Hitachi 220-856 User's Manual
Contents
1. L A WHITE X err _ wn 8 GREEN switch D must be insulated with 101 shrink tubing or electrical tape A Motor leads A H LO A Power supply leads Le J X S 68 18 Fig 20 01314 20 307 830 Pressure Control Adjustment A WARNING USE EXTREME CAUTION WHEN PERFORMING THIS ADJUSTMENT PROCEDURE to reduce the risk of a fluid injection injury or other serious bodily injury which can result from component rupture electric shock fire explosion or moving parts This procedure sets the sprayer to 2750 psi 190 bar MAXIMUM WORKING PRESSURE Perform this procedure whenever the microswitch or pressure control assembly is reinstalled or replaced Improper calibration can cause the sprayer to over pressurize resulting in component rupture fire or explosion It may also prevent the sprayer from obtaining the maximum working pressure resulting in poor sprayer performance Service Tools Needed See Fig 21 e NEW 50 foot 3000 psi minimum grounded flex ible airless spray hose A 223 541 Nipple B 1 4 npt x 1 4 npsm 162 453 Swivel C 1 4 npt m x 1 4 npsm swivel 156 823 Tee D 1 4 npt m 104 984 0 5000 psi fluid filled pressure gauge E 1 4 npt 102 814 Needle valve 102 715 or 103 067 3 8 in open end wrench Mineral spirits 5 gallon pail and water F2. tor is normal Have the commutator resurfaced by a qualified motor repair shop if the brushes seem to wear too fast 5 Install the new brush C so its lead is in the long slot H of the holder See Fig 13 Slide the termi nal E under the terminal screw washer Make sure the motor lead G is still connected the at the screw Tighten the screw F See Fig 12 6 Place the spring B on the brush as shown in Fig 13 The spring must coil as shown Push in and hook the spring clip D See Fig 13 Repeat for the other side 9 Test the brushes Remove the connecting rod pin 50 See 15 page 14 With the sprayer off turn the pressure control knob fully counterclockwise to minimum pressure Plug in the sprayer Turn the sprayer on Slowly increase the pressure until the motor is at full speed Inspect the brush and commutator contact area for excessive arcing Arcs should not trail or circle around the commu tator surface CAUTION Do not touch the brushes leads springs or brush holders while the sprayer is plugged in to reduce the risk of electric shock and serious bodily injury 10 Install the brush inspection plates gaskets and covers 11 Break in the brushes Operate the sprayer for at least one hour with no load Then reinstall the connecting rod pin 50 Ase ae N AA Hook of spring clip Fig 11 AN 10 mm minimum Fig 12 G 01227 A Spring must coil in thi
3. ati 4000W minimum Wetted Parts FINCK ei Ne eR EE See manual 307 273 Displacement Pump See manual 307 806 SPrayer nessieira mir Zinc plated Carbon Steel Stainless Steel Fluid Inlet 3 4 npt m with 30 ID chamfer Fluid Outlet Size 2 eee eee eee 1 4 npsm m Dimensions Weight 4 95 Ib 43 kg Height 41 in 1041 mm Length 20 5 in 521 mm Width 20 5 in 521 mm NOTE Delrin is a registered trademark of the DuPont Co Graco Phone Number TO PLACE AN ORDER contact your Graco distrib utor or call this number to identify the distributor closest to you 1 800 328 0211 Toll Free Accessories Must Be Purchased Separately Displacement Pump Repair 222 588 See contents in manual 307 806 Repair instructions are included with the kit Motor Brush Replacement Kit 220 853 See procedure on page 16 DANGER LABELS The English language DANGER label shown on page 4 is also on your sprayer If you have painters who do not read English order one of the following labels to apply to your sprayer The drawing below shows the best place ment of these labels for good visibility Order the labels free of charge by calling 1 800 328 0211 Apply other language in this area on other side of motor ae 185 955 185 962 186 042 186 046 186 050 185 954 French Spanish German Greek Korean English 307 830 27 Graco
4. damage See the warning section FIRE OR EXPLOSION HAZ ARD on page 2 for more detailed grounding instructions Connect the hoses and gun to the sprayer Use a 1 4 in ID 50 ft 15 m long minimum main hose 85 For more flexible gun movement install a 3 16 in ID 3 ft 0 9 m hose 86 between the main hose and the gun 87 Don t use thread sealant and don t install the spray tip yet Fill the packing nut wet cup 221 1 3 full with Throat Seal Liquid TSL supplied Check the electrical service a Electrical requirements 120 VAC 60 Hz 15A minimum b Use a grounded electrical outlet located at least 20 ft 6 m from the spray area c Do not remove the grounding prong of the power supply cord and do not use an ungrounded adapter d Extension cord specifications 15A 3 wires grounding type Note that long lengths reduce sprayer performance A maximum extension cord length of 200 ft 60 m is recommended Flush the pump to remove the oil left in to protect pump parts after factory testing See Flushing on page 9 Prepare the paint Remove any paint skin Stir the paint thoroughly Strain the paint through a fine nylon mesh bag to remove particles that could clog the filter if used or the spray tip 307 830 5 Setup A Keep 1 3 full with TSL at all times A Never install any shutoff device here 01744C Fig 1 6 307 830 Startup Use this procedure to help you st
5. 16 18 LOCKWASHER spring 3 8 CAPSCREW hex hd 5 16 18 x 7 8 LABEL identification TAG caution PRESSURE RELIEF VALVE WHEEL semi pneumatic HUBCAP RETAINING SPRING PIN hdless 5 16 dia x 1 BEARING HOUSING CONNECTING ROD CAPSCREW sch 1 4 20 x 1 LOCKWASHER 1 4 GEAR REDUCER THROAT SEAL LIQUID 8 oz PLUG See page 23 SCREW SPRING CLIP large DRAIN HOSE SPRING CLIP small LABEL LABEL Danger LABEL Danger HOSE grounded nylon 1 4 ID cpld 1 4 npsm f 50 ft 15 m spring guards both ends 1 HOSE grounded nylon 3 16 ID cpld 1 4 npsm f 3 ft 0 9 m long spring guards both ends 1 SPRAY GUN See manual 308 235 for parts Includes RAC IV DripLess Tip Guard and 517 size SwitchTip 1 9 5 in Er E EE OE an Pani Qn7oHaiasaapnHHanwnaa A Replacement Danger and Warning labels tags and cards are available at no cost 307 830 25 Notes 26 307 830 Technical Data Electri Motor saroi eects Bidets eas re Aan ete wate 3 4 HP DC Electric COM usc raaa Saeed 14 AWG 3 wire Power Requirements 120 VAC 60 Hz 15A Maximum Working Pressure 2750 psi 190 bar Maximum Delivery 000 0 75 gpm 2 8 Ipm Cycles Gallon liter 0 0 cece eee eee 260 70 TIP S ZE esate neti art ade Ree ees one gun to 0 025 tip with latex at 2000 psi 138 bar Generator saa noiis ae ooo
6. INSTRUCTIONS PARTS LIST gt 307 830 Rev F eq This manual contains important GRACO Ss Rev E e warnings and information Firstehoice wh n upersedes Rev E READ AND KEEP FOR REFERENCE quality counts INSTRUCTIONS EM590 Airless Paint Sprayer 2750 psi 190 bar 19 MPa Maximum Working Pressure Model 220 856 Series D Basic sprayer on Upright cart without hose or gun Model 231 590 Series A Same as 220 856 and includes 50 ft 15 1 m hose 3 ft 0 9 m whip hose and spray gun with RAC IV DripLess Tip Guard and 517 size SwitchTip 01744C ia GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 http www graco com COPYRIGHT 1987 GRACO INC Graco Inc is registered to S EN ISO 9001 Table of Contents WAPrNINGS sss ga een ee doa E eid Eada win tetas 2 Seter a h 40 Pe Sowe es Pies Pb gees oenee ye Es 5 SlaMUP 22 4 dedi eihan wane hand he ai pian aed 7 Maintenance iua napada s wA EE ei ERRE 8 FUSNIN eaer a Saleh ANASARE 9 Application Methods onnaa 10 Troubleshooting 0 0 cee eee 11 Motor Brush Replacement 000005 13 Displacement Pump 00 eee eee eee 14 Connecting Rod and Bearing Housing 15 Drive HOUSING 6 eet ees 16 MOON 3 Gd oun gtd nau tls Die ep bos Pale 6 17 Pressure Control sia cicee cnn e ternare rren anin 19 Pressure Control Adjustment 21 Parts Pressure Control 0 00 0 e c
7. Warranty Graco warrants all equipment listed in this manual which is manufactured by Graco 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 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 warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or 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 of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance or 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 claimed defect If the claimed defect is verified Graco will repair o
8. aceable 115 107 256 CIRCUIT BREAKER items 105a to 105f 118 218 916 TRIAC 105a 105 679 ON OFF SWITCH 119 108 783 SCREW fil hd no 8 32 x 13 16 105b 107 255 GUARD 120 100 284 NUT hex no 8 32 105c 105 659 BOOT on off switch 121 218 168 JUMPER WIRE 105d 100 840 ELBOW street 1 4 npt m x f 105e 157 350 TEE 2 1 4 npt f x 1 4 npt m 105f 162 453 NIPPLE 1 4 npt m x 1 4 nspm 106 100 035 SCREW pan hd no 8 x 5 16 107 157 021 LOCKWASHER no 8 internal a or cr are available at no cost Xe en ee ee ee ee ee ee ee 307 830 Qty Py AE GEE E E T e AT a A Replacement Danger and Warning labels tags and cards 23 Parts Upright Sprayer Model 220 856 Series D Includes items 1 to 81 Detail A Model 231 590 Series A 14 Includes items 1 to 87 Detail B ine Ad 24 307 830 Parts Upright Sprayer Model 220 856 Series D Includes items 1 to 81 Model 231 590 Series A Includes items 1 to 87 Ref No 14a 14b 14c 14d 15 15a Part No 220 365 101 242 176 884 107 310 102 070 111 590 179 781 220 347 181 072 180 573 222 580 112 746 178 941 189 918 107 210 106 115 183 536 183 333 107 156 220 859 178 967 107 089 100 069 110 293 214 570 100 040 162 453 220 855 185 954 100 069 107 263 102 799 107 447 106 078 185 000 183 371 220 858 177 762 108 460 Description CART ASSEMBLY Includes
9. airing any part of the spray system DO NOT lose the thrust balls 14c 16b or allow them to fall between the gears The balls heavily NOTE Refer to Fig 18 covered with grease usually stay in the shaft recesses but could become dislodged If caught 1 Remove the four screws 13 and front cover 12 between gears and not removed the balls will seri Disconnect the hose 30 and drain hose 80 ously damage the drive housing If they are not in place the bearings will wear prematurely 2 Remove the pressure control cover 21 Discon nect the four motor leads 10 While supporting the motor to keep the sprayer from tipping remove the capscrews 35 which 3 Unscrew the connector nut 103 at the pressure hold the motor to the cart Lift the motor off the control Swing the conduit 27 away from the cart connector 4 Remove the conduit seal 18 from around the 11 Mounithe naw moigmtothe part wires in the pressure control Pull the motor leads through the elbow one at a time 12 Liberally apply bearing grease to the gear cluster 56 Be sure the thrusts balls 14c 16b are in place CAUTION 13 Place the dark washer 14b and then the light one Always pull the motor leads one at a time to avoid 14a on the shaft protruding from the big gear in loosening the terminals the drive housing Align the gears and push the new drive housing straight onto the motor and its 5 Loosen the nut of the connect
10. art and operate the 5 Check all fluid connections for leaks Follow sprayer properly and safely the Pressure Relief Procedure on page 11 before tightening connections A WARNING 6 Install the spray tip and tip guard Engage the trigger safety latch Install the spray tip according INJECTION HAZARD to the instructions supplied with it Wn To reduce the risk of serious bodily injury follow the Pressure Relief Proce 7 Adjust the spray pattern dure Warning on page 11 before check ing or repairing any part of the spray system a Increase the pressure slowly just until spray from the gun is completely atomized Use the lowest pressure needed to get the desired results This reduces overspray and fogging NOTE Flush the sprayer if this is a first time startup See page 9 decreases tip wear and extends sprayer life b If more coverage is needed use a larger tip NOTE See Fig 3 except where noted rather than increasing the pressure A c Test the spray pattern Adjust the spray tip 1 Turn the pressure adjusting knob A fully pattern according to the instructions supplied counterclockwise to minimum pressure with the gun or tip 2 Put the intake tube 3 in the fluid container AAN Trigger safety latch shown engaged SAFE y Trigger safety latch shown disengaged OFF SAFE 3 Plug in the sprayer CAUTION Do not run the pump without fluid in it for more than 30 seconds to avoid damage to the displacement pump packing
11. atch when not spraying Avoid all ignition sources such as static electricity from plastic drop cloths open flames such as pilot lights hot objects such as cigarettes f Never spray without a tip guard arcs from connecting or disconnecting power cords or turning light ditches on and off In case of accidental skin injection seek immediate Surgical Treatment Fallureto to low this warning can resultindeath orserious injury Failure to follow this warning can result in amputation or serious injury READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE 4 307 830 Setup A WARNING To reduce the risk of serious bodily injury caused by static sparking fluid injection or over pressuri zation and rupture of the hose or gun all hoses must be electrically conductive the gun must have a tip guard and each part must be rated for at least 2750 psi 190 bar 19 MPa Working Pressure To avoid damaging the pressure control which may result in poor equipment performance and compo nent damage 1 Always use grounded flexible spray hose 85 at least 50 ft 15 m long Never use a wire braid hose as it is too rigid to act as a pulsation dampener Never install any shutoff device between the filter 15 and the main hose See Fig 1 A WARNING FIRE AND EXPLOSION HAZARD Proper electrical grounding is essential to reduce the risk of fire or explosion which can result in serious bodily injury and property
12. aus 23 Parts Upright Sprayer 02 0000e 25 Technical Data 0 0c ccc eee ees 27 Graco Phone Number 00000 cece eee 27 ACCESSOMICS acute cee ee AAS 27 Graco Warranty 0000s 28 Symbols Warning Symbol A WARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions Caution Symbol CAUTION This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions WARNING FIRE AND EXPLOSION HAZARD Improper grounding poor ventilation open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury e lf there is any static sparking or you feel an electric shock while using this equipment stop spray ing immediately Do not use the equipment until you identify and correct the problem Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed Keep the spray area free of debris including solvent rags and gasoline Electrically disconnect all equipment in the spray area Extinguish all open flames or pilot lights in the spray area Do not smoke in the spray area Do not turn on or off any light switch in the spray area while operating or if fumes are present Do not operate a gasoline engine in the spray area Use only with a grounded outlet that matches the grounded p
13. ble with the equipment wetted parts Refer to the Tech nical Data section of all equipment manuals Read the fluid and solvent manufacturer s warnings Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use could result in a chemical reaction with the possibility of explosion Do not use hoses to pull equipment Route hoses away from traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 82 C 180 F or below 40 C 40 F Do not lift pressurized equipment Comply with all applicable local state and national fire electrical and safety regulations NOTE This is an example of the DANGER label on your sprayer This label is available in other languages free of E See page 27 to order ae FIRE AND SKIN INJECTION EXPLOSION HAZARD HAZARD Spray painting flushing or cleaning equipment with flammable liquids in Liquids can be injected into the body by high pressure airless spray or confined areas can result in fire or explosion leaks especially hose leaks Use outdoors or in extremely well ventilated areas Ground equipment f Keep body clear of the nozzle Never stop leaks with any part of the hoses containers and objects being sprayed body Drain all pressure before removing parts Avoid accidental trigger ing of gun by always setting safety l
14. comes first fill the cavity B in the connecting rod with SAE non detergent motor oil See Detail A 8 Coat the surfaces of the connecting rod and bear ing with SAE non detergent motor oil Liberally pack the needle bearing A with industrial grade heavy duty extreme pressure lithium soap grease See Detail A 9 Assemble the connecting rod 52 and bearing housing 51 10 Align the connecting rod 52 with the crank C and push the bearing housing 51 onto the drive housing 14 11 Assemble the remaining parts Refer to page 14 to reinstall the pump Detail A Fig 16 01750B 307 830 15 Drive Housing 5 Lightly tap the lower rear of the drive housing 14 with a plastic mallet to loosen it from the motor 16 Pull the drive housing 14 off the motor A WARNING INJECTION HAZARD To reduce the risk of serious bodily injury follow the Pressure Relief Proce dure Warning on page 11 before check A CAUTION DO NOT drop the gear cluster 56 when removing the drive housing 14 The gear may stay engaged ing or repairing any part of the spray system NOTE Refer to Fig 17 for this procedure in the motor or drive housing NOTE Stop the sprayer at the bottom of its stroke to DO NOT lose the thrust balls 14c 16b or allow get the crank C in its lowest position To lower it them to fall between the gears The balls heavily manually carefully rotate the blades of the fan with a co
15. connect the spray hose Hold the nut B steady with a wrench and unscrew the filter 15 2 Hold the elbow 105d steady with a wrench and disconnect the hose 30 Disconnect the drain hose 80 3 Remove the pressure control cover 21 4 Disconnect the three power supply cord leads See Fig 20 5 Disconnect the four motor leads See Fig 20 6 Unscrew the conduit nut 103 See Fig 19 Pull the pressure control away from the conduit while carefully guiding the wires through the connector 7 Loosen the knurled part of the strain relief bushing 101 and unscrew the fitting from the pressure control See Fig 19 CAUTION Failure to observe the following precautions may cause poor performance or excessive pressure and permanent damage to the pressure control Always use at least 50 ft 15 2 m of grounded flexible spray hose Never use a wire braid spray hose Never add any type of shutoff device between the pump outlet and the spray gun Check the filter if used for clogging or incorrect assembly if tip clogging frequency increases Never allow flushing water or water base paint to freeze in the system 44 01755A 307 830 19 Pressure Control e All wires to the over pressure switch C and the pressure
16. e switch D must be insulated with shrink tubing or electrical tape A Motor leads Conduit seal 18 shown installed in con duit connector 103 VAN See Detail above 01754C Fig 18 18 307 830 Pressure Control A WARNING INJECTION HAZARD To reduce the risk of serious bodily injury follow the Pressure Relief Proce dure Warning on page 11 before check ing or repairing any part of the spray system 8 Remove the mounting screws 35 and pull the pressure control away from the sprayer See Fig 19 9 Remove the mounting plate 11 and secure it to the new pressure control See Fig 19 10 Reassemble the new pressure control in the reverse order of disassembly A C A UTION 11 Adjust the pressure control See page 21 Do not remove the nipple 105e or elbow 105d from the pressure control unless they are damaged Twisting or jarring the these fittings could alter the factory setting of the control or permanently damage it If they must be removed use extreme care Hold the corresponding hex B steady with a wrench and then remove the part A WARNING All wires connected to the over pressure switch C and the pressure switch D must be insulated at the terminals to reduce the risk of electric shock if someone touches these parts when the power is on When installing the new pressure control be sure the these terminals are covered with shrink tubing or electrical tape See Fig 20 1 Dis
17. ean the 2 Remove the filter bowl B and screen C Rein screen separately 3 Turn the pressure adjusting knob A fully counter clockwise to the minimum pressure 01749A 307 830 9 Application Methods Hold the gun perpendicular to the surface Keep the gun at an even 12 to 14 in 300 to 356 mm from the surface you are spraying See Fig 7 Begin moving the gun horizontally at a steady rate Start the spray stroke off the target surface and pull the trigger as the gun is moving Then while the gun is still moving and as you approach the other edge of the surface release the trigger This method avoids ex cess paint buildup at the end of each stroke 0072 Fig 7 Move the gun at a speed that provides a full wet coating to be applied without runs or sags Lap each stroke 50 over the previous stroke to produce a uniform paint thickness Spray in a uniform pattern from right to left and then left to right for a professional finish See Fig 8 OVERLAP EACH STROKE 50 0672 Fig 8 10 307 830 The best way to control the rate of coverage is with the gun tip size A small tip orifice applies less paint A larger tip orifice applies more paint The width of the pattern depends on the fan pattern of the tip you choose Do not try to increase coverage by increasing the fluid pressure Use the lowest pressure needed for good results This prolongs the life of your sprayer and reduces paint
18. he spray tip from the gun A WARNING 5 Put the suction tube into a grounded metal pail INJECTION HAZARD with 1 2 gallon of compatible solvent To reduce the risk of serious bodily injury follow the Pressure Relief Proce 6 Start the sprayer See page 7 To save the fluid in l dure Warning on page 11 before check the sprayer as you start to flush trigger the gun ing or repairing any part of the spray system into another container until the next fluid appears then trigger the gun back into the fluid you are pumping Circulate the flushing fluid a couple of A CAUTION minutes to thoroughly clean the system NEVER allow water or water base material to freeze 7 Raise the suction tube and trigger the gun to force solvent from the hose Do not run the pump dry for more than 30 seconds to avoid damaging the pump packings Relieve pressure in the pressure control Doing so prevents the sprayer from being started and causes serious damage to the pressure control Pump the water out with mineral spirits 8 Remove the suction tube and clean separately A WARNING Install the filter screen Hand tighten the bowl FIRE AND EXPLOSION HAZARD To reduce the risk of static sparking and splashing when flushing always remove the spray tip from the gun and hold a metal part of the gun firmly to the side of grounded metal pail 1 Relieve pressure Engage the trigger safety latch By stall the bowl and support D only Cl
19. ief Procedure page 11 first Follow the cleaning instructions given in your separate gun or spray tip instruction manual Shutdown and Care 1 Keep the packing nut wet cup 221 1 3 full of TSL Throat Seal Liquid supplied at all times to help prevent fluid buildup on the piston rod and premature wear of packings Follow the Pressure Relief Procedure page 11 before adding TSL Keep the packing nut wet cup just tight enough to stop leakage See Fig 5 Overtighten ing causes binding and excessive packing wear Follow the Pressure Relief Procedure page 11 Then use a round punch or brass rod and light hammer to adjust the nut Clean the fluid filter 15 often and whenever the sprayer is stored Follow the Pressure Relief Procedure page 11 before cleaning the filter Lubricate the bearing housing A after every 100 hours of operation Follow the Pressure Relief Procedure page 11 Remove the front cover Fill the bearing housing cavity with SAE 10 non detergent oil See Fig 4 307 830 5 For very short shutoff periods leave the suction tube in the paint relieve pressure and clean the spray tip 6 Flush the sprayer at the end of each work day and fill it with mineral spirits to help prevent pump corrosion and freezing See page 9 A CAUTION To prevent pump corrosion and to reduce the chance of fluid freezing in the pump or pressure control in cold weather never leave water or any type of paint in
20. ig 21 NEVER attempt to increase the sprayer s maximum working pressure by performing these adjustments in any other way Normal operation of the sprayer at higher pressures may result in component rupture fire or explosion To perform this adjustment howev er the sprayer pressure must be temporarily in creased above the normal working pressure Use a new 50 foot 15 2 m spray hose rated for at least 3000 psi 210 bar MAXIMUM WORKING PRESSURE when performing this procedure A used under rated hose could develop a high pres sure leak or rupture Procedure A WARNING INJECTION HAZARD To reduce the risk of serious bodily injury follow the Pressure Relief Proce dure Warning on page 11 before check ing or repairing any part of the spray system 1 Remove the old spray hose Install the new hard ware and hose as shown in Fig 21 On the other end of the hose install the needle valve Procedure continued on page 22 01315 307 830 21 Fig 22 0750 NOTE Refer to Fig 22 for the remainder of this procedure 2 Remove the plug 68 3 Open the needle valve slightly Turn the pressure adjusting knob A to the minimum setting 4 Plug in the sprayer and turn the switch E ON Increase the pressure just enough to start the sprayer Fully prime the hose being sure to elimi nate all air from the system 5 Open the needle valve a just enough to allow the Pressure Control Adjustment pump
21. ilter if used is dirty or unacceptable Increase the pressure Replace pump See page 14 Clean filter See instructions supplied with it Fluid supply is low or empty Refill and prime pump Check fluid supply often to prevent running pump dry Paint too viscous Wrong type hose Paint runs or sags Spitting from gun Static sparking from gun Spray or work being sprayed is not properly grounded 1 The electric motor has an over temperature switch which automatically resets upon cooling If it opens and the electric motor shuts itself off unplug the power supply cord and let the sprayer cool for 30 to 60 minutes Always use the lowest pressure setting needed when spraying Prevent overspray from restricting the motor air pas sages check and clean often 2 Freezing results from failure to replace the water base paint or flushing water with mineral spirits and usually causes permanent damage to the pressure control 12 307 830 Spray tip too big or worn Change spray tip Thin paint Use minimum 50 ft 15 m grounded flex ible hose wire braid hose is unacceptable Spray tip to big or worn Change spray tip Air in fluid pump or hose Check for loose connections at pump intake and tighten Then prime pump Spray tip is partially clogged Clear tip See page 8 Fluid supply is low or empty Refill and prime pump Check fluid supply often to prevent running pump dry Correct problem before continuing F
22. items 1a 1g RETAINING RING WASHER plain 5 8 PLUG plastic SPRING SNAP BUTTON SLEEVE CART HANDLE KIT strainer INTAKE TUBE DISPLACEMENT PUMP See manual 307 806 for parts RETAINER NUT NUT hex PAIL HANGER CAPSCREW sch 1 4 20 x 1 LOCKWASHER spring 3 8 MOUNTING BRACKET DRIVE HOUSING COVER SCREW ovh 8 32 x 3 8 DRIVE HOUSING Includes items 14a 14d WASHER silver colored WASHER bronze colored BALL 1 4 sst GREASE FLUID FILTER Includes items 15a and 15b See manual 307 273 for parts PLUG NIPPLE 1 4 npsm x 1 4 npt MOTOR Includes items 16a 16d LABEL Danger BALL sst 1 4 TERMINAL TERMINAL CONDUIT SEAL see page 23 SCREW ovh 10 24 x 3 8 PRESSURE CONTROL COVER LABEL identification PRESSURE CONTROL See page 23 for parts LABEL Warning 45 CONDUIT CONNECTOR Qty ae NNNNNN O E E E E p E oo ai oo STE Ae S E E EN Ref No 27 30 87 Part No 065 099 223 766 162 453 100 188 100 214 110 963 183 510 178 034 237 677 106 062 104 811 176 817 176 818 218 035 218 034 100 643 105 510 179 961 206 994 101 754 110 037 181 102 186 495 186 494 186 126 185 955 187 959 223 541 214 701 235 459 Description Qty ELECTRICAL CONDUIT specify length when ordering HOSE nylon 1 4 ID cpld 1 4 nspm fbe 29 740 mm long spring guards both ends NIPPLE 1 4 npsm x 1 4 npt NUT hex 5
23. lost by overspray For interior corners aim the gun toward the center of the corner to be sprayed By dividing the spray pattern this way the edges on both sides are sprayed evenly See Fig 9 Fig 9 0673 If there is a wind angle the spray pattern into the wind to minimize drifting Paint from the ground to the roof Shrubs Tie back shrubs with rope and stakes Cover them with a dropcloth as the painter approaches the area Remove the dropcloth as soon as the area is painted to prevent damage Concrete walks If the walkways will be walked on cover them with a canvas dropcloth to avoid slipping Otherwise a plastic cloth can be used Electrical outlets and lamps Protect electrical outlets with masking tape Cover lamps with plastic bags secured with masking tape Nearby objects Move portable objects upwind of the surface to be sprayed If there is a nearby home make a protective barrier by hanging plastic drop cloths between two long poles Troubleshooting A WARNING Pressure Relief Procedure 5 Engage the gun safety latch To reduce the risk of serious bodily injury always follow this procedure before checking or repairing the sprayer 6 Open the pressure drain valve Leave the valve open until you are ready to spray again Engage the gun safety latch Turn the ON OFF switch to OFF If you suspect that the spray tip or hose is completely Unplug the power supply cord clogged or that pressure has no
24. lug of this equipment 2 307 830 ns A WARNING INJECTION HAZARD Spray from the gun leaks or ruptured components can inject fluid into your body and cause extremely serious injury including the need for amputation Fluid splashed in the eyes or on the skin can also cause serious injury e Fluid injected into the skin is a serious injury The injury may look like just a cut but it is a serious injury Get immediate medical attention Do not point the gun at anyone or at any part of the body Do not put your hand or fingers over the spray tip Do not stop or deflect leaks with your hand body glove or rag Do not blow back fluid this is not an air spray system Always have the tip guard and the trigger guard on the gun when spraying Check the gun diffuser operation weekly Refer to the gun manual Be sure the gun trigger safety operates before spraying Lock the gun trigger safety when you stop spraying Follow the Pressure Relief Procedure on page 11 if the spray tip clogs and before cleaning checking or servicing the equipment Tighten all fluid connections before operating the equipment Check the hoses tubes and couplings daily Replace worn or damaged parts immediately Do not repair high pressure couplings you must replace the entire hose Fluid hoses must have spring guards on both ends to help protect them from rupture caused by kinks or bends near the couplings TOXIC FLUID HAZARD Hazardou
25. mp See Fig 14 1 Flush the sprayer Relieve pressure 2 Remove the clips 74 76 and drain hose 75 3 Hold the intake valve 222 steady with a wrench and unscrew the suction tube 3 4 Use a screwdriver to push the retaining spring 49 up and then push out the pin 50 5 Loosen the locknut 6 Unscrew the pump 4 a O 14 307 830 Connecting Rod and Bearing Housing A WARNING INJECTION HAZARD To reduce the risk of serious bodily injury follow the Pressure Relief Proce dure Warning on page 11 before check ing or repairing any part of the spray system NOTE Refer to Fig 16 1 Remove the pail hanger 7 2 Remove the front cover 12 3 Remove the pump as described on page 14 4 Remove the four screws 9 and lockwashers 10 Pull the bearing housing 51 and connecting rod assembly 52 off the crankshaft C 5 Clean and inspect the crankshaft C Wipe it clean with a rag don t use solvent If the crankshaft is badly worn replace the drive assembly 14 See page 21 6 Clean and inspect the bearing housing 51 and connecting rod 52 including the needle bearing A Replace both parts if either is worn or dam aged See Detail A 7 Clean the mating surfaces of the bearing and drive housings A CAUTION To extend the service life of the connecting rod bearing lubricate it properly After every 100 hours of operation or whenever servicing the pump whichev er
26. old hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es ADDITIONAL WARRANTY COVERAGE Graco does provide extended warranty and wear warranty for products described in the Graco Contractor Equipment Warranty Program All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Sales Offices Minneapolis Detroit Los Angeles Foreign Offices Belgium Canada England Korea France Germany Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 http www graco com PRINTED IN U S A 307 830 April 1987 Revised December 1997 28 307 830
27. ollow the warning section FIRE OR EXPLO SION HAZARD on page 2 3 Over pressurization results from 1 using less than 50 ft 15 m of flexible spray hose 2 from using a wire braid spray hose 3 from adding a shutoff device between the pump outlet and the spray gun 4 from attaching a spray hose to the pressure drain valve or 5 from using a clogged or incorrectly assembled filter if used Motor Brush Replacement NOTE Replace the brushes when they have worn to less than 10 mm See Fig 12 Always replace both brushes at the same time A Brush Repair Kit 220 853 and spring clip 110 816 are available NOTE Replacement brushes may last only half as long as the original ones To maximum brush life break in new brushes by operating the sprayer with no load remove the pump connecting rod pin for at least one hour 01745C Fig 10 A WARNING INJECTION HAZARD To reduce the risk of serious bodily injury follow the Pressure Relief Proce dure Warning on page 11 before check ing or repairing any part of the spray system 1 Remove both inspection covers A See Fig 10 2 Pushin the spring clip E to unhook it and then pull it out See Fig 11 3 Loosen the terminal screw F Pull the brush lead E away leaving the motor lead G in place Remove the brush C and spring B See Fig 12 4 Inspect the commutator for excessive pitting burning or gouging A black color on the commuta
28. or 25 at the motor locating pins Pull the conduit 27 away from the motor and then pull the wires through the conduit one at a time 14 Continue reassembling the sprayer Follow the NOTE and WARNING below 6 Remove the connector 25 elbow from the motor BREEN EO Me WIES rough ione aka Amg NOTE Use a turning motion on the conduit when 7 Remove the screws 42 from the recess of the feeding wires through it drive housing 14 Remove the screws 72 and h 54 f th f th tor s front end ers 54 from the rear of the motor s front en A WARNING All wires connected to the over pressure switch C and the pressure switch D must be insulated at 8 Remove the screws 53 and washers 54 from INST S ALOK MOLL Sunt ene bell the terminals to reduce the risk of electric shock if someone touches these parts when the power is on When installing the new pressure control be sure these terminals are covered with shrink tubing or electrical tape 9 Lightly tap the lower rear of the drive housing 14 with a plastic mallet to loosen the assembly from the motor 16 Pull the drive housing assembly off the motor 307 830 17 Partial Wiring Conduit Seal Detail Diagram All wires to the over pressure switch C and 54 the pressur
29. r 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 Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors gas engines 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 In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods s
30. rn or damaged Replace piston See page 14 See the PROBLEM Not Intake valve ball check not seating Service pump See page 14 enough paint pressure on page 12 also Pump is frozen o is Pump is frozen o Thaw Pressure control tozen or damaged Try to thaw2 or replace pressure control by overpressurization as Drive assembly damaged Drive assembly damaged damaged Replace drive housing See page 16 drive housing Replace drive housing See page 16 page 16 Pump worn or damaged Replace pump See page 14 Sprayer is not primed Follow the procedure on page 7 again 307 830 11 Troubleshooting PROBLEM CAUSE SOLUTION Paint leaks into wet cup Packing nut is loose Tighten See page 8 Throat packings are worn or Replace packings See page 14 damaged Excessive surging from spray Spray tip or fluid filter is plugged Disassemble and clean Spray tip too big or worn Change spray tip Wrong type hose Use minimum 50 ft 15 m grounded flex ible hose wire braid hose is Paint too viscous Thin the paint Not enough paint pressure Tails or fingers in spray pattern clogged Pressure setting too low Spray tip too big or worn Change the spray tip Pressure control frozen or damaged Try to thaw2 or replace pressure control by overpressurization Pump worn or damaged Pressure setting too low Increase pressure Fluid outlet f
31. s A WARNING FIRE AND EXPLOSION HAZARD To reduce the risk of static sparking and splashing when flushing always remove the spray tip from the gun and hold a metal part of the gun firmly to the side of grounded metal pail 4 Prime the pump a Open the pressure drain valve 44 Turn on the sprayer switch 105a Slowly turn the pressure adjusting knob A clockwise until the sprayer starts When fluid comes from the valve close it b Disengage the trigger safety latch See Fig 2 Holding a metal part of the gun firmly against a grounded metal pail trigger the gun until all air is forced out of the system and the paint flows freely from the gun 017450 c Release the trigger and engage the trigger Fig 3 safety latch g 307 830 7 bs Maintenance A WARNING INJECTION HAZARD To reduce the risk of serious bodily injury follow the Pressure Relief Proce dure Warning on page 11 before check ing or repairing any part of the spray system Cleaning a Clogged Tip A WARNING To reduce the risk of serious bodily injury from from fluid injection NEVER operate the spray gun with the tip guard removed DO NOT hold your hand body or a rag in front of the spray tip when cleaning or checking for a clog Always point the gun toward the ground or into a pail DO NOT try to blow back paint this is NOT an air spray sprayer Clean the front of the tip frequently Follow the Pressure Rel
32. s direction Fig 13 307 830 13 Eepecement Pump Repairing the pump See manual 307 806 for pump repair instructions Reinstalling the pump See Fig 14 and 15 1 Rotate the crankshaft A so the connecting rod is in its lowest position 2 The pump piston rod 223 should protrude about 1 in 25 mm above the pump cylinder 3 Screw the pump into the bearing housing 51 until its pin hole is aligned with the connecting rod 52 pin hole Insert the pin 50 Position the spring 49 so it covers the ends of the pin See Fig 15 A WARNING Be sure the retaining spring 49 is firmly and com pletely in the groove of the connecting rod to prevent the pin 50 from working loose due to vibration If the pin works loose it or other parts could break off due to the force of the pumping action resulting in serious bodily injury pump or property damage Torque to 80 ft lb 107 N m 4 Adjust the pump so the cylinder s top threads are flush with the face B of the bearing housing and the outlet nipple 32 is straight back See Fig 15 01746B Fig 14 5 Torque the locknut 6 to 80 ft lb 107 N m A WARNING 6 Reassemble the remaining parts in the reverse order of removal INJECTION HAZARD To reduce the risk of serious bodily K w injury follow the Pressure Relief Proce dure Warning on page 11 before check ing or repairing any part of the spray system Removing the pu
33. s fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin inhaled or swallowed Know the specific hazards of the fluid you are using Store hazardous fluid in an approved container Dispose of hazardous fluid according to all local state and national guidelines Always wear protective eyewear gloves clothing and respirator as recommended by the fluid and solvent manufacturer MOVING PARTS HAZARD Moving parts can pinch or amputate your fingers e Keep clear of all moving parts when starting or operating the pump e Before servicing the equipment follow the Pressure Relief Procedure on page 11 to prevent the equipment from starting unexpectedly 307 830 3 WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury INSTRUCTIONS e This equipment is for professional use only Read all instruction manuals tags and labels before operating the equipment Use the equipment only for its intended purpose If you are not sure call your distributor Do not alter or modify this equipment Use only genuine Graco parts Check equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure of the lowest rated system component Refer to the Technical Data on page 27 for the maximum working pressure of this equipment Use fluids and solvents which are compati
34. t been fully relieved after following the steps above VERY SLOWLY Disengage the gun safety latch Hold a metal part loosen the tip guard retaining nut or hose end cou of the gun firmly to the side of a grounded metal pling to relieve pressure gradually then loosen pail and trigger the gun to relieve pressure completely Now clear the tip or hose Check everything in the chart before disassembling the sprayer PROBLEM CAUSE SOLUTION Electric motor won t run Power cord or extension cord un Check reset or replace plugged or damaged or building cir cuit breaker or fuse has tripped Motor overload switch has opened Unplug sprayer relieve pressure allow motor to cool decrease pressure Pressure setting too low Increase pressure Pressure control frozen or damaged Try to thaw2 or replace pressure control by over pressurization Electric motor stops while Power cord or extension cord un Check reset or replace spraying plugged or damaged or building circuit or fuse is blown Motor overload switch has opened Unplug sprayer relieve pressure allow motor to cool clear motor air passages of dirt and overspray decrease pressure Wrong type extension cord Use maximum 200 ft 61 m 3 wire 12 gauge grounded extension cord Electric motor runs but low Piston ball check not seating Service pump See page 14 paint output or no paint out put and pump is not stroking Piston packings wo
35. the sprayer when it is not in use Freezing can seriously damage the sprayer or result in a loss of pressure or stalling 7 Coil the hose and hang it on the hose rack when storing it even for overnight to help protect the hose from kinking abrasion coupling damage etc 7460A Fig 4 01748C Flushing NOTE Several flushes may be required to clean the system and prepare it for the next fluid or storage Use this chart to determine the required flushes and use the procedure below for flushing Use this category for flushing a brand new sprayer and flushing after storage System has this Next fluid to be Flushing order Before you spray or store fluid in it sprayed Flush 1 Flush 2 Flush 3 sprayer Oil based solvent Oil based paint Mineral spirits none none Prime with oil or paint new color Oil based solvent or Water based paint Mineral spirits Warm soapy Clean water Prime with water paint water Oil based solvent or Prepare for storage Mineral spirits none none Relieve pressure paint Leave drain valve open Water or water Water based Warm soapy Clean water none Prime with water based paint paint new color water Water or water Oil based paint Warm soapy Clean water Mineral spirits Prime with oil based paint water Water or water Prepare for storage Warm soapy Clean water Mineral spirits Relieve pressure based paint water Leave drain valve open 4 Remove t
36. to run continuously and turn the pressure adjusting knob to maximum Very slowly start to close the needle valve Observe the pressure at which the pump stalls which should be approxi mately 2750 psi 190 bar 22 307 830 6 NOTE If the pressure is lower than 2750 psi 190 bar Unplug the sprayer and relieve pressure Insert the wrench through the hole C and tighten the adjust ment nut B 1 8 turn or less Repeat steps 5 and 6 If the pressure is higher than 2750 psi 190 bar Unplug the sprayer and relieve pressure Insert the wrench through the hole C and loosen the pres sure adjustment nut B 1 8 turn or less Repeat steps 5 and 6 Repeat this procedure until the proper stall pressure is obtained Now check to see at what pressure the sprayer starts to run again after it stalls Plug in the spray er turn it on close the needle valve and set the pressure at maximum Allow the sprayer to run until it stalls In Step 8 the slower the pressure is raised the easier it is to note the exact stall pressure Closing the needle valve quickly causes the pressure to rise too fast which gives a false reading 8 NOTE Open the needle valve very slowly while observing the pressure gauge Check to see if the pressure drops to approximately 2350 psi 161 bar before the sprayer starts again If the pressure is not approximately 2350 psi 161 bar Shut off and unplug the sprayer but do not relieve press
37. ure Turn the differential wheel D just one notch and repeat Steps 5 and 6 Check the pressure drop again and repeat if necessary If you adjust the differential wheel recheck the stall pressure steps 5 and 6 to be sure the it has not changed 10 Relieve pressure Flush the water out with mineral spirits Relieve pressure Install the plug 68 Remove the test equipment Parts Pressure Control Part No 220 858 Pressure Control Assembly 104 105c 105b Includes replaceable items listed below LAS es mpd G X yf 105 Z a eee 105f 105d 113 110 112 dele 118 k GREEN RED RED 16c A 120 107 119 Ref Ref No Part No Description Qty No Part No Description 101 108 295 STRAIN RELIEF BUSHING 110 100 072 NUT hex No 6 32 102 220 945 POWER SUPPLY CORD 8 5 111 220 924 VARISTOR RECTIFIER 103 108 460 45 CONDUIT CONNECTOR 112 103 181 LOCKWASHER no 6 1044 183 466 LABEL Warning 113 107 070 SCREW flat hd no 6 32 x 5 8 105 220 905 PRESSURE CONTROL BOX bare 114 107 254 BOOT circuit breaker Includes repl
38. vered with grease usually stay in the shaft screwdriver recesses but could become dislodged If caught between gears and not removed the balls will seri 1 Remove the front cover 12 ously damage the drive housing If they are not in place the bearings will wear prematurely 2 Remove the four screws 9 Lightly tap the lower rear of the bearing housing 51 with a plastic mallet to loosen it from the drive housing 14 Pull the bearing housing connecting rod pump assembly off the drive housing 14 6 Liberally apply bearing grease to the gear cluster 56 Be sure the thrusts balls 14c 16b are in place 7 Place the dark washer 14b and then the light one 3 Remove the screws 42 from the recess of the 14a on the shaft protruding from the big gear in drive housing 14 Remove the screws 72 53 the drive housing Align the gears and push the from the rear of the motor s front end bell new drive housing straight onto the motor and its locating pins 4 Remove the screws 53 from the rear of the motor s front end bell 8 Continue reassembling the sprayer l 1 01752C Fig 17 16 307 830 Motor A CAUTION DO NOT drop the gear cluster 56 when removing the drive housing 14 The gear may stay engaged in the motor or drive housing A WARNING INJECTION HAZARD To reduce the risk of serious bodily injury follow the Pressure Relief Proce dure Warning on page 11 before check ing or rep
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