball (220*) in piston housing (206).

5. Apply blue Loctite to piston seat (213) threads and

screw assembly onto rod, hand tight.

TIP: Draw a line across male gland, nut and piston

housing for an alignment reference before tightening

piston and nut.

6. Place piston seat (213) in a vise. Hold packing nut

(208) steady with one wrench and use a torque

wrench to tighten rod assembly to 90--125 ft-lb

(122--170 N.m). Make sure reference line made in

step 5 is aligned.

7. Grease throat of intake housing (227). Assemble

into throat: male gland (204*), flat side first; alter-

nate white packings (225*) and purple packings

(203*) and then female gland, all with lips facing

down. Install packing nut (202) and hand tighten,

firmly.

8. Grease piston packings and inside throat pack-

ings.

9. Grease new o-rings (205*) and install on cylinder

(221). Slide cylinder into bottom of intake housing

(227) until you hear it snap.

10. Guide piston rod assembly into cylinder so piston

rod flats are aligned with opening in front of pump.

Push down until you hear another snap. Turn

pump over and push assembly in completely.

11. Align rod hole to front of pump with a screw driver.

12. Grease o-ring (223*), install on plug (224), install

plug and screws (222) loosely. Torque screws to

50--70 in--lb (5.6--8 N.m) in a crosswise pattern.

13. Install ball (216*) and ball guide (217) into foot

valve. Place pump assembly on foot valve and

push into place.

14. Screw on lug nut (214). Tighten lug nut securely

with a hammer.

TIP: Lug nut must be tight or pump will not prime.

Draw a line between intake housing and lug nut for an

alignment reference during operation.

309662 13

Pump Repair

TI3015A

Fig. 7

205*

221 217

214

216*

215

219*

207*

208*

206

*209

*211

*210

*218

212

220*

202

*226

*203

*204

225*

201

227

Grease inside of throat

before installing packings

Lips of v-packings in throat

must face down

Grease inside of packings

after installing 32

Lips of v-packings on

piston must face up

Grease outside of packings

after installing

8Lips of u-cup seal on

piston must face down

9If piston seat and rod were

separated, apply Loctite primer,

then red Loctite, and torque to

80--100 ft--lb (110--135 N.m)

Tighten with hammer

Torque piston housing to piston seat

(213) to 90--125 ft--lb (122--170

N.m) without changing alignment of

packing nut

TI3015A

14 309662

Bearing Housing & Connecting Rod

Removal

To reduce risk of injury due to sprayer starting

unexpectedly, shut off engine before performing

checks or service.

WARNING

1. Fig. 8. Perform steps 1--8 of Displacement Pump,

Removal, page 10.

2. Remove four screws (40) and front cover (21).

3. Remove four screws (48) and lockwashers (49)

from bearing housing (23).

4. Pull connecting rod assembly (22) and lightly tap

lower rear of bearing housing (23) with a plastic

mallet to loosen it from drive housing (20). Pull

bearing housing and connecting rod assembly off

drive housing.

5. Inspect crank (A) for excessive wear and replace

drive housing, if necessary, page 15.

Installation

1. Evenly lubricate inside of bronze bearing (E) in

bearing housing (23) with high-quality motor oil.

Liberally pack top roller bearing (B), lower bearing

bearing grease.

2. Assemble connecting rod (22) and bearing housing

(23).

3. Clean mating surfaces of bearing housing (23) and

drive housing (20).

UTION

Do not use bearing housing screws (48) to align or

seat bearing housing with drive housing. Align these

parts with locating pins (D), to avoid premature

bearing wear.

4. Align connecting rod with crank (A) and carefully

align locating pins (D) in drive housing (20) with

holes in bearing housing (23). Push bearing hous-

ing onto drive housing or tap it into place with a

plastic mallet.

5. Install four screws (48) and lockwashers (49) on

bearing housing (23). Torque screws evenly to 25

ft-lb (34 N.m).

6. Do steps 2 -- 5 of Displacement Pump,Installa-

tion, page 10.

TI3021c

Torque to

25 ft--lb (34 N.m)

Fig. 8

See page 10 to

remove pump

Liberally pack with

bearing grease

(20d), supplied

Lubricate with

high quality

motor oil

48,49

23 22

85b

309662 15

Drive Housing

TI3023A

Torque to

25 ft--lb

(34 N.m)

Fig. 9

150a

Apply remaining

grease to these

areas

To reduce risk of injury due to sprayer starting

unexpectedly, shut off engine before performing

checks or service.

WARNING

1. Fig. 9. Disconnect siphon hose elbow (150a), drain

hose (64) and material hose (not shown) from

pump outlet. Disconnect cables. Remove screws

(21) and front cover (19).

2. Remove four screws (40) and lockwashers (56)

from bearing housing (39).

3. Lightly tap back of bearing housing (39) with a

plastic mallet. Pull pump, bearing housing and

connecting rod away from drive housing (8) as one

assembly.

4. Remove bearing housing screws (93) and lock-

washer (36) and pinion housing screws (59) and

lockwashers (36).

5. Lightly tap around drive housing (8) to loosen drive

housing. Pull drive housing straight off pinion

housing (58). Be prepared to support combination

gear (91), which may also come out.

6. Liberally apply bearing grease (supplied with

combination gear) to combination gear (91) and to

areas called out by note 2.

7. Place bronze colored washer (8g) and then silver-

colored washer (8g) on shaft protruding from big

bearing of drive housing (8). Align gears and push

new drive housing straight onto pinion housing and

locating pins (A).

8. Reassemble sprayer. Or, go to next section in this

manual if further service is needed.

16 309662

Pinion Assembly/Rotor/Field/Shaft/Clutch

Removal

To reduce risk of injury due to sprayer starting

unexpectedly, shut off engine before performing

checks or service.

WARNING

If pinion assembly (58) is not removed from clutch

housing (88), do 1. through 4. Otherwise, start at 5.

1. Remove drive housing (8); page 15.

2. Disconnect field cable from flow control.

3. Fig. 10. Remove five screws (99) and

lockwashers (43) and pinion assembly (58).

99 43

Fig. 10 8700A

4. Fig. 11. Place pinion assembly (58) on bench with

rotor side up.

5. Remove four screws (95) and lockwashers (43).

Install two screws in threaded holes (E) in rotor.

Alternately tighten screws until rotor comes off.

8701B

Fig. 11

6. Fig. 12. Remove retaining ring (58e).

7. Tap pinion shaft (58d) out with plastic mallet.

Fig. 12

58e

58d

8703B

8. Fig.13. Use an impact wrench or wedge something

between armature (89) and clutch housing to hold

engine shaft during removal.

9. Remove four screws (2) and lockwashers (43).

10. Remove armature (89).

Fig. 13

8704A

309662 17

Pinion Assembly/Rotor/Field/Shaft/Clutch

Installation

1. Fig. 14. Lay two stacks of two dimes on smooth

bench surface.

2. Lay armature (89) on two stacks of dimes.

3. Press center of clutch down on bench surface.

Fig. 14

8705A

0.12 ±.01 in. (3.0 ±.25 mm)

4. Install armature (89) on engine drive shaft.

5. Install four screws (2) and lockwashers (43) with

torque of 125 in-lb.

6. Fig. 12. Tap pinion shaft (58d) in with plastic

mallet.

7. Install retaining ring (58e) with beveled side facing

field.

8. Fig. 11. Place pinion assembly (58) on bench with

rotor side up.

9. Apply locktite to screws. Install four screws (2) and

lockwashers (43). Alternately torque screws to 125

in-lb until rotor is secure. Use threaded holes to

hold rotor.

10. Fig. 10. Install pinion assembly (58) with five

screws (99) and lockwashers (43).

11. Connect field cable to flow control.

Collar

Removal

1. Fig. 15. Loosen two screws (2) on collar (86),

2. Push screwdriver into slot in collar (86) and re-

move collar.

Installation

1. Fig.15. Install engine shaft key (90).

2. Tap collar (86) on engine shaft (A) with plastic

mallet.

3. Press collar (86) onto engine shaft (A). Maintain

dimension shown note 2 in Fig. 15. Chamfer must

face engine.

Check dimension: Place rigid, straight steel bar (B)

across face of clutch housing (88). Use accurate

measuring device to measure distance between

bar and face of collar. Adjust collar as necessary.

Torque two screws (16) to 125 ±10 in-lb (14 ±1.1

N¡m). Fig. 15

03483

Face of clutch housing

1.812 ±.010 in. (46.02 ±.25 mm)

Torque to 125 ±.10 in-lb (14 ±1.1 N¡m)

4Chamfer this side

18 309662

Clutch Housing

Removal

1. Fig. 16. Remove four capscrews (42) and lock-

washers (29) which hold clutch housing (88) to

engine.

2. Remove screw (101) from under mounting

plate (D).

3. Remove engine key (90).

4. Pull off clutch housing (88).

Installation

1. Fig. 16. Push on clutch housing (88).

2. Install four capscrews (42) and lockwashers (29)

and secure clutch housing (88) to engine. Torque

to 200 in-lb (22.6 NSm).

3. Install capscrew (101) from beneath mounting

plate (D). Torque to 26 ft-lb (35.2 NSm).

Fig. 16

101

8708A

309662 19

Engine

Removal

1. Remove Pinion Assembly/Rotor/Field/Pinion/

Clutch, Clamp and Clutch Housing,asin-

structed on pages 16, 17, and 18.

2. Fig. 17. Disconnect all necessary wiring.

3. Fig. 18. Remove two locknuts (18) and

screws (17) from base of engine.

4. Lift engine carefully and place on work bench.

NOTE: All service to the engine must be performed by

an authorized HONDA dealer.

Installation

1. Lift engine carefully and place on cart.

2. Fig. 18. Install two screws (17) in base of engine

and secure with locknuts (18). Torque to 200 in-lb

(22.6 NSm).

3. Fig. 17. Connect all necessary wiring.

4. Install Pinion Assembly/Rotor/Field/Pinion/

Clutch, Clamp and Clutch Housing,as

instructed on pages 16 and 17 and 18.

SPRAYER WIRING DIAGRAM

Fig. 17

6Wires

Red, Yellow, Green,

Blue, White, Black

2X Red

2X Black

TI3110A

Transducer

Air valve Flow sensor regulator

Flow control

Fig. 18

8710A

20 309662

Parts - Sprayer

1Danger and warning labels, tags, and cards are free.

DETAIL A

ti4365d

95 43

Ref 8h

122

104

117

43 88 21

3, page 20

118

130

102

128

83,

page

119

Page 22

112

123

105

8, page 21

59 58, page 21

29,

101

Ref 8g

TI4365a

BOTTOM VIEW

72 1

100

152

153

158

159

162

140

150

164

185

309662 21

Parts - Sprayer

Ref No. Part No. Description Qty Ref No. Part No. Description Qty

1 187604 SLEEVE, cart 2

2 108803 SCREW, hex, socket head 6

3 235706 PUMP, texture, 3 gpm 1

4 157705 UNION, swivel 1

6 116354 BUSHING, strain relief 1

7 15B560 SPACER, bolt 1

8 287128 KIT, repair, drive housing 1

9 234234 KIT, control board 1

12** 116252 SCREW, #8 taptite phil 4

13 15B935 WIRE, jumper 1

14 183350 WASHER 2

16 193682 PLUG, tube 2

17 110837 SCREW, flange, hex 2

18 110838 NUT, lock 2

19 241308 COVER, drive 1

21 114818 SCREW, self--tap, filhd 4

22 15W085 CYLINDER, air 1

23 114263 FITTING, connector, male (for 1030fc) 1

23 104172 FITTING, connector, male (for 1030) 1

24 237686 CLAMP, grounding assy 1

25 112798 SCREW, thread forming, hex hd 1

26 224442 KIT, repair, suction, (55 gal) 1

27 187111 SCREW, quick disc 2

28** 15c004 LABEL, crtl box cover 1

29 100214 WASHER, lock 4

30 111834 NIPPLE, pipe, hex 1

31 157785 UNION, swivel 1

32 114530 ENGINE, gas, 5.5 hp, Honda 1

33 245162 FRAME, cart 1

34 113084 RIVET, blind 2

35 192014 PLATE, indicator 1

36 104008 WASHER, lock, spring 6

37 183169 SPRING, retaining 1

38 183210 PIN, str, hdls 1

39 287129 HOUSING, bearing 1

40 114666 SCREW, cap, socket hd 4

41 15W086 ADAPTER, dump valve 1

42 108842 SCREW, cap, hex hd 4

43 105510 WASHER, lock, spring (hi--collar) 15

44 117740 KNOB, switch 1

45 111457 PACKING, o--ring 1

46 164856 FITTING, nipple, reducing 1

47 257111* KIT, dump valve, repair 1

49 15B680 PLATE, control box 1

50 234232 KIT, flow sensor 1

51 104811 CAP, hub 2

52 112827 BUTTON, snap 2

53 115244 NUT, regulator 1

54 15B558 HOUSING, control 1

55 15B684 PANEL, control 1

56 106115 WASHER, lock spring (hi--collar) 4

58 245399 KIT, repair, pinion housing 1

59 101864 SCREW, cap, sch 4

60 240997 CONDUCTOR, ground 1

61 102478 STRAP, tie, wire 1

62 194125 LABEL, danger, English 1

63a 287130 TRANSDUCER, pressure, (for 1030fc) 1

63b 15C238 PLUG, manifold, (for 1030) 1

64 235738 HOSE, drain, 12 ft 1

66 117741 SCREW, mach, phillips 2

68 111831 SCREW, cap, skt, button hd 1

69 109466 NUT, lock, hex 2

70 15B671 SWITCH, rotary 1

72Y194126 LABEL, warning 1

73 188509 CLIP, spring 2

75Y290228 LABEL, caution 1

76** 15C003 LABEL, display LCD 1

79 114151 ELBOW, male, swvl (1030fc, 5/32 in. tube) 1

79 112698 ELBOW, male, swvl (1030, 1/4 in. tube) 1

80 15C002 LABEL, identification 1

81 114687 CLIP, retainer 1

82 122115 SCREW, cap, sch 3

83 256918 KIT, dump valve (see pg 23) 1

84 114672 WASHER, thrust 2

85 15B766 MANIFOLD, dump valve 1

86 193680 COLLAR, shaft 1

87 193510 HUB, armature 1

88 193531 HOUSING, clutch 1

89† ARMATURE, clutch, 5 in 1

90 183401 KEY, parallel 1

91 241440 GEAR, combination 1

92 114699 WASHER, thrust 1

93 114686 SCREW, cap, socket hd 2

94† ROTOR, clutch, 5 1

95 101682 SCREW, cap, sch 4

96 100020 WASHER, lock 3

99 100644 SCREW, cap, sch 5

100 114678 BUSHING, strain relief 1

101 113802 SCREW, hex hd, flanged 1

102 114984 SCREW, tapping, phillips pan hd 2

104 111483 CLAMP, cable 2

105 206994 FLUID, TSL 8 oz bottle 1

112 108795 SCREW, mach, pnh 4

117 245245 HANDLE, cart 1

118 198723 CLIP, axle 2

119 198720 WHEEL, semi pneumatic, 12 in. 2

120 114331 SCREW, mach, pnh, sems 6

122 111482 RIVET, snap 2

123 108068 PIN, spring straight 2

124 115522 SCREW, mach, pnh 3

128 241279 ROD, connecting 1

130 116891 WASHER 4

138 112774 SCREW, mach 9

140 235490 GUN, texture (see manual 308274) 1

144 15C005 LABEL, flow control 1

145Y189246 LABEL, warning 1

146** 15B668 LABEL, instruction 1

148 188634 LABEL, outlet 1

150 235737 HOSE SET, 1/2” air x 3/4” fluid (50 ft) 1

151 15B683 VALVE, air 1

152 117780 FITTING, tee male branch 1

153 110980 CLAMP, hose 1

154 117781 SCREW, machine, pnh 2

155 C27076 NUT 2

156 15C190 PLATE, retaining 1

157 115492 SCREW, mach, slot hex wash hd 2

158 15C173 HOSE, 5/32” blue tubing 1

159 15C174 HOSE, 5/32“ black tubing 1

160 102040 NUT, lock. hex 2

162 15C040 LABEL, instruction 1

163** 246606 KIT, digital display 1

164 15C283 TUBE, nylon 1

185 111340 GASKET 1

* Kit 257111 seat, sst tip, and o-rings, Series C

* Kit 256918 seat, sst tip, and o-rings, Series A, B or C

** Kit 246606 items:12, 28, 76 and 146

† Kit 241113 items: 89 and 94

YDanger and warning labels, tags, and cards are free.

22 309662

Parts - Flow Control

See page 21 for parts description and page 20 for location on sprayer.

144

28163

146

44 124

145

138

120

167

157

154

155

151

148

172

168

169

170

171

ti4366b

174

162

173 138

Kit 248327

160

Ref

No. Part No. Description Qty

138† 112774 SCREW, mach 9

157† 115492 SCREW, mach, slot hex wash hd 2

160† 102040 NUT, hex, 1/4--20 2

162† 15D885 LABEL, instructions 1

167† 15D864 BRACKET, 1030FC, air filter 1

168† 155494 UNION, swivel, 90 degree 1

169† 155665 UNION, adapter 1

170† 155699 ELBOW, street 1

171† C20483 NIPPLE, hex, 3/8 npt 1

172† 106148 FILTER, air, 3/8 npt 1

173† 15D863 SPACER, standoff, 1030FC, filter 2

174† 119251 SCREW, self--tap, filhd, 8--32 2

176† 106151 VALVE, drain, auto 1

180‡ 156823 UNION, swivel 1

181‡ 162453 ADAPTER 1

182‡ FLOW SWITCH 1

† Included in Kit 248327 which may be ordered separately

‡ Included in Kit 248328 which may be ordered separately

1Danger and warning labels, tags, and cards are free.

Flow

Sensor Regulator

ti4366a

182181180

160

176

309662 23

Parts - Dump Manifold

See page 21 for parts description and page 20 for location on sprayer.

23n

22n

68n

79n

47n

63a

45n

41n

82n

96n

85n

1Prime Valve Repair Kit 257111 Installation

1. Replace all parts shown for (47).

2. Apply blue LockTite to threads of screw (68).

3. Detail A. Hold piston assembly of air cylin-

der (22) with 3/16 in. hex driver and torque

screw (68) to 40 to 50 in-lb.

4. Detail C. Place valve seat (b) with rounded

end out toward screw head. Place dark

color o--ring (c), carbide seat (d) either side

up, and white o--ring (e).

Torque screw (82) to 40 to 50 in-lb.

TI3122A

Detail A

158 (blue)

159 (black)

Detail B. Orient vent port down. Detail C

TI3008e

TI10246f

TI10245f

63bn

nParts included in kit 256918.

Detail B

24 309662

Parts - Displacement Pump

Model 235166, Series A

Includes items 201227

Ref

No. Part No. Description Qty

201 188437 PISTON ROD 1

202 187068 PACKING NUT 1

203 188560* V-PACKING, poly 2

204 187939* GLAND, male 1

205 188557* O-RING 2

206 187934 PISTON HOUSING 1

207 188559* O-RING, fluoroelastomer 1

208 188434* NUT 1

209 188432* GLAND, male 1

210 188561* V-PACKING, poly 2

211 188433* GLAND, female 1

212 188627 BACKUP WASHER, nylon 1

213 235165 PISTON SEAT 1

214 187929 LUG NUT 1

215 235963 INTAKE HOUSING 1

216 102973* BALL, intake, 1.25 in. Dia. 1

217 187064 BALL GUIDE 1

218 188558* U-CUP SEAL, poly/fluoroelastomer1

219 187072* V-PACKING, poly 3

220 102972* BALL, piston; 0.875 in. Dia. 1

221 187066 CYLINDER 1

225 187071* V-PACKING, poly 3

226 187070* GLAND, female 1

227 187933 HOUSING, outlet 1

228 183210 PIN 1

232 235962 SEAL, foot valve 1

* Included in Repair Kit 235186, purchased separately. Kit

includes pressure drain valve u-cup packing, 111829.

TI3020A

202

*205

221

*205

206

208

220

213

217

216*

215

214

201

227

*226

*204 218

212

211*

209

207

219

203*

*225

228

232

*210

309662 25

Parts - Pinion and Drive Housing Repair Kits

Ref No. 58 and 8

Pinion Housing Repair Kit Ref No. 8: Drive Housing Repair Kit

Ref

No. Part No. Description Qty

Ref

No. Part No. Description Qty

58 245399 KIT, repair, pinion housing 1

58b 105489 PIN 2

58d* 241114 PINION SHAFT 1

58e 112770 RETAINING RING, large 1

*Must be ordered separately.

8 287128 KIT, repair, drive housing 1

8g 194173 WASHER 1

8h 116192 WASHER 1

8p 290228 LABEL, caution 1

59 (Ref)

36 (Ref)

58d

58e

58b

91 (Ref)

92 (Ref)

17 (Ref)

81 (Ref)

84 (Ref)

Pinion housing assembly (58) includes clutch field and connector

TI0177B

26 309662

Accessories

USE ONLY GENUINE GRACO PARTS AND ACCESSORIES

Air And Material Hose Kit 235737

Max. Working Pressure

Fluid: 750 psi (5.18 MPa, 51.7 bar)

Air: 300 psi (2.07 MPa, 20.7 bar)

50 ft (15.2 m) hoses to supplement 50 ft (15.2 m) hose

kit supplied with sprayer. Use up to three more hose

kits. DO NOT use this kit at sprayer outlet as it does

not have a spring guard on material hose.

309662 27

Technical Data

Honda GX160 Engine

Power Rating @ 3600 rpm

ANSI 5.5 Horsepower.........................

DIN 6270/DIN 6271

NA 2.9 Kw--4.0 Ps...........................

NB 3.6 Kw--4.9 Ps...........................

Maximum Working Pressure 1000 psi..............

(7.0 MPa, 70 bar)

Cycles/gallon (liter) 42 (11)........................

Maximum Delivery 3 gpm (11 liter/min).............

Fuel Tank Capacity 0.95 gallon (3.7 liter)............

Pump Inlet Size 2 inch quick disconnect............

Fluid Outlet Size 3/4 npsm(f)......................

Wetted Parts

Displacement Pump Nickle-plated carbon steel,....

Stainless steel, Chrome-plated stainless steel,

Poly, Tungsten carbide, fluoroelastomer

Sound Data

Sprayer:

Sound Pressure Level 97dB(A)*.................

Sound Power Level 105dB(A)*..................

*Measured readings at 1 m, normal load.

Gun:

Sound Pressure Level 96dB(A)**................

Sound Power Level 104dB(A)**.................

**Measured while spraying simulated acoustical texture

under typical conditions as specified by material

manufacturer.

Dimensions

Weight (dry, without packaging) 150 pound (68 kg)...

Height 32 inch (813 mm).........................

Length 30 inch (762 mm).........................

Width 23 inch (584 mm)..........................

28 309662

Graco Warranty and Disclaimers

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 originalpurchaser 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

equipmentdetermined 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 sub-

stitution 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

equipmentwill be returned to the original purchaser transportation prepaid. If inspection of the equipment does notdisclose 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 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 mak-

ing 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 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 reconnais-

sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires

exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.

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.

This manual contains English. MM309662

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440- 1441

www.graco.com

Written in USA 12/2002, Rev 08/2009

Graco Inc Texspray 235490 Users Manual 309662L 1030 FC, Repair

235490 to the manual d4417984-aec6-482a-abfa-8adc530f7f4b

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