Graco 235706 Operation manual

INSTRUCTIONS-PARTS LIST 308270
Rev B
DISPLACEMENT PUMP
Model 235706, Series A
3 GPM pump for use with the GM1030 TexSpray Sprayer
1000 psi (70 bar) MAXIMUM WORKING PRESSURE
Model 235965, Series A
2 GPM pump for use with the GM1030 TexSpray Sprayer
1000 psi (70 bar) MAXIMUM WORKING PRESSURE
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . .
Remove/Install Pump 3. . . . . . . . . . . . .
Repair 4. . . . . . . . . . . . . . . . . . . . . . . . . .
Parts (Model 235706) 6. . . . . . . . . . . . .
Parts (Model 235965) 6. . . . . . . . . . . . .
Technical Data 8. . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 8. . . . . . . . . . . .
Warranty 8. . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
COPYRIGHT 1993, GRACO INC.
This manual contains IMPORTANT
WARNINGS and INFORMATION
READ AND RETAIN FOR REFERENCE
Model 235706 shown
01900

2308270
WARNINGS
HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY.
FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS.
Read and understand all instruction manuals before operating the equipment.
PRESSURE RELIEF PROCEDURE
This procedure applies when the 3 GPM and 2 GPM pump is
used with the GM1030 TexSpray Sprayer and Easy Spray
Control. If you are using the pump in any other approved
application, follow the Pressure Relief Procedure given in the
system manuals supplied for your application.
Fluid pressure is relieved automatically when the gun trigger
is released. However, to further reduce the risk of injury,
including injury from moving parts, always follow this proce-
dure when not spraying and before checking or adjusting the
system.
1. Turn the Easy Spray Control to OFF.
2. Turn the engine stop lever to OFF.
EQUIPMENT MISUSE HAZARD
General Safety
Misuse of the spray equipment or accessories, such as
overpressurizing, modifying parts, using incompatible chemi-
cals and fluids, or using worn or damaged parts, can cause
them to rupture and result in fluid injection, splashing in the
eyes or on the skin, or other serious bodily injury, or fire, ex-
plosion or property damage.
NEVER alter or modify any part of this equipment; doing so
could cause it to malfunction.
CHECK all spray equipment regularly and repair or replace
worn or damaged parts immediately.
Always wear protective eyewear, gloves, clothing and respi-
rator as recommended by the fluid and solvent manufacturer.
System Pressure
The MAXIMUM WORKING PRESSURE of these pumps is
1000 psi (70 bar).
The GM1030 TexSpray Sprayer, Gun and Hose Set are
designed to work together. This unique combination of
components is possible because of the unit’s Easy Spray
Control which ensures that no fluid can be trapped under
pressure in the gun or hose. When used according to the
instructions, the fluid pressure will not exceed the working
pressure rating of the components.
Fluid and Solvent Compatibility
All chemicals used in the sprayer must be chemically com-
patible with the wetted parts in the TECHNICAL DATA on
page 8. Consult your chemical supplier to ensure compati-
bility.
HOSE SAFETY
Use only genuine Graco hoses and replacement hoses
as shown on page in the GM1030 TexSpray manual. The
hose used at the sprayer outlet must have a spring guard at
that end.
Tighten all fluid connections securely before each use.
Do not use a damaged or repaired hose. Before each use,
check the entire hose for cuts, leaks, abrasion, bulging cover,
or damage or movement of the hose couplings. If any of
these conditions exist, replace the hose immediately.
Handle and route hoses carefully. Do not pull on hoses to
move equipment. Keep hoses clear of moving parts and hot
surfaces of the pump and gas engine. Do not use fluids or
solvents which are not compatible with the inner tube and
cover of the hose. DO NOT expose Graco hoses to tempera-
tures above 180 F (82 C) or below –40 F (–40 C).
If the hose develops a leak, split or rupture due to any kind of
wear, damage or misuse, the spray coming from it can
cause splashing on the eyes or skin or property damage.
FIRE OR EXPLOSION HAZARD
The GM 1030 TexSpray Sprayer is intended for use outside
and with texture materials at low application pressures. If you
are using the sprayer for any other approved application, you
must provide complete system grounding as explained in the
system manual supplied for your application.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers or other body
parts. KEEP CLEAR of moving parts when starting or operat-
ing the sprayer. Follow the Pressure Relief Procedure
above before checking or servicing any part of the sprayer, to
prevent it from starting accidentally.
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards
– particularly the General Standards, Part 1910, and the Construction Standards, Part 1926 – should be consulted.

308270 3
REMOVING & INSTALLING A DISPLACEMENT PUMP
Removal
To reduce the risk of serious bodily injury, always
shut off the engine and disconnect the spark plug
before performing any checks or service.
WARNING
1. Flush the sprayer. Remove the suction hose.
Remove the outlet hose.
To reduce the risk of pinching or amputating a fin-
ger, keep fingers away from the connecting link
and pin while jogging the engine.
WARNING
2. Start the engine. Jog the Easy Spray Control (E)
between PRIME and OFF until the connecting link
stops near the bottom of the stroke and is fully ex-
posed. See Fig 2. Shut off the engine.
3. Unscrew the collar (C) and disconnect the power
supply cord from the control (E). See Fig 2.
4. Loosen the two mounting screws (D). See Fig 1.
5. Use a screwdriver to gently pry the retaining ring
up (B) from the back of the connecting link (C).
Then push the pin in so it falls out the back.
6. Remove the two mounting screws (D) while sup-
porting the weight of the pump with your free hand.
7. Disconnect the cables (D) from the pressure drain
valve. See Fig 3.
8. Unscrew the gauge, using a 1.062” wrench.
Unscrew the pressure drain valve assembly from
the the pump.
Installation
1. Screw the pressure drain valve into the pump.
Install the gauge.
2. Push the pin (228) slightly into the connecting link
(C), but not into the mating hole of the pump.
3. Pull the piston rod (201) out of the pump 2 to 3 in
(50 to 75 mm).
4. Align the flats of the pump piston rod and the
pump outlet. Lift the pump into position and gently
push on the pin while moving the pump slightly
until the pin slips into the hole. Be sure the retain-
ing ring (B) snaps down over the end of the pin.
Check the back of the bearing housing to be sure
the parts are installed properly.
To reduce the risk of serious injury or property
damage, be sure the retaining spring is firmly
and completely in the groove of the connecting
link to prevent it from working loose due to vibra-
tion. See Fig 1.
WARNING
5. Lift the pump to align the mounting holes and in-
stall the mounting screws. IMPORTANT – torque
the screws to 20 ft-lb (27 N.m). See Fig 1.
6. Connect all cables to the pressure drain valve. See
Fig 3. Plug in the power cord so the notch (F) in
the collar (G) and the tab (H) in the socket align.
Screw on the collar. See Fig 2.
0407
Torque to 20 ft–lb (27 N.m)
Fig 1
228
A
B
C
D
228
201
C
B
1
1
2
3
2
Back of pump
Cutaway view shows how pin (228) goes
through connecting rod
3
Fig 2
H
F
G
E
01782
Fig 3
D
01901

4308270
DISPLACEMENT PUMP REPAIR
To reduce the risk of serious bodily injury, always
shut off the engine and disconnect the spark plug
before performing any checks or service.
WARNING
Disassemble the pump
1. See page 3 for how to remove the pump.
2. Use a hammer on the tabs of the lug nut (214) to
loosen the foot valve housing.
3. Disassemble the pump, but do not disassemble
the piston rod (201) from the piston housing (206)
unless one of those parts needs to be replaced.
Due to the high-strength (red) Loctite used at the
joint of these two parts, the joint must be heated
before disassembly. Refer to Fig 4.
Clean and inspect all parts
1. Use a compatible solvent to thoroughly clean all
parts and remove all traces of sealant.
2. Inspect the parts, including the seats, for nicks and
scratches. Replace worn or damaged parts as they
cause the packings to wear more quickly and may
result in poor pump performance.
Repair Kit
A Packing Repair Kit is available. See page 6 or 7 to
order. Use all the parts in the kit for the best results.
Change the pressure drain valve u–cup packing
(included in kit) when you repack the pump.
Parts included in the kit are marked with an asterisk in
the text and drawings. For example, 208*.
Reassemble the pump
NOTE: Refer to Fig 4.
1. If you disassembled the piston rod (201) and pis-
ton housing (206), clean the threads thoroughly.
Apply Loctite primer and then red Loctite to the
threads and torque to 80 to 100 ft-lb (110 to
135 N.m). Allow to dry at least one hour.
2. Assemble onto the piston seat (213): washer
(212); u–cup seal (218*) with lips toward ring;
female gland (211*) and then alternate the white
(210*) and purple packings (219*), all with lips
facing up; male gland (209*).
3. Install the nut (208*) on the piston seat (213).
Hand tighten the nut very firmly.
4. Install the ball (220*) in the piston housing (206).
5. Apply blue Loctite (supplied in kit) to the piston
seat (213) threads and screw the assembly onto
the rod, hand tight.
TIP: Use a felt tip marker to draw a line across the
male gland, nut and piston housing to use as a visual
reference when tightening the piston and nut.
6. Place the piston seat (213) in a vise. Hold the
packing nut (208) steady with one wrench and use
a torque wrench to tighten the rod assembly to
90–125 ft-lb (122–170 N.m). Make sure the line
you made in step 5 is still aligned.
7. Grease the throat of the intake housing (227).
Assemble into the throat: male gland (204*), flat
side first; alternate white packings (225*) and
purple packings (203*) and then the female gland,
all with lips facing down. Install the packing nut
(202) and tighten firmly by hand.
8. Grease the piston packings and inside the throat
packings.
9. Grease the new o–rings (205*) and install on the
cylinder (221). Slide the cylinder into the bottom of
the intake housing (227) until you hear it snap.
10. Guide the piston rod assembly into the cylinder so
the piston rod flats are aligned with the opening in
the front of the pump. Push down until you hear
another snap. Turn the pump over and push the
assembly the rest of the way in.
11. If the rod hole is not aligned with the front of the
pump, use a screw driver through the rod hole to
turn it into place.
12. Grease the o–ring (223*), install on the plug (224),
install the plug and the screws (222) loosely.
Torque the screws to 50–70 in–lb
(5.6–8 N.m) in a crosswise pattern.
13. Install the ball (216*) and ball guide (217) into the
foot valve. Place the pump assembly on the foot
valve and push into place.
14. Screw on the lug nut (214). Use a hammer to
tighten the lug nut securely.
TIP: The lug nut must be very tight or the pump will not
prime. Use a felt tip marker to draw a line between the
intake housing and the lug nut to use as a visual align-
ment reference during operation.
15. Install the pump and prime it. Check the packing
nut (202) and tighten it just enough to prevent
leakage.

308270 5
DISPLACEMENT PUMP
Fig 4
205*
205*
221
217
214
216*
215
219*
207*
208*
206
*209
*211
*210
*218
*212
220*
222
224
*223
202
*226
*203
*204
225*
201
3
4
5
10
7
8
227
2
1
2
Grease inside of throat
before installing packings
3
1
Lips of v–packings in throat
must face down
Grease inside of packings
after installing
3
2
4
5
Torque 50–70 in–lb
(5.6–8 N.m)
in crosswise pattern
6
Lips of v–packings on
piston must face up
7
6
Grease outside of packings
before installing
8Lips of U–cup seal on
piston must face down
9If piston seat and rod were
separated, apply Loctite
primer, then red Loctite, and
torque to 80–100 ft–lb
(110–135 N.m)
10
9
Tighten with hammer
Torque piston housing
to piston seat (213) to
90–125 ft–lb (122–170
N.m) without changing
alignment of packing
nut
01785
~
76
213

6308270
PARTS LIST & DRAWING – 3 GPM PUMP
Model 235706, Series A
Includes items 201228
Ref
No. Part No. Description Qty
201 188437 PISTON ROD 1
202 187068 PACKING NUT 1
203 188560* V–PACKING, poly 2
204 187939* GLAND, male 1
205 188557* O–RING 2
206 187934 PISTON HOUSING 1
207 188559* O–RING, Viton 1
208 188434* NUT 1
209 188432* GLAND, male 1
210 188561* V–PACKING, poly 2
211 188433* GLAND, female 1
212 188627* BACKUP WASHER, nylon 1
213 235165 PISTON SEAT 1
214 187929 LUG NUT 1
215 235732 INTAKE HOUSING 1
216 102973* BALL, intake, 1.25” OD 1
217 187064 BALL GUIDE 1
218 188558* U–CUP SEAL,
poly/Viton 1
219 187072* V–PACKING, poly 3
220 102972* BALL, piston, 0.875” ID 1
221 187066 CYLINDER 1
222 111729 SCREW, No. 10–32 x
5/8” 4
223 188554* O–RING 1
224 188629 PLUG, “3 GPM”1
225 187071* V–PACKING, poly 3
226 187070* GLAND, female 1
227 187933 HOUSING, outlet 1
228 183210 PIN 1
232 235962 SEAL, foot valve 1
*These parts also included in
Packing Repair Kit 235186.
Keep a kit on hand to reduce down time.
Kit also includes one U–Cup packing,
111829, for the pressure drain valve.
202
*205
221
*205
206
208*
220*
213
217
216*
215
214
201
227
222
*224 223*
*226
*204
218*
212*
211*
209*
207*
219*
*210
203*
*225
228
01899
232

308270 7
PARTS LIST & DRAWING – 2 GPM PUMP
Model 235965, Series A
Includes items 201232
Ref
No. Part No. Description Qty
201 188580 PISTON ROD 1
202 187068 PACKING NUT 1
203 188656* V–PACKING, leather 2
204 188568* GLAND, male 1
205 188557* O–RING 2
206 188625 PISTON HOUSING 1
207 188555* O–RING, Viton 1
208 188578* NUT 1
209 188566* GLAND, male 1
210 188657* V–PACKING, leather 2
211 188565* GLAND, female 1
212 188626* BACKUP WASHER, nylon 1
213 235733 PISTON SEAT 1
214 187929 LUG NUT 1
215 235963 INTAKE HOUSING 1
216 102973* BALL, intake, 1.25” OD 1
217 187064 BALL GUIDE 1
218 188556* U–CUP SEAL,
poly/Viton 1
219 188553* V–PACKING, poly 3
220 101859* BALL, piston, 0.75” OD 1
221 188624 CYLINDER 1
222 111729 SCREW, No. 10–32 x
5/8” 4
223 188554* O–RING 1
224 188628 PLUG, “2 GPM”1
225 188550* V–PACKING, poly 3
226 188567* GLAND, female 1
227 187933 HOUSING, outlet 1
228 183210 PIN 1
232 235962 SEAL, foot valve 1
*These parts also included in
Packing Repair Kit 235973.
Keep a kit on hand to reduce down time.
Kit also includes one U–Cup packing,
111829, for the pressure drain valve.
202 206
*205
208*
221
220*
*205
213
217
216*
215
214
201
227
222
*224 223*
*226
*204
218*
212*
211*
209*
207*
219*
*210
203*
*225
228
01899
232

8308270
TECHNICAL DATA
Maximum Working Pressure 1000 psi (70 bar). . . . . . .
Cycles/Gallon (liter) Model 235706: 42 (11). . . . . . . . . .
Model 235965: 66 (18)
Maximum Delivery Model 235706:. . . . . . . . . . . . . . . . .
3 GPM (11 liter/min)
Model 235965:
2 GPM (7.6 liter/min)
Pump Inlet Size 2” quick disconnect. . . . . . . . . . . . . . . .
Fluid Outlet Size 3/4 npt(f). . . . . . . . . . . . . . . . . . . . . . . .
Wetted Parts Nickel–Plated Carbon Steel,. . . . . . . . . .
Stainless Steel, Chrome–Plated Stainless Steel,
Poly, Tungsten Carbide, Viton
Viton
GRACO PHONE NUMBER
TO PLACE AN ORDER, contact your Graco distributor,
or call this number to identify the distributor closest to
you: 1–800–690–2894 Toll Free
GRACO WARRANTY and DISCLAIMERS
WARRANTY
Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on
the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this
warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defec-
tive. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written rec-
ommendations.
This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by faulty installation,
misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility with Graco
equipment of structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, instal-
lation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor
for verification of the claim. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any
defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts,
labor and transportation.
DISCLAIMERS AND LIMITATIONS
The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or
implied), including warranty of merchantability or warranty of fitness for a particular purpose, and of any non–contractual
liabilities, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequen-
tial damages or loss is expressly excluded and denied. In no case shall Graco’s liability exceed the amount of the purchase price.
Any action for breach of warranty must be brought within two (2) years of the date of sale.
EQUIPMENT NOT COVERED BY GRACO WARRANTY
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with
respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not
manufactured by Graco (such as electric motor, switches, hose, etc.) are subject to the warranty, if any, of their manufacturer.
Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
Sales Offices: Minneapolis, Detroit
International Offices: China; Korea; Hong Kong; Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN U.S.A. 308270 2/93, Revised 08/2000