Graco PT2500 User manual

   
INSTRUCTIONS–PARTS LIST 307–738
Rev. L
Supersedes K
and PCN L
1/4 GALLON PER MINUTE, 230 V AC, 50 HZ
PT2500
Electric Airless Paint Sprayer
210 bar Maximum Working Pressure
Model 218–730, Series D
This model includes gun, hose, Reverse-A-Clean 
Dripless T
ip Guard and SwitchT ip Spray T ip
U.S. Patent No. 4,616,982
U.K. Patent No. 2,165,591
Other Foreign Patents Pending
Always Professional Results 
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1985, GRACO INC.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE



Welcome to Graco’ s Painter ’ s T eam
Before you use the PT2500 Sprayer, please read this entire instruction manual.
the manual contains important information that will help you operate the sprayer
safely and ef ficiently , and will help you keep the sprayer in top operating
condition.
Table of Contents
PT2500 Sprayer Description 3. . . . . . . . . . . . . . . . . . . . .
Warnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application Methods 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawings and Lists 21. . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 24. . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual
Change Summary
This manual was updated to include the changes from
PCN L.
CAUTION
A torque wrench is needed to properly check and
tighten
the valves and screws on this sprayer . Failure
to torque these parts at the specified intervals (see
page 12) will result in leaking and damage to the
sprayer.
French 185–956
Spanish 185–961
German 186–041
Greek 186–045
Korean 186–049
English 185–953
Danger Labels
The DANGER label shown on below is also on your sprayer . If
you have painters who do not read that language, order one of
the following labels to apply to your sprayer . Apply the label at A
for the best visiblity . Order the labels directly from your Graco
distributor without charge.
A
Liquids can be injected into the body by high pressure airless spray
or leaks – especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts.A void accidental trig -
gering
of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical
T reatment”.
Failure to follow this warning can result in amputation or serious
injury.
FIRE AND
EXPLOSION HAZARD
SKIN INJECTION
HAZARD
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
Spray painting, flushing or cleaning equipment with flammable liq -
uids
in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equip -
ment,
hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic drop
cloths, open flames such as pilot lights, hot objects such as ciga -
rettes,
arcs from connecting or disconnecting power cords or turn -
ing
light switches on and off.
Failure to follow this warning can result in death or serious injury .

 
Sprayer Description
KEY
A Hydraulic
pump
B Rac IV DripLess tip guard
and spray tip
4 Pressure control knob
5 Hydraulic oil fill cap
11 On/Of f switch
18 Motor
21 Diaphragm
22
Paint pump
27 Strainer
59
Drain tube
63 Fluid outlet
66 Bypass valve
67 Outlet
84
Paint hose
85 Spray Gun
59



27
66
4
63
A
5
85
84
B
18
11
21
22




Decrease
pressure (counterclockwise).
Increase pressure (clockwise).
Open (counterclockwise).
Close (clockwise).








Decrease
pressure (counterclockwise).
Increase pressure (clockwise).
Open (counterclockwise).
Close (clockwise).
Motor
The sprayer has a 1/2 HP , 230 V AC, 50Hz, single phase,
1425 rpm motor (18). The motor is supplied with a three-
wire power supply cord and a three-prong plug. The
sprayer
ON/OFF switch is located on the box on the side
of the motor. The motor drives the hydraulic pump. The
motor
runs continuously when it is turned on to keep the
paint at the desired pressure.
Paint Pump
The paint pump (22) is immersed into a 5 gallon paint pail,
so the pump is actually being pressure fed without the
mess
and trouble of pouring paint into a hopper .
Hydraulic Pump
The hydraulic pump (A) is located inside the hydraulic
reservoir. The motor drives an eccentric bearing which
pushes
the piston in and out of the hydraulic pump. The
pump reciprocates the hydraulic fluid to operate the dia -
phragm.
Diaphragm
The diaphragm (21) separates the hydraulic and paint
portions
of the paint pump. Hydraulic oil causes the dia -
phragm to move up and down almost 30 times per sec-
ond,
no matter what pressure you are spraying at.
Pressure Control Knob
The paint pressure is regulated by turning the pressure
control knob (4) clockwise to increase pressure and
counterclockwise
to decrease pressure.
Bypass V alve
The
bypass valve (66) has two functions: (1) to assist in
priming the paint pump during initial startup, and (2) to
provide positive relief of paint pressure from the gun,
hose
and sprayer .
Paint Hose
One electrically conductive nylon paint hose (84) is
supplied
with sprayer Model 218–730. This 7 m hose has
a 6 mm ID, 1/4 npsm(fbe) couplings and spring guards
on
both ends.
Spray Gun, Reverse-A-Clean (RAC) IV T ip Guard
and Spray T ip
The
spray gun (85) has a tough, lightweight plastic body .
The gun has a trigger safety lever which prevents acci-
dentally triggering the gun when the lever is set in the
safe
position. (See WARNINGS , page 4.)
The RAC IV T ip Guard (B) uses high pressure fluid to un -
clog
the spray tip without removing it from the gun. (See
page 16.) The RAC IV includes a safety tip guard which
helps reduce the risk of a fluid injection injury . A No. 315
spray tip for use with latex paint is also included.

4307-738
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury .

This equipment is for professional use only .

Read all instruction manuals, tags, and labels before operating the equipment.
 Use the equipment only for its intended purpose. If you are not sure, call Graco T echnical Assis -
tance at 1–800–543–0339.
 Do not alter or modify this equipment.
 Check equipment daily . Repair or replace worn or damaged parts immediately .
 Do not exceed the maximum working pressure of the lowest rated system component. Refer to
the T echnical Data on page 24 for the maximum working pressure of this equipment.
 Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer ’ s warn -
ings.

Do not use hoses to pull equipment.
 Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex -
pose Graco hoses to temperatures above 82  C (180  F) or below –40  C (–40 F).

Do not lift pressurized equipment.
 Comply with all applicable local, state, and national fire, electrical, and safety regulations.
 Hearing protection is recommended when working around the sprayer. Refer to the Technical
Data section on page 24 for the sound data.
WARNING
WARNING
INSTRUCTIONS

307-738 5
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
 Know the specific hazards of the fluid you are using.
 Store hazardous fluid in an approved container . Dispose of hazardous fluid according to all local,
state and national guidelines.
 Always wear protective eyewear , gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer .
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause ex -
tremely serious injury , including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause serious injury .
 Fluid injected into the skin is a serious injury . The injury may look like just a cut, but it is a serious
injury . Get immediate medical attention.
 Do not point the gun at anyone or at any part of the body .

Do not put your hand or fingers over the spray tip.
 Do not stop or deflect leaks with your hand, body , glove or rag.
 Do not “blow back” fluid; this is not an air spray system.
 Always have the tip guard and the trigger guard on the gun when spraying.
 Check the gun dif fuser operation weekly . Refer to the gun manual.
 Be sure the gun trigger safety operates before spraying.
 Lock the gun trigger safety when you stop spraying.
 Follow the Pressure Relief Procedure on page 8 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
T ighten all fluid connections before operating the equipment.
 Check the hoses, tubes, and couplings daily . Replace worn or damaged parts immediately . Do
not repair high pressure couplings; you must replace the entire hose.
 Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
WARNING
WARNING

6307-738
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury
.
 If there is any static sparking or you feel an electric shock while using this equipment, stop
spraying immediately . Do not use the equipment until you identify and correct the problem.
 Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
 Keep the spray area free of debris, including solvent, rags, and gasoline.
 Electrically disconnect all equipment in the spray area.
 Extinguish all open flames or pilot lights in the spray area.
 Do not smoke in the spray area.
 Do not turn on or of f any light switch in the spray area while operating or if fumes are present.
 Do not operate a gasoline engine in the spray area.
WARNING
WARNING
MOVING P ARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
 Keep clear of all moving parts when starting or operating the pump.
 Before servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the
equipment from starting unexpectedly .

 
Setup
1. Prepare the paint according to the manufactur-
er’s
recommendations.
This is probably the most important step
toward trouble-free spraying!
Remove any skin that may have formed on the top
of the paint. If necessary , thin the paint. Finally ,
strain the paint through a fine nylon mesh bag
(available at most paint dealers) to remove par -
ticles that could clog the spray tip.
2. Install a spray tip and RAC IV tip guard on the
spray
gun as instructed in manual 307–848.
3. Connect the hose and gun. Connect the other end
of the hose to the sprayer .
4.
Check the hydraulic oil level. Unscrew the fill cap
(5). The oil should be 25 mm from the top of the plate.
If the oil is low, fill as necessary with lightweight hy-
draulic oil; use only Graco Hydraulic Oil, Part No.
218–797.
Install the fill cap. See Fig. 1.
5. Check the electrical service which must be 230
VAC,
50 Hz, 10 Amp (minimum). Be sure the electri -
cal
outlet is properly grounded.
Y ou can use up to 30 m of 3 strand, 1.5 mm wires
extension cord. Longer extension cords may af fect
the sprayer performance. Use more spray hose,
not longer extension cords.
Do not remove the third (grounding) prong of the
plug, and do not use an adapter .
6. Plug in the sprayer . First be sure the ON/OFF
switch (11) is OFF and the pressure control (4) is
turned
fully counterclockwise . Plug the sprayer into
a grounded outlet that is at least 6 m away from the
spray area to reduce the chance of a spark igniting
spray
vapors or dust particles.
Fig. 1
25 mm

5
Fig. 2

11
4


Decrease
pressure (counterclockwise).
Increase pressure (clockwise).




Startup
CAUTION
The wallet sized warning card provided with the gun
should be kept with the operator at all times. The card
contains important information on reducing the risk of
a fluid injection injury , and treatment information
should an injection injury occur. Additional copies of
this
card are available at no cost.
Pressure Relief Procedure
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally . Fluid
under high pressure can be injected through the
skin and cause serious injury . T o reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
 are instructed to relieve the pressure,
 stop spraying,
 check or service any of the system equipment,
 or install or clean the spray tip.
WARNING
1. Engage the gun safety latch.
2. T urn the ON/OFF switch to OFF .
3. Unplug the power supply cord.
4. Disengage the gun safety latch. Hold a metal part
of the gun firmly to a grounded metal pail. T rigger
the gun to relieve pressure.
5. Engage the gun safety latch.
6. T urn the bypass valve counterclockwise one turn
to drain paint back into the pail.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above , VER Y SLOWL Y loos -
en the tip guard retaining nut or hose end coupling to
relieve pressure gradually , then loosen completely .
Now clear the tip or hose obstruction.
1. Open the bypass valve (66) ONE turn counter-
clockwise.
Do not place the pump intake in the pail
yet. See Fig. 3.
2. Turn the pressure control fully (4) clockwise to in-
crease
pressure. See Fig. 3.
3. Remove the inlet strainer (27) and place your hand
over
the inlet valve to be sure it is drawing a vacuum.
NOTE: If the inlet valve (26) is not drawing a vacuum,
turn
the sprayer OFF . T urn the sprayer over . Press down
on the stem (A) inside the inlet valve lightly with a small
screwdriver, and pour about a teaspoon of mineral spirits
or solvent into the valve. See Fig. 4. Release the valve
and
turn the sprayer upright. With the pressure turned up,
turn on the sprayer . This should free any sticking parts in
the pump. Now check again for a vacuum. Shut of f the
sprayer
and install the inlet strainer (27).
4. Place the paint pump assembly into a properly pre-
pared
5 gallon pail of paint.
5. Turn the sprayer ON and allow the paint to circulate
through the bypass valve (4) for one or two minutes.
NOTE: If the paint does not circulate back into the pail,
turn down the pressure and turn the motor on and of f sev -
eral
times to help prime the sprayer .

307-738 9
Startup
6. Turn the bypass valve (66) clockwise (finger tight)
to
close it; this allows the pump to build up pressure.
Fig. 3
Fig. 4


27
66
4




Decrease
pressure
(counterclockwise).
Increase pressure (clockwise).
Open (counterclockwise).
Close (clockwise).




22
26
A
7. Release the trigger safety lever and trigger the gun
onto
a piece of paper to check the spray pattern. Ad -
just
the pressure setting to obtain the best atomiza -
tion and spray pattern.
Always use the lowest
pressure necessary .
Excessive pressure cause
premature
tip wear and pump wear .
NOTE: If
you cannot obtain a good spray pattern or ade -
quate
atomization, your paint may be too thick. Thin the
paint according to the manufacturer ’ s recommendations
until you can get good atomization.
8. Whenever you stop spraying, even for a moment, al -
ways
set the trigger safety lever to prevent acciden -
tally
trigger the gun.
9. Whenever you stop spraying for more than a mo-
ment, or if you must leave the sprayer unattended,
shut
it of f and follow the Pressure Relief Procedure
on page 8.
NOTE: The sprayer will not restart if it was left pressur -
ized
after shutting it off. Relieve pressure, then start the
sprayer.
Fig. 5 



Lubricate
the threads.
T orque to 19–23 N.m.
T orque to 36–41 N.m.
22
26
25

 
10. After the first 3 to 5 hours of operation torque the
four screws (25) on the bottom of the paint pump (22)
to 19–23 N.m. See Fig. 5.
11. Also torque the inlet valve (26) to 36–41 N.m.
CAUTION
Failure to properly tighten the inlet valve and screws
at the intervals indicated will result in oil leaking from
the hydraulic system into the paint, and can cause
costly
damage to the sprayer .
12.
Repeat these torques after another 3 to 5 hours of
operation, and then after each 25 hours of operation
(about weekly).
startup procedure continued on page 10

10 307-738
Startup
CAUTION
Never start the electric motor with the inlet valve
removed
to avoid damaging the diaphragm.
13. If you have a Reverse-A-Clean IV tip guard on your
gun and the tip clogs while spraying, release the gun
trigger, lock the trigger safety lever , and rotate the
spray
tip handle 180  . See Fig. 6.
14. Unlock the safety lever and trigger the gun into a
grounded metal waste container. Hold a metal part
of
the gun firmly to the side of the container to reduce
the risk of static sparking and splashing. The fluid
pressure should force the obstruction from the tip.
Lock
the safety lever .
15. Return
the handle to the original position, unlock the
safety lever, and resume spraying.
Fig. 6 
16. If the tip is still clogged , lock the trigger safety lever ,
shut
of f and unplug the sprayer , and open the bypass
valve one turn counterclockwise . Disassemble the
tip in the reverse order of assembly (see manual
307–848).
Thoroughly clean all parts in a compatible
solvent and inspect for wear or damage. Replace
parts as needed and reassemble. Be sure to use a
new
seal and gasket when changing tips.
17. If you have a tip guard on your gun which is not self-
clearing, follow step 12 on page 9.
18. Spraying techniques are given on page 16.
19. Important maintenance procedures are given on
pages
12, 13, and 14.

307-738 11
Notes

12 307-738
Maintenance
Thorough flushing and proper maintenance are
essential to keep the sprayer working properly
and
avoid costly damage to the sprayer or the ob -
ject being sprayed.
Diaphragm Failure: Always replace the diaphragm
after
every 500 hours of operation (once every 4 to 6
months). The diaphragm weakens with use. If the
diaphragm
ruptures, hydraulic oil and paint may mix,
damaging the sprayer and/or the surface of the object
being sprayed may be damaged.
Follow the Maintenance Intervals outlined below .
CAUTION
Maintenance Intervals
Flushing Immediately after each use.
Lubricate the intake valve. Immediately after each use.
Tighten the paint pump
screws
and the inlet valve.
1. After the first 3 to 5 hours of
operation.
2. After the next 3 to 5 hours
of
operation.
3. Each 25 hours thereafter
(about weekly).
Check or change the hydrau -
lic
oil.
1. Check the oil after each
use
of the sprayer .
2.
Change the oil after the first
20 hours of operation.
3. Change the oil each 50
hours
thereafter (about twice
monthly).
Replace the diaphragm. After every 190,000 liters of
paint
sprayed (4 to 6 months).
Flushing Procedure
1. Shut off the sprayer. Lock the gun trigger safety le-
ver.
Open the bypass valve (66) ONE turn counter-
clockwise. Raise the paint pump just above the
paint
and turn on the sprayer to drain the paint. Now
turn of f the sprayer . See Fig. 7.
2. Place the paint pump in a grounded flushing pail of
solvent.
3. Check to be sure the trigger safety lever is locked.
Remove the spray tip from the gun. Unlock the safety
lever. Hold a metal part of the gun firmly to the side
of a grounded metal pail. Close the bypass valve
(66).
T rigger the gun into the pail. T urn on the spray -
er. Watch the side of the pail for solvent to appear .
Then
release the gun trigger . T urn of f the sprayer .
4. With the bypass valve (66) closed, turn on the spray -
er,
trigger the gun into the flushing pail and allow the
solvent to circulate through the hose and gun for two
to three minutes, using the lowest possible pressure.
See Fig. 8. Release the gun trigger and lock the safe -
ty
lever . T urn of f the sprayer .
Fig. 7 





Decrease pressure
(counterclockwise).
Increase pressure (clockwise).
Open (counterclockwise).
Close (clockwise).
66
4




11
Maintain firm met -
al–to–metal
contact
between gun and
container
Fig. 8
ÄÄ
ÄÄ
ÄÄ




307-738 13
Maintenance
5. Open the bypass valve (66) ONE turn counter-
clockwise.
6. Raise
the paint pump above the solvent, turn on the
sprayer, and allow the pump to run itself dry . T urn the
sprayer OFF.
7. Using
a clean pail of water or solvent, and the lowest
possible pressure, flush again to be sure all paint par -
ticles
are removed.
8. Remove the paint strainer and clean it thoroughly .
9. Now lubricate the inlet valve.
Lubricate the Inlet V alve. See Fig. 9.
1. Follow the Pressure Relief Procedure on page 8.
Remove
the inlet screen.
2. Turn the sprayer over . Press down lightly on the stem
of the inlet valve with a small screwdriver . Pour about
a teaspoon of mineral spirits or solvent into the valve,
then remove the screwdriver .
3. Set the sprayer upright. Increase the pressure con-
trol setting half way . T urn on the sprayer for a few se -
conds,
then turn it OFF .
4. Now tighten the paint pump screws and the inlet
valve.
Fig. 9

22
26
A
The maintenance procedure is continued on the next
page.

14 307-738
Maintenance
T ighten the Paint Pump Screws and Inlet V alve
See Fig. 10.
1. Follow the Pressure Relief Procedure on page 8.
2. Torque the four screws (25) on the paint pump (22)
to
19–23 N.m.
3. T orque the inlet valve (26) to 36–41 N.m.
Check and/or Change the Hydraulic Oil
See Fig. 1 1.
1. Follow the Pressure Relief Procedure on page 8.
2. Remove the fill cap (5). The oil should be 25 mm from
the top of the plate. If the oil is low , add oil as neces -
sary. use only Graco lightweight hydraulic oil, part
no. 218–797. Reinstall the fill cap, hand tight, if you
are
not going to change the oil.
3. To change the oil, turn the sprayer over and drain the
oil through the fill cap hole.
Whenever you remove the fill cap, be very careful not
to let any dirt, paint particles, or other contaminants
get into the hydraulic system. Contaminants can
cause
damage to the hydraulic system.
CAUTION
4. Fill the hydraulic pump housing with 55 ml of Graco
lightweight hydraulic oil. Reinstall the fill cap.
5. Plug in the sprayer . T urn the pressure control (4) fully
counterclockwise (no pressure). T urn on the
sprayer
and let it run for two minutes to fill the hydrau -
lic system. Increase the pressure to the maximum
and
turn the sprayer on and of f four times to help rid
the hydraulic system of air .
Fig. 10 



Lubricate
the threads.
T orque to 19–23 N.m.
T orque to 36–41 N.m.
22
26
25

 
Fig. 1 1
25 mm

5

307-738 15
Notes

16 307-738
Application Methods
Always hold the gun perpendicular to the surface and
keep
the gun at an even 300 to 356 mm from the surface
you are spraying. See Fig. 12.
Begin moving the gun in a horizontal direction at a steady
rate. Start the spray stroke of f the target surface and pull
the trigger as the gun is moving. Then, while the gun is
still
moving, and as you approach the other edge, release
the trigger. This method avoids excess paint build-up at
the end of each stroke.
Fig. 12
RIGHT
WRONG

The correct speed for moving the gun will allow a full, wet
coating to be applied without runs or sags. Lapping each
stroke about 50% over the previous stroke produces uni -
form
paint thickness. Spraying in a uniform pattern alter -
nately from right to left and then left to right, provides a
professional
finish. See Fig. 13.
Fig. 13 
The best way to control the rate of coverage is with the
gun
tip size. A small tip orifice applies less paint. A larger
tip orifice applies more paint. The width of the pattern de -
pends
on the fan pattern of the tip you choose.
Do not try to increase coverage by increasing the fluid
pressure!
Using the lowest pressure necessary to get the
results you want will help prolong the life of your sprayer
and minimize paint lost by overspray .
For interior corners, such as on a bookcase or inside a
cabinet, aim the gun toward the center of the corner to
spray. By dividing the spray pattern this way, the edges
on
both sides are sprayed evenly . See Fig. 14.
Fig. 14 
If there is a wind, angle the spray pattern into the wind to
minimize drifting. Paint from the ground to the roof.
T o avoid getting paint on these objects:
Shrubs. When next to the house, tie back shrubs from the
surface to be painted with rope and stakes. Then cover
them
with a canvas dropcloth as the painter approaches
the area. Remove the canvas dropcloth as soon as the
area
is painted to prevent possible damage to the shrubs.
Concrete walks. If the walkways will be walked on, cover
them with a canvas dropcloth to avoid slipping. Other-
wise
a plastic cloth is all that is needed.
Electrical outlets and lamps. Protect electrical outlets
with masking tape. Cover lamps with plastic bags se-
cured
with masking tape.
Nearby objects. Move objects such as automobiles, pic -
nic
tables, lawn furniture, etc. upwind of the surface to be
sprayed. In the case of a nearby home, make a protective
barrier by hanging plastic between two long poles.

307-738 17
Troubleshooting
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
follow the illustrated Pressure Relief
Procedure warning on page 8 when -
ever you are instructed to relieve pressure.
NOTE: Repairs, other than those for which instructions
are
given on page 19, should be performed by a trained
and qualified repair agency .
NOTE:
If your sprayer is not operating well, or will not op -
erate at all, check for obvious problems first. Follow the
Startup procedure exactly (see page 8). Then if the
sprayer won’t start, use the T roubleshooting Chart for
help
in identifying the possible cause.
NOTE: Remember , taking the time after each use of the
sprayer to perform all of the maintenance procedures
given
on pages 12, 13, and 14 will help prevent down time
and costly repair bills.
PROBLEM CAUSE SOLUTION
Poor spray pattern Spray tip worn Change tip
Paint too thick Thin, try larger tip
Spray gun won’t shut of f W orn ball Repair gun; order kit no. 218–588
W orn dif fuser Replace gun
Paint build-up between needle and
diffuser
Disassemble and clean gun
Spray gun leaks W orn seal or loose fluid fitting Repair gun; order Kit no. 218–588;
tighten
fluid fitting.
Spray gun won’t spray , or low
output from gun
Paint supply empty Refill and reprime system.
Spray tip clogged Use Reverse-A-Clean feature to
clear
tip clog; see page 10
Gun filter , if used, is clogged Clean or replace.
Sprayer will not start Sprayer not plugged in Plug in.
ON/OFF switch turned of f T urn switch on.
Sprayer left pressurized when shut
off
Relieve pressure first, then start.
Motor overheated Shut off, relieve pressure, allow to
cool
NOTE: Sprayer restarts automati-
cally
when cool if it is left on
Blown building fuse or circuit
breaker tripped
Replace or reset
No voltage or low voltage in
electrical outlet
Test the outlet or try plugging spray -
er
into another outlet
Damaged power supply cord or
extension cord, or wrong type of
extension cord
Return for repair; use only 3 strand,
1.5mm (minimum) wire extension
cord
with a 3 prong plug and a maxi -
mum
length of 30 m.
Starter switch (18a) damaged Replace; see page 19.
Motor worn or damaged Return for repair
Motor runs but sprayer won’t run Air in diaphragm housing Bleed air

18 307-738
PROBLEM CAUSE SOLUTION
Sprayer starts but will not suck paint Paint supply empty Refill and prime pump
Inlet screen clogged Clean
Inlet valve stuck or damaged See page 19.
Outlet valve stuck See page 19.
Air trapped in hydraulic system See page 19, Diaphragm , step 9
Hydraulic oil level low or empty See page 14.
Wrong grade of hydraulic oil or
wrong
fluid in hydraulic system
Use only Graco approved hydraulic
oil, part no. 218–797
Inlet valve not tight T ighten; see page 14.
Damaged diaphragm Replace; see page 19.
Sprayer sucks paint but does not
build
up pressure
Pressure control valve not turned up Adjust
Outlet valve stuck, dirty or had worn
parts
See page 19.
Hydraulic oil low See page 14.
Inlet valve leaks See page 19.
Damaged diaphragm Replace; see page 19.
Damaged bypass valve Replace.
Damaged hydraulic system Return sprayer for repair .
Damaged paint pump Replace.
Sprayer sucks paint, builds pres-
sure but pressure drops when gun
No spray tip on gun Shut of f sprayer and install tip
sure, but pressure drops when gun
is
triggered
Spray tip orifice too large for the
paint
or worn tip
T ry a smaller tip or a new tip
Inlet screen clogged Clean
Optional gun filter clogged Clean or replace
Optional gun filter screen too fine for
type of paint
Install larger mesh filter or strain and
thin the paint
Paint too thick Thin and/or strain
W orn outlet valve Replace; see page 19.
Leaking bypass valve Replace.
W orn or damaged inlet valve See page 19.
Worn or damaged pressure control
valve
See page 19.
Pressure fluctuations Outlet valve stuck, dirty or worn See page 19.
Leaking or dirty bypass valve Replace.
Dirty , leaking, worn or damaged
inlet valve
Replace; see page 19.
Dirty pressure control knob Clean or replace; see page 19.
Damaged diaphragm, or paint
pump,
or hydraulic system
Return for repair .
Paint in hydraulic system Ruptured diaphragm Return for repair .
Hydraulic oil in paint Ruptured diaphragm Return for repair .

 
Service
Repairs, other than those for which instructions are given
below, should be performed by a trained and qualified re -
pair
agency .
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
follow the illustrated Pressure Relief
Procedure warning on page 8 when -
ever you are instructed to relieve pressure.
Inlet Check Valve. See Fig. 15.
6. Unscrew the inlet check valve (26) from the paint
pump (22).
7. Clean
the gasket (26a), the inlet valve (26), and the
paint pump (22) threads and check for erosion. If any
of the parts are eroded, replace them.
8. Be sure the threads in the paint pump are clean.
9. Lubricate the threads of the inlet valve with petro-
leum
jelly . Install the gasket on the valve, then install
the valve and torque it to 36–41 N.m.
Outlet Check Valve. See Fig. 15.
10. Unscrew the plug (28d) and the housing (28b).
11. Use a pick, such as a dentist’ s pick, to remove the
seal
(28a) from the paint pump (23). The seal may be
hard to remove. DO NOT LEA VE THE SEAL IN THE
PAINT PUMP HOUSING.
12. Clean the parts thoroughly, including the threads in
the
pump, with a compatible solvent. Check all parts
for wear or damage and replace as needed.
13. Lubricate the threads of the housing (28b) and plug
(28d).
14. Install a NEW seal (28a) in the pump housing. AL-
WAYS
replace the seal (28a). Do not try to reuse the
old seal as it will be deformed.
Be sure you do not install a new seal until the old one
is removed. Having two seals in the valve will cause
performance problems.
CAUTION
15. Install the housing (28b) and torque to 14–17 N.m.
16. The last coil on one end of the spring is turned in.
Place
this end over the stud in the plug (28d). Install
the ball (28e), washer (28f) and plug, and torque to
plug
to 32–34 N.m.
Pressure Control. See Fig. 15.
When removing the pressure control (4) to check or clean
it, always replace the seal (4a). When replacing the pres -
sure
control, torque the new control (4) to 14–17 N.m.
Starter Switch. See Fig. 15.
Remove the cover of the switch box. Remove the two
screws
holding the starter switch (18a). Remove the old
switch and install a new one.
Diaphragm. See Fig. 15.
17. Remove the inlet strainer (27). Remove the four paint
pump screws (25) and lockwashers (24).
18. Remove the bypass valve (66) and the fluid outlet
nipple (67), and then remove the screws (35) and
shield (3).
19. Remove
the screw (36) and lockwasher (37) from the
bracket (38).
20. Pull
the paint pump assembly away from the hydrau -
lic
housing (20) and remove the old diaphragm (21).
CAUTION
Never start the electric motor with the inlet valve (26)
removed to avoid damaging the diaphragm.
CAUTION
Be careful not to get any dirt or paint on the new dia -
phragm or the hydraulic housing. Contaminants in
the hydraulic system can cause the sprayer to mal-
function
and result in costly damage to the sprayer .
DO
NOT T AMPER with the nut (C). The nut is factory
set to hold the spring to a specific dimension.
21. Check the gasket (22a) for wear or damage and re -
place it if needed. Clean the top of the paint pump
and
the hydraulic housing thoroughly .
22. Install the new diaphragm assembly (21), lubricate
the internal threads of the housing (20), and reas-
semble
the parts.

 
Service
23. Lubricate the screws (25) and then install and torque
them to 19–23 N.m .
CAUTION
Whenever you remove the paint pump screws,
torque them as instructed above, and then retorque
them
after 3 to 5 hours of operation.
24. Check the hydraulic oil level and add Graco-ap-
proved
oil as necessary until the level is 25 mm from
the top of the plate. See Fig. 1 1, page 14.
25. Turn the pressure control fully counterclockwise
(no
pressure). Plug in the sprayer and turn it on. Run
the sprayer for two minutes to fill the hydraulic sys-
tem.
Increase the pressure to maximum and turn the
sprayer on and of f four times to help rid the hydraulic
system of air .
Fig. 15
21
22a
22b
26a
26
27
25
24
28d
28f 28c
28e
28b
28a
C
4
4a
38
37
36
66
35
3
67
20
28
18a





Torque
to 14–17 N.m.
Apply sealant to the threads.
Lubricate the internal threads.
T orque to 14–17 N.m.
T orque to 32–34 N.m.
Lubricate the threads.
T orque to 36–41 N.m.
T orque to 19–23 N.m.
Do not alter the position of the nut.
The start switch is located
in the switch box.
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