Graco T-Max 405 A Series Repair Manual
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Graco T-Max 405 A Series Repair Manual

Texture sprayer for water-based materials only, 40 bar 4 mpa, 580 psi maximum working pressure
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Repair
T-Max 405
Texture Sprayer
– For Water-Based Materials Only –
40 Bar (4 MPa, 580 psi) Maximum Working Pressure
Model 248195, Series A
Model 248269, Series A
Model 249075, Series A
Read warnings and instructions.
. . . . . . .
309973
. . . . . . .
309978
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 2004, Graco Inc. is registered to I.S. EN ISO 9001
t
309977 rev. F
ti4100a

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Summary of Contents for Graco T-Max 405 A Series

  • Page 1 Read warnings and instructions..309973 ..309978 ti4100a GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 Copyright 2004, Graco Inc. is registered to I.S. EN ISO 9001...

  • Page 2: Table Of Contents

    ......Graco Phone Number ......

  • Page 3: Warnings

    D Check equipment daily. Repair or replace worn or damaged parts immediately. D Do not alter or modify equipment. D Use equipment only for its intended purpose. Call your Graco distributor for information D Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

  • Page 4: General Repair Information

    General Repair Information Pressure Relief Grounding and Electrical Requirements WARNING WARNING Improper installation or alteration of the grounding PRESSURIZED EQUIPMENT HAZARD plug will result in a risk of electric shock, fire or The system pressure must be manually relieved to explosion that could cause serious injury or death.
  • Page 5 D Do not use a compressor with an output pressure greater than 250 psi (1.7 MPa, 17 bar). WARNING D Attach Graco 25 mm x 5m hose to pump outlet. The motor has a thermal overload switch that shuts down the motor if it overheats.

  • Page 6: Troubleshooting

    Troubleshooting See Pressure Relief Procedure on page 4. MOTOR WON’T OPERATE TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column 1. Pressure control knob setting. Motor will not run 1.
  • Page 7 Troubleshooting MOTOR WON’T OPERATE (Continued) TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column Basic Electrical Problems 5. That motor leads are securely fastened and 5.
  • Page 8 Troubleshooting LOW OR FLUCTUATING OUTPUT TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column Low Output 1. For worn spray tip. 1. Follow Pressure Relief Procedure Warn- ing, then replace tip.
  • Page 9 Troubleshooting LOW OR FLUCTUATING OUTPUT TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column Motor runs and pump strokes 1. Material supply. 1. Refill hopper and reprime pump. 2.
  • Page 10 Troubleshooting MOTOR IS HOT AND RUNS INTERMITTENTLY TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column Motor is hot and runs intermit- 1. Determine if sprayer was operated at high 1.

  • Page 11: Spin Test

    Spin Test Setup 2. If uneven or no resistance, check for: broken brush springs, brush leads, motor leads; loose brush terminal screws, motor lead terminals; worn Electric Shock Hazard; page 3. brushes. Repair as needed; page 11. 3. If still uneven or no resistance, replace motor; To check armature, motor winding and brush electrical page 13.
  • Page 12 Motor Brush Replacement 9. Inspect commutator for excessive pitting, burning CAUTION or gouging. A black color on commutator is normal. Have commutator resurfaced by a motor repair When installing brushes, follow all steps carefully to shop if brushes wear too fast. avoid damaging parts.

  • Page 13: Motor Replacement

    Motor Replacement Removal 8. Tip motor and drive housing assembly back and remove two screws (86) and washers (84). Relieve pressure; page 4. CAUTION Do not drop gear cluster (D) when removing drive 2. Fig. 5. Remove pump module (A). housing (37).
  • Page 14 Motor Replacement 2 Yellow ti4811a Fig. 6 309977...

  • Page 15: Pressure Control Repair

    Pressure Control Repair Motor Control Board Diagnostics Note: Keep a new transducer on hand to use for test. CAUTION Relieve pressure; page 4. Do not allow sprayer to develop fluid pressure with- out transducer installed. 3. Plug in power cord. 2.

  • Page 16: Motor Control Board

    Pressure Control Repair Motor Control Board Removal Installation Refer to Wiring Diagram, page 27. CAUTION Electrostatic discharges can damage components on Relieve pressure; page 4. motor control board. Use a ground strap when handling or installing motor control board. 2. Remove five screws (12) and motor cover (18). 1.

  • Page 17: Pressure Control Transducer

    Pressure Control Repair Pressure Control Transducer Pressure Adjust Potentiometer Removal Removal Refer to Wiring Diagram, page 27. Refer to Wiring Diagram, page 27. Relieve pressure; page 4. Relieve pressure; page 4. 2. Remove five screws (12) and motor cover (18). 2.

  • Page 18: Pump Repair

    Pump Repair Removal Relieve pressure; page 4. 2. Perform Storage More than 24 hours procedure in Operation Manual 309973, 309974 or 309975. 3. Fig. 8. Loosen clamp rod (20). Fig. 10 11. Fig. 11. Unscrew pump (31) from bearing housing (34).
  • Page 19 Pump Repair Disassemble Pump 5. Fig. 14. Remove packing nut (216). Push piston rod (203) from outlet housing (202). TIP: It may be easier to leave the pump connected to the connecting rod and bearing housing if the only assemblies to be cleaned and inspected is the intake housing or piston valve.
  • Page 20 Assemble Pump 3. Install clamp (209) on pump cylinder (201). Torque clamp to 25 in-lb (2.82 Nm). 1. Fig. 16. Place end of piston rod (203) in vise. Install new piston seal (222). Torque piston valve to 27 ft-lb (36.6 Nm). 217* 222* 220*...

  • Page 21: Bearing Housing & Connecting Rod

    Bearing Housing & Connecting Rod Removal 4. Align connecting rod with crank (A) and carefully align locating pins (D) in drive housing (37) with holes in bearing housing (34). Push bearing Relieve pressure; page 4. housing onto drive housing or tap it into place with a plastic mallet.

  • Page 22: Drive Housing

    Drive Housing Removal CAUTION Do not drop combination gear (29) and thrust wash- Relieve pressure; page 4. ers (10,11,14) when removing drive housing (37). Combination gear and thrust washers may stay 2. Fig. 5. Remove pump module (A). engaged in motor front end bell or drive housing. a.
  • Page 23 Drive Housing Installation a. Align connecting rod with crank (G) and carefully align locating pins (H) in drive housing (37) with 1. Fig. 21. Install thrust washers (10,11,14) on holes in bearing housing (34). combination gear (29). Install combination gear in drive housing (37).

  • Page 24: Parts Drawing

    Parts Drawing 46,page 29 ti4101b 31 pg. 28 37 pg. 26 25,page 26 309977...

  • Page 25: Parts List

    Parts List Models 248195, 248269, 249075; Series A Part No. Description Part No. Description 100004 SCREW, cap, hex hd 15D151 RING, retainer, hopper 101242 RING, retaining, ext. 248519 HOSE, fluid 25 mm x 5 m 101566 NUT, lock (includes 165) 102040 NUT, lock, hex 100333...
  • Page 26 Parts Drawing ti4097b Model 249075 Model 248195 Italy Denmark Switzerland Model 248269 309977...

  • Page 27: Wiring Diagram

    Parts List Models 248195, 248269, 249075; Series A Part No. Description Part No. Description 106115 WASHER, lock spring (hi–collar) 100644 SCREW, cap, sch 107210 SCREW, cap, socket hd 107218 SCREW, cap, sch 114672 WASHER, thrust 101888 SCREW, cap, sch 114699 WASHER, thrust 192840 LABEL, warning...
  • Page 28 Parts Drawing 217* 222* 229* 220* 51, page 24 43, page 24 89, page 24 27, page 24 50, page 24 48, page 24 ti4796a 309977...
  • Page 29 Parts – Pump 248764 Model 248764, Series A Part No. Description Qty. Part No. Description Qty. 15D113 CYLINDER, pump 248529 KIT, repair, seal, throat 15D108 HOUSING, outlet 217* 248232 VALVE, piston 15D532 ROD, piston 220* 101822 BALL, bearing 248769 KIT, repair, housing, intake 222* 15D116 SEAL, piston...
  • Page 30 Notes 309977...

  • Page 31: Technical Data

    Technical Data Maximum air working pressure ....250 psi Dimensions (1.7 MPa, 17 bar) Length ....23 in.

  • Page 32: Graco Warranty

    With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.

This manual is also suitable for:

T-max 405 248195T-max 405 248269T-max 405 249075

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