Graco Inc. 310778N Paint Sprayer User Manual
Contents
1. 12 Hydraulic Oil Filter Change 14 2 310778N The following Warnings are for the safe setup use grounding maintenance and repair of this equipment The excla mation point symbol alerts you to a general warning and the hazard symbols refer to procedure specific risks Refer back to these Warnings Ay WARNING go FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion e Use equipment only in well ventilated area Do not fill fuel tank while engine is running or hot shut off engine and let it cool Fuel is flammable and can ignite or explode if spilled on hot surface When flammable liquid is sprayed or used for flushing or cleaning keep sprayer at least 20 feet 6 m away from explosive vapors e Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc e Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground equipment and conductive objects in work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify an2. BP _ ececececec a 119 96 FiG 3 10 310778N Engine Engine Removal Installation NOTE All service to the engine must be performed by 1 Install rocker plate 99 dampeners 153 and washers an authorized HONDA dealer 154 on engine 119 with four screws 23 washers 7 and nuts 24 torque to 125 in Ib 14 1 N m 2 Install engine and rocker plate 99 on sprayer 3 Swing motor retainer bracket 105 in Tighten motor knob A WARNING 55 N 4 Do Fan Belt Installation page 10 E w asee ma Relieve pressure page 6 1 Do Fan Belt Removal page 10 Fig 4 Loosen motor knob 55 Swing motor retainer bracket 105 out 3 Remove engine 119 and rocker plate 99 from sprayer 4 Remove four screws 23 washers 7 and nuts 24 and remove rocker plate 99 dampeners 153 and washers 154 from engine 119 FiG 4 310778N 11 Hydraulic Motor Rebuild Hydraulic Motor Rebuild Removal Installation A WARNING Relieve pressure page 6 Place drip pan or rags under sprayer to catch hydraulic oil that leaks out during repair Remove pump pin 92 and retainer clip 120 page 15 Fig 5 Remove hydraulic lines 93 95 from fittings 16 at 4 WARNING z FLYING PARTS HAZARD Detent spring has high energy potential If detent spring is released without due care detent spring and balls could fly into the eyes of the disassembler We
3. Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale 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 of 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 or replace free of charge any defecti
4. 17 Parts Drawing GH 200 GH 230 GH 300 EH 200 Sprayers Parts Drawing GH 200 GH 230 GH 300 EH 200 Sprayers 140 T O 10 52 310778N 18 Parts Drawing GH 200 GH 230 GH 300 EH 200 Sprayers Parts List GH 200 GH 230 GH 300 EH 200 Sprayers Ref No PartNo 5 117471 6 100016 7 100023 100132 10 117560 17 107188 22 110792 23 113664 106212 24 110838 101566 27 112166 30 108842 116645 34 112717 119438 37 116793 40 116754 43 248978 119401 15E588 44 119433 119432 45 116915 46 116919 51 117284 52 15B438 55 15D862 56 154594 58 156401 62 246172 68 155457 69 15E342 884 194126 96 15E410 97 246167 98 246178 249003 99 15F157 15E583 15E585 310778N Description SCREW 1 4 20 flat head mach WASHER lock WASHER flat GH 200 GH 230 EH 200 GH 300 SCREW set socket head O RING ELBOW male 90 deg SCREW cap hex hd GH 200 GH 230 EH 200 GH 300 NUT lock GH 200 GH 230 EH 200 GH 300 SCREW cap sch SCREW cap hex hd GH 200 GH 230 GH 300 WASHER GH 200 GH 230 EH 200 GH 300 FITTING elbow hydraulic PLUG hex head hydraulic PULLEY 5 50 in dia GH 200 GH 230 includes 106 133 GH 300 EH 200 BELT V gripnotch GH 200 GH 230 EH 200 ax41 in GH 300 ax44 in CAP breather filler FILTER hydraulic suction GRILL fan guard KNOB pressure NUT hand O RING O RING GASKET reservoir COVER reservoir TANK reservoir
5. hydraulic fluid GH NUT lock hex SCREW shoulder socket head NUT lock SPACER shaft engine GH 300 GUARD shield engine GH 300 SCREW cap socket Qty _ _ ll ba 0 ND oA A A Danger and Warning labels are available at no cost 19 Parts Drawing GH 200 GH 230 GH 300 EH 200 Sprayers Parts Drawing GH 200 GH 230 GH 300 EH 200 Sprayers 114 tre AL te a 124 ME E 3 7 z AL BRE A FILIE LI gt U JJ U pu f 2 I M NI DA i i wer Y ZZ N ti5410d Ls 20 310778N Parts List GH 200 GH 230 GH 300 EH 200 Sprayers Parts List GH 200 GH 230 GH 300 EH 200 Sprayers Ref No Part No Description Qty Ref No Part No Description Qty 15E594 GH 200 EH 200 1 8t x 100069 BALL 15E597 GH 230 GH 300 1 117 100139 PLUG pipe 95 TUBE hydraulic return 13t 104092 SCREW cap sch 15E595 GH 200 EH 200 1 14 105765 O RING 15E598 GH 230 GH 300 1 157 SCREW cap hex hd 103 246169 HOSE drain 1 16 117607 FITTING elbow std thd includes 110 18t 108014 O RING 107 206994 FLUID TSL 8 oz 1 20t x 120990 SPRING compression 110 241920 DEFLECTOR threaded15E676 1 21 117608 FITTING nipple straight 111 PUMP displacement Manual 309277 248971 GH 200 EH 200 Series A 248736 GH 230 GH 300 Series A 287814 GH 200 Series B 287815 GH 230 GH
6. or 207428 1 gallon 3 8 liter 3 Check oil level 47 Hydraulic Oil Filter Change 310778N Displacement Pump Displacement Pump See manual 309277 for pump repair instructions Installation Removal A WARNING 1 Flush pump If pin works loose parts could break off and project 4h WARNING through the air and result in serious injury or property damage Make sure pin is properly installed OA gt d CAUTION Relieve pressure page 6 If the pump jam nut loosens during operation the 1 Fig 7 Remove suction tube 114 and paint hose 63 threads of the bearing housing and drive train will be remove at swivel end damaged Tighten jam nut as specified 1 Fig 10 Screw jam nut to bottom of pump threads Screw pump completely into manifold Unscrew pump from manifold until pump outlet aligns with hose Hand tighten jam nut then tap 1 8 to 1 4 turn with hammer or torque to 200 ft lb 270 N m ti2272a FIG 7 2 Fig 8 Push retaining spring up push out pin 92 Fic 10 RA P 92 2 Fig 11 Slowly pull engine starter rope until pump rod pin hole is aligned with hydraulic rod hole Fig 8 Push pin 92 into hole Push retaining spring 120 into groove FiG 8 ti2272b 3 Fig 9 Loosen jam nut Unscrew pump ti2272e Fic 11 3 Fig 12 Fill packing nut with Graco TSL ti2272f ti2272c FIG 9 FiG 12 310778N 15 Parts Parts Parts Drawing GH 200
7. 3 8 X 1 4 in npt Qty 1 1 202b 202 202a ti5413b 23 24 310778N Technical Data Technical Data Sprayer Hydraulic Hydraulic Motor HP Maximum Maximum Tip size Fluid Inlet Fluid Outlet in Pressure Reservoir Delivery in psi bar Capacity gpm lpm Gallons Liters 0 046 0 033 3 8 3 8 0 052 0 037 3 8 3 8 0 057 0 039 3 8 3 8 GH 200 i 0 031 0 021 3 8 3 8 120 Vac EH 200 A 0 037 0 025 3 8 3 8 240 Vac Basic Sprayer Wetted Parts Zinc and nickel plated carbon steel stainless steel PTFE acetal chrome plating leather V Maxt UHMWPE alumi num stainless steel tungsten carbide ceramic nylon aluminum Dimensions Sprayer Weight Ib kg Height in cm Width in cm Length in cm Handle Up Handle Down y th GH 200 Gas 163 73 35 24 121 92 121 92 48 GH 230 Gas 168 75 6 48 GH 300 Gas 195 87 75 48 121 92 48 48 121 92 121 92 GH 200 120 Vac 186 83 7 EH 200 240 Vac 186 83 7 Sound Levels Sound Pressure 1 96 dB A Sound Power 0 00 eee eeee 110 dB A Measured at maximum normal load conditions Gas only Accessories Must be purchased separately GRACO APPROVED HYDRAULIC OIL 169236 5 Gallons 19 liters 207428 1 Gallons 3 8 liters 310778N 25 Graco Standard Warranty Graco Standard Warranty
8. 84tx 192656 PISTON 854 192840 LABEL ADanger and Warning labels are available at no charge Included in Trip Rod Piston Cap Kit 288754 GH200 288755 GH230 GH 300 N Included in hydraulic cylinder Sleeve Kit 246176 GH 200 248991 GH 230 GH 300 Included in Trip Rod Piston Kit 246255 GH 200 248975 GH 230 GH 300 i h h h l 86 193394 NUT retaining Included in Seal Kit 246174 gt ehr T A a Included in Hydraulic Motor Repair Kit 198629 GH 200 EH 200 1 Used on EH 200 15E596 GH 230 GH 300 1 94 TUBE hydraulic supply 310778N 21 GH 200 Sprayers with Spray Gun and Hoses GH 200 Sprayers with Spray Gun and Hoses 248560 Includes 201 and 202 Ref No 201 202 202a 202b 202c 202d Ref No 201 202 202a 202b 202c 202d 22 Part No 248559 287037 240797 238358 246220 159841 Description GH 200 See cover and Parts pages 16 21 KIT gun Contractor 3300 psi 227 bar 22 7 MPa Includes 202a 202d HOSE grounded nylon 3 8 in ID cpld 3 8 18 npsm 50 foot 15 m spring guards both ends 3300 psi 227 bar 22 7 MPa HOSE grounded nylon 3 16 in ID cpld 1 4 npt m x 1 4 npsm f 3 foot 0 9 m spring guards both ends 3300 psi 227 bar 22 7 MPa Contractor Spray Gun Includes 517 RAC X SwitchTip and HandTite Guard See 309639 for parts ADAPTER 3 8 X 1 4 in npt Qty 1 1 202 202
9. GH 230 GH 300 EH 200 Sprayers 310778N 16 Ref No PartNo 6 100016 9 100084 19 108068 27 112166 35 112827 39 119408 47 246173 48 116923 49 116967 54 111841 70 15B563 75 183350 79 amp 189246 81 192027 914 194317 100 198841 103 246169 108 101754 112 248818 113 15E599 116 248815 121 116756 310778N Parts Parts List GH 200 GH 230 GH 300 EH 200 Sprayers Description WASHER lock BALL metallic PIN spring straight SCREW cap sch BUTTON snap WHEEL pneumatic FILTER oil spin on SCREW hex head SPRING compression WASHER plain 5 8 CLIP retainer WASHER LABEL warning SLEEVE cart LABEL Danger English RETAINER ball press bypass HOSE drain PLUG HANDLE cart HOUSING filter CART frame GH FITTING elbow street 45 deg Qty 12 342424 44 ANDANDO AANNONN Ref No Part No Description Qty 122 162485 NIPPLE adapter 2 132 109032 SCREW mach pnh 4 150 245103 DRAIN VALVE 150a 193710 SEAL seat valve 150b 193709 SEAT valve 150c 114797 GASKET 150d VALVE ASSEMBLY 150e 114708 SPRING compression 150f 15G563 HANDLE valve cap 150g 116424 NUT cap 164 117285 O RING 165 15C766 TUBE diffusion 166 244067 FILTER fluid 60 mesh black 167 15C765 CAP filter 174 110966 NUT N oo oo oo A Replacement Danger and Warning labels tags and cards are available at no cost Included in Manifold Kit 287285 Included in Drain Valve Kit 245103
10. LABEL warning PULLEY fan TUBE hydraulic case drain includes 56 PUMP hydraulic GH 200 GH 300 GH 230 EH 200 BRACKET engine mount GH 200 GH 230 GH 300 EH 200 Qty 4 12 o ROAR AA Ref No 101 102 105 106 109 115 117 119 119 126 133 1394 140 148 153 154 155 170 172 173 175 176 177 Part No 15E674 15E677 15E679 15E681 15E587 15E476 248978 15E586 15B314 237686 248976 248973 248943 248944 248945 248946 802264 116298 803900 117632 119484 100002 198492 15A464 115477 15E888 195515 108851 198585 102040 119434 116969 15E764 15E973 C20010 Description LABEL brand GH 200 GH 230 GH 300 EH 200 TUBE suction BRACKET retainer motor SPACER shaft engine GH 200 GH 230 includes 43 133 GH 300 EH 200 WIRE ground assembly w clamp RAIL belt guard assembly includes 55 170 172 173 GUARD belt assembly painted includes 51 139 148 ENGINE includes 7 23 24 26 30 34 99 106 33 153 154 ENGINE GX160K1QX2 5 5 HP ENGINE GX200QX2 6 5 HP ENGINE GX270GA2 9 0 HP MOTOR electric see Manual 310812 ENGINE without kit parts ENGINE GX160K1QX2 5 5 HP ENGINE GX200QX2 6 5 HP ENGINE GX270GA2 9 0 HP KEY square 3 16 x 1 25 GH 200 GH 230 EH 200 GH 300 SCREW set sch LABEL warning LABEL control SCREW mach torx pan hd DAMPENER motor mount GH 200 GH 230 GH 300 WASHER plain LABEL
11. 300 Series B 114 246168 TUBE suction 5 gallon includes 33 120 116551 RING retaining 122 162485 NIPPLE adapter 53 117328 FITTING nipple straight 123 155494 UNION swivel 90 deg 5710 O RING 124 114958 STRAP tie 611 ROD hydraulic motor 127 116813 FITTING nipple hydraulic 15A693 GH 200 EH 200 129t 15B063 LABEL 15E241 GH 230 GH 300 143 LABEL 28 117739 WIPER rod 29 112342 BEARING rod 31 112561 PACKING block 32 117441 VALVE ball 33 189920 STRAINER 1 11 1 2 npsm 36 117609 FITTING tee branch str thd 414 15B564 SCREW cap socket low head 421 114231 NUT lock hex 50 117283 O RING m m DB oo DSH A T m m e a KR a h 63 243814 HOSE coupled 15E676 GH 200 1 641 CAP hydraulic head assembly 15E678 GH 230 1 656 15A726 NUT jam 15E680 GH 300 1 66 SLEEVE hydraulic cylinder 15E682 EH 200 1 246176 GH 200 EH 200 1 157 15B804 LABEL Graco logo 2 248991 GH 230 GH 300 1 171 15E683 LABEL 1 67 MANIFOLD adapter 180v 15F242 GUARD pump rod 1 15A728 GH 200 EH 200 1 181 113263 SCREW 1 15E243 GH 230 GH 300 1 1827 114231 NUT 1 717 WASHER sealing 18310 STOP valve 1 2 72txe 117645 SPRING compression 1840 FITTING cap nut 73t 178207 BEARING piston 7414 178226 SEAL piston 76t 15B463 RETAINER spring 7714 SLEEVE valve 7810 YOKE assembly with trip rod 246610 GH 200 EH 200 248823 GH 230 GH 300 83 192654 STOP valve
12. Repair y G GH 200 GH 230 GH 300 Series A amp B EH 200 Series A Hydraulic Sprayers rz Korean Patent 10 0647761 31 0778N Use with Architectural Coatings and Paints 3300 psi 2 8 MPa 228 bar Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual Save these instructions Z 120 Vac CSA UL 240 Vac 60 Hz 120 Vac 50 Hz 248559 248560 248565 248566 248949 Y 248950 Y 248943 Y 248944 Y 248561 248562 248563 248564 248567 248945 w 248946 w SI SI SI S SI SI Ny s NIN NNS s PROVEN QUALITY LEADING TECHNOLOGY T Graco Inc P O Box 1441 Minneapolis MN 55440 1441 C Copyright 2004 Graco Inc is registered to 1 S EN ISO 9001 11003 Table of Contents WARNING s 24 242 4 42 ee 3 Displacement Pump 1112211111112 15 General Repair Information 5 Parts ica da kobi devi Je eee 16 Maintenance ooocooocoon ee eee eee 6 GH 200 Sprayers with Spray Gun and Hoses 22 Troubleshooting 000ee cece eee eee eee 7 GH 230 Sprayers with Spray Gun and Hoses 22 Hydraulic Pump oo ooooo o 8 GH 300 Sprayers with Spray Gun and Hoses 23 Fan Belts a le Draka 10 Technical Data oooooooooooommo o 25 Engine cco 2 A eee eee os 11 Graco Standard Warranty 111 111 1 26 Hydraulic Motor Rebuild
13. Replace hydraulic oil and filter element with Graco hydraulic oil 169236 5 gallon 20 liter or 207428 1 gal lon 3 8 liter and filter element 246173 page 6 Replace belt SPARK PLUG Use only BPR6ES NGK or W20EPR U NIPPONDENSO plug Gap plug to 0 028 to 0 031 in 0 7 to 0 8 mm Use spark plug wrench when installing and removing plug 310778N Troubleshooting Troubleshooting Problem Cause Solution Gas engine pulls hard won t start Hydraulic pressure is too high Turn hydraulic pressure knob counter clockwise to lowest setting Gas engine will not start Switch OFF low oil no gasoline Consult engine manual supplied Gas engine doesn t work properly Elevation Consult engine manual supplied Refer to 6 5 HP Engine Repair Kit 246311 Gas engine operates but displace ment pump doesn t operate Pump valve is OFF Pressure setting too low Displacement pump outlet filter if used is dirty or clogged Tip or tip filter if used is clogged Hydraulic fluid too low Belt worn or broken Hydraulic pump worn or damaged Dried paint seized paint pump rod Hydraulic motor not shifting Set pump valve ON Increase pressure See manual 310765 Clean filter Remove tip and or filter and clean Shut off sprayer Add fluid See page 6 Replace Bring sprayer to Graco distributor for repair Service pump See manual 309277 Set pump valve OFF Turn pressure down Turn engin
14. a ti5413a GH 230 Sprayers with Spray Gun and Hoses 248562 Includes 201 and 202 Part No 248561 287042 240797 238358 246240 159841 Description GH 230 See cover and Parts pages 16 21 KIT gun Silver 3300 psi 227 bar 22 7 MPa Includes 202a 202d HOSE grounded nylon 3 8 in ID cpld 3 8 18 npsm 50 foot 15 m spring guards both ends 3300 psi 227 bar 22 7 MPa HOSE grounded nylon 3 16 in ID cpld 1 4 npt m x 1 4 npsm f 3 foot 0 9 m spring guards both ends 3300 psi 227 bar 22 7 MPa Silver Spray Gun Includes 517 RAC X SwitchTip and HandTite Guard See 309740 for parts ADAPTER 3 8 X 1 4 in npt Qty 4 4 4 202 310778N GH 300 Sprayers with Spray Gun and Hoses GH 300 Sprayers with Spray Gun and Hoses 248564 Includes 201 and 202 Ref No 201 202 202a 202b 202c 202d Part No 248563 287042 240797 238358 246240 159841 310778N Description GH 300 See cover and Parts pages 16 21 KIT gun Silver 3300 psi 227 bar 22 7 MPa Includes 202a 202d HOSE grounded nylon 3 8 in ID cpld 3 8 18 npsm 50 foot 15 m spring guards both ends 3300 psi 227 bar 22 7 MPa HOSE grounded nylon 3 16 in ID cpld 1 4 npt m x 1 4 npsm f 3 foot 0 9 m spring guards both ends 3300 psi 227 bar 22 7 MPa Silver Spray Gun Includes 517 RAC X SwitchTip and HandTite Guard See 309740 for parts ADAPTER
15. ar safety glasses when removing or installing detent spring and balls Failure to wear safety glasses when top left and right side of hydraulic motor 4 Loosen jam nut 65 5 Unscrew and remove hydraulic motor cap 64 6 Slide piston rod hydraulic motor cap assembly A from hydraulic motor cylinder 7 Remove yoke 78 a Fig 5 Clamp hydraulic motor cap in vise with hydraulic motor piston rod facing up removing detent spring could result in eye injury or blindness _ Fig 5 Put hydraulic motor cap 64 in vise 2 Install yoke spring retainer piston and trip rod assembly in hydraulic motor cap Use shortened Allen wrench to install two screws 13 in spring retainer to secure piston rod assembly to hydraulic motor cap b Use shortened Allen wrench to remove two screws i 3 I t ly A into h t 13 from spring retainer 83 Remove yoke spring 3 A sa assembly A into hydraulic motor a a and trip rod assembly om Myaraulig 4 Screw down hydraulic motor cap 64 Unscrew hydraulic motor cap until inlet and outlet align with hydraulic line fittings and test hole in hydraulic motor cap points toward belt guard 117 5 Torque jam nut 65 against hydraulic motor cap 64 to gt yo 150 ft lb 17 N m 6 Fig 5 Install hydraulic lines 93 95 to fittings 16 to top left and right side of hydraulic motor torque to 40 ft lb 54 2 N m Pull start rope slowly to align pin holes of hydraul
16. d correct the problem SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment DE 1 El GE PRESSURIZED EQUIPMENT HAZARD A Fluid from the gun dispense valve leaks or ruptured components can splash in the eyes or on skin and cause serious injury e Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately W ELECTRIC SHOCK HAZARD w Improper grounding setup or usage of the system can cause electric shock e Turn off and disconnect power cord before servicing equipment e Use only grounded electrical outlets e Use only 3 wire extension cords e Ensure ground prongs are intact on sprayer and extension cords o RECOIL HAZARD I Brace
17. e OFF Pry rod up or down until hydraulic motor shifts Displacement pump operates but output is low on upstroke Piston ball check not seating prop erly Piston packings worn or damaged Service piston ball check See manual 309277 Replace packings See manual 309277 Displacement pump operates but output is low on downstroke and or on both strokes Piston packings worn or damaged Intake valve ball check not seating properly Suction tube air leak Tighten packing nut or replace pack ings See manual 309277 Service intake valve ball check See manual 309277 Tighten suction tube Paint leaks and runs over side of wet cup Loose wet cup Throat packings worn or damaged Tighten packing nut enough to stop leakage Replace packings See manual 309277 Excessive leakage around hydraulic motor piston rod wiper Piston rod seal worn or damaged Replace these parts Fluid delivery is low Pressure setting too low Displacement pump outlet filter if used is dirty or clogged Intake line to pump inlet is not tight Hydraulic motor is worn or damaged Large pressure drop in fluid hose Increase pressure See manual 310765 Clean filter Tighten Bring sprayer to Graco distributor for repair Use larger diameter or shorter hose The sprayer overheats Paint buildup on hydraulic components Oil level is low Clean Fill with oil See page 6 Spitting from gun Air in fluid pump
18. fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property damage gt gt SUCTION HAZARD Never place hands near the pump fluid inlet when pump is operating or pressurized Powerful suction could cause serious injury Do CARBON MONOXIDE HAZARD Exhaust contains poisonous carbon monoxide which is colorless and odorless Breathing carbon mon oxide can cause death Do not operate in an enclosed area Do TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines A BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equipment fluid has cooled completely V GD PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eyewear e Clothing and respirat
19. ic motor and displacement pump 111 Connect with pump pin 92 install retainer clip 120 page 15 8 Start engine and operate pump for 30 seconds Turn engine OFF Check hydraulic oil level and fill with Graco hydraulic oil page 6 A WARNING FLYING PARTS HAZARD Detent spring has high energy potential If detent spring is released without due care detent spring and 7 balls could fly into the eyes of the disassembler Wear safety glasses when removing or installing detent spring and balls Failure to wear safety glasses when removing detent spring could result in eye injury or blindness c Cover spring retainer 83 with a rag to contain detent spring 20 and balls 8 when they are removed from yoke Remove detent balls and spring Remove spring retainer d Put yoke in vise and remove piston rod assembly from yoke 12 310778N Fic 5 310778N CON A 7 A Hydraulic Oil Filter Change Removal A WARNING Relieve pressure page 6 14 Fig 6 Place drip pan or rags under sprayer to catch hydraulic oil that drains out 2 Remove drain plug 40 Allow hydraulic oil to drain 3 Unscrew filter 47 slowly oil runs into groove and drains out rear Installation 1 Install drain plug 40 and oil filter 47 Tighten oil filter 3 4 turn after gasket contacts base Fic 6 2 Fill with five quarts of Graco hydraulic oil 169236 5 j gallon 20 liter
20. nut or hose end coupling to relieve pressure gradually then loosen completely Now clear tip or hose CAUTION For detailed engine maintenance and specifications refer to separate Honda Engines Owner s Manual supplied DAILY Check engine oil level and fill as necessary DAILY Check hydraulic oil level and fill as necessary DAILY Check hose for wear and damage DAILY Check gun safety for proper operation DAILY Check pressure drain valve for proper operation DAILY Check and fill the gas tank DAILY Check that displacement pump is tight DAILY Check level of TSL in displacement pump pack ing nut Fill nut if necessary Keep TSL in nut to help prevent fluid buildup on piston rod and premature wear of packings and pump corrosion AFTER THE FIRST 20 HOURS OF OPERATION Drain engine oil and refill with clean oil Reference Honda Engines Owner s Manual for correct oil viscosity WEEKLY Remove engine air filter cover and clean ele ment Replace element if necessary If operating in an unusually dusty environment check filter daily and replace if necessary Replacement elements can be purchased from your local HONDA dealer WEEKLY DAILY Remove any debris or media from hydraulic rod AFTER EACH 100 HOURS OF OPERATION Change engine oil Reference Honda Engines Owner s Manual for correct oil viscosity SEMI ANNUALLY Check belt wear page 10 replace if necessary YEARLY OR 2000 HOURS
21. or as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection 310778N General Repair Information General Repair Information SAE O Ring Installation Y 1 Unscrew lock nut to touch fitting a 2 ny A WARNING L MOVING PARTS HAZARD y To reduce risk of serious injury do not touch moving 2 Lubricate o ring A A u parts with fingers or tools while testing repair Shut off gt sprayer when repairing Install all covers gaskets 1414a screws and washers before operating sprayer 3 Screw in fitting hand tight 1 1 Keep all screws nuts washers gaskets and electrical fittings removed during repair procedures These parts If are not normally provided with replacement assemblies 2 Test repair after problem is corrected 3 If sprayer does not operate properly review repair procedure to verify procedure was done correctly If 1i5415a necessary see Troubleshooting Guide page 7 for other possible solutions E li 4 Unscrew fitting until oriented properly 4X WARNING a BEIM HOT SURFACES HAZARD EXPLOSION HAZARD Hydraulic system and engine may be very hot during operation and could burn skin if touched ti Flammable materials spilled on hot engine could cause fire or explosion 5 Tighten lock nut to indicated torque Mak her i t 4 Install belt guard before operation of sprayer and re
22. or hose Loose intake suction Fluid supply is low or empty Check for loose connections on siphon assembly tighten then reprime pump Tighten Refill supply container Excessive hydraulic pump noise Low hydraulic fluid level Shut off sprayer Add fluid See page 6 Check hydraulic fluid level often Do not allow it to become too low Use only Graco approved hydraulic fluid page 6 310778N Hydraulic Pump Hydraulic Pump Removal 44 WARNING Relieve pressure page 6 Let hydraulic system cool before beginning service 1 N O NO O Eg 12 Place drip pan or rags under sprayer to catch hydraulic oil that leaks out during repair Remove drain plug 40 and oil filter 47 and allow hydraulic oil to drain Fig 2 Disconnect suction tube 114 Disconnect paint pump 111 page 15 Remove screw 172 nut 173 and belt guard 117 Raise motor and remove belt 44 Remove two set screws 133 and fan pulley 96 Remove case drain tube 97 Remove elbow 22 Remove tube 94 from elbow 37 Remove elbow 37 from hydraulic pump 98 Remove eight screws 27 reservoir cover 68 filter assembly 46 and gasket 62 Remove four screws 5 and hydraulic pump 98 from reservoir cover 68 Installation SS 0 NM pr 12 13 Install hydraulic pump 98 to reservoir cover 68 with four screws 5 torque 100 in Ib 11 N m Install gasket 62 and
23. place ie cii a Be plepelly if damaged Belt guard reduces risk of pinching and loss i of fingers see preceding WARNING LT Grounding LI Ground sprayer with grounding clamp to earth ground for safe sprayer operation Fig 1 k ry 6250 FiG 1 310778N 5 Maintenance Maintenance 44 WARNING SKIN INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying acciden tally Fluid under high pressure can be injected through the skin and cause serious injury To reduce the risk of an injury from injection splashing fluid or moving parts follow the Pressure Relief Procedure whenever you e are instructed to relieve the pressure e stop spraying e check or service any of the system equipment e or install or clean the spray tip Pressure Relief Procedure 1 Lock gun trigger safety 2 Turn engine ON OFF switch to OFF 3 Move pump valve to OFF down and turn pressure control knob fully counterclockwise 4 Unlock trigger safety Hold metal part of gun firmly to side of grounded metal pail and trigger gun to relieve pressure 5 Lock gun trigger safety 6 Open pressure drain valve Leave valve open until ready to spray again If you suspect that the spray tip or hose is completely clogged or that pressure has not been fully relieved after following the steps above VERY SLOWLY loosen tip guard retaining
24. reach 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 TO PLACE AN ORDER contact your Graco distributor or call 1 800 690 2894 to identify the nearest distributor 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 This manual contains English MM 310778 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 http www graco com 8 2004 Revised 10 2008 26 310778N
25. reservoir cover 68 with eight screws 27 torque 90 in Ib 10 N m Install elbow 37 in hydraulic pump 98 Install elbow 37 in tube 94 Torque to 15 ft lb 20 3 N m Install elbow 22 torque to 15 ft lb 20 3 N m Install case drain tube 97 torque to 25 ft lb 33 9 N m Install fan pulley 96 with two set screws 133 Raise motor and install belt 44 Install belt guard 117 with screw 172 and nut 173 Connect paint pump 111 page 15 Fig 2 Connect suction tube 114 Install drain plug 40 torque to 110 in Ib 12 4 N m Install oil filter 47 tighten 3 4 turn after gasket contacts base Fill hydraulic pump with Graco hydraulic oil page 6 through elbow 22 port until full Fill reservoir with remaining hydraulic oil Start up and allow pump to operate at low pressure for approximately 5 minutes to purge all air Check oil hydraulic oil and top off if required 310778N ti5406a 40 FiG 2 310778N Fan Belt Fan Belt Removal Installation 1 Thread belt 44 around drive pulley 43 and fan pulley 96 4 WARNING Let engine 119 down to put tension on belt 2 3 Rotate belt guard 117 down N 4 Tighten belt guard knob 55 I Relieve pressure page 6 1 Fig 3 Loosen belt guard knob 55 2 Rotate belt guard 117 up 3 Lift engine 119 up to remove tension on belt 44 4 Remove belt from pulley 43 and fan pulley 96 117
26. ve 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 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 sold hereto whether due to a breach of contract b
27. yourself gun may recoil when triggered and cause you to fall which could cause serious injury 310778N 3 WARNING bg MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts e Keep clear of moving parts Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure in this manual Disconnect power or air supply L Y EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals e Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings Check equipment daily Repair or replace worn or damaged parts immediately Do not alter or modify equipment Use equipment only for its intended purpose Call your Graco distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or
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