Repair TexSpray 1030t FC 309662J German Patent No. P 43 18 679.3--09 - For portable spray application of architectural paints and coatings 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 A TexSpray 1030 FC sprayer, 235490 TexSpray gun and 50 ft (15 m) air and fluid hose set Important Safety Instructions Read all warnings and instructions in this manual.
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.
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: D Use equipment only in well ventilated area.
WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. INSTRUCTIONS D Read all instruction manuals, tags, and labels before operating the equipment. D Use equipment only for its intended purpose. Call your Graco distributor for information. D Do 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.
Component Description Flow and Air Control Prime Valve Fig. 1. The flow control (A) has a shut off and pressure relief feature to soft start each time the gun is triggered, instead of a blast of unatomized material. The flow control has three modes: Fig. 1. The prime valve (C) relieves system pressure and stops the pump when the gun trigger is released.
Component Description Compressor Requirements NOTE: This sprayer requires an external air compressor. CAUTION 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 Elastomerics (textured) Air Requirements* Minimum Compressor Size* 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.
Troubleshooting WARNING To reduce risk of injury due to sprayer starting unexpectedly, shut off engine before performing checks or service. Check everything in chart before disassembling sprayer. PROBLEM CAUSE SOLUTION Engine does not start Engine switch not ON Turn engine switch ON Out of gas 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.
Troubleshooting (Continued) PROBLEM CAUSE SOLUTION Engine operates, but displacement pump does not (Continued) Connecting rod worn or damaged Replace connecting rod. See page 14. Drive housing worn or damaged Replace drive housing. See page 15. Pinion assembly worn or damaged Service pinion assembly. See page 16. Flow control is set to PRIME Set flow control to LOW/MED/HIGH while triggering gun. Fluid system over--pressurized Spraying material is too thick or the material hose is too long.
Troubleshooting (Continued) PROBLEM CAUSE SOLUTION Displacement pump output low on downstroke or both strokes Material leaks into wet-cup Siphon hose strainer is clogged Clean strainer Piston packings worn or damaged Replace packings. See page 12. 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.
Displacement Pump Repair Removal 2. Fig. 5. Start engine. Jog flow control between PRIME and OFF until connecting rod stops near bottom of stroke. Shut off engine. WARNING 3. Loosen two quick disconnect screws (27). To reduce risk of injury due to sprayer starting unexpectedly, shut off engine before performing checks or service. 4. Pry retaining spring (37) up on connecting rod (128). Push pin (38) out with a screwdriver. 1. Fig. 4. Flush sprayer.
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).
Pump Repair WARNING To reduce risk of injury due to sprayer starting unexpectedly, shut off engine before performing checks or service. 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.
Pump Repair 1 1 2 3 Grease inside of throat before installing packings Lips of v-packings in throat must face down Grease inside of packings after installing 6 Lips of v-packings on piston must face up 7 Grease outside of packings after installing 8 Lips of u-cup seal on piston must face down 9 10 227 2 3 If piston seat and rod were separated, apply Loctite primer, then red Loctite, and torque to 80--100 ft--lb (110--135 N.
Bearing Housing & Connecting Rod Removal WARNING To reduce risk of injury due to sprayer starting unexpectedly, shut off engine before performing checks or service. 1. Fig. 8. Perform steps 1--8 of Displacement Pump, Removal, page 10. 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 housing onto drive housing or tap it into place with a plastic mallet. 5.
Drive Housing 59 A 8g 8h WARNING 36 To reduce risk of injury due to sprayer starting unexpectedly, shut off engine before performing checks or service. 58 2 91 84 92 8 84 36 2. Remove four screws (40) and lockwashers (56) from bearing housing (39). 93 1 40 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). 56 39 3.
Pinion Assembly/Rotor/Field/Shaft/Clutch Removal 6. Fig. 12. Remove retaining ring (58e). WARNING To reduce risk of injury due to sprayer starting unexpectedly, shut off engine before performing checks or service. 7. Tap pinion shaft (58d) out with plastic mallet. If pinion assembly (58) is not removed from clutch housing (88), do 1. through 4. Otherwise, start at 5. 58e 1. Remove drive housing (8); page 15. 58d 2. Disconnect field cable from flow control. 3. Fig. 10.
Pinion Assembly/Rotor/Field/Shaft/Clutch Installation 1. Fig. 14. Lay two stacks of two dimes on smooth bench surface. 6. Fig. 12. Tap pinion shaft (58d) in with plastic mallet. 2. Lay armature (89) on two stacks of dimes. 7. Install retaining ring (58e) with beveled side facing field. 3. Press center of clutch down on bench surface. 4a 8. Fig. 11. Place pinion assembly (58) on bench with rotor side up. 0.12 ±.01 in. (3.0 ±.25 mm) Fig. 14 8705A 4. Install armature (89) on engine drive shaft. 5.
Clutch Housing Removal 1. Fig. 16. Remove four capscrews (42) and lockwashers (29) which hold clutch housing (88) to engine. 90 88 2. Remove screw (101) from under mounting plate (D). 3. Remove engine key (90). 4. Pull off clutch housing (88). 29 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).
Engine Removal 1. Remove Pinion Assembly/Rotor/Field/Pinion/ Clutch, Clamp and Clutch Housing, as instructed 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. 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.
Parts - Sprayer 61 13 DETAIL A 52 60 164 TI4365a 1 95 43 81 94 59 58, page 21 36 100 BOTTOM VIEW 117 104 34 24 35 32 112 Ref 8g 8, page 21 91 92 72 1 122 14 Ref 8h 123 75 1 128 38 37 99 84 43 88 17 1 90 A 43 2 25 24 89 158 36 159 93 19 21 40 39 87 43 2 C 56 62 29, 42 Page 22 86 185 101 83, page 23 80 3, page 20 85 27 33 64 18 162 26 ti4365c 130 102 16 51 153 118 119 140 152 73 105 150 1 20 309662 Danger and warning labels, tags, and cards ar
Parts - Sprayer Ref No. Part No.
Parts - Flow Control See page 21 for parts description and page 20 for location on sprayer. C 171 172 170 169 168 138 174 167 160 162 145 160 1 54 46 173 176 157 Kit 248327 163 6 138 28 53 55 50 66 9 120 146 151 70 76 44 124 12 69 7 155 309662 154 4 148 144 ti4366b 1 Danger and warning labels, tags, and cards are free. B Ref No. Part No.
Parts - Dump Manifold See page 21 for parts description and page 20 for location on sprayer. 159 (black) 79n 158 (blue) 30 3 41n 23n 63a 22n 45n 68n 1 63bn 96n 82n 47n 31 TI3122A 3 2 85n TI3008e 3 Detail A 1 Prime Valve Repair Kit 234231 Installation 1. Replace all parts shown for (47). Detail B TI10245e 2 Torque screw (82) to 40 to 50 in-lb. 3 Detail B. Dump valve adapter (41) must be installed with smaller ID bore and OD orientation groove (if present) toward air cylinder assembly.
Parts - Displacement Pump Model 235166, Series A 206 202 Includes items 201227 208* 228 Ref No. Part No.
Parts - Pinion and Drive Housing Repair Kits Ref No. 58 and 8 Pinion Housing Repair Kit Ref No. Part No. Ref No. 8: Drive Housing Repair Kit Description Qty 58 245399 KIT, repair, pinion housing 58b 105489 PIN 58d* 241114 PINION SHAFT 58e 112770 RETAINING RING, large *Must be ordered separately. 58e 58d 1 2 1 1 Ref No. Part No.
Accessories USE ONLY GENUINE GRACO PARTS AND ACCESSORIES Air And Material Hose Kit Max. Working Pressure Fluid: 750 psi (5.18 MPa, 51.7 bar) Air: 300 psi (2.07 MPa, 20.7 bar) 235737 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.
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 . . . . . . . . . . . . .
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 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.
