Repair Instructions - Graco PT2500 Instructions And Parts List

Repairs, other than those for which instructions are given
below, should be performed by a trained and qualified re-
pair agency.
WARNING
To reduce the risk of serious injury, including fluid in-
jection, splashing in the eyes or on the skin, or injury
from moving parts, always follow the Pressure Re-
lief Procedure Warning on page 11 before check-
ing or repairing any part of the spray system.
Inlet Check Valve (See Fig 15)
1. Unscrew the inlet check valve (26) from the paint
pump (22).
2. Clean the gasket (26a), the inlet valve (26), and the
paint pump (22) threads and check for erosion. If any
of the parts are eroded, replace them.
3. Be sure the threads in the paint pump are clean.
4. Lubricate the threads of the inlet valve with petro-
leum jelly. Install the gasket on the valve, then install
the valve and torque it to 320–360 in–lb (36–41 N.m).
Outlet Check Valve (See Fig 15)
1. Unscrew the plug (28d) and the housing (28b).
2. Use a pick, such as a dentist's pick, to remove the
seal (28a) from the paint pump (23). It may be hard
to remove. DO NOT LEAVE THE SEAL IN THE
PAINT PUMP HOUSING.
3. Clean the parts thoroughly, including the threads in
the pump, with a compatible solvent. Check all parts
for wear or damage and replace as needed.
4. Lubricate the threads of the housing (28b) and plug
(28d).
5. Install a NEW seal (28a) in the pump housing. AL-
WAYS replace the seal (28a). Do not try to reuse the
old seal as it will be deformed.
CAUTION
Be sure you do not install a new seal until the old one
is removed. Having two seals in the valve will cause
performance problems.
6. Install the housing (28b) and torque to 125–150 in–lb
(14–17 N.m) .
7. The last coil on one end of the spring is turned in.
Place this end over the stud in the plug (28d). Install
the ball (28e), washer (28f) and plug, and torque to
plug to 380–300 in–lb (32–34 N.m).
Pressure Control (See Fig 15)
1. When removing the pressure control (4) to check or
clean it, always replace the seal (4a). When replac-
ing the pressure control, torque the new control (4)
to 125–150 in–lb (14–17 N.m).

REPAIR INSTRUCTIONS

Starter Switch (See Fig 15)
1. Remove the cover of the switch box. Remove the two
Diaphragm (See Fig 15)
1. Remove the inlet strainer (27). Remove the four paint
2. Remove the bypass valve (66) and the fluid outlet
3. Remove the screw (36) and lockwasher (37) from the
4. Pull the paint pump assembly away from the hydrau-
Never start the electric motor with the inlet valve (26)
removed, as it will severely damage the diaphragm.
Be careful not to get any dirt or paint on the new dia-
phragm or the hydraulic housing. Contaminants in
the hydraulic system can cause the sprayer to mal-
function and result in costly damage to the sprayer.
DO NOT TAMPER with the nut (C). The nut is factory
set to hold the spring to a specific dimension.
5. Check the gasket (22a) for wear or damage and re-
6. Install the new diaphragm assembly (21), lubricate
7. Lubricate the screws (25) and then install and torque
Whenever you remove the paint pump screws,
torque them as instructed above, and then retorque
them after 3 to 5 hours of operation.
8. Check the hydraulic oil level and add Graco-ap-
9. Turn the pressure control fully counterclockwise
screws holding the starter switch (18a). Remove the
old switch and install a new one.
pump screws (25) and lockwashers (24).
nipple (67), and then remove the screws (35) and
shield (3).
bracket (38).
lic housing (20) and remove the old diaphragm (21).
CAUTION
CAUTION
place it if needed. Clean the top of the paint pump
and the hydraulic housing thoroughly.
the internal threads of the housing (20), and reas-
semble the parts.
them to 170–200 in–lb (19–23 N.m ).
CAUTION
proved oil as necessary until the level is 1 in. (25 mm)
from the top of the plate. See Fig 11.
(no pressure). Plug in the sprayer and turn it on. Run
the sprayer for two minutes to fill the hydraulic sys-
tem. Increase the pressure to maximum and turn the
sprayer on and off four times to help rid the hydraulic
system of air.