Graco 24V016 Use and care manual

333233D
EN
Repair-Parts
Electric Driver for
High Pressure Airless Sprayer
Electric driver for application of protective coatings. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
Model 24V016
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
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2 333233D
Contents
Related Manuals .........................2
Warnings .................................3
Installation ................................5
Power Supply ...........................5
Connect Power ..........................5
Grounding ..............................6
Install Vented Oil Cap Before Using Equipment . 7
Setup .....................................7
Pressure Relief Procedure ...................7
Operation .................................7
Maintenance ...............................8
Preventative Maintenance Schedule ..........8
Change the Oil ..........................8
Check Oil Level ..........................8
Bearing Pre-Load ........................8
Troubleshooting ............................ 9
Power Saving Mode ......................9
Error Codes .............................9
Repair ...................................12
Replace Shaft Bearing Assembly ...........12
Replace Fan Fuses ......................13
Replace Fan Assembly ...................13
Replace Electronics Cover ................15
Repair Token Cable ......................18
Software Update Procedure ...............19
Parts ....................................20
Electric Driver ..........................20
Parts List - Electric Driver (24V016) .........21
Mounting Hole Pattern ....................22
Wiring Diagram ............................23
Dimensions ...............................24
Technical Data ............................25
Graco Standard Warranty ...................26
Related Manuals
Manuals are available at www.graco.com.
Component manuals in English:
333208 Electric High Pressure Sprayer Manual

Warnings
333233D 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion 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 or on warning labels, 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
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
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.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are antistatic or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.

Warnings
4 333233D
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•Do not exceed the maximum working pressure or temperature rating of the 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 equip-
ment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your
material, request MSDS from distributor or retailer.
•Do not leave the work area while equipment is energized or under pressure.
•Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufac-
turer’s replacement parts only.
•Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
•Make sure all equipment is rated and approved for the environment in which you are using it.
•Use equipment only for its intended purpose. Call your distributor for information.
•Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Do not kink or over bend hoses or use hoses to pull equipment.
•Keep children and animals away from work area.
•Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut 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 and disconnect all power sources.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury,
hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:
•Protective eyewear, and hearing protection.
•Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNING

Installation
333233D 5
Installation
Power Supply
See Table 1 for power supply requirements. The system
requires a dedicated circuit protected with a circuit
breaker.
Select the minimum cord wire gauge based on length
according to the table below:
Connect Power
1. Cut power cord wires to the following lengths:
• Ground wire - 6.5 inches (16.5 cm)
• Power wires - 3.0 inches (7.6 cm)
• Add ferrules as necessary. See FIG.1.
2. Bring cord to unit and remove four screws to sepa-
rate junction box cover (G) with power switch (E)
from remainder of sprayer. See FIG.2.
3. With power switch (E) and junction box cover (G)
detached from machine, wires inside junction will
appear as below.
NOTE: Two wires will be installed in both terminals.
See FIG.3:
• For Series A and B: terminals 1L1 and 3L2
• For Series C: terminals 1L1 and 5L3
NOTE: Press gasket against back sealing face of
junction box to ease installation of power cord.
4. Insert power cord (from step 1) through cord grip
(C2) and into junction box (S).
NOTE: Power wires should be installed into termi-
nals. See FIG.3:
• Series A and B: terminals 2T1 and 4T2
• Series C: terminals 2T1 and 6T3
Improper wiring may cause electric shock or other
serious injury. All electrical wiring must be done by a
qualified electrician and comply with all local codes
and regulations.
Table 1: Power Supply Specifications
Voltage Phase Hz Current
200-240 VAC 1 50/60 20 A
Length Gauge mm2
50 ft (15.24 m) 12 AWG 3.31
100 ft (30.48 m) 10 AWG 5.26
200 ft (60.96 m) 6 AWG 13.29
300 ft (91.44 m) 4 AWG 21.14
FIG. 1: Power Cord
GROUND
POWER
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FIG. 2: Power Switch
FIG. 3: Terminal Connections
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Installation
6 333233D
5. Attach ground wire to ground terminal inside junc-
tion box (S).
NOTE: The power cord attaches to a separate
ground screw than the ground screw that is already
attached.
6. Place fan wires and other power wires into open
area on either side of disconnect block (J) as space
permits. Reinstall junction box cover. See FIG.4.
7. Replace junction box screws and washers removed
in step 2 and tighten cord grip to securely hold
power cord in junction box (S). See FIG.5.
Grounding
Driver: The driver is grounded through the power cord.
NOTICE
If wires get pinched when the screws are tightened,
damage will occur. Make sure all wires are routed
correctly before installation.
FIG. 4: Grounding Wire
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FIG. 5: Junction Box Screws and Strain Relief
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
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Setup
333233D 7
Install Vented Oil Cap Before
Using Equipment
The driver gear-box is shipped from the factory pre-filled
with oil. The temporary unvented cap (PX) prevents oil
leaks during shipment. This temporary cap must be
replaced with the vented oil cap (P), supplied with the
equipment, before use.
Setup
1. Pull pressure adjustment knob (H) out and turn
counterclockwise until it stops. Push the knob in to
lock.
2. Turn power switch (E) OFF. Connect unit to power
source. See FIG. 2, page 5.
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Pull pressure adjustment knob (H) out and turn
counterclockwise until it stops. Push the knob in to
lock.
2. Relieve all fluid pressure as explained in your sepa-
rate sprayer manual.
Operation
The motor will adjust the speed to maintain a constant
fluid pressure.
1. Pull the control knob (H) out to set. Turn the knob
clockwise to increase the pressure, or
counter-clockwise to decrease the pressure. Push
the knob to lock. See FIG.7.
FIG. 6: Unvented and Vented Oil Caps
FIG. 7: Pressure Adjustment Knob
PX
P
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This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.

Maintenance
8 333233D
Maintenance
Preventative Maintenance
Schedule
The operating conditions of your particular system
determine how often maintenance is required. Establish
a preventative maintenance schedule by recording when
and what kind of maintenance is needed, and then
determine a regular schedule for checking your system.
Change the Oil
NOTE: Change the oil after a break-in period of 200,000
to 300,000 cycles. After the break-in period, change the
oil once per year.
1. Place a minimum 2 quart (1.9 liter) container under
the oil drain port. Remove the oil drain plug (15).
Allow all oil to drain from the driver.
2. Reinstall the oil drain plug (15). Torque to 18-23 ft-lb
(25-30 N•m).
3. Open the fill cap (P) and add Graco Part 16W645
ISO 220 silicone-free synthetic EP gear oil. Check
the oil level in the sight glass (K). (See FIG. 8.) Fill
until the oil level is near the halfway point of the sight
glass. The oil capacity is approximately 1.0 - 1.2
quarts (0.9 - 1.1 liters). Do not overfill.
4. Reinstall the fill cap.
Check Oil Level
Check the oil level in sight glass (K). (See FIG. 8.) The
oil level should be near the halfway point of the sight
glass when the sprayer is not running. If oil is low, open
fill cap (P) and add Graco Part No. 16W645 ISO 220 sil-
icone-free synthetic EP gear oil. See FIG.8.
The oil capacity is approximately 1.0 - 1.2 quarts (0.9 -
1.1 liters). Do not overfill.
Bearing Pre-Load
See FIG. 8. The bearing pre-loads (R) are factory set
and are not user adjustable. Do not adjust the bearing
pre-loads.
NOTICE
Do not open/remove gear cover. The gear side is not
intended to be serviced. Opening the gear cover may
alter the factory set bearing pre-load and may reduce
the product life.
NOTICE
Only use oil with Graco part number 16W645. Any
other oil may not lubricate properly and can cause
damage to the drive train.
FIG. 8: Sight Glass and Oil Fill Cap
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Troubleshooting
333233D 9
Troubleshooting
Power Saving Mode
When fast blinking is displayed, the sprayer has entered
Power Saving Mode mode. When the sprayer is on and
pressurized but the pump has not moved any material in
30 minutes, the sprayer will enter Power Saving Mode
and will only control up to 75% of the maximum pressure.
Power Saving Mode will be exited when:
• Material starts to dispense and causes the pump to
move, OR
• The pressure knob is adjusted, OR
• Power is cycled OFF and ON
Error Codes
Error codes can take two forms:
Alarm: alerts you to the alarm cause and shuts down
the pump.
Deviation: alerts you to the problem, but pump may
continue to run past the set limits until the system’s
absolute limits are reached.
NOTE: The blink code is displayed using the power indi-
cator (L) on the driver. The blink code given below indi-
cates the sequence. For example, blink code 2 indicates
two blinks, a pause, and then the sequence repeats.
NOTE: To clear an error code, first try turning the pres-
sure adjustment knob (H) counterclockwise until it stops.
If the status indicator (L) does not stop blinking shortly
after turning the knob to zero, cycle the power by turning
the power switch (E) to the off position for at least 30
seconds before turning it back on.
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Blink Code Error Type Troubleshooting Steps
1 Alarm Voltage Too Low
• Verify that line voltage is within the range specified in Technical Data, page 24.
• Use the recommended cord (see page 5).
• Cycle power and check status indicator to see if error is still active.
2 Alarm Voltage Too High
• Verify that line voltage is within the range specified in Technical Data, page 24.
• Cycle power and check status indicator to see if error is still active.
• Verify that the outlet check valve is installed on pump and functions properly. A
faulty outlet check valve can result in excessive pump speed, causing high volt-
age internally to the electric driver.
3 Deviation Low Temperature
• Warm equipment.
• Contact your Graco distributor or Tech Service for more information.

Troubleshooting
10 333233D
4 Deviation High Temperature
The temperature of the system is near the maximum operation temperature. The
performance has been reduced to prevent the sprayer from completely shutting
down.
• Check fan operation. Clean fan and driver housing. Verify fuses are intact in junc-
tion box.
• Reduce pressure, duty cycle, or gun tip size.
• Move unit to a cooler location.
5 Alarm Motor Temperature Fault
Motor is running too hot. Allow unit to cool.
• Check fan operation. Clean fan and driver housing. Verify fuses are intact in junc-
tion box.
• Reduce pressure, duty cycle, or gun tip size.
• Move unit to a cooler location.
6 Alarm Board Temperature Fault
The control board is running too hot. Allow unit to cool.
• Check fan operation. Clean fan and driver housing. Verify fuses are intact in junc-
tion box.
• Reduce pressure, duty cycle, or gun tip size.
• Move unit to a cooler location.
7 Alarm Encoder Calibration Error
• Cycle power and check status indicator to see if error is still active.
• Calibrate the encoder (see page 17).
• Contact your Graco distributor or Tech Service for more information.
8 Alarm Encoder Error
• Cycle power and check the status indicator to see if the error is still active.
• Verify that the encoder cable is connected securely.
• The encoder may need to be replaced.
• Contact your Graco distributor or Tech Service for more information.
9 Alarm Software Versions Do Not Match
• Obtain software update token and follow Software Update procedure
(contact your Graco distributor or Tech Service for more information).
10 Alarm Circuit Board Communication Failure
• Cycle power and check status indicator to see if error is still active.
• Contact your Graco distributor or Tech Service for more information.
11 Alarm Internal Circuit Board Hardware Failure
• Cycle power and check status indicator to see if error is still active.
• Contact your Graco distributor or Tech Service for more information.
12, 13 Alarm Internal Software Error
• Cycle power and check status indicator to see if error is still active.
• Contact your Graco distributor or Tech Service for more information.
Fast Flash Deviation See Power Saving Mode, page 9.
Blink Code Error Type Troubleshooting Steps