Graco Pro 230ES Use and care manual

Repair and Parts
Pro 230ES and Pro 270ES Electric
Airless Sprayers
3A2817A
EN
Pro 230ES Model: 262863
Pro 270ES Model: 262864
3000 psi (20.7 MPa, 207 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual and in other manuals. Save these
instructions.
Related Manuals
3A2813
312830
312015 ti19332a
262863

Warnings
23A2817A
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
GROUNDING
This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of
electric shock by providing an escape wire for the electric current. This product is equipped with a cord
having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that
is properly installed and grounded in accordance with all local codes and ordinances.
• Improper installation of the grounding plug is able to result in a risk of electric shock.
• When repair or replacement of the cord or plug is required, do not connect the grounding wire to
either flat blade terminal.
• The wire with insulation having an outer surface that is green with or without yellow stripes is the
grounding wire.
• Check with a qualified electrician or serviceman when the grounding instructions are not completely
understood, or when in doubt as to whether the product is properly grounded.
• Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a
qualified electrician.
• This product is for use on a nominal 120V circuit and has a grounding plug similar to the plug
illustrated in the figure below.
• Only connect the product to an outlet having the same configuration as the plug.
• Do not use an adapter with this product.
Extension Cords:
• Use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle that
accepts the plug on the product.
• Make sure your extension cord is not damaged. If an extension cord is necessary, use 12 AWG
(2.5 mm2) minimum to carry the current that the product draws.
• An undersized cord results in a drop in line voltage and loss of power and overheating.
ti9164
Ground

Warnings
3A2817A 3
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:
• Do not spray flammable or combustible materials near an open flame or sources of ignition such as
cigarettes, motors, and electrical equipment.
• Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity cre-
ates a risk of fire or explosion in the presence of paint or solvent fumes. All parts of the spray system,
including the pump, hose assembly, spray gun, and objects in and around the spray area shall be
properly grounded to protect against static discharge and sparks. Use Graco conductive or grounded
high-pressure airless paint sprayer hoses.
• Verify that all containers and collection systems are grounded to prevent static discharge. Do not use
pail liners unless they are antistatic or conductive.
• Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2 adapter.
• Do not use a paint or a solvent containing halogenated hydrocarbons.
• Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area. Keep pump
assembly in a well ventilated area. Do not spray pump assembly.
• Do not smoke in the spray area.
• Do not operate light switches, engines, or similar spark producing products in the spray area.
• Keep area clean and free of paint or solvent containers, rags, and other flammable materials.
• Know the contents of the paints and solvents being sprayed. Read all Material Safety Data Sheets
(MSDS) and container labels provided with the paints and solvents. Follow the paint and solvents
manufacturer’s safety instructions.
• Fire extinguisher equipment shall be present and working.
• Sprayer generates sparks. When flammable liquid is used in or near the sprayer or for flushing or
cleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors.
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 cord before servicing equipment.
•Connect only to grounded electrical outlets.
•Use only 3-wire extension cords.
•Ensure ground prongs are intact on power and extension cords.
•Do not expose to rain. Store indoors.
WARNING

Warnings
43A2817A
SKIN INJECTION HAZARD
High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that
injection occurs, get immediate surgical treatment.
•Do not aim the gun at, or spray any person or animal.
•Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with
any part of the body.
•Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.
•Use Graco nozzle tips.
•Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while spray-
ing, follow the Pressure Relief Procedure, page 9 for turning off the unit and relieving the pressure
before removing the nozzle tip to clean.
•Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn off
the unit and follow the Pressure Relief Procedure, page 9 for turning off the unit.
•Check hoses and parts for signs of damage. Replace any damaged hoses or parts.
•This system is capable of producing 3000 psi. Use Graco replacement parts or accessories that are
rated a minimum of 3000 psi.
•Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.
•Verify that all connections are secure before operating the unit.
•Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.
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, page 9 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.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property
damage.
•Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents.
•Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for
compatibility.
WARNING

Warnings
3A2817A 5
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, fol-
low the Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swal-
lowed.
•Read MSDSs to know the specific hazards of the fluids you are using.
•Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
RECOIL HAZARD
Gun may recoil when triggered. If you are not standing securely, you could fall and be seriously injured.
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

Component Identification
63A2817A
Component Identification
Model 262863 shown
ti19331a
B
H
E
G
C
F
D
J
K
Q
R
A
S
T
ti9667a
M
ti16978a
V (SG2/SG3)
W
L
X
V

Component Identification
3A2817A 7
A Airless spray gun Dispenses fluid.
B Power switch Turns sprayer ON and OFF.
C Pressure control knob Increases (clockwise) and decreases (counter-clockwise) fluid pres-
sure in pump, hose, and spray gun.
D Pump fluid outlet fitting Threaded connection for paint hose.
E Filter Filters fluid coming out of pump to reduce tip plugging and improve fin-
ish.
FEndurance™Pump Pumps and pressurizes fluid and delivers it to paint hose.
G Suction tube Draws fluid from paint pail into pump.
H Prime tube (with diffuser) Drains fluid in system during priming and pressure relief.
JPrime/Sprayvalve
• In PRIME position (pointing down) directs fluid to prime tube.
• In SPRAY position (pointing forward) directs pressurized fluid to
paint hose.
• Automatically relieves system pressure in overpressure situations.
K Serial Tag (below sprayer frame) Sprayer model and serial number information
L Inlet screen Prevents debris from entering pump.
M Paint hose Transports high-pressure fluid from pump to spray gun.
Q Tip guard Reduces risk of fluid injection injury.
R Reversible spray tip
• Atomizes fluid being sprayed, forms spray pattern and controls fluid
flow according to hole size.
• Reversed, it unclogs plugged tips without disassembly.
S Gun trigger safety lever Prevents accidental triggering of spray gun.
T Gun fluid inlet fitting Threaded connection for paint hose.
V Gun fluid filter Filters fluid entering spray gun to reduce tip clogs.
W Hose wrap Rack Stows paint hose.
X Pail hanger For transporting pail by its handle.

Installation
83A2817A
Installation
Grounding
• The sprayer cord includes a grounding wire with an
appropriate grounding contact.
• The plug must be plugged into an outlet that is prop-
erly 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.
Do not use an adapter.
Thermal Overload
Motor has a thermal overload sensor to shut itself down
if overheated. If unit overheats, perform Pressure Relief
Procedure, page 9, and allow approximately 45 minutes
for unit to cool before attempting to resume operation.
Power Requirements
• Requires 100-120 VAC, 50/60 Hz, 15A, 1 phase.
• Use an extension cord with an undamaged ground
contact.
• If an extension cord is necessary, use a 3-wire, 12
AWG (2.5 mm2) minimum.
Pails
•Solvent and oil/based fluids: follow local code.
Use only conductive metal pails, placed on
a grounded surface such as concrete.
• Do not place pail on a nonconductive surface such
as paper or cardboard which interrupts grounding
continuity.
•Grounding a metal pail: connect a ground wire to
the pail by clamping one end to pail and other end to
a true earth ground such as a water pipe.
•To maintain grounding continuity when flushing
or relieving pressure: hold metal part of spray gun
firmly to side of a grounded metal pail. Then trigger
gun.
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.
ti2810a
ti5572b
ti5850a
ti5851a
ti5310c

Installation
3A2817A 9
Trigger Lock
Always engage the trigger lock when you stop spraying
to prevent the gun from being triggered accidentally by
hand or if dropped or bumped.
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Turn power OFF and unplug sprayer.
2. Turn pressure to lowest setting.
3. Trigger gun to relieve pressure.
4. Turn prime valve down.
If you suspect spray tip or hose is completely clogged,
or that pressure has not been fully relieved after follow-
ing these steps, VERY SLOWLY loosen tip guard retain-
ing nut or hose end coupling to relieve pressure
gradually, then loosen completely. Now clear tip or hose
obstruction.
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.
ti8908a
Trigger Locked Trigger Unlocked
ti8909a
ti2707a ti2718a
TIB
-
WASTE
WASTE
ti2599a
ti2719a

General Repair Information
10 3A2817A
General Repair Information
• Keep all screws, nuts, washers, gaskets, and electri-
cal fittings removed during repair procedures. These
parts usually are not provided with replacement kits.
• Test repairs after problems are corrected.
• If sprayer does not operate properly, review repair
procedure to verify you did it correctly. See Trouble-
shooting, page 11.
• Install motor shroud before operation of sprayer and
replace if damaged. Motor shroud directs cooling air
around motor to prevent overheating. It can reduce
risk of burns, fire or explosion, or cut fingers.
To reduce risk of serious injury, including electric shock:
• Do not touch moving or electric parts with fingers or
tools while testing repair.
• Unplug sprayer when power is not required for test-
ing.
• Install all covers, gaskets, screws and washers
before you operate sprayer.
Flammable materials spilled on hot, bare motor could
cause fire or explosion. To reduce risk of burns, fire or
explosion, do not operate sprayer with cover removed.
NOTICE
To reduce risk of pressure control malfunction:
• Use needle nose pliers to disconnect wire.
Never pull on wire, pull on connector.
• Mate wire connectors properly. Center flat
blade of insulated male connector in female
connector.
• Route wires carefully to avoid interference
with other connections or pressure control.
Do not pinch wires between cover and con-
trol box.
NOTICE
• Do not run sprayer dry for more than 30 seconds.
Doing so could damage pump packings.
• Protect the internal drive parts of this sprayer
from water. Openings in the cover allow for air
cooling of the mechanical parts and electronics
inside. If water gets in these openings, the
sprayer could malfunction or be permanently
damaged.
• Prevent pump corrosion and damage from freez-
ing. Never leave water or water-base paint in
sprayer when its not in use in cold weather.
Freezing fluids can seriously damage sprayer.
Store sprayer with Pump Armor to protect
sprayer during storage.

Troubleshooting
3A2817A 11
Troubleshooting
Type of Problem
What to Check
(if check is OK, go to next)
What to DO
(When check is not OK, refer to
this column
Basic fluid pressure problems Pressure control knob setting.
Motor will not run if at minimum set-
ting (fully counter-clockwise).
Slowly increase pressure to see if
motor starts.
Spray tip or fluid filter may be
clogged.‘
Relieve pressure, page 9 and clear
clog, or clean filter; refer to separate
gun or tip instruction manual.
Basic mechanical problems Pump frozen or paint hardened in
pump.
Thaw sprayer if water or
water-based paint has frozen in
sprayer. Place sprayer in warm area
to thaw. Do not start sprayer until
thawed completely. If paint hard-
ened (dried) in sprayer, replace
pump packings. See page 17, Dis-
placement Pump Replacement.
Displacement pump connecting rod
pin must be completely pushed into
connecting rod and retaining spring
must be firmly in groove of pump
pin. See page 17, Displacement
Pump Replacement.
Push pin into place and secure with
spring retainer.
Motor. Remove drive housing
assembly. See Drive Housing
Replacement, page 20.
Replace motor if fan won’t turn. See
Fan Replacement, page 23.
Motor control board. Board shuts
down and displays error code.
See Motor Control Board diag-
nostics, page 30.
Basic Electrical Problems Electric supply. Meter must read
85-130 VAC fro 120V models.
Reset building circuit breaker.
Replace building fuse. Try another
outlet.
Extension cord. Check extension
cord continuity with volt meter.
Replace extension cord.
Sprayer power supply cord. Inspect
for damage such as insulation or
wires.
Replace power supply cord. See
ON/OFF Switch/Power Cord
Board Kit, page 27.
Motor leads are securely fastened
and properly mated.
Replace loose terminals, crimp to
leads. Be sure terminals are firmly
connected.
Clean circuit board terminals.
Securely reconnect leads.

Troubleshooting
12 3A2817A
Basic Electrical Problems - These
problems only apply to Pro 230ES
model sprayers with brush motors.
They do not apply to Pro 270ES
model sprayers.
Motor armature for shorts using
armature tester (growler) or perform
spin test. See Motor Diagnostics,
page 22.
Replace motor, page 33.
For loose motor brush lead connec-
tions and terminals.
Tighten terminal screws. Replace
brushes if leads are damaged.
Brush length which must be 1/2 in.
minimum. NOTE: Brushes do not
wear at the same rate on both sides
of motor. Check both brushes.
Replace brushes. See Motor
Brush Replacement, page 24.
Broken or misaligned motor brush
springs. Rolled portion of spring
must rest squarely on top of brush.
Replace spring if broken. Realign
spring with brush.
Motor brushes may be binding in
brush holders.
Clean brush holders. Remove car-
bon with small cleaning brush. Align
brush leads with slot in brush holder
to assure free vertical brush move-
ment.
Motor armature commutator for
burn spots, gouges or extreme
roughness.
Remove motor and have motor
shop resurface commutator, of pos-
sible. See Motor Replacement,
page 33.
Note: For the following electric prob-
lems, refer to wiring diagrams, page
25, to identify Test Points.
Power supply cord. Connect volt
meter between TP1 (neutral) and
TP2. Plug in sprayer. Meter must
read 85-130 VAC for 120V models.
Unplug sprayer.
Replace ON/OFF switch. See
On/Off Switch Replacement, page
25.
All terminals for damage or loose fit. Replace damaged terminals and
reconnect securely.
Type of Problem
What to Check
(if check is OK, go to next)
What to DO
(When check is not OK, refer to
this column

Troubleshooting
3A2817A 13
Low Output For worn spray tip. Relieve pressure, page 9. Then
replace tip. See your separate gun
manual for additional instruction.
Verify pump does not continue to
stroke when gun trigger is released.
Service pump. See Displacement
Pump Replacement, page 17.
Filter clogged. Relieve pressure, page 9. Check
and clean air filter.
Prime valve leaking. Relieve pressure, page 9. Repair
prime valve.
Suction hose kinks and/or loose
connection.
Connect kink and/or tighten any
loose connections.
Electric supply with volt meter. Low
voltages reduce sprayer perfor-
mance. Meter must read 85-130
VAC for 120V models.
Reset building circuit breaker;
replace building fuse. Repair electri-
cal outlet or try another outlet.
Extension cord size and length;
must be at least 12 gauge wire and
no longer than 300 ft. Longer cord
lengths reduce sprayer perfor-
mance.
Replace with a correct, grounded,
extension cord.
Leads from motor to pressure con-
trol circuit board for damaged or
loose wires or connectors. Inspect
wiring insulation and terminals for
signs of overheating.
Be sure male terminal blades are
centered and firmly connected to
female terminals. Replace any
loose terminal or damaged wiring.
Securely reconnect terminals.
Low stall pressure. Do either or both:
a. Turn pressure control knob
fully clockwise. Make sure
pressure control knob is
properly installed to allow full
clockwise position.
b. Try a new transducer.
Type of Problem
What to Check
(if check is OK, go to next)
What to DO
(When check is not OK, refer to
this column

Troubleshooting
14 3A2817A
These problems only apply to Pro
230ES model sprayers with brush
motors. They do not apply to Pro
270ES.
Motor armature for shorts by using
an armature tester (growler) or per-
form spin test, page 22.
Replace motor. See page 33.
Loose motor brushes and terminals. Tighten terminal screws. Replace
brushes if leads are damaged.
Worn motor brushes. (Brushes
must be 1/2 in. minimum)
Replace brushes.
Broken and misaligned motor brush
springs. Rolled portion of spring
must rest squarely on top of brush.
Replace spring if broken. Realign
spring with brush.
Motor brushes are binding in brush
holders.
Clean brush holders, remove car-
bon dust with small cleaning brush.
Align brush lead with slot in brush
holder to assure free vertical brush
movement.
Motor runs and pump strokes Low paint supply. Refill and reprime pump.
Intake strainer clogged. Remove and clean, then reinstall.
Suction tube or fittings loose. Tighten; use thread sealant or seal-
ing tape on threads necessary
See if intake valve ball and piston
ball are seating properly. See pump
manual.
Remove intake valve and clean.
Check balls and seats for nicks,
replace if necessary. Strain paint
before using to remove particles
that could clog pump. See pump
manual.
Leaking around throat packing nut
which may indicate worn or dam-
aged packings. See pump manual.
Replace packings. Also check pis-
ton valve seat for hardened paint or
nicks and replace if necessary.
Strain paint before using to remove
particles that could clog pump. See
pump manual.
Pump rod damage. Replace pump, page 17.
Motor runs but pump does not
stroke.
Displacement pump pin damaged
or missing.
Replace pump pin if missing. Be
sure retainer spring is fully in groove
all around connecting rod, page 17.
Connecting rod assembly damaged. Replace connecting rod assembly.
See pump manual.
Gears or drive housing, page 20. Inspect drive housing assembly and
gears for damage and replace if
necessary, page 20.
Type of Problem
What to Check
(if check is OK, go to next)
What to DO
(When check is not OK, refer to
this column

Troubleshooting
3A2817A 15
Motor is hot and runs intermittently Determine if sprayer was operated
at high pressure with small tips,
which causes low motor RPM and
excessive heat buildup.
Decrease pressure setting or
increase tip size.
Be sure ambient temperature where
sprayer is located is not more than
90°F (32.22°C) and sprayer is not
located in direct sun.
Move sprayer to shaded, cooler
area if possible.
Building circuit breaker opens as
soon as sprayer switch is turned on.
CAUTION
Any short in any part of the motor
power circuit will cause the control
circuit to inhibit sprayer operation.
Correctly diagnose and repair all
shorts before checking and replac-
ing control board.
All electrical wiring damaged insula-
tion and all terminals for loose fit or
damage. Also, wires between pres-
sure control and motor. See page
31.
Repair or replace any damaged wir-
ing or terminals. Securely reconnect
all wires.
For missing inspection plate gasket,
see page 29, bent terminal forks or
other metal to metal contact points
which case a short.
Correct faulty conditions.
Motor control board by performing
control board diagnostics. See page
17. If diagnostics indicate, substitute
with a good board.
CAUTION: Do not perform this
check until motor armature is deter-
mined to be good. A bad motor
armature can burn out a good
board.
Replace with a new pressure con-
trol board. See page 29.
Building circuit breaker opens as
soon as sprayer switch is turned on.
This problem only applies to Pro
230ES model sprayers with brush
motors. They do not apply to Pro
270ES
Motor armature for shorts. Use an
armature tester (growler) or perform
spin test. See page 22. Inspect
windings for burns.
Replace motor. See page 33.
Building circuit breaker opens as
soon as sprayer is plugged into out-
let and sprayer is NOT turned on.
Basic Electric Problems, page 11 of
Troubleshooting.
Perform necessary procedures.
ON/OFF switch. See page 25. Be
sure sprayer is unplugged! Dis-
connect wires from switch. Check
switch with ohmmeter. Reading
must be infinity with ON/OFF switch
OFF, and zero when switch is ON.
Replace ON/OFF switch. See page
25.
Damaged or pinched wires in pres-
sure control. See page 29.
Replace damaged parts. See page
29.
Type of Problem
What to Check
(if check is OK, go to next)
What to DO
(When check is not OK, refer to
this column

Troubleshooting
16 3A2817A
Sprayer quits after spraying for 5 to
10 minutes.
Basic Electrical Problems, page 11
of Troubleshooting.
Perform necessary procedures.
Electrical supply volt meter. Meter
must read 86-130 VAC for 120V
models.
If voltage is too high, do not operate
sprayer until corrected.
Tightness of pump packing nut.
Over tightening tightens packings
on rod, restricts pump action, and
overloads motor.
Loosen packing nut. Check for leak-
ing around throat. Replace pump
packings, if necessary. See pump
manual.
Type of Problem
What to Check
(if check is OK, go to next)
What to DO
(When check is not OK, refer to
this column

Displacement Pump Replacement
3A2817A 17
Displacement Pump Replacement
See manual 312015 for pump repair instructions.
Removal
1. Flush pump.
2. Relieve pressure, page 9.
3. Loosen screws (12). Push cover (70) up and pull off
sprayer.
4. Remove suction tube (60) and hose (45).
5. Cycle motor until pump pin (32) is in position to be
removed.
6. Disconnect power cord from outlet.
7. Using a flat screwdriver, push retaining spring (31)
up. Push out pump pin (32).
8. Loosen pump jam nut (29). Unscrew and remove
pump (41).
ti19380a
12
70
ti19382a
45
60
ti19378a
32
ti6106b
32
31
ti19381a
29
41

Installation
18 3A2817A
Installation
1. Extend pump piston rod full. Apply grease to top of
pump rod at (A) or inside connecting rod (43). Install
jam nut (29) on pump threads.
2. Install pump rod (A) into connecting rod (43).
3. Install pump pin (32). Slide retainer spring (31)
down into groove over pump pin.
4. Push pump (41) up until pump threads engage.
5. Screw in pump until threads are flush with top of
drive housing opening.
6. Align pump outlet to back.
If pump pin works loose, parts could break off due to
force of pumping action. Parts could project through air
and result in serious injury or property damage.
NOTICE
If the pump jam nut loosens during operation, the
threads of the drive housing will be damaged.
ti7392a
29
43
A
ti19379a
ti6108b
31
32
ti6111a
ti19377a

Installation
3A2817A 19
7. Turn jam nut (29) counter-clockwise until it stops.
Tighten jam nut by hand, then tap 1/8 to 1/4 turn
with a 20 oz (maximum) hammer to approximately
75 ft-lb (102 N•m).
8. Install suction tube (60) and high pressure hose
(45). Tighten fittings.
9. Fill packing nut with Graco TSL until fluid flows onto
top of seal.
10. Replace cover (70) over screws. Push cover down
into place. Tighten screws (12).
ti19382a
45
60
ti19376a

Drive Housing Replacement
20 3A2817A
Drive Housing Replacement
Removal
1. Relieve pressure, page 9.
2. Disconnect power cord from outlet.
3. Remove screws (12) and pump rod cover (70).
4. Remove pump, Displacement Pump Replacement,
page 17.
5. Remove screws (12) from shroud (23).
6. Remove screws (12) from front cover (22).
7. Remove screws (47).
8. Pull drive housing (42) off motor (54).
9. Remove gear cluster (44) and (40) and thrust
washer (25) from drive housing.
Installation
1. Apply a heavy coat of grease to gears and needle
bearing surfaces.
2. Install washers (8, 10) on back of gear (40). Install
gear in motor end bell. Using grease for retention,
place washer (10) over bearing inside housing (42).
3. Install washers (1, 9) on back of gear (44). Install in
motor endbell.
4. Install thrust washer (25) on gear (44).
5. Push drive housing (42) on motor endbell as you
guide gear crank (44) through hole in connecting
rod (43).
6. Install screws (47).
7. Install cover (22) and screws (12).
8. Install shroud (23) and screws (12).
9. Install pump; see Displacement Pump Replace-
ment, page 17.
10. Install pump rod cover (70) with screws (12).
NOTICE
Do not drop gear cluster (44) and (40) when remov-
ing from drive housing (42). Gear cluster may stay
engaged in motor front end bell or drive housing.