Graco EM 380 Operation manual

INSTRUCTIONS-PARTS LIST G
fey7;464
This manual contains IMPORTANT
WARNINGS and INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
ORACO
SUPERSEDES A
SERVICE INSTRUCTIONS FOR
EM 380 PORTABLE ELECTRIC/AIRLESS
PAINT SPRAYER
Model 217-380, 50 Hz
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440
@ COPYRIGHT 1981 GRACO INC.

Table of Contents Page
Troubleshooting . . . . _ . . . . . ..........
. . .
Pumps.. . . . . . Y.. . . . . . . . . .......... . . . . . .
. . . .
:
Connecting Rod Et Bearing. . . . . . . . .
. . .
Drive Assemblv. . . . , . . . . . .
ElFeric Motor 1 . . . . . . . . . .
.......... . . . . . .
. . .
:
.......... . . . . . . . .
Press&& ‘&ktGl’. ‘. ‘. ‘.-. ‘. ‘. ‘. ‘. . . .......... . . . . . . . .
. . ;
.......... . . . . . . . . . .
Parts List. . . . . . . . . . . . . . . . .......... . . . . . . . . 180
NOTE: Numbers in parentheses in the text refer to the reference
numbers on Figs l-11 and the parts drawing and list.
I
WARNING I
Before servicing, always shut off the unit, unplug the power cord and relieve fluid
pressure. To relieve pressure, trigger the spray gun, engage the trigger safety and
open the drain valve.
TRIGGER GUN OPEN DRAIN VALVE
2 307-464

SERVICE ^ ,
Service instructions are given in the following
paragraphs. Check everything in the chart before dis-
assembling any part of the sprayer.
WARNING
Always disconnect sprayer from power source
and relieve system pressure before attempting any
service.
TROUBLESHOOTING GUIDE
PROBLEM CAUSE SOLUTION
Electric motor won’t run Power cord unplugged, or building circuit fuse Check, replace
blown
Overload switch has opened Unplug cord’. decrease pressure
Pressure setting too low Increase
Electric motor stops while spraying Power cord unplugged o* hl,‘:~‘, ~-’ Git fuse Check, replace
blown
Overload switcCl has opened Unplug cord”, relieve pressure, allow
to cool, decrease pressure
Pressure setting too low Increase
Tip or filter plugged Remove and clean
Electric motor runs but output low Piston ball check not seating Service, see disp. pump service
Piston packings worn or damaged Replace, see disp. pump service
Intake valve ball check not seating Service, see disp. pump service
Displacement pump frozen or gear train damage Thaw**, replace
Electric motor runs, but no output Displacement pump frozen or gear train damage Thaw’”
Electric motor labors when starting, Capacitor failure Replace capacitor
blowing fuses
Paint leaks into wet-cup Throat packings worn or damaged Replace, see disp. pump service
Excessive surge at spray gun Tip or filter plugged Remove and clean
Spray tip too big or worn Change tip see manual 307-321
Paint too viscous Thin
Wrong type hose Use minimum 50 ft (15.2 m) static free
nylon hose only -wire braid hose unac
ceptable
Not enough paint pressure Pressure setting too low Increase
Spray tip too big or worn Change tip - see manual 307-321
Tails or fingers in spray pattern Pressure setting too low Increase
Outlet filter dirty or plugged Clean
Spray tip too big or worn Change tip see manual 307-321
Paint supply low or pail empty Fill
Paint too viscous Thin
Wrong type hose Use -?inimL*m 50 ft (15.2 m) static free
rylr~ hose only -wire braid hose unac
ceptable
Paint runs or sags Outlet filter dirty or plugged Clean-see manual 307-273
Spitting from spray gun Paint supply low or pail empty Fill
Sprayer sucking air or gun needle not seating Tighten fittings, service gun -see
manual 307-046
Static sparking from spray gun Sprayer or work not grounded Check, ground
*The electric motor has an overheating protector switch which automatically resets on cooling. If it opens. unplug unit and let it
cool for 30 to 60 minutes. Also try to correct the cause of overheating. Always use the lowest pressure setting needed.
**Freezing results from failure to replace flushing water with mineral spirits solvent.

Flush if possible. Shut off sprayer and unplug power
cord, trigger spray gun and open filter drain valve to
release pressure (provide a container to catch drainage)
and engage trigger safety.
Loosen hose clamp (17) and remove suction hose (42).
Unscrew sealing nut (21) from pump. See Fig 1.
Disconnect tube fitting (8) from male connector (10).
See Fig 1.
Use a screwdriver to push retaining spring (33) aside
and push out pin (34).
Loosen locknut (74) and unscrew pump from drive
assembly (55).
When installing a new or repaired pump, first rotate
crankshaft so connecting rod (54) is in its lowest posi-
tion. Push pump piston rod (79) all the way down into
pump cylinder (78). Screw pump into drive assembly
(55) until you feel piston rod pressing against connec-
ting rod. Unscrew pump until outlet lines up with outlet
tube (52). then unscrew another complete turn.
Tighten locknut (74). Locknut must be very tight to
avoid loosening from vibration.
Align holes in piston rod (79). and coupling (36) and in-
stall pin (34) and retaining spring (33).
Reassemble remaining parts, reverse from disassembly.
(Repair kit 217-079 available).
Shut off and unplug sprayer, trigger the spray gun,
engage the trigger safety and open filter drain valve to
release pressure (provide a container to catch drainage).
Use repair kit no. 215-902 to repair pump. Use all parts
in kit, even if old ones look good.
Remove pump from sprayer as described above.
Disassembling Pump:
Unscrew intake valve (80) from cylinder (78). If valve is
seized in housing, squirt penetrating oil around threads
and genfly tap around housing with a light hammer to
loosen. See Fig 2 and 4. Remove ball guide (721, stop
pin (71) and ball (60). Clean and inspect parts for wear
r or damage.
NOTE: Test intake valve by filling it with solvent and
seeing if any leaks past ball. It shouldn’t
leak. Valve must be clean for this test; any
dirt will hold ball off seat and let solvent leak
past.
Fig 1
4 307464
Fig 2

Unscrew and remove packing nut (70). Using a rubber
mallet, tap piston rod (79) down and pull out through
bottom ofcylinder (78). See Fig 3 and 4.
Remove glands (66 Et 69) and packings (67 & 68).
Clean and inspect piston rod and inside of cylinder for
nicks, scratches or scoring which could cause leaking or
premature wear of packings.
Clamp flats of piston rod in a vise. Use a large
screwdriver to unscrew adapter (76) from valve (81).
Remove seal (61) and washers (77). See Fig 3 and 4.
Use a wrench to loosen nut (65) and unscrew valve (81)
from piston rod. Remove ball (59). Remove nut, glands
(62 Et 64) and packings (63 Et 75).
-
0
&b-
76
80
Assembling Pump
When assembling pump, coat packings, piston rod and
inside of cylinder with hydraulic oil.
When reassembling piston, install new glands and pack-
ings in correct order, alternating leather and plastic
packings. See Fig 3. “V” of packings must face up
against fluid pressure. See Fig 4. Tighten nut (65) to
10.5 in-lb (1.2 N-m) to seat packings, then back off and
tighten hand tight.
Place new ball in piston rod (79). Apply locking com-
pound to threads of valve (81) and screw it into rod. Us-
ing a torque wrench on nut (65) and a screwdriver on
valve (811, tighten nut against piston rod to 18-29 ft-lb
(24-27 N.m) torque, without changing the tightness of
the nut against packings.
Install new seal and washers on adapter (76) and screw
into valve (81).
Install throat packings, glands and packing nut, leaving
packing nut loose. “V” of packings must face down
against fluid pressure. Put plastic packing (68) on top of
leather packings.
Insert piston rod through bottom of pump cylinder.
Assemble and install intake valve and tighten packing
nut just enough to stop leakage - no tighter.
d!v-
81
Fig 3
I
l-
“V” FACES
DOWN
I AGAINST
PRESSURE
78
“V” FACES
UP AGAINST
PRESSURE
‘1 1 /-“l;‘l’,“CES
i(I
AGAINST
PRESSURE
Fig 4
307464 5

REMOVING and REPLACING CONNECTING ROD and BEARING
Shut off and unplug sprayer, trigger spray gun and
open filter drain valve to release pressure (provide a
container to catch drainage) and engage trigger safety.
Remove pump as described above.
Remove the 6 screws (19) and cover (35). Remove the 2
screws and lockwashers (20 and 18). Remove bearing
(53) and connecting rod (541, sliding connecting rod off
of crankshaft. See Fig 5.
Use a screwdriver to push retaining spring (33) aside
and remove pin (34) from coupling (36). Remove coupl-
ing from connecting rod.
Pull connecting rod out of bearing. Wipe clean (don’t
use solvent) and inspect surfaces of bearing and con-
necting rod link for wear or damage. If either needs
replacing, you should replace both. When installing rod
and bearing, coat surfaces with SAE 10 non-detergent
motor oil.
Clean and inspect crankshaft. Wipe clean with a rag; do
not use solvent. If crankshaft is badly worn, replace
drive assembly.
Clean and inspect connecting rod needle bearing.
Repack bearing with industrial heavy duty extreme
pressure lithium soap grease.
NOTE:
After every 100 hours of operation, or
whenever servicing the pump (whichever
comes first), fill the cavity in connecting rod
(54) with SAE 10 non-detergent motor oil.
-35
REMOVING and REPLACING DRIVE ASSEMBLY
Shut off and unplug sprayer, trigger spray gun and
open filter drain valve to release pressure (provide a
container to catch drainage) and engage trigger safety.
Fig 6
6
307464

Remove pump, connecting rod and bearing as describ-
ed above.
Remove screws and lockwashers (A&B) and remove
drive housing (Cl. Remove screws and lockwashers (82
Et 83) and remove motor housing (D). See Fig 6.
Clean and inspect gear (37) for wear or damage.
Replace if necessary. To remove, drive out pin (27) and
pull off of motor shaft. Apply molybdenum disulfide
spray lubricant to gear, allow to dry, then apply in-
dustrial heavy duty extreme pressure lithium soap
grease.
Install new drive assembly in reverse order of removal.
REPLACING CAPACITOR
Remove cover of capacitor (91 I. See Fig 7. Remove flag
connectors from old capacitor. Connect flag connectors
of new capacitor and replace cover.
NOTE: The replacement capacitor includes new
resistor, installed.
REMOVING and REPLACING ELECTRIC MOTOR , I,
Shut off and unplug sprayer, trigger spray gun and
open filter drain valve to release pressure (provide a
container to catch drainage) and engage trigger safety.
Disconnect red, pink and brown wires from circuit
board (E). Disconnect green and yellow wire from
grounding screw(F) and black wire from top of pressure
control (G).
Disconnect tube fitting (8) from nipple (IO). See Fig 1.
Remove drive assembly as described above. You can
leave pump, connecting rod and bearing assembled to
drive assembly.
Unscrew nuts on both ends of conduit (I 1 from connec-
tors. Remove screws (71, nuts (3) and lockwashers (4).
See Fig 7. Remove motor from frame while carefully
guiding wires through connector in control box.
Remove conduit (I) from wires.
Drive out pin (27) and remove gear (37). See Fig 7.
Remove screws (25) and cover (41) from pressure con-
trol (50). See Fig 8.
Loosen locknut and unscrew connector (13) from
motor, being careful to avoid twisting wires.
Install new motor in reverse order of removal.
PMoToR
3
Fig 7 Fig 8
307464 7

REMOVING and REPLACING PRESSURE CONTROL .,<;s;;:$r.,.r,;g; y:f:i.;:/,.,:.i, ’ ., ,’ ;, i ;: i’., -: ,; ,:;;
Shut off and unplug sprayer, trigger spray gun and
open filter drain valve to release pressure (provide a
container to catch drainage) and engage trigger safety.
Disconnect swivel union (84) from nipple (K) to remove
filter (47). See Fig 9.
Disconnect tube (52) from elbow (L). See Fig 10.
Remove screw (5) and lockwasher (4) and remove
pressure control (50) from frame.
L84
Fig 9
Remove screws (25) and cover (411 from pressure con-
trol (50). See Fig 11.
Disconnect red, pink and brown wires from circuit
board (86). Disconnect green and yellow wire from
grounding screw (F), and black wire from top of
pressure control (GI. See Fig 11.
NOTE: Circuit board (86) is not included with pressure
control (50) replacement. Order separately if
new circuit board is needed.
Unscrew nut on end of conduit (I) from connector (131.
See Fig 11. Pull pressure control (50) away from conduit
while carefully guiding wires through connector (13).
Loosen knurled part of power cord strain relief (HI, and
unscrew it from pressure control. Slide strain relief up
on power cord to provide clearance, and unscrew con-
duit connector (13). See Fig 11,
,
Fig 10
Replace in reverse of order of removal.
8
307464

H
W/YELLOW
GREEN AND
Fig 11
307464 9

PARTS DRAWING
PARTS LIST
FIEF
NO.
PART
NO.
065499
loo-188
106214
100538
101-344
101907
101-908
101-909
102-556
102-799
102-932
102-952
103-927
104-008
105-508
105509
105-521
106-108
106075
105680
170-113
170-960
176-250
176-529
176-817
176-818
178-128
176-824
177-670
176-865
176-915
177-229
176-920
208663
210-541
21 O-657
214-570
214-701
307-464
Ref No. 50
Includes 1 of items 13 and 87-90
DESCRIPTION QTY
CONDUIT. electrical 4.25 in. (108 mm)
NUT, hex,’ 5/16-18
LOCKWASHER, spring, 3/8”
CAPSCREW, hex hd, 5/16-18 x l/2”
CAPSCREW, hex hd, 5/16-18 x 718”
NUT, fitting, tube, for 3/8” tube
FERRULE, fitting, tube, for 3/8” tube
CONNECTOR, male,
l/2-18 x 3/8” tube, l/4 nptfm)
RIVET, blind
TERMINAL, cable
CONNECTOR, conduit, 90”
STRAINER
CLAMP, hose
LOCKWASHER, spring, 5/16”
SCREW, math, filh, 6-32 x l/2
CAPSCREW, socket head,
5/16-18 x 7/8”
PLUG, tubing
MOTOR, electric 0.5 HP (0.37285 kWl,
includes (1) Ref No. 86 when ordered as
replacement
SCREW, math, oval head, lo-24 x l/2
PIN, spring, straight, 0.167” dia, 0.94”
long
TUBE, suction
PLATE, designation
LABEL, warning
LABEL, warning
SPRING, retaining
PIN, str, hdls, 0.3125” dia x 1.023”
COVER, gear box
COUPLING, pump
GEAR, pinion
TUBE, suction
BRACKET, mounting
COVER
HOSE, suction, nylon 3/4” ID x 36”
(914 mm)
GUN, airless, see 307646 for parts
HOSE, spray; cpld l/4 npsmffbe) swivel;
l/4” ID; nylon; 50 ft (15 m); spring guard
one end; static free
VALVE, ball, see 306-861 for parts
FILTER, fluid, see 307-273 for parts
HOSE, whip end, cpld l/4 npt(m) x
l/4 npsm(fJ; 3/16” ID, static free; 36”
(914 mm) long
:A”::
FOR
PARTS
38
DISPLACEMENT PUMP
REPAIR KIT 217-079
(Order separately)
:, Consists of:
Ref No.
Qtv
‘I
E i
:; 1
63 2
ii 1
E :
69
575
:
2

\
37
327 7 /(
55
Ref 7
REF PART
NO. NO.
49 215502
50 217-010
596-421
176-999
215-903
215-904
217-027
216-001
216-xxx
45
DESCRIPTION
FRAME, sprayer
CONTROL, pressure; includes item 13,
87-96.
TERMINAL, snap-on
TUBE
BEARING
CONNECTING rod
DRIVE assembly
KIT, spray tip, see 307-321 for parts
SPRAY TIP, cylinder;
Reverse-A-Clean Ill, standard
(customer’s choice, see 367-321)
QN
1
1
REF
NO.
82
E
86
87
it
90
91
::
94
PART
NO.
166-115
100-659
155-665
106-109
217-011
105-659
105-679
105-746
105-771
177-762
106657
206994
DESCRIPTION
QN
LOCKWASHER, spring, 3/8”
CAPSCREW, socket hd, 3/8-16 x 1”
UNION, straight adapter, 3/8 npt(m) x
3/8 npsm(f) swivel
BOARD, circuit
CORD, supply, power
BOOT. switch
TOGGLE, switch
RELIEF, strain, cord
CAPACITOR, start; includes resistor
LABEL, warning
CAPSCREW, socket head, 5/16-18 x 2”
THROAT SEAL LIQUID, 1 pt
307-464 11

R@f No. 58 ’
Includes items 50-81
69--@
9
78
-4 I ’
I 7’7
THE GRACO WARRANTY
Grace Inc. warrants all equipment manufactured by it and bearing its
name to be free from defects in material and workmanship under
normal use and service. This warranty extends to the original
purchaser for a period of 12 months from the date of purchase and
applies only when the equipment is installed and operated in
accordance with written factory recommendations. This warranty
does not cover damage or wear which, in the reasonable judgment of
Grace, arises from misuse, abrasion, corrosion, negligence, accident,
substitution of non-Grace parts, faulty installation or tampering.
This warranty is conditioned upon the prepaid return of the equipment
claimed to be defective for examination by Grace to verify the claimed
defect. If the claimed defect is verified, Grace 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 workmanship or material,
repairs will be made at a reasonable charge and return transportation
will be charged.
THIS LIMITED WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF
ANY OTHER WARRANTIES (EXPRESS OR IMPLIED) INCLUDING
WARRANTY OF MERCHANTABILITY OR WARRANTY OF
FITNESS FOR A PARTICULAR PURPOSE AND OF ANY NON-
CONTRACTUAL LIABILITIES INCLUDING PRODUCT LIABILITIES
BASED ON NEGLIGENCE OR STRICT LIABILITY. EVERY FORM OF
LIABILITY FOR DIRECT, SPECIAL OR CONSEQUENTIAL
DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED.
EQUIPMENT NOT COVERED BY GRACO WARRANTY. Accessories
or components of equipment sold by Grace that are not manufactured
by Grace (such as electric motors, switches, hose, etc.) are subject to
the warranty, if any, of their manufacturer. Grace will provide
purchaser with reasonable assistance in making such claims.
REF PART
NO. NO.
215-453
Series C
l l 105-444 105-445
l l 105-522 176-747
l 176-749
l 176-750 176-751
*176-754
l 176-755
l 176-997
l 176-758 176-757
176-759 176-760
176-761 176-762
* 176-883 176-882
l 176-884
176-885 176-887
215-455
215-582
DESCRIPTION
QN
DISPLACEMENT PUMP ASSY
Includes items 59-81
BALL, stainless steel, 0.3125”
BALL, stainless steel, 0.5”
SEAL, “U’ CUP, polyurethane
GLAND packing, female
. PACKING, “V” leather
GLAND, packing, male
. NUT, hex l/2-20
GLAND, packing, male
PACKING, “V” leather
: PACKING, “v” polyethylene
GLAND, packing, female
NUT, packing
. PIN, stop, ball
GUIDE, ball
GASKET, copper
NUT, hex, l-1/2-18
PACKING, “V” polyethylene
ADAPTER, “U” cup
. WASHER, backup
CYLINDER
ROD, piston
VALVE, intake
VALVE, piston
3
1
1
1
1
306 8 307 Numbers in description refer to separate instruction
manuals.
*Recommended “tool box” spare parts. Keep on hand to
reduce down time.
Order parks by name and number. Always give the model
number and series letter of the assembly for which you are
ordering.
SERVICE INFORMATION
Listed below by the assembly changed is the ULD and
NEW part number.
]I
INTERCHANGEABILITY NOTE: The NEW part replaces
the OLD part listed directly above it.
QUANTITY CHANGE NOTE: The quantity of 101-907
(Ref. No. 8) and 101-903 (Ref. No. 9) has been changed
from 2 to 1.
TECHNICAL DATA
Electric motor : 0.5 hp (0.3785 kW). 1425 rpm,
220 V, 50 HzAc, single phase
with automatic reset thermal
overload switch.
Electric cord
Paint filter
Paint Pump
Wetted parts
Operating weight : 68 lb (30 Kg) approximately
Electrical requirements : 220 V. 15 amp circuit
: No. 14 gauge, 3-wire; use 14 ga
(mint 3-wire extension cord.
: 60 mesh (250 micron) stainless
steel screen with 3/8 npt(f) inlet
and l/4 npt(f 1 outlets; reusable
we.
: 2500 psi I172 bar) maximum
working pressure; 0.33 gpm (1.25
liter/min) output.
: Delrin, Leather, Stainless
Steel, Polyethylene, Tungsten
Carbide, Polyurethane, Nylon,
Aluminum, Nitralloy.
Factory Branches: Atlanta, Dallas, Detroit, Los Angeles, West Caldwell (N.J.1
Subsidiary and Affiliate Companies: Canada; England; Switzerland; France; Germany; Hong Kong; Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440
PRINTED IN U.S.A. 307.464 2-81 Revised 5-81
PTFE