Graco TexSpray 235490 Operating instructions

ti3005c
Repair
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440- 1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
0.9 to 3.0 gpm (3.4 to 11.4 lpm) Flow Rate
750 psi (5.1 MPa, 51 bar) Maximum Working Pressure
500 psi (3.4 MPa, 34 bar) Recommended Maximum Working Pressure
Model 234113, Series C
TexSpray 1030 FC sprayer, 235490 TexSpray gun
and 50 ft (15 m) air and fluid hose set
309662L
‘
CONTENTS
Warnings 2..............................
Component Description 5..................
Maintenance 6...........................
Troubleshooting 7........................
Repair 10...............................
Parts 20.................................
Accessories 26...........................
Technical Data 27........................
Dimensions 27...........................
Warranty 28.............................
308274.......
309663.......
- For portable spray application of architectural paints and coatings -
TexSpray 1030tFC
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
German Patent No. P 43 18 679.3--09

2 309662
Specifications
This equipment is not intended for use with flammable or combustible materials used in places such as
cabinet shops or other “factory” or fixed locations. If you intend to use this equipment in this type of
application, you must comply with NFPA 33 and OSHA requirements for the use of flammable and
combustible materials.
Warnings
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.

309662 3
The following are general Warnings related to the safe setup, use, maintenance and repair of this equipment.
Additional, more specific warnings may be found throughout the text of this manual where applicable.
WARNING
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:
DUse equipment only in well ventilated area.
DEliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop clothes (potential static arc).
DSprayer generates sparks. When flammable liquid is used in or near sprayer or for flushing or
cleaning, keep sprayer at least 20 ft (6 m) away from explosive vapors.
DDo not clean with materials having flash points lower than 70_F(21_C). Use water--based materi-
als or mineral spirits type material only. For complete information about your fluid, request the
MSDS from the fluid distributor or retailer.
DKeep work area free of debris, including solvent, rags and gasoline.
DDo not plug or unplug power cords or turn lights on or off when flammable fumes are present.
DGround equipment and conductive objects in work area. Read Grounding instructions.
DIf there is static sparking or you feel a shock, stop operating immediately. Do not use equipment
until you identify and correct the problem.
SKIN INJECTION HAZARD
High pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like
just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
DDo not point gun at anyone or any part of the body.
DDo not put your hand over the spray tip.
DDo not stop or deflect leaks with your hand, body, glove, or rag.
DEngage trigger lock when not spraying.
DFollow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking or servicing equipment.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in this equipment. Such use could result in a serious chemical reaction,
with the possibility of explosion, which could cause death, serious injury and/or substantial property
damage.

4 309662
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse equipment only for its intended purpose. Call your Graco distributor for information.
DDo not exceed the maximum working pressure or temperature rating of the lowest rated system
component. This gun has a 150 psi (10 bar) maximum fluid working pressure at a 125 psi (9
bar) maximum incoming air pressure. Read Technical Data in all equipment manuals.
DDo not alter or modify equipment.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not lift pressurized equipment.
DRoute the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180_F(82_C) or below --40_F(--40_C).
DDo not use hoses to pull equipment.
DKeep children and animals away from work area.
DComply with all applicable safety regulations.
DDo not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in this equipment, which contains aluminum and/or zinc parts. Such
use could result in a serious chemical reaction, with the possibility of explosion, which could cause
death, serious injury and/or substantial property damage.
DWear eye and ear protection when operating this equipment. Keep body parts away from front of
gun. See Sound Data in TECHNICAL DATA.
TOXIC FLUID HAZARD
Toxic fluid or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
DRead MSDS’s to know the specific hazards of the fluids you are using.
DStore hazardous fluid in approved containers and dispose of it according to all applicable guide-
lines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes, but is not limited to:
DProtective eye wear.
DClothing and respirator as recommended by the fluid and solvent manufacturer.
DGloves.
DHearing protection.

309662 5
Component Description
Flow and Air Control
Fig. 1. The flow control (A) has a shut off and pressure
relief feature to soft start each time the gun is trig-
gered, instead of a blast of unatomized material. The
flow control has three modes:
DLOW/MED/HIGH: Triggering the gun sends an air
signal to the flow control that closes the prime valve
and starts the pump which fills the material hose.
When the gun trigger is released, the prime valve
opens and relieves the system pressure into the
supply container. When the gun is triggered the
automatic pressure relief, special TexSpray hoses
and pump design eliminate blasts of material and
spray pulsing to ensure consistent atomization.
DOFF: Puts the sprayer in neutral/relieve pressure --
neither the pump nor the gun will operate and there
is no material pressure in the pump, hose or gun.
DPRIME: The prime valve remains open so material
circulates through the pump and back to the supply
container through the drain hose.
The air control (B) increases or decreases the air
pressure to the sprayer from the air supply.
Fig. 1
OFF
PRIME
LOW/MED/HIGH
AB C
TI3101b
158
Blue
159
Black
Prime Valve
Fig. 1. The prime valve (C) relieves system pressure
and stops the pump when the gun trigger is released.
TexSpray Gun, 235490
EQUIPMENT MISUSE HAZARD
The TexSpray Gun 235490 is for use
only with the GM 1030 TexSpray 234113
which is designed so the fluid pressure
of the gun will not exceed the working pressure
rating of the components. The maximum fluid work-
ing pressure of the GM 1030 TexSpray is 750 psi
(5.1 MPa, 51 bar), but the recommended maximum
is 500 psi (3.4 MPa, 34 bar).
WARNING
INSTRUCTIONS
Fig. 2. Air flow is controlled at the gun. During priming,
turn the gun air control valve (D) in fully to prevent air
from mixing with the fluid, which allows you to check
and adjust the fluid flow accurately. (When this valve is
closed the air exits the rear of the gun.) During opera-
tion, open the air control valve to introduce air at the
correct volume for the desired spray pattern. The gun
also has a trigger bail (E) to reduce operator fatigue
when spraying large surfaces.
01808
Fig. 2 E
D
TexSpray Hoses
CAUTION
Use Graco hoses designed for this sprayer. Using
other hoses will damage the flow control.

6 309662
Component Description
Compressor Requirements
NOTE: This sprayer requires an external air compres-
sor.
C
A
UTION
Install an air filter on external air compressor to
reduce contamination to spray system.
Air compressor range: 10 scfm to 35 scfm, 30 to 140
psi (0.2--0.97 MPa, 2 to 9.7 bar)
Material Air Requirements* Minimum
Compressor
Size*
Elastomerics
(textured)
30 scfm at 90 psi
(0.84 m3/min at
0.63 MPa, 6.3 bar)
15 HP
Simulated
Accoustical
20 scfm at 60 psi
(0.56 m3/min at
0.42 MPa, 4.2 bar)
5.5 HP
Splatter Coat
and
Knockdown
15 scfm at 40 psi
(0.42 m3/min at
0.28 MPa, 2.8 bar)
8HP
Orange Peel 20 scfm at 60 psi
(0.56 m3/min at
0.42 MPa, 4.2 bar)
8HP
* Material, temperature and volume affect cfm needed
to properly atomize material.
Maintenance
C
A
UTION
DFor detailed engine maintenance and specifica-
tions, refer to separate HONDA engine manual.
DClose black fuel shutoff lever whenever you are
transporting sprayer to prevent fuel from flooding
engine.
DKeep sprayer upright and level when operating it
and when transporting it. This prevents crankcase
oil from leaking into combustion chamber, which
makes startup very difficult.
Daily: Check engine oil level and fill as needed.
Daily: Check and fill gas tank.
Daily: Check sprayer air filter, clean and replace
element as needed.
After first 20 hours of operation and each 100
hours thereafter: Change oil.
Weekly: Remove engine air filter cover and clean
element. In very dusty environments, check filter daily.
Replace element as needed. Replacement elements
can be purchased from your local HONDA dealer.
Spark plug: Use only a (NGK) BP6ES or BPR6ES
plug. Gap plug to 0.025 to 0.030 in. (0.7 to 0.8 mm).
Always use a spark plug wrench.
6 months: Clean Air Flow Sensor as follows:
1. Fig. 3. Loosen adapter (A). Pull down quick re-
lease (C) and swing out flow sensor regulator.
Disconnect connector (B).
2. Remove inlet fitting (D), retainer ring (E), piston (F)
and spring (G) from flow sensor regulator (H).
C
A
UTION
Do not scratch or nick piston (F) or inside of flow
sensor regulator (H).
3. Clean all parts (D, E, F, G). Clean inside of (H)
with a pipe cleaner.
4. Assemble all parts and install flow sensor regula-
tor.
Flow
Sensor Regulator
A
C
ti4366a
Flow
Sensor Regulator
B
D E FG H
Fig. 3

309662 7
Troubleshooting
To reduce risk of injury due to sprayer starting
unexpectedly, shut off engine before performing
checks or service.
WARNING
Check everything in chart before disassembling sprayer.
PROBLEM CAUSE SOLUTION
Engine does not start Engine switch not ON Turn engine switch ON
Outofgas Fill gas tank
Spark plug cable disconnected or
spark plug damaged
Connect spark plug cable or replace
spark plug
Oil seepage into combustion
chamber
Remove spark plug. Pull starter rope 3 or
4 times. Clean and install spark plug. Try
to start. Keep sprayer upright and do not
overfill engine crankcase to avoid oil
seepage.
Oil level low Add oil to engine crankcase
Engine operates, but
displacement pump does not
Flow control set to OFF Set flow control to PRIME mode or LOW/
MED/HIGH while triggering gun
Air compressor not on or insufficient
air flow from compressor
Start air compressor
Increase SCFM or compressor size.
Check air passages and tips for obstruc-
tions.
Check air filter element for clogs.
Air pressure set to low Check display for air pressure. System
requires a minimum of 40 psi (0.28 MPa,
2.8 bar) to operate. Increase pressure by
adjusting air control knob.
Sprayer engine RPM too low Increase engine speed
Clutch connector into back of circuit
board is loose.
Check and ensure a tight connection.
Air filter dirty Clean or replace filter element.
Air flow sensor dirty or damaged Check air filter.
Clean air flow sensor (see page 4) or re-
place as needed.
Air transducer failed Check display for correct air pressure
reading. Replace circuit board as need-
ed.
Fluid transducer failed Check connection at circuit board.
Replace fluid transducer.
Clutch not engaging Worn or damaged clutch. See page 18.
Fluid transducer failure. Air transducer
failure.
Displacement pump rod seized by
dry coating
Service pump. See page 10.

8 309662
Troubleshooting (Continued)
PROBLEM CAUSE SOLUTION
Engine operates, but
d
i
s
p
l
a
c
e
m
e
n
t
p
u
m
p
d
o
e
s
n
o
t
Connecting rod worn or damaged Replace connecting rod. See page 14.
d
i
sp
l
acement pump
d
oes not
(
Continued
)
Drive housing worn or damaged Replace drive housing. See page 15.
(
C
o
n
t
i
n
u
e
d
)
Pinion assembly worn or damaged Service pinion assembly. See page 16.
Engine operates, displace-
ment pump operates, but no
m
a
t
e
r
i
a
l
p
r
e
s
s
u
r
e
a
t
g
u
n
Flow control is set to PRIME Set flow control to LOW/MED/HIGH while
triggering gun.
mater
i
a
l
pressure at gun. Fluid system over--pressurized Spraying material is too thick or the mate-
rial hose is too long. Use a less course
material or a shorter hose.
Gun nozzle/disk is clogged Check and clean nozzle/disk as needed.
Switch to a larger nozzle/disk.
Material flowing out drain line Check for air leaks to dump valve.
Check dump valve for wear, replace as
needed.
Air flow sensor dirty or damaged.
Pump is packed out Disassemble and clean pump (see page
8), hose(s) and gun.
Low fluid delivery Siphon hose strainer is clogged. Clean or remove strainer
Engine RPM too low Increase engine speed. See Startup,
procedure in operator manual.
Flow control set too low Increase flow control to MED or HIGH
Hose too long or material too
coarse
Change to a shorter hose or less coarse
material.
Material flowing out drain line Check drain line for a constant flow of
material when sprayer is operating in
LOW/MED/HIGH mode.
Check for air leaks to prime valve.
Check dump valve for wear, replace as
needed.
Gun nozzle/disk is clogged Check and clean nozzle/disk as needed.
Switch to a larger nozzle/disk.
Pump is packed out Disassemble and clean pump (see page
8), hose(s) and gun.
Loss of air control or volume
at gun
Gun air passages clogged with
material
After releasing gun trigger, make sure
system is fully depressurized before trig-
gering gun again. This helps prevent
material backing into gun passages.
Air filter dirty Clean or replace element
Air flow sensor dirty or damaged Check air filter.
Clean air flow sensor (see page 4) or re-
place as needed.
Displacement pump output
l
o
w
o
n
u
p
s
t
r
o
k
e
Piston ball (220) not seating Clean piston area. See page 12.
l
ow on upstro
k
ePiston packings worn or damaged Replace packings. See page 12.
Siphon hose coupling gasket (1e)
worn or missing.
Replace or install gasket
Pump cylinder o-ring (205) worn or
missing
Replace o-ring

309662 9
Troubleshooting (Continued)
PROBLEM CAUSE SOLUTION
Displacement pump output
l
o
w
o
n
d
o
w
n
s
t
r
o
k
e
o
r
b
o
t
h
Siphon hose strainer is clogged Clean strainer
l
ow on
d
ownstro
k
eor
b
ot
h
strokes Piston packings worn or damaged Replace packings. See page 12.
Material leaks into wet-cup Intake valve ball (216) not seating
properly
Clean and service intake valve. See
page 12.
Clutch (9) worn or damaged Replace clutch. See page 18.
Air leak at pump foot valve or
siphon tube elbow
Be sure foot valve is tight each day.
Be sure seal in elbow is in place and is
not worn or damaged.
Material leaks into wet-cup Loose wet-cup (202) Tighten wet-cup enough to stop leakage
Throat packings worn or damaged Replace packings. See page 12.
Displacement rod (201) worn or
damaged
Replace displacement rod. See page 12.
Intermittent material flow out
of gun
Material supply is low or empty Refill and prime pump. See Startup proce-
dure in operator manual. Check material
supply often to prevent running pump dry.
Air control on gun is set too high. Reduce the air flow through the gun by
turning the air control knob on the back of
the gun.
Hose too long or material too
coarse
Change to a shorter hose or less coarse
material.
Heavy or poorly atomized mate-
rial when gun is first triggered
(lack of soft start)
Fluid pressure was not allowed to
fully self relieve after releasing gun
trigger
Wait longer between releasing gun trigger
and re--triggering.
(
)
Gun was not fully triggered immedi-
ately when squeezed, causing gun
air passages to clog with material.
Always squeeze trigger fully to prevent
just air from turning on, which starts pump
and pressurizes hoses. Disassemble and
clean gun.
Air valve failure Check and replace as needed
Air flow sensor dirty or damaged Check air filter.
Clean air flow sensor (see page 4) or re-
place as needed.
Pump does not shut off after
gun trigger is released
Air leaks in the system after the air
flow sensor
Check and tighten all connections be-
tween the air flow sensor and the gun.
Air leaks in gun Check gun for excessive air leaks and re-
pair.
See manual 309661
Air flow sensor dirty or damaged Check air filter.
Clean air flow sensor (see page 4) or re-
place as needed.
Premature prime valve fail-
ures
Pump does not shut off after gun
trigger is released.
Read “Pump does not shut off after gun
trigger is released” and fix appropriate
problem.
Repair or replace Prime Valve.
See page 19.

10 309662
Displacement Pump Repair
Removal
To reduce risk of injury due to sprayer starting
unexpectedly, shut off engine before performing
checks or service.
WARNING
1. Fig. 4. Flush sprayer. Remove suction hose elbow
(150a), pump outlet hose (A) and drain hose (64).
Fig. 4
ti12869a
27
63
22
3
150a
A
64
85
159
158
MOVING PARTS HAZARD
To reduce risk of amputating fingers,
keep fingers away from connecting rod
and pin while jogging engine.
WARNING
0407
Torque to 20 ft--lb (27 N.m)
Fig. 5
38
23
37
128
27
38
201
128
61
1
1
2
3
2
Back of pump
Cutaway view shows how pin (38) goes
through connecting rod
3
3
2. Fig. 5. Start engine. Jog flow control between
PRIME and OFF until connecting rod stops near
bottom of stroke. Shut off engine.
3. Loosen two quick disconnect screws (27).
4. Pry retaining spring (37) up on connecting
rod (128). Push pin (38) out with a screwdriver.
5. Fig. 6. Remove cover (C) to control housing (54)
by removing four screws (12). Detach pressure
transducer cord (63, Fig. 4) from control board (9)
at port (D). Remove pressure transducer cord from
control box.
6. Fig. 4. Remove air hoses (158) and (159) from
prime valve manifold (85). Note correct air hose
connection to ports on air cylinder (22). Use 5/16
inch wrench to hold ring on hose fitting while
removing hose from fitting.
7. Support weight of pump (3) and remove two quick
disconnect screws (27).
8. Unscrew assembled dump valve manifold (85) and
air cylinder (22) from pump (3).
Fig. 6
ti3007b
12
D
9
C
54
Repair
See page 12 for pump repair instructions.