Graco EM 380 Operation manual

INSTRUCTIONS-PARTS LIST
307-371
Rev. C
OnAco
SUPERSEDES B
SERVICE INSTRUCTIONS FOR
EM 380 PORTABLE ELECTRIC/AlRLESS
PAINT SPRAYE,R
Model 226-820
GRACO INC. P.O. BOX 1441 MINNEAPOLIS. MN 55440
@ COPYRIGHT 1980 GRACO INC.

Table of Contents Page
Troubleshooting.. ..................................... 3
Pumps. .............................................. .4
Connecting Rod & Bearing.. ........................... .6
Drive Assembly.. ...................................... .6
Electric Motor. ....................................... .7
Filter.. ............................................... .8
Pressure Control.. .................................... .8
Parts List.. .......................................... .lo
NOTE: Numbers in parentheses in the text refer to the reference
numbers on Figs 1-11 and the parts drawing and list.
WARNING
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.
I
UNPLUG CORD TRIGGER GUN ENGAGESAFETY . OPEN DRAINVALVE
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2 307-371
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SERVICE
Service instructions are given in the following WARNING
paragraphs. Check everything in the chart before dis-
assembling any part of the sprayer.
Always disconnect sprayer from power source
and relieve system pressure beforeanempting any
service.
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3OUBLESHOOTING GUIDE
'ROBLEM
ilectric motor won't run
Ilectric motor stops while spraying
3ectric motor runs but output low
ilecaic motor runs, but no output
3ectric motor labors when sarting,
,lowing fuses - '..
'aint leaks into wet-cup ' .
Scxcessive surge at spray gun
..
Not enough paint pressure
Tails or fingers in spray panem
Paint NT!S or sags
Spming from spray gun
Smtic sparking from spray gun
CAUSE
Power cord unplugged, or building circuit fuse
SOLUTION
Check. replace
blown
Overload switch has opened Unplug cord., decrease pressure
Pressure setting too low Increase
Power cord unplugged, or building circuit fuse Check, replace
blown
Overload switch has opened Unplug.cord*, relieve pressure, allow
Pressure setting too low Increase
to mol, decrease pressure
-
lip or filter plugged
Piston ball check not seating
Pion packings worn or damaged
Intake Mlve bail check not seating
Disalaceme& ourno frozen or clear train damanr
_.r "" ~~~~~~~ ~
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Displacement pump frozen or gear train damagf
Capacitor failure ..
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Throat packings worn or damaged
Tip or filter plugged
Spray tip too big or worn
Paint too'viscous
Wrong type hose
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Pressure setting too low
Spray tip too big or worn
Pressure setting too low
Outlet filter dirty or plugged
spray tip too big or worn
Paint supply low or pail empty
Paint too viscous
Wrong type hose
Remove and clean
Service, see disp. pump service
I
!+lace, SF &sp. pump senrice . ,. I
Senice, see disp. pump service
Thaw**, replace
Thaw.. ...
~ .,-.: :.; >:: ..,' . I . .... ....
Replace, see dsp. pump service
&move and clean
............
chiiii tip - see manual 307-321
~ ~n' :
Use minimum 50 ft (15.2 ml static free
nylon hose only -wire braid hose unac,
ceotable
Increase . .
, ........
~ Change tip - see manual 30?-321
InCreasa . .
Clean
Change tip -.see manual 307-321
Fin
Thin
nvlon hose only
-wire braid hose unac.
Use minimum 50
ft (15.2 ml
&tic free
. ciptabla
Outlet filter dirty or plugged
Paint supply low or pail empty
Clean-see manual 307273
Fill
Sprayer sucking air or gun needle not seating Tighten fittings,
service gun -see
Check, ground
Sprayer or worknot grounded
manual 307445
'The electric motor has an overheating protector switch which automatically resets on cooling. If it opens, uvplug unit and let it
cool for 30 to W minutes. Also try to correct the cause of overheating. Always use the lowest pressure semng needed.
*.Freezing results from failure to replace flushing water with mineral spirii solvent.
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.. 307-371 ,: 3 ,' ".
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REMOVING and REPLACING PUMP
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 18) from male connector (10).
See Fig 1.
Use a screwdriver to push retaining spring 133) aside
and push out pin (34).
Loosen locknut (74) and unscrew pump from drive
assembly (55).
When installing a new or repaired pump, fint rotate
tion. Push pump piston rod (79) all the way down into
crankshaft so connecting rod (54) is in its lowest posi-
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 (741. Locknut must be very tight to
avoid loosening from vibration.
Align holes in piston rod (791 and coupling 1361 and in-
stall pin (34) and retaining spring 133).
Reassemble remaining parts, reverse from disassembly.
Fig 1
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SERVICING PUMP
(Repair kit 215902 availablel.
Shut off and unplug sprayer, open filter drain valve to
release pressure (provide a container to catch drainage)
and engage the trigger safety.
Use repair kit no. 215902 to repair pump. Use all parts
in kt, even if old ones look good.
Remove pump from sprayer as described above.
Unscrew intake valve (80) from cylinder (78). If valve is
Disassembling Pump
seized in housing, squirt penetrating oil around threads
and gently tap around housing with a light hammer to
loosen. See Fig 2 and 4. Remove ball guide (721, stop
pin (71) and ball (601. Clean and inspect parts for wear
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.
4 307-371
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Unscrew and remove packing nut (70). Using a rubber '1 '. Assembling Pump .' ' '
mallet. tao niston rod (791 down and uull out through When assembling pump, coat packings, piston rod and
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bottom of cylinder 1781. See Fig 3 and4.
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inside of cylinder .. with hydraulic oil.
Remove glands (66 & 69) and packings (67 b 68). When reassembling piston, inell new glands and pack-
ings in correct order, altematmg leather and plastic
Clean and inspect piston rod and inside of cylinder for packings. See Fig 3. "V" of packings must face up
nicks, scratches or scoring which could cause leaking or against fluid pressure. See Fig 4. Tighten nut (65) to
premature wear of packings. 10.5 in-lb (1.2 N.m) to seat packings, then back off and
tighten hand tight.
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.
Place new ball in piston rod (79). Apply, locking corn-
ing a torque wrench on nut 165) and a screwdriver on
pound to threads of valve 181 1. and screw It into rod. Us-
Use a wrench to loosen nut (651 and unscrew valve (81) valve (81). tighten nut against piston rod to 18-29 ft-lb
from piston rod. Remove ball (59). Remove nut, glands (24-27 N.m) torque,
without changing the tightness of
(62 & 64) and packings (63 & 75).
the nut against packings.
L
Install new seal and washers on adapter 176) 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
lnseipiston rod through bottom of pump cylinder.
Assemble and install intake valve and tighten packing
nut just enough to stop leakage - no tighter. ' ".:
leather packings. .. . ~. . ....
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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 drainage1 and engage trigger safety.
Remove pump as described above.
Remove the 6 screws (191 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.
and remove pin 1341 from coupling (36). Remove coupl-.
Use a screwdriver to push retaining spring (331 aside
ing from connecting rod.
use solvent1 and inspect surfaces of bearing and con-
Pull connecting rod out of bearing. Wipe clean (don't
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 evely 100 hours of operation, or
whenever servicing the pump (whichever
comes first), fill the cavity in connecting rod
I541 with SAE 10 non-detergent motor oil.
Fig 5
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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
6 307-371
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Remove pump, connecting rod and bearing as describ- Clean and inspect gear: (37) for wear or damage.
ed above. Replace if necessary. To remove, drive out pin (27) and
pull off of motor shaft. Apply molybdenum disulfide
drive housing (C). Remove screws and lockwashers (82
Remove screws and lockwashers (A&B) and remove spray lubricant to gear, allow to dry, then apply in-
dustrial heavy duty extreme pressure lithium soap
& 83) and remove motor housing (DL See Fig 6.
grease.
.q
...</ Install new drive assembly in reverse order of removal.
REPLACING CAPACITOR
Remove cover (E) of capacitor (91). See Fig 7. Remove
flag connectors from old capacitor. Connect flag con-
NOTE: The replacement capacitor includes new
nectors of new capacitor and replace cover.
resistor, installed.
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REMOVING and REPLACING'ELECTRIC MOTOR
Shut off and unplug sprayer, trigger spray gun and Disconnect red, pink and brown wires from circuit
open filter drain valve to release pressure (provide a
board (E). Disconnect green and yellow wire from
container to catch drainage) and engage trigger safety. grounding screw IF) and black wire from top
of pressure
control IG).
Disconnect tube fitting (8) from nipple (101. See Fig 1.
Unscrew nuts on both ends of conduit (1) from connec-
Remove drive assembly as described above.' You can tors. Remove screws (7). nuts (3) and lockwashers (4).
drive assembly.
leave pump, connecting rod and bearing assembled to
guiding wires through 'connector in control box.
See Fig 7. Remove motor from frame while carefully
Remove conduit (1) from wires. .'
Drive out pin (27) and remove gear (37). See Fig 7.
Loosen locknut and unscrew connector (13)'from
Remove screws (25) and cover (41) from pressure con- motor, being careful to avoid twisting wires.
trol (50). See Fig 8.
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Install new motor in reverse order of removal.
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.. .307-371'
7

REMOVING and REPLACING PRESSURE.CONTROL
r WARNING
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(J). Changing the setting may cause unsafe high
Do not alter the factory adjusted pressure switch
pressure or poor performance.
*-?A .'
Shut-off end 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 (28) and
unscrew nipple 128) from pressure control. See Fig 9.
Disconnect tube (52) from elbow (15). See Fig 10.
Unscrew elbow (15) from fitting in pressure control (50).
pressure
control
(50)
and
filter 147) from
frame.
Remove screw
15)
and lockwasher
(4) and remove
.I
Remove screws (25) and cover (41) from pressure con-
trol (50). See Fig 11.
board (86). Disconnect green and yellow wire from
Disconnect red, pink and brown wires from circuit
grounding screw (FI, 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 (11 from connectar (13).
while carefully guiding wires through connector (131.
See Fig 11. Pull pressure control (50) awayfrom conduit
Loosen knurled part of power cord strain relief (HI, and
on power cord to provide clearance, and unscrew con-
unscrew it from pressure control. Slide strain relief up
duit connector (13). See Fig 11.
-u
Fig 9
52
Replace in reverse of order of removal.
Fig 10
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8 307-371

Fig 11
SSEMBLY PART REF PART
:HANGED
'' STATUS ' NO. NO. NAME
inal Agpl OLD
NEW 11
102-556 Rivet
1Md88 Rivat
DL0
OLD
1c5.678 Sew 141
105677
Scm 14)
NEW
26 loMm scrsw181
OLD
NEW
28 157-350 Nipple
16S198 Nipple
OLD
NEW 41
177-Z9 Cover
176918
Cow
OLD
NEW
82 10625 Lockwasher
1W-133 -Lockwasher
ADD
ADD
87 21- Power
cord
88 105659 Switch Boot
ADD
E3 105679 Switch Toggle
ADO
ADD
90 105746 Swin Rdid
91 105771 Capacitor
ADD
ADD
93 1W-m Capscrew
S2 177-762 Labs1
ADD
DELETE
94 "94 TSL
1W.072 Nut
DELETE
105656 Screw
DELETE 176937 Spacsr
DELETE
DEL-CTE
DELET
103-181 Lockwasher
17691
Label
106516 Nut
lis0 Pump
OLD
176iE Packing I21
15453 OLD 176756 Packing
111
ierk to C NEW 68 176997 Packing
13)
NTERCHANGEABILITY NOTE NEW parts replace
)LD parts listed directly above them. .
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: 307-371 'j. 9

PARTS DRAWING
REF
PART
NO. NO.
3
1
4
5
7
9
8
10
11
12
13
14
15
17
18
19
20
P
23
25
n
m
29
30
31
32
3
-34
35
36
38
37
41
40
42
44
45
47
46
48
49
o&ce9
100-188
100214
100-538
101-344
101-907
101-908
101-909
102-556
102-799
102.932
102-99
!@%no
103.927
1W
105-508
105-509
105521
105-524
108075
105-680
157-350
170-113
172412
176250
176524
176817
176818
17-
176-824
176825
176865
176915
177-229
176920
208663
210-561
210-&7
214-530
214-m1
216502
NIPPLE, hex, reducing, 3Anpt x 1
TUBE. wction
PLATE, designation
LABEL. warning
LABEL.rmming
SPRING, retaining
COVER,
gear
box
PIN, rU.
hdis. 0.3125" dia
x 1.023"
COUPLING, pump
GEAR, pinion
TUBE. wction
BRACKET, mounting
COVER
/4 npt
HOSE,runion,nylon3/4"IDx30"
GUN,airlass,res307"6forpm
1762mml
HOSE. spray: cpld
1/4 npsmifbel swivel:
1/4"ID:nylon:50f1115ml:rpringguard
oneend:staticfm
VALVE. ball.see306-861 forpans
FILTER.fluid.res307-mforpns
HOSE, whip end, cpld V4nptlm) x
1/4npsmlf1;3/16'IO,staticfres:W'
1914 mml long
FRAME.spprayer ' .
..
Ref No. 50
Includes 1 of items 13 and 87-90
55 7
DISPIACEMENT PUMP
REPAIR KIT 217479
(Order
separatehll
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1