Graco magnum pro plus a20 Repair Manual Download

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Table of Contents

332697C

Table of Contents

Specifications   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Identification A20 and A30 . . . . . . . . . 8
Component Identification A45 and A60 . . . . . . . .  10
Grounding and Electrical Requirements . . . . . . .  12

Thermal Overload . . . . . . . . . . . . . . . . . . . . . . . 12

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Relief Procedure . . . . . . . . . . . . . . . . 13

General Repair Information   . . . . . . . . . . . . . . . . .  14
Basic Troubleshooting  . . . . . . . . . . . . . . . . . . . . .  15
Advanced Troubleshooting   . . . . . . . . . . . . . . . . .  20

Motor Does Not Operate . . . . . . . . . . . . . . . . . .  20
Circuit Breaker is Tripping . . . . . . . . . . . . . . . . .  23
Erratic Motor Operation . . . . . . . . . . . . . . . . . . .  24
Low or Fluctuating Output . . . . . . . . . . . . . . . . .  25
Excessive Pressure Build Up   . . . . . . . . . . . . . .  26

Motor Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 27

A20, A30, and A45 . . . . . . . . . . . . . . . . . . . . . . 27
A60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Summary of Contents for magnum pro plus a20

Page 1: ...erial request MSDS from distributor or retailer Models 16W108 16E664 16E665 16W515 17C243 17C244 17C245 17C246 IMPORTANT SAFETY INSTRUCTIONS Read all warnings and instructions in this manual Save these instructions See page 3 for model series information including dispense rate recommended hose length guns and maximum working pressure ti22086a ti22045a Pro Plus A45 Model 16E665 Series A and B ti22...

Page 2: ...rocedure 13 General Repair Information 14 Basic Troubleshooting 15 Advanced Troubleshooting 20 Motor Does Not Operate 20 Circuit Breaker is Tripping 23 Erratic Motor Operation 24 Low or Fluctuating Output 25 Excessive Pressure Build Up 26 Motor Diagnostics 27 A20 A30 and A45 27 A60 27 Pressure Control Switch Diagnostics 28 Pump Diagnostics 28 Control Board Diagnostics 29 List of Kits 30 Parts 33 W...

Page 3: ...3 and OSHA requirements for the use of flammable and combustible materials Model Name Series Maximum Dispense Rate lpm gpm Hose Length and Diameter Gun Model Maximum Working Pressure bar MPa PSI A20 A 0 91 lpm 0 24 gpm 6 4 mm x 7 5 m 1 4 in x 25 ft SG2 207 21 3000 A30 A and B 1 02 lpm 0 27 gpm 6 4 mm x 7 5 m 1 4 in x 25 ft SG3 207 21 3000 A45 A and B 1 17 lpm 0 31 gpm 6 4 mm x 15 m 1 4 in x 50 ft ...

Page 4: ... 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 under stood or when in doubt as to wh...

Page 5: ...iners 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 combustible materials are used in or near the s...

Page 6: ...uipment Keep children and animals away from work area Comply with all applicable safety regulations 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 ...

Page 7: ...r 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 CALIFORNIA PROPOSITION 65 This product contains...

Page 8: ...uations L Inlet screen Prevents debris from entering pump M Paint hose Transports high pressure fluid from pump to spray gun N Handle Used to help transport sprayer 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 Reverse unclogs plugged tips without disassembly S Gun trigger sa...

Page 9: ...Component Identification A20 and A30 332697C 9 Component Identification A20 and A30 A20 shown ti22057a V H N B J W C C1 A U D L G S R Q T M Z X A20 A30 AA ...

Page 10: ...lve PRIME position directs fluid to prime tube SPRAY position directs pressurized fluid to paint hose Automatically relieves system pressure in overpressure situations K Ball Knocker A60 Sprayer Only Automatically taps the inlet ball when you turn the sprayer on L Inlet screen Prevents debris from entering pump M Paint hose Transports high pressure fluid from pump to spray gun Q Tip guard Reduces ...

Page 11: ...onent Identification A45 and A60 332697C 11 Component Identification A45 and A60 A60 shown ti9346a ti22086a ti9670a ti9669a L G C H K W B U J F1 F C1 X E D Z ti22077a AA AB Y ti22176a ti22177a M A V R Q S T ...

Page 12: ...onger extension cords may reduce sprayer performance Fluid supply container follow local code Solvent pails used when flushing follow local code Use only conductive metal pails placed on a grounded surface such as concrete Do not place the pail on a nonconductive surface such as paper or cardboard which interrupts grounding continuity Grounding the metal pail connect a ground wire to the pail by c...

Page 13: ...Trigger the gun to relieve pressure 4 Engage trigger lock NOTE Leave Prime Spray valve in the PRIME position until you are ready to spray again If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after following the steps above VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually then loosen completely Clear hose or ...

Page 14: ...otor could cause fire or explosion To reduce risk of burns fire or explosion do not operate sprayer with cover removed 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 NOTICE Do not ...

Page 15: ...let Reset building circuit breaker or replace fuse Extension cord is damaged Replace extension cord Read Grounding and Electrical Require ments page 12 Sprayer power cord is damaged Check for broken insulation or wires Replace power cord if damaged Paint and or water is frozen or hard ened in pump Unplug sprayer from outlet If frozen do NOT try to start sprayer until it is completely thawed or you...

Page 16: ... tap in pump If you do not hear tap AutoPrime is damaged Take sprayer to Graco MAGNUM authorized service center Inlet valve check ball or seat is dirty or worn Remove inlet fitting Clean or replace ball and seat Outlet valve check ball is stuck or worn A60 Insert screw driver in slot and remove Easy Access door page 11 Unscrew outlet valve with a 3 4 in socket Remove and clean assembly Replace if ...

Page 17: ...is Take sprayer to Graco MAGNUM authorized service center Pump check ball is stuck Read Pump does not prime section in Basic Troubleshooting page 15 Pump cycles but paint only dribbles or spurts when spray gun is trig gered Pressure is set too low Slowly turn Pressure Control Knob clockwise to increase pressure set ting which will turn motor on to build pressure Spray tip is clogged Unclog spray t...

Page 18: ...re worn or debris is clogging valve Check for worn pump valves a Prime sprayer with paint b Trigger gun momentarily When trigger is released pump should cycle momentarily and stop If pump continues to cycle pump valves may be worn c Remove valves and check for debris Material is too thick Thin material Hose is too long if extra section is added Remove section of hose Spray gun stopped spraying Suc...

Page 19: ...ystem is over pressurizing Take sprayer to Graco MAGNUM authorized service center Paint leaks down outside of pump Pump packings are worn A60 Replace pump packings A20 A30 and A45 Replace pump Motor is hot and runs intermittently Motor automatically shuts off due to excessive heat Damage can occur if cause is not corrected See Thermal Overload page 12 Vent holes in enclosure are plugged or sprayer...

Page 20: ...zen or hardened in pump See Basic Troubleshooting page 15 Gears are damaged Remove motor enclosure and rotate motor fan to check for bad gears If gears bind or slip remove pump cover and replace failed gears See List of Kits page 30 A60 Yoke is broken because pump is locked up due to dried paint or worn packings Repair or replace using Gear Yoke Kit See List of Kits page 30 Replace pump packings o...

Page 21: ... for burn spots gouges and extreme roughness If damaged or if shorts are evident replace motor using Motor Kit See List of Kits page 30 Fuse is blown Find cause for blown fuse before replacing Turn the motor fan to check for a locked gear or pump Use a continuity meter to check for a short to ground caused by a pinched wire A60 Replace the fuse with correct fuse kit See List of Kits page 30 A20 A3...

Page 22: ...ect both wires from power switch 3 Check for continuity between switch terminals 4 Toggle switch ON and OFF There should be continuity in the ON position only 5 Replace power switch if no continuity in ON position A60 diagnosis only Motor thermal overload cutoff switch damaged WARNING See Thermal Overload on page 12 1 Unplug sprayer power cord 2 Remove motor harness from control board 3 Check for ...

Page 23: ... is good A bad motor armature can burn out a good motor control board See Control Board Diagnostics page 29 Replace control board if damaged using Control Board Kit See List of Kits page 30 Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on NOTE Remove enclosure mounting screws and pull enclosure away from drive housing Take care not to pull on le...

Page 24: ...t Check electric supply with volt meter Meter must read 220 240 VAC If voltage is too high do not use outlet until corrected Also see Basic Electrical Problems and Sprayer Wiring Problems pages 21 22 Motor is overheating Warning See Thermal Overload page 12 After motor cools operate sprayer and determine if motor stops when trigger on gun is released If sprayer runs continuously replace Pressure C...

Page 25: ...e Replace extension cord See Grounding and Electrical Requirements page 12 Leads from motor or pressure switch to control board are damaged loose pinched or overheated Be sure terminals are centered and firmly connected Inspect for pinched wiring and wiring insulation and terminals for signs of overheating Replace any loose terminals or damaged wiring Securely reconnect terminals Motor brushes are...

Page 26: ... Kits page 30 Specific Problem Cause Solution Excessive Pressure Build Up Specific Problem Cause Solution Prime Spray Valve actuates automatically relieving pressure through drain tube Pressure control switch has pinched wires or switch is worn Replace pressure control switch using Pressure Control Switch Kit page 28 Water or paint entered pressure control switch or shorted control board Use Press...

Page 27: ...oth brushes by looking at brush torsion spring If spring is not bottomed out in slot for brush spring brush length is acceptable If brushes are worn out replace motor A60 Check for electrical continuity in motor armature windings and brush as follows If Motor Diagnostics reveal a damaged motor or if motor brushes are shorter than 1 4 in 6 4 mm or if the motor shaft cannot turn replace the motor us...

Page 28: ...h needs to be replaced 5 Use ohmmeter to measure across two terminals in pressure control connector No continuity should exist when pressure control knob is at lowest pressure setting full counter clockwise Replace pressure control switch if continuity exists 6 Use ohmmeter to measure across two terminals in pressure control connector Continuity or closed circuit should exist when pressure control...

Page 29: ...rol board NOTE Pressure control switch does not have to be installed in pump 8 Turn pressure control adjustment knob C to max imum pressure setting 9 Plug electrical cord into 240 VAC receptacle 10 Turn power switch B ON If motor runs replace failed pressure switch Pressure Control Switch Kit See List of Kits page 30 If motor does not run replace control board repeat test Control Board Kit See Lis...

Page 30: ...17C246 Hose cpld 1 4 x 50 w connector 257566 A20 A30 and A45 Inlet Strainer 245673 A60 Inlet Strainer 16E839 A30 Stand 16C815 A20 Stand 257569 A45 Left Leg 257568 A45 Right Leg 16W946 A60 Left Leg 16W947 A60 Right Leg 16G226 A30 series A and A45 series A Power Cord CEE 16W951 A20 A30 series B and A45 series B Power Cord 16W948 A60 Power Cord 289107 A60 AutoPrime 246286 A20 A30 A45 and A60 Pressure...

Page 31: ...List of Kits 332697C 31 16W860 A20 Pump Complete 16G227 A30 and A45 Pump Complete 16W941 A60 Pump Complete 256212 A60 Lacquer Conversion Kit Kit Number Models Kit Description ...

Page 32: ...Notes 32 332697C Notes ...

Page 33: ...Parts 332697C 33 Parts A20 Pump Models 16W108 17C243 23 38 46 48 50 53 66 36 2 3 1 37 18 68 51 19 21 33 7 27 42 49 14 10 15 55 37 70 49 46 47 48 69 ti22185b ...

Page 34: ...464 LABEL control 1 37 16F635 LABEL control 1 38 LABEL A20 front 16W631 Model 16W108 1 17C447 Model 17C243 1 42 16W860 KIT repair pump complete includes 48 49 50 and 53 1 46 123849 SPRING compression 1 47 124249 BALL ceramic si n 1 48 16E844 KIT repair inlet valve includes 46 47 1 49 16E845 KIT repair outlet valve 1 50 235014 KIT repair valve drain includes 55 1 51 246286 KIT repair pressure contr...

Page 35: ...Parts 332697C 35 A20 Frame Models 16W108 17C243 29 34 25 28 9 9 26 20 24 41 13 23 31 71 13 ti22518a ...

Page 36: ...IT repair stand includes 23 1 25 116255 SWITCH ROCKER SPST 1 26 115477 SCREW mach torx pan hd 6 28 16G223 KIT repair control board 1 29 16W951 KIT repair cordset 1 31 HOSE cpld 1 4 in x 25 ft 245449 Model 16W108 1 247339 Model 17C243 1 34 16G596 LABEL warning 1 41 16W431 KIT accessory gun SG3 1 71 16W227 FILTER EMI 1 179960 SIGN warning not shown 1 Replacement Danger and Warning labels tags and ca...

Page 37: ...Parts 332697C 37 A30 Pump Models 16E664 Series A and B 17C244 Series A 5 9 55 36 72 72c 72a 72b 1 1a 1b 1d 1c 1e 2 74 4 7 8 31 16 17 30 18 1f 73 36 37 67 66 38 66 70 ti17725c ...

Page 38: ...464 LABEL control 1 9 115498 SCREW mach slot hex wash hd 1 16 16W952 KIT repair cover includes 17 18 1 17 120724 SCREW 4 18 LABEL A30 front 16F802 Model 16E664 1 17C448 Model 17C244 1 30 197607 TUBE suction set 1 31 16F635 LABEL control Magnum 1 36 195400 CLIP spring 2 37 195697 STRAINER 1 38 244035 DEFLECTOR barbed 1 55 16W319 COVER gear 1 66 115489 CLAMP drain tube 2 67 195084 TUBE drain 1 70 11...

Page 39: ...Parts 332697C 39 A30 Frame Series A Model 16E664 Series A 41 40 6 4 10 11 11 12 56 57 19 50 51 52 52 53 10 102 39 121 122 123 125 22 57 ti18695b ...

Page 40: ...set 1 39 16G596 LABEL warning 1 40 245449 HOSE cpld 1 4 in x 25 ft 1 41 16W431 KIT accessory gun SG3 1 47 179960 SIGN warning not shown 1 50 256992 HANDLE painted 1 51 116139 GRIP handle 1 52 122233 BOLT carriage 3 53 102040 NUT lock hex 3 56 16F567 BRACKET control board EMI filter 1 57 115492 SCREW mach slot hex wash hd 4 102 121423 RETAINER wire 1 121 245648 FILTER EMI 1 122 115632 CLAMP power c...

Page 41: ...Parts 332697C 41 A30 Frame Models 16E664 Series B 17C244 Series A 4 57 12 50 52 52 53 109 56 22 53 57 125 39 11 41 40 11 19 51 121 54 ti22460a ...

Page 42: ...51 KIT repair cordset 1 39 16G596 LABEL warning 1 40 HOSE cpld 1 4 in x 25 ft 1 245449 Model 16E664 1 247339 Model 17C244 1 41 16W431 KIT accessory gun SG3 1 47 179960 SIGN warning not shown 1 50 256992 HANDLE painted 1 51 116139 GRIP handle 1 52 122233 BOLT carriage 3 53 102040 NUT lock hex 3 56 16W317 FILTER EMI bracket assembly includes 57 121 1 57 115492 SCREW mach slot hex wash hd 4 102 12142...

Page 43: ...Parts 332697C 43 A45 Pump Models 16E665 Series A and B 17C245 Series A 1 101 74 72 72c 72a 72b 9 2 5 4 63 7 8 31 16 17 1b 1d 1c 30 101 18 1f 1a 1e 68 66 67 66 38 37 36 70 73 ti17724c ...

Page 44: ...CREW mach slot hex wash head 1 16 16W952 KIT repair cover includes 17 18 1 17 120724 SCREW 4 18 LABEL A45 front 16F803 Model 16E665 1 17C449 Model 17C245 1 30 16D951 TUBE suction 1 31 16F635 LABEL control magnum 1 36 195400 CLIP spring 1 37 195697 STRAINER 1 38 244035 DEFLECTOR barbed 1 63 16W319 COVER gear 1 66 115489 CLAMP drain tube 2 67 195108 TUBE drain 1 68 16D907 HANGER pail 1 70 116295 CLA...

Page 45: ...Parts 332697C 45 A45 Frame Model 16E665 Series A 65 40 41 39 125 65 64 58 12 54 21 102 11 10 20 55 51 22 10 121 122 123 59 56 57 52 53 60 61 11 6 4 ti18694a ...

Page 46: ...not shown 1 51 15R602 AXLE cart 1 52 115095 WHEEL 9 in 2 53 112612 CAP hub 2 54 260212 SCREW hex washer hd thd form 4 55 120788 SCREW carriage 2 56 256993 HANDLE painted 1 57 115480 KNOB t handle 2 58 257326 RACK hose painted 1 59 120689 NUT hex acorn 5 16 18 nickel 2 60 121481 NUT u type tinnerman 1 61 120093 SCREW self drilling 1 64 16F567 BRACKET control board EMI filter 1 65 115492 SCREW mach ...

Page 47: ...Parts 332697C 47 A45 Frame Models 16E665 Series B 17C245 Series A 12 39 10 125 65 55 4 11 54 61 21 52 53 60 6 109 51 20 10 59 58 57 56 11 57 65 121 64 22 ti22517a ...

Page 48: ...l 17C245 41 16W431 KIT accessory gun SG3 1 47 179960 SIGN warning not shown 1 51 15R602 AXLE cart 1 52 115095 WHEEL 9 in 2 53 112612 CAP hub 2 54 260212 SCREW hex washer hd thd form 4 55 120788 SCREW carriage 2 56 256993 HANDLE painted 1 57 115480 KNOB t handle 2 58 257326 RACK hose painted 1 59 120689 NUT hex acorn 5 16 18 nickel 2 60 121481 NUT u type tinnerman 1 61 120093 SCREW self drilling 1 ...

Page 49: ...ts 332697C 49 A60 Pump Models 16W515 17C246 62 40 27 43 21 30 31 64 93 83 74 86 76 82 81 87 90 91 92 85 88 28 26 37 32 34 39 29 35 61 61 15 13 14 12 11 10 36 53 41 33 46 52 5 16 17 18 62 23 60 50 ti22196b ...

Page 50: ...trol includes 61 1 39 16W945 KIT repair cover includes 29 30 31 46 53 1 40 256938 KIT repair motor 1 41 118444 SCREW mach slot hex wash hd 2 43 260212 SCREW hex washer hd thd form 4 46 LABEL A60 front 16W632 Model 16W515 1 17C450 Model 17C246 1 50 16G596 LABEL warning 1 52 16F635 LABEL control 1 53 115478 SCREW mach torx slt pan hd 4 60 16W431 KIT accessory gun SG3 1 61 121939 SCREW plastite 8 hex...

Page 51: ...Parts 332697C 51 A60 Frame Models 16W515 17C246 2 4 9 42 8 45 44 6 43 3 1 ti22459a ...

Page 52: ...46 KIT repair left leg includes 43 1 3 16W362 AXLE cart 1 4 16W200 SHELF motor 1 6 257326 RACK hose 1 7 256993 HANDLE painted 1 8 112612 CAP hub 2 9 120689 NUT hex acorn 5 16 18 nickel 2 42 115094 WHEEL 10 in 2 43 260212 SCREW hex washer hd thd form 4 44 120788 SCREW carriage 2 45 115480 KNOB t handle 2 Ref Part Description Qty ...

Page 53: ...7C 53 Wiring Diagram A30 Series A and A45 Series A Models 16E664 Series A and 16E665 Series A 9 ti16291a ON OFF Black Motor Power Cord Ref Power Cord Black Motor Lead Power Cord Green Wire Brown Wire Blue Wire Lead Switch ...

Page 54: ...A 16E664 Series B 16E665 Series B Models 17C243 Series A 17C244 Series A ti22198b Power Cord Power Cord Ref EMI Filter Ferrite Harness Black Motor Lead Black Motor Lead Power Cord Pressure Control ON OFF Blue Wire Switch with White Heat Shrink Green Wire Brown Wire ...

Page 55: ...Wiring Diagram 332697C 55 A60 Models 16W515 17C246 ti22243b Power Switch Blue Pressure Brown Wire Green Yellow Wire Motor Brown Wire AutoPrime Wire Control ...

Page 56: ...uid outlet fitting 3 4 in internally threaded standard garden hose Inlet screen on suction tube 1190 micron 16 mesh Wetted parts pump and hose stainless steel zinc plated carbon steel brass ultra high molecular weight poly ethylene UHMWPE Carbide Nylon Aluminum PVC polypropylene fluroelastomer Wetted parts gun aluminum brass carbide nylon ultra high molecular weight polyethylene UHMWPE zinc Genera...

Page 57: ...ed standard gar den hose 7 8 14 UNF external thread Inlet screen on suction tube 1190 micron 16 mesh 1680 micron 12 mesh Wetted parts pump and hose stainless steel zinc plated carbon steel brass ultra high molecular weight poly ethylene UHMWPE Carbide Nylon Aluminum PVC polypropylene fluroelastomer stainless steel zinc plated carbon steel brass leather ultra high molecular weight polyethylene UHMW...

Page 58: ...Notes 58 332697C Notes ...

Page 59: ...Notes 332697C 59 Notes ...

Page 60: ...rtation 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 THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR P...

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Graco magnum pro plus a20, Repair Manual

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