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Repair
t
TexSpray1030 FC
German Patent No. P 43 18 679.3--09 309662J
- For portablesprayapplicationofarchitecturalpaintsandcoatings -
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
Model234113,SeriesA
TexSpray 1030 FC sprayer, 235490 TexSpray gun
and 50 ft (15 m) air and fluid hose set
ImportantSafetyInstructions
Read all warnings and instructions in this
manual. Save these instructions.
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Specifications Thisequipment isnot intended forusewith flammableorcombustiblematerialsused in placessuch as cabinetshopsorother“factory”orfixed locations. Ifyou intend to usethisequipmentin thistypeof application, you mustcomplywith NFPA33and OSHArequirementsfortheuseofflammableand combustiblematerials. Warnings WarningSymbol CautionSymbol WARNING CAUTION This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not foll
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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 FIREANDEXPLOSIONHAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: D Use equipment only in well ventilated area. D Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps
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WARNING EQUIPMENT MISUSEHAZARD Misuse can cause death or serious injury. INSTRUCTIONS D Read all instruction manuals, tags, and labels before operating the equipment. D Use equipment only for its intended purpose. Call your Graco distributor for information. D Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. This gun has a150psi (10bar) maximumfluid working pressureat a125psi (9 bar) maximumincoming airpressure. ReadTechnical Data in all equi
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ComponentDescription Flow andAirControl PrimeValve Fig. 1. The flow control (A) has a shut off and pressure Fig. 1. The prime valve (C) relieves system pressure relief feature to soft start each time the gun is trig- and stops the pump when the gun trigger is released. gered, instead of a blast of unatomized material. The flow control has three modes: TexSprayGun,235490 D LOW/MED/HIGH: Triggering the gun sends an air signal to the flow control that closes the prime valve WARNING and starts the p
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ComponentDescription Afterfirst20hoursofoperation and each 100 CompressorRequirements hoursthereafter: Change oil. NOTE: This sprayer requires an external air compres- sor. Weekly: Remove engine air filter cover and clean element. In very dusty environments, check filter daily. Replace element as needed. Replacement elements CAUTION can be purchased from your local HONDA dealer. Install an air filter on external air compressor to reduce contamination to spray system. Sparkplug: Use only a (NGK)
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Troubleshooting WARNING To reduce risk of injury due to sprayer starting unexpectedly, shut off engine before performing checks or service. 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 Connect spark plug cable or replace spark plug damaged spark plug Oil seepage into combustion Remove spark plug. Pull starter rope 3 or chamber 4 times. Clean a
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Troubleshooting (Continued) PROBLEM CAUSE SOLUTION Engine operates, but Connecting rod worn or damaged Replace connecting rod. See page 14. d diisp splla accem ement ent pum pump p d do oes es not not Drive housing worn or damaged Replace drive housing. See page 15. ((Cont Continued inued)) Pinion assembly worn or damaged Service pinion assembly. See page 16. Engine operates, displace- Flow control is set to PRIME Set flow control to LOW/MED/HIGH while ment pump operates, but no triggering gun.
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Troubleshooting (Continued) PROBLEM CAUSE SOLUTION Displacement pump output Siphon hose strainer is clogged Clean strainer llo ow w on on d do owns wnsttrro okkeo e orr b bo otth h Piston packings worn or damaged Replace packings. See page 12. strokes Material leaks into wet-cup Intake valve ball (216) not seating Clean and service intake valve. See properly page 12. Clutch (9) worn or damaged Replace clutch. See page 18. Air leak at pump foot valve or Be sure foot valve is tight each day. sipho
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DisplacementPumpRepair 2. Fig. 5. Start engine. Jog flow control between Removal PRIME and OFF until connecting rod stops near bottom of stroke. Shut off engine. WARNING 3. Loosen two quick disconnect screws (27). To reduce risk of injury due to sprayer starting unexpectedly, shut off engine before performing 4. Pry retaining spring (37) up on connecting checks or service. rod (128). Push pin (38) out with a screwdriver. 1. Fig. 4. Flush sprayer. Remove suction hose elbow 5. Fig. 6. Remove cover
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DisplacementPumpRepair 3. Lift pump (3) into position and push in pin (38). Be Installation sure retaining spring (37) snaps down over end of 1. Fig. 4. Screw assembled dump valve manifold (85) pin. and air cylinder (22) into pump (3). 2. Fig. 5. Pull piston rod (201) out of pump (3) 2 to 3 4. Support weight of pump (3) and fasten two quick disconnect screws (27). Torque screws to 20 ft-lb inches (50 to 75 mm). (27 N.m). WARNING 5. Fig. 4. Reattach air hoses (158) and (159) to prime MOVING PARTS
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PumpRepair 3. Install nut (208*) on piston seat (213). Hand tight- WARNING en nut firmly. 4. Install ball (220*) in piston housing (206). To reduce risk of injury due to sprayer starting unexpectedly, shut off engine before performing 5. Apply blue Loctite to piston seat (213) threads and checks or service. screw assembly onto rod, hand tight. DisassemblePump TIP: Draw a line across male gland, nut and piston housing for an alignment reference before tightening 1. SeeDisplacement Pump Repair on
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PumpRepair 202 1 Grease inside of throat 1 before installingpackings 227 Lips of v-packings in throat 2 mustfacedown *226 Grease inside of packings 3 2 3 after installing *203 2 3 225* Torque piston housing to piston seat *204 5 (213) to 90--125 ft--lb (122--170 N.m) without changing alignment of 201 packing nut 9 Lips of v-packings on 6 pistonmustfaceup 205* 220* Grease outside of packings 7 5 after installing 206 207* Lips of u-cup seal on 8 208* piston must face down *209 219* 6 7 If piston s
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BearingHousing&ConnectingRod Removal 4. Align connecting rod with crank (A) and carefully align locating pins (D) in drive housing (20) with holes in bearing housing (23). Push bearing hous- WARNING ing onto drive housing or tap it into place with a plastic mallet. To reduce risk of injury due to sprayer starting unexpectedly, shut off engine before performing 5. Install four screws (48) and lockwashers (49) on checks or service. bearing housing (23). Torque screws evenly to 25 ft-lb (34 N.m). 1
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DriveHousing 59 A WARNING 36 8h 8g To reduce risk of injury due to sprayer starting 58 unexpectedly, shut off engine before performing checks or service. 2 91 1. Fig. 9. Disconnect siphon hose elbow (150a), drain 92 hose (64) and material hose (not shown) from 84 pump outlet. Disconnect cables. Remove screws 8 (21) and front cover (19). 84 36 2. Remove four screws (40) and lockwashers (56) 93 from bearing housing (39). 39 56 1 40 3. Lightly tap back of bearing housing (39) with a 19 plastic mall
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PinionAssembly/Rotor/Field/Shaft/Clutch Removal 6. Fig. 12. Remove retaining ring (58e). WARNING To reduce risk of injury due to sprayer starting 7. Tap pinion shaft (58d) out with plastic mallet. unexpectedly, shut off engine before performing checks or service. If pinion assembly (58) is not removed from clutch housing (88), do 1. through 4. Otherwise, start at 5. 58e 1. Remove drive housing (8); page 15. 58d 2. Disconnect field cable from flow control. 3. Fig. 10. Remove five screws (99) and
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PinionAssembly/Rotor/Field/Shaft/Clutch Installation 1. Fig. 14. Lay two stacks of two dimes on smooth 6. Fig. 12. Tap pinion shaft (58d) in with plastic bench surface. mallet. 2. Lay armature (89) on two stacks of dimes. 7. Install retaining ring (58e) with beveled side facing field. 3. Press center of clutch down on bench surface. 8. Fig. 11. Place pinion assembly (58) on bench with 4a 0.12 ±.01in. (3.0 ±.25 mm) rotor side up. 9. Apply locktite to screws. Install four screws (2) and lockwasher
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ClutchHousing Removal 1. Fig. 16. Remove four capscrews (42) and lock- washers (29) which hold clutch housing (88) to engine. 90 88 2. Remove screw (101) from under mounting plate (D). 3. Remove engine key (90). 4. Pull off clutch housing (88). 29 Installation 42 1. Fig. 16. Push on clutch housing (88). 2. Install four capscrews (42) and lockwashers (29) D and secure clutch housing (88) to engine. Torque to 200 in-lb (22.6 NSm). 101 8708A Fig. 16 3. Install capscrew (101) from beneath mounting p
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Engine Removal Installation 1. RemovePinion Assembly/Rotor/Field/Pinion/ 1. Lift engine carefully and place on cart. Clutch, Clamp andClutch Housing,asin- structed on pages 16, 17, and 18. 2. Fig. 18. Install two screws (17) in base of engine and secure with locknuts (18). Torque to 200 in-lb 2. Fig. 17. Disconnect all necessary wiring. (22.6 NSm). 3. Fig. 18. Remove two locknuts (18) and screws (17) from base of engine. 3. Fig. 17. Connect all necessary wiring. 4. Lift engine carefully and plac
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Parts -Sprayer 61 13 DETAILA 52 60 1 164 95 43 TI4365a 94 81 59 58,page 21 14 36 Ref8h 112 100 BOTTOMVIEW 32 Ref8g 35 123 34 8,page 21 24 117 91 104 75 1 92 72 122 1 128 38 37 19 99 84 56 21 62 43 1 88 17 36 93 159 90 40 A 158 89 39 43 2 25 87 24 43 2 83, 80 page 29, 23 3,page 20 85 C 42 Page 22 86 27 185 101 33 64 18 162 26 ti4365c 130 102 16 152 153 118 73 51 105 119 140 150 1 Danger and warning labels, tags, and cards are free. 20 309662
