Graco 310645P Rtx 1500 Users Manual Electric Texture Sprayer, Repair Parts (English)

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310645P

Repair and Parts

RTX 1500 Electric Texture Sprayer

- For Water-Based Materials Only -

(Consult your Material Supplier for Warnings and Application Requirements)

Models: Page 2

Maximum Working Air Pressure: 45 psi (3.1 bar)

Maximum Working Fluid Pressure: 100 psi (6.9 bar)

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

NOTICE

Use RTX 1500 non-bleeder texture gun 248091.

All other guns will damage sprayer.

ti4305a

EN

Models

2310645P

Models

*Auxiliary Air Hookup Kit

RELATED MANUALS

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.

Manual

Model Electric

Requirements

Country

Operation

287328*

Gun

Languages

248201 120V, 60 Hz, 15 A N. America 310624 310694 310616 English

248536 110V, 60Hz, 15A UK 310624 310694 310616 English

248370 / 248315 230V. 50 Hz, 10 A Europe 310624 310616 French

248370 230V. 50 Hz, 10 A Europe 310624 Dutch

248370 230V. 50 Hz, 10 A Europe 310625 310616 Spanish

248370 / 248315 230V. 50 Hz, 10 A Europe 310625 Italian

248370 230V. 50 Hz, 10 A Europe 310625 Portuguese

248370 / 248315 230V. 50 Hz, 10 A Europe 310625 German

248315 230V. 50 Hz, 10 A Europe 310697 Swiss

248315 230V. 50 Hz, 10 A Europe 310697 Danish

248370 230V. 50 Hz, 10 A Europe 310697 Norwegian

248370 230V. 50 Hz, 10 A Europe 310697 Swedish

248370 230V. 50 Hz, 10 A Europe 310698 Polish

248370 230V. 50 Hz, 10 A Europe 310698 Russian

248370 230V. 50 Hz, 10 A Europe 310698 Greek

248315 230V. 50 Hz, 10 A Asia 310699 Chinese

248315 230V. 50 Hz, 10 A Asia 310699 Japanese

248315 230V. 50 Hz, 10 A Asia 310699 Korean

248315 230V. 50 Hz, 10 A Australia 310699 310694 310616 English

Model Country Manual Languages

ALL ALL 310645 English

Warnings

310645P 3

Warnings

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 section may appear throughout the body 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:

• Use equipment only in well ventilated area.

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

• Ground equipment in the 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.

Equipment Misuse Hazard

Equipment misuse can cause death or serious injury.

• Do not exceed maximum working pressure or temperature rating of 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

equipment manuals. Read fluid and solvent manufacturer’s warnings.

• Check equipment daily. Repair or replace worn or damaged parts immediately.

• Do not alter or modify this equipment.

• Use the equipment only for its intended purpose. Call your Graco distributor for information.

• For professional use only.

• Route hoses away from traffic areas, sharp edges, moving parts and hot surfaces.

• Do not use hoses to pull equipment.‘

•

• Comply with all applicable safety regulations.

Electric Shock Hazard

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-wire extension cords.

• Ensure ground prongs are intact on sprayer and extension cords.

Warnings

4310645P

WARNING

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.

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

• Do not put your hand over the spray tip.

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

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

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

checking, or servicing equipment.

Cleaning Solvent Hazard with Plastic Parts

Use only compatible water-based solvents to clean plastic structural or pressure-containing parts. Many

solvents can degrade plastic parts to the point where they could fail. Such failure could cause serious

injury or property damage. See Technical Data on page 34 of this instruction manual and in all other

equipment manuals. Read fluid and solvent manufacturer’s warnings.

Moving Parts Hazard

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,

follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

Personal Protective Equipment

Wear appropriate protective equipment when operating, servicing or when in the operating area of this

equipment to help protect yourself from serious injury, including eye injury, inhalation of toxic fumes,

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

• protective eye wear

• clothing and respirator as recommended by fluid and solvent manufacturer

• hearing protection

•gloves

CALIFORNIA PROPOSITION 65

The engine exhaust from this product contains a chemical known to the State of California to cause

cancer, birth defects or other reproductive harm.

NOTICE

Water or material remaining in unit when temperatures are below freezing can damage pump and/or delay startup.

To insure water and material are completely drained out of unit:

• Remove hose from material outlet,

• Tip sprayer forward 45° to allow material (water) to flow out of pump inlet.

• Before adding material or starting unit in cold weather, circulate warm water through pump.

Component Identification

310645P 5

Component Identification

A

C

F

H

K

L

E

B

D

P

T

U

S

R

V

W

M

ti4500a

Component Identification

6310645P

Component Identification

ITEM COMPONENT

A Main Power Switch

B Nozzle Storage

C Hopper

D Hopper Connect/Disconnect

E Graco RotoFlex™ HD Pump

F Material Outlet

H Air Outlet

K Fluid Flow Regulator and Pressure Gauge

L Gun Nozzle (5 sizes)

M Gun (see manual 310616)*

P Prime Switch

R Power Cord

S Pump Access Screw

T Hose - 25-ft.

U Material Thickness Gauge

V Cleaning Ball

W Spare Hose Gaskets

Preparation

310645P 7

Preparation

Pressure Relief Procedure

1. Turn Main Power Switch

(A) OFF.

2. Turn fluid flow regulator

(K) all the way down to

reduce pressure.

3. Open gun air valve (aa).

4. Trigger gun, spray-

ing material back

into hopper (C).

Grounding and Electric

Requirements

The sprayer must be grounded. Grounding reduces the

risk of electrical shock by providing an escape wire for

the electrical current.

• The sprayer cord includes a

grounding wire with an appro-

priate grounding prong.

• The plug must be plugged

into an outlet that is properly

installed and grounded in

accordance with all local

codes and ordinances.

• Do not modify plug! If it will

not fit in outlet, have

grounded outlet installed by a

qualified electrician.

• Sprayer model electric

requirements are provided on

page 2.

Extension Cords

• Only use an extension cord

with an undamaged 3-prong

plug.

• For up to 100 ft (30.48 m) cord,

use 3-wire, 12 AWG (2.5 mm2)

minimum.

ti4303a

K

ti4000a

A

ti4294a

Ground

ti4295a

ti4296a

ti4297a

Ground

ti4295a

Preparation

8310645P

Auxiliary Air Compressor

• Use Auxiliary Air Hookup Kit 287328 when addi-

tional atomization air is necessary.

Generators

7500 W (7.5 KW) minimum.

Tips for Using Generators

• Before running sprayer, make sure it is at room tem-

perature. This will reduce startup current.

• Run generator at full throttle.

Hose Lengths

• The system comes with a twin line hose set consist-

ing of a 1 in. ID x 25 ft (25 mm x 7.6 m) material

hose and a 3/8 in. ID air hose. Additional hose sec-

tions can be added. Total final length of hose used

should not exceed 100 feet in length.

NOTICE

Attaching auxiliary air to sprayer without using the

Auxiliary Air Hookup Kit will damage sprayer.

NOTICE

Sprayer air hose fitting can get hot! Allow sprayer to

cool down 5 minutes before removing air hose.

Removing and Replacing Hopper, Front and Back Covers

310645P 9

Removing and Replacing Hopper, Front and Back

Covers

Before performing any service on sprayer

always:

• Read all warnings, page 3.

• Read operating instructions manual, page 2.

•Relieve Pressure, page 7.

• Turn main power switch (A) OFF.

• Unplug sprayer from outlet.

• Remove air and material hoses.

• Clean sprayer. See Operation Manual 310624 or

310625.

Hopper

Removing Hopper

1. To remove hop-

per loosen fit-

ting. Fittings are

hand-tightened

and should not

require tools to

loosen.

2. Lift hopper

straight up, off

frame.

Replacing Hopper

1. To replace hop-

per, position

drain over fit-

ting as far as it

will

go, making sure

identification

label faces out.

2. Hand tighten fit-

ting.

Front Cover

Removing Cover

1. Remove hopper.

2. Unscrew

and remove

knob (S).

3. Place you

hand under

front, bot-

tom edge of

cover.

(3a) Lift

cover up,

(3b) then

pull bottom

toward you

and out to remove cover.

Replacing Cover

1. Place your

hand under

front, bottom

edge of

cover. (1a)

Position top

edge of

cover under

top metal lip

on sprayer

frame.

(1b) Then

push up on

cover so

lower plastic edge of cover has room to clear front

metal frame and slide cover into place. To position

cover correctly, it will go in at an angle.

2. Replace knob (S). Hand tighten fitting.

3. Replace hopper.

ti4503a

ti4504a

ti4408a

S

3a

3b

ti4411a

S

1a

1b

Removing and Replacing Hopper, Front and Back Covers

10 310645P

Back Cover

To access the motor and all other components, it is nec-

essary to remove the hopper, front and back covers.

Removing Cover

1. Completely

remove 6

screws (2 on

top and each

side) from

cover.

2. Lift cover up

and then tilt it

back and off

sprayer frame.

Replacing Cover

1. To reposition

cover on sprayer

frame, tip the

cover back,

toward you and

slide it down, into

place in the base

of the frame. Then

push the top back

into place. Align

screw holes in

side and top of

cover with holes in

frame.

2. Replace and

tighten screws.

ti4430a

ti4431a

ti4432a

ti4433a

RotoFlex™ HD Pump

310645P 11

RotoFlex™ HD Pump

Use RotoFlex HD Pump Replacement Kit 287314.

NOTE: After replacing RotoFlex HD Pump hose, always

follow Hose Break-In Procedure, page 13, before oper-

ating sprayer.

Disassembly

First read and follow instructions in the Before perform-

ing any service on sprayer section, page 9.

Then remove hopper and front cover, page 9.

1. Loosen and remove

hose extension.

2. Loosen and remove

knob.

3. Slide RotoFlex HD

hose off rollers.

4. Rotate pump assem-

bly sideways. Pull

entire assembly out of

front of sprayer frame.

5. Separate the inner and

outer hose brackets.

6. Slide hose ends out of

slots in outer hose

bracket (slide out of

short slot first).

7. Pull hose out of inner

hose bracket.

8. Discard pump hose.

ti4377a

ti4378a

ti4374a

ti4519a

ti4376a

ti4379a

RotoFlex™ HD Pump

12 310645P

Reassembly

1. Bend and kink new

pump hose from kit in

the middle as shown,

making sure dots on

hose fittings face each

other.

2. Insert hose ends

through holes in inner

hose bracket, keeping

dots on fittings facing

each other and kinked

portion of hose hori-

zontal to the under-

side of bracket.

3. Slide hose ends into

outer hose bracket,

making sure dots on

fittings face each other

and alignment holes

are together (slide into

long slot first).

4. Slide plates together,

inserting inner plate in

outer plate, matching

alignment holes.

5. Replace bracket

assembly in housing

making sure the

mounting screw

hole, located in the

top center of the

inner plate, faces up.

6. Slide pump hose

around rollers. Make

sure the rollers are

horizontally parallel

to each other.

7. Slide feet on the bot-

tom of hose bracket, into

the slot on the bottom of

sprayer.

8. Replace knob. Hand

tighten.

9. Reattach hose extension.

10. Replace front cover and

hopper. See Removing

and Replacing Hopper,

Front and Back Cover,

page 9.

ti3127a

DOTS

ti4386a

alignment

holes

ti4383a

ti4520a

ti4429a

ti4381a

RotoFlex™ HD Pump

310645P 13

Hose Break-In Procedure

1. Make sure fluid flow regula-

tor (K) is turned all the way

down.

2. Pour approxi-

mately 1 gallon

hot water in

sprayer hopper

to lubricate the

pump.

3. Turn power switch (A)

on.

4. Hold in prime switch

(P).

5. Turn fluid flow regula-

tor (K) up to full pressure.

6. Run sprayer dry for 1 to

1-1/2 minutes.

ti4303a

K

ti4301a

WATER

ti4653a

ti4364a

P

K

ti4655a

Compressor and Motor Repair

14 310645P

Compressor and Motor Repair

For 120 V sprayer use Compressor and Motor Replace-

ment Kit, 287315.

For 230 V sprayer use Compressor and Motor Replace-

ment Kit, 287344.

Kits include motor/compressor and mounting hardware.

Disassembly

First read and follow instructions in the Before perform-

ing any service on sprayer section, page 9.

Then remove hopper, front and back covers, page 9.

Remove hose extension and RotoFlex HD Pump

assembly from frame, page 11.

1. Remove two screws and

access cover on the left

side of the motor.

2. Remove ground nut and

disconnect green ground

wire.

3. Disconnect black and

white wires to motor.

4. Loosen 4 bolts (2 each

side) to loosen tension

on belt.

5. Slide belt off motor

pully.

6. Disconnect air line from

compressor to cooler

and remove.

7. Remove 3 screws on

right side of cover and

remove cover.

ti4457a

ti4458a

ti4405a

ti4388b

ti4459a

ti4460a

ti4478a

ti4479a

Compressor and Motor Repair

310645P 15

8. Loosen 2 shoulder

bolts about 2-3 turns.

Do not remove them.

9. Remove single shoul-

der bolt on other side

of motor completely.

10. Slide out motor

assembly.

11. Completely remove

old shoulder bolts and

rubber mounts.

12. Thoroughly clean inside housing to remove dust

and debris.

Reassembly

1. Using two new shoulder

bolts and rubber mounts

included in your kit, insert

bolts into openings until

they start to snug up on

rubber mounts.

2. Slide new motor into

sprayer frame, aligning

motor frame opening

under bolts. Tighten

bolts.

3. Replace shoulder

bolt on left side with

new bolt from your

kit. Tighten bolt.

4. Replace end cover.

Replace and tighten 3

screws.

5. Reattach air line to

cooler and compressor.

Tighten fitting.

6. Slide belt over pulleys

and set tension. See

Replacing Belt, page 19.

ti4463a

ti4425a

ti4462a

ti4464a

ti4465a

ti4468a

ti4424a

ti4484a

ti4485a

ti4516a

Compressor and Motor Repair

16 310645P

7. Reattach black and white

wires to motor.

NOTE: Wires are not polar-

ity sensitive.

8. Replace reattach green

ground wire and grounding

nut.

9. Replace cover plate and

screws.

10. Replace RotoFlex HD

Pump and hose exten-

sion, page 12.

11. Replace front and back

covers and hopper. See

Removing and Replac-

ing Hopper, Front and

Back Cover, page 9.

ti4412a

ti4470a

ti4471a

Compressor Rebuild Kit

310645P 17

Compressor Rebuild Kit

To replace piston, seals and sleeve.

For 120 V sprayer use Compressor Rebuild Kit 287330.

For 230 V sprayer use Compressor Rebuild Kit 287331.

Disassembly

First read and follow instructions in the Before perform-

ing any service on sprayer section, page 9.

Then remove back cover, page 9.

1. Disconnect air line to

motor.

2. Remove 3 screws in

side of motor cover.

Remove cover.

3. Remove fan bolt from

center of fan and

remove fan from hous-

ing.

4. Remove 3/8 in. bolt

holding piston to

motor shaft.

5. Loosen 4 bolts on

top of motor hous-

ing.

6. Remove bolts and

housing from

motor.

7. Remove piston rod

from motor.

8. Using parts in kit

replace piston,

seals and sleeve.

ti4460a

ti4478a

ti4479a

ti4706a

ti4707a

ti4708a

ti4709a

ti4710a

Compressor Rebuild Kit

18 310645P

Reassembly

1. Insert new piston rod

from kit in motor housing.

2. Replace and

tighten piston bolt.

3. Replace top motor

hosing and 4 bolts.

4. Tighten bolts.

5. Replace motor

fan and center fan

bolt.

6. Tighten bolt.

7. Replace motor

cover and

screws.

8. Reconnect air

line from motor to

cooler.

9. Replace back cover.

See Removing and

Replacing Hopper,

Front and Back

Cover, page 9.

ti4700a

ti4701a

ti4703a

ti4704a

ti4485a

Removing and Replacing Belt

310645P 19

Removing and Replacing Belt

Use Belt Replacement Kits 118845.

First read and follow instructions in the Before perform-

ing any service on sprayer section, page 9.

Then remove hopper, front and back covers, page 9.

Remove hose extension and RotoFlex HD Pump

assembly from frame, page 11.

Removing Belt

1. Loosen 4 bolts (2 each

side) to loosen tension on

belt.

2. Loosen 2 bolts (1 each

side) holding down sup-

port rod.

3. Using a screw driver for

leverage, lift up on

motor support rod on

one side of motor and

ease it out of the hold-

ing bracket far enough

to remove old belt. Dis-

card old belt.

At the same time, slide

in the new belt.

Replacing Belt

1. Using new belt from Kit,

position new belt

around pulleys making

sure the teeth in the

belt are properly

engaged with teeth on

pulleys.

2. Replace support rod.

Tighten 2 bolts (1 each

side) to secure support-

ing rod.

3. Insert crow bar under

assembly as shown

and raise motor

assembly until desired

belt tension is

achieved.

4. While holding motor

assembly in place with

crow bar. Spin pulley to

assure proper belt

engagement. Adjust

motor assembly position

as necessary.

ti4388b

ti4388a

ti4459a

ti4391a

ti4392a

ti4393a

ti4469a

ti4472a

Removing and Replacing Belt

20 310645P

NOTE: A correctly tensioned belt will feel very tight. To

measure correct tension apply 4-5 lbs pressure at belt

midpoint with thumb. Belt should have approximately

1/8 in (3.175 mm) deflection.

NOTE: A loose belt will not last long. If in doubt, tighten

more.

5. Tighten all 4 bolts.

6. Turn belt one more

time with your hand

to make sure teeth

are properly engaged

and tension is cor-

rect.

7. Replace RotoFlex

HD Pump and hose

extension, page 12.

8. Replace back and

front covers and hop-

per. See Removing and Replacing Hopper, Front

and Back Cover, page 9.

ti4477a

ti4394a

ti4473a

Roller Replacement

310645P 21

Roller Replacement

Use Roller Replacement Kit 287321.

Kit includes 2 rollers, 4 nylon washer, and 2 retaining

rings.

Disassembly

First read and follow instructions in the Before perform-

ing any service on sprayer section, page 9.

Then remove hopper, front and back covers, page 9.

Remove hose extension and RotoFlex HD Pump

assembly from frame, page 11.

1. Remove snap ring.

2. Remove roller assembly

from rotor pins (a).

3. Clean rotor pins (a) and

check for damage. If

pins are worn or dam-

aged, replace rotor

assembly, (Rotor

Assembly Replace-

ment, page 22).

Reassembly

1. Replace roller assembly.

2. Reinstall snap ring.

3. Replace RotoFlex HD

Pump and hose extension,

page 12.

4. Replace back and front

covers and hopper. See

Removing and Replacing

Hopper, Front and Back

Cover, page 9.

ti4396a

ti4397a

a

ti4398a

ti4399a

Rotor Assembly Replacement

22 310645P

Rotor Assembly Replacement

Use Pump Assembly Replacement Kit 287255.

Disassembly

First read and follow instructions in the Before perform-

ing any service on sprayer section, page 9.

Then remove hopper, front and back covers, page 9.

Remove hose extension and RotoFlex HD Pump

assembly from frame, page 11.

1. To prevent rotor assembly

from moving, insert a long

screw driver or pry bar in

the pulley.

2. Remove large bolt and

washer in center of rotor

assembly.

3. Pull rotor assembly off

shaft.

Reassembly

1. Put new rotor assembly from kit on shaft.

2. Insert a wrench in the

pulley to prevent it from

moving.

3. Replace bolt. Torque to

40 ft. lb.

4. Replace RotoFlex HD

Pump and hose extension,

page 12.

5. Replace back and front

covers and hopper. See

Removing and Replacing

Hopper, Front and Back

Cover, page 9.

ti4714a

ti4711a

ti4714a

ti4712a

Air Cylinder and Solenoid Valve

310645P 23

Air Cylinder and Solenoid Valve

Use Cylinder Replacement Kit, 287323.

For 120 V sprayer use Solenoid Replacement Kit

15D560.

For 230V sprayer use Solenoid Replacement Kit

287351.

Disassembly

First read and follow instructions in the Before perform-

ing any service on sprayer section, page 9.

Then remove hopper, front and back covers, page 9.

Remove hose extension and RotoFlex HD Pump

assembly from frame, page 11.

1. Remove hose from quick

release fitting by using your

fingers on one hand to push

in on ring while at the same

time, using the other hand,

gently pull the hose out of

the fitting.

2. Remove electric wire ter-

minal connections.

3. Remove cotter key

located on the end of the cyl-

inder pin, by using a pliers to

straighten the ends and pull

it out of the hole.

4. Gently push cylinder

forward, relieving

tension on pin. Pull

out pin.

NOTE: If replacing solenoid valve only, it can be

done at this time.

a. Use adjustable wrench to rotate entire

solenoid valve assembly counterclockwise from

cylinder.

b. Replace solenoid valve and continue with step 4

of reassembly.

5. Lift cylinder up and pull it

back.

6. Remove dampening

grommet.

7. Using a 15/16 in.

wrench, loosen nut,

located inside sprayer

frame at the end of the

air cylinder.

8. Using a 15/16 in. wrench,

loosen nut on the other

side of the sprayer

frame.

9. Pull cylinder out of

sprayer frame.

If replacing cylinder only,

remove solenoid valve

(see a and b above) and

reinstall on new cylinder.

ti4406a

ti4416a

ti4453a

ti4409a

ti4518a

ti4415a

ti4414a

Air Cylinder and Solenoid Valve

24 310645P

Reassembly

1. Insert crowned backing

nut on shaft of cylinder.

2. Using new cylinder from

kit, position cylinder in

sprayer frame, inserting

end of cylinder through

pump bracket mounting

hole.

3. Install locking nut flush to end of shaft.

4. Install dampening grommet.

5. Align hole in end of air cyl-

inder and replace pin.

6. Replace cotter pin

through hole in pin,

bending ends to

secure.

7. Reattach electric wire

terminals. Terminals are

not polarity sensitive

and can be connected to

either post.

8. Gently push hose in

quick release fitting.

9. Replace RotoFlex HD

Pump and hose

extension, page 12.

10. Replace front cover

and hopper. See

Removing and Replacing Hopper, Front and Back

Cover, page 9.

ti4421a

ti4410a

ti4455a

ti4456a

ti4417a

ti4407a

Relief Valve and Flow Sensor Manifold

310645P 25

Relief Valve and Flow Sensor Manifold

For 120 V sprayer use Relief Valve Replacement Kit

15D559.

For 230 V sprayer use Relief Valve Replacement Kit

287350.

Disassembly

First read and follow instructions in the Before perform-

ing any service on sprayer section, page 9.

Then remove hopper, front and back covers, page 9.

1. Remove air line to

regulator.

2. Remove air line from

cooler to manifold.

3. Disconnect wires to

Relief Valve. Pay attention to their location to insure

they are reattached correctly.

4. Remove 2 nuts secur-

ing Relief Valve to

sprayer.

5. Remove Relief Valve

from sprayer frame.

Reassembly

1. Position new relief valve from Kit in back of sprayer.

2. Replace and tighten screws.

3. Reattach wires to Relief Valve.

4. Reattach air line from cooler to manifold.

5. Reattach air line to regulator.Replace RotoFlex HD

Pump and hose extension, page 12.

6. Replace front cover and hopper. See Removing and

Replacing Hopper, Front and Back Cover, page 9.

ti4423a

ti4418a

ti4419a

Air Flow Sensor Replacement

26 310645P

Air Flow Sensor Replacement

For 120 V sprayer use Sensor Replacement Kit 287326.

For 230 V sprayer use Sensor Replacement Kit 287345.

NOTE: If you are just replacing the sensor, you do not

have to remove the motor first.

Disassembly

First read and follow instructions in the Before perform-

ing any service on sprayer section, page 9.

Then remove hopper, front and back covers, page 9.

Remove hose extension and RotoFlex HD Pump

assembly from frame, page 11.

1. Disconnect all

wire connec-

tions.

2. Rotate counter-clockwise

to remove sensor from

manifold.

Reassembly

1. Rotate new sensor

from kit clockwise, all

the way into opening in

Relief Valve housing.

Lightly tighten nut.

2. Reconnect all wires.

3. Replace RotoFlex HD

Pump and hose

extension, page 12.

4. Replace back and

front covers and hop-

per. See Removing

and Replacing Hop-

per, Front and Back

Cover, page 9.

ti4481a

ti4482a

WHITE WIRE

ti4480a

ti4486a

ti4487a

WHITE WIRE

ti4488a

Troubleshooting

310645P 27

Troubleshooting

Problem Cause Solution

Sprayer won’t run or stops intermit-

tently

Power switch not on Turn switch on.

No power at wall outlet Check outlet by plugging in another

appliance. If appliance does not

work, try another outlet.

Wrong size generator Use a 7500 watt or larger generator.

Refer to Generator Requirements,

page 8.

Temperature too cold Allow unit to warm up.

Too many items on same circuit Unplug other items from circuit.

Internal thermal switch tripped Self-resetting. Allow unit to cool down

15 minutes and restart. Usually

occurs when wrong size extension

cord is used.

Extension cord too long or wrong

gauge

Use a 12 gage extension cord or

remove extension cord. Refer to

Grounding and Electric Require-

ments, page 7.

Breaker tripped Reset breaker.

Pump won’t pump material or low

output

Air lock Open air valve on gun.

Mix too thick Add water to thin material. Use Mate-

rial Thickness Gauge.

Loose fittings Check and retighten all fittings.

Plugged gun Relieve Pressure, page 7. Remove

gun from hose. Clean gun.

RotoFlex HD Pump worn out Replace hose.

Pump cold or material frozen in pump Move pump to warm room and allow

it to warm up or run hot water through

sprayer.

Sensor is bad Replace, page 26

Check air system for leaks Remove shroud and examine for air

leaks

Loose wire Remove shroud and examine wiring

No air pressure Rebuild compressor

Troubleshooting

28 310645P

Soft start won’t work/pump, always

loaded

Sensor is bad Change sensor, page 26

Air leak due to bad seal keeps valve

open

Replace seal

Normal soft start system delay Release trigger for 10-15 seconds.

Retry.

Switch is not operating properly Replace switch

Damaged solenoid valve on cylinder Check gun supply, hose and sprayer

for leaks

AIr leak

Material runs out of bottom of sprayer RotoFlex HD Pump worn out Replace hose.

Loose fittings Check and retighten all fittings.

No air from compressor Gun air valve closed Open gun air valve.

Gun needle plugged Clean needle and retry.

Lines not connected Check all quick disconnect connec-

tions to gun and hoses.

Damaged hose Replace hose.

Worn compressor Service compressor. Contact a quali-

fied Graco Service Center.

Speed of application too slow Material too thick Thin material.

Nozzle too small Change nozzles to a larger size. See

Operation Manual, Recommended

Nozzle Selection Chart, page 20.

Speed of application too slow (cont.) Flow control set too low Increase flow control setting

Plugged or dirty gun Relieve Pressure, page 7. Clean

gun.

Kinked hose Unkink hose.

Gun fluid flow adjustment set too low Increase flow adjustment with flow

adjustment nut.

Intermittent flow/sputtering or air in

material

Hopper connection not tight Check gasket. TIghten connection.

Debris in system Clean

Air quick disconnect does not stay

connected.

Dirty or corroded fitting Clean thoroughly. Soak in oil. Apply a

few drops of light oil.

Gun will not shut off Worn nozzle or needle. Relieve Pressure, page 7. Replace

worn parts.

Debris in needle passage Relieve Pressure, page 7. Clean.

Fluid leaking at Flow Adjustment Nut Damaged seal. Relieve Pressure, page 7. Replace

seal.

Needle adjustment won’t adjust Dirty threads Clean threads

Nozzle not on gun Put nozzle on gun

Flow nut set to maximum adjustment Turn flow nut adjustment the other

way

Problem Cause Solution

Air Diagram

310645P 29

Air Diagram

Wiring Diagram

Air Cylinder

Guage

Air Flow Control

Air Cooler

Air Compressor

One Way Valve One Way Valve

Gun

Regulator

ti4369a

50

8

39

51

32

50

50

150/151

Green

Black

White

Power

Switch

Prime

Switch

Air Cylinder

Air Compressor

Air Flow

Control

ti4370d

Parts

30 310645P

Parts

56

49

53

41

13

62

63

37

38A

38

1E

42

38B

4

36

45

73

1A

1B

88

88

63

62

57

52

1D

102

52

34

921

1B

31

94333

22

40

1949A

49B

49C

55

101

67

Parts List

310645P 31

Parts List

▲Replacement Danger and Warning labels, tags and

cards are available at no cost.

Ref. Part Description

Qty

.

1 287315 KIT, compressor replacement

(includes 1A and 1B-1E),

120V sprayers

1

287330 KIT, compressor rebuild,

120V sprayers

287344 KIT, compressor replacement

(includes 1A, and 1B-1D),

230V sprayers

287331 KIT, compressor rebuild,

230V sprayers

1A 119872 SCREW, shoulder 3

1B 118886 GROMMET, isolator 3

1D 119381 COVER, terminal 1

1E 121479 CAPACITOR, start 1

4 118845 BELT 1

9 117728 FITTING, compression, union 2

13 15D156 PULLEY, rotor 1

16 118888 HOSE, air (includes 1/4 in. tubing

and one-way valve)

1

19 15D862 NUT, hand 1

21 118876 TUBE, air, aluminum 1

22 117637 NUT, compression 1

31 112395 SCREW, cap 4

32 15D633 WIRE, jumper 1

33 103473 STRAP, tie, wire 2

34 15B815 COOLER 1

36 101242 RING, retaining, ext. 2

37 287255 ROTOR, pump, assbly

(includes 38, 38A, 38B)

1

38 287321 KIT, roller replacement

(includes 38A, 38B and two roll-

ers)

2

38A 113983 RING, retaining, ext 2

38B 117726 WASHER, nylon 4

39 15D628 CONDUCTOR, ground 1

40 103785 RIVET 2

41 287327 KIT, repair, shaft, bracket, pump

assbly.

1

42 287256 BRACKET, compressor 1

43 118869 TUBE 1

45 15D610 SHAFT, motor, mount 1

49 287346 SHIELD, rear, assbly

(includes 19, 49A, 49B, 49C)

1

49A 15D561 COVER, tool tray 1

49B▲15D939 LABEL, warning, English, French,

Spanish

287336 KIT, label, warning, all languages

except those included in 15D939

49C▲15D940 LABEL, identification

51 15D634 WIRE, jumper 1

52 116937 BEARING, flanged, bronze 2

53 117633 SCREW, slot hex wash hd 8

54 116666 TUBE, air 1

55 287304 HOSE SET, twin line, 1 in. x 25-ft 1

56 15C090 GAUGE, thickness, fluid 1

57 183401 KEY, parallel 2

58 116720 COUPLER, air, quick disconnect 1

62 108851 WASHER, plain 2

63 106276 SCREW, cap, hex head 2

67 248515 BALL, sponge, 30 mm (5 pk) 2

73 112785 SCREW, flanged, hex head 2

74 115498 SCREW, mach, slot, hex, wash hd 1

82 118887 HOSE, air (includes 1/4 in. tubing

and one-way valve)

1

88 118866 WASHER, flat 1

101 248091 GUN, non-bleeder 1

102 122104 VALVE PLATE, compressor 1

Ref. Part Description

Qty

.

Parts

32 310645P

Parts

3

6

7

10

14

19

18

23

24

25

26

29

30

35

58

59

71

70

66

72

ti4372C

12

27

60

20 77

15

5A

5B

5

17

55

93

93

89

90

91

92

81

83

28

8

154

150a 150b 150c152a 152c 152d152b 152e

153

151

A

A

93

Parts List

310645P 33

Parts List

Ref. Part Description

Qty

.

3 118844 REGULATOR, air, 1/8 in. NPT 1

5 287323 KIT, cylinder, replacement,

(includes 5A, 5B, 89)

1

5A 15D576 SPACER, crowned 1

5B 118871 NUT, lock, 1/2-20 1

6 117720 GAUGE, pressure 1

7 115244 NUT, regulator 1

8▲186620 LABEL, ground, symbol 1

10 117693 SWITCH, power 1

12 119064 SWITCH, power, prime 1

14 15D559 VALVE, assembly, 120V (includes

sensor) sprayer

1

287350 VALVE, assembly, 230V (includes

sensor) sprayer

15 15D560 VALVE, cylinder, 120V sprayer 1

287351 VALVE, cylinder, 230V sprayer 1

16 118888 HOSE, air (includes 1/4 in. tubing

and one-way valve)

1

17 15C968 TUBE, air 1

18 287347 HOPPER, texture (includes

bracket)

1

19 15D862 NUT, hand 1

20 287326 KIT, sensor only, 120V 1

287345 KIT, sensor only, 230V

23 287348 SHIELD, front (includes 28) 1

24 108471 KNOB, pronged 1

25 15D589 BRACKET, hose, outer 1

26 15D588 BRACKET, hose, inner 1

27 287314 KIT, RotoFlex HD Pump 1

28▲189286 LABEL, warning 1

29 118885 HOSE, coupled (includes grom-

met)

1

30 287254 FRAME, texture, blue 1

32 15D633 WIRE, jumper 1

35 116478 WHEEL, pneumatic 2

49B▲15D939 LABEL, warning, English, French,

Spanish

287336 KIT, label, warning, all languages

except those included in 15D939

49C▲15D940 LABEL, identification

51 15D634 WIRE, jumper 1

54 116666 TUBE, air 1

55 287304 HOSE SET, twin line, 1 in. x 25-ft 1

58 116720 COUPLER, air, quick disconnect 1

59 104641 FITTING, bulkhead 1

60 116658 FITTING, tube, male, 1/4 NPT 1

66 116171 BUSHING, strain relief 1

70 116411 SPRING, compression 2

71 116477 WASHER, flat, nylon 2

72 101242 CAP, end 4

74 115498 SCREW, mach, slot, hex, wash hd 1

77 102040 NUT, lock, hex 2

81▲198492 LABEL, warning 2

82 118887 HOSE, air (includes 1/4 in. tubing

and one-way valve)

1

83▲15D089 LABEL, warning, hot surface 1

89 801012 GROMMET 1

90▲15D951 LABEL, identification 1

91▲15D953 LABEL, identification 1

92▲15D952 LABEL, identification 1

93 118872 GASKET 4

150 CORD, power

150a 15D630 Americas/Canada, 120V, 60 Hz 1

150b 15E056 Europe/Asia, 230V, 50 Hz

(hardwired, rubber cord)

1

150c 15E061 United Kingdom, 110V, 60, Hz 1

151 15D902 CORD, power, Europe/Austra-

lia/China, 230V, 50 Hz (requires

cordset adapter, 152, following)

1

152 ADAPTER, cordset, (for 15D902),

152a 242001 Europe 1

152b,c,d 287121 Italy, Denmark, Switzerland 1

152e 242005 Australia/China 1

153 195551 RETAINER, (for 15D902) 1

154 15F966 BAFFLE, hopper 1

Ref. Part Description

Qty

.

Technical Data

34 310645P

Technical Data

*Measured while spraying at 1 m.

#Measured per ISO-3744

Maximum working fluid pressure 100 psi (6.9 bar)

Maximum working air pressure 45 psi (3.1 bar)

Material pressure operating range 0-100 psi (0 to 6.9 bar)

Compressor

Type Oilless

Air delivery 6.5 CFM @ 40 psi (184.1 lpm @ 2.8 bar)

Motor

120V, 60 Hz 15A

230V, 50 Hz 10A

Hopper capacity 15 US gallons (57 liters)

Maximum delivery with texture material 2.0 gpm (7.57 lpm)

Dimensions

Length 27 in. (685.8 mm) with handles

Width 26 in. (660.4 mm)

Height 40 in. (1016 mm)

Weight

With hoses and gun 147 lb (66.68 kg)

Without hoses and gun 131 lb (59.47 kg)

Wetted parts PVC, Buna-N, anodized aluminum, powder coat

aluminum, brass, polyethylene, SST, UHMW

Sound data

Sound pressure level* 85.8 db(A)

Sound power level# 100.1 db(A)

Generator (minimum size requirement) 7500W (7.5 kW)

Maximum external working air pressure (must use

External Air Hookup Kit 287328 ONLY)

120 psi (8.3 bar)

Notes

310645P 35

Notes

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.

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 310645

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2004, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revised March 2014

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, Graco 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 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 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 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

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 procédures concernées.

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.