Graco Inc. 224483 Paint Sprayer User Manual
Contents
1. REF REF NO PART NO DESCRIPTION QTY NO PART NO DESCRIPTION QTY NOTE Items 19h to 19p are not included in a kit Order them 19a 221 032 PINION SHAFT ASSEMBLY separately as needed Includes items 19b to 19f 19h 108 692 BEARING needle roller 19b 183 395 SHAFT pinion 193 107 088 BEARING needle needle 19c 108 797 BEARING ball 19k 100 069 BALL sst 19d 108 798 BEARING ball 19m 108 799 RING retaining internal 19e 108 796 RING retaining external 19n 105 489 PIN dowel 19f 183 396 HUB armature 19p 183 394 HOUSING pinion SS h h h b 19p 19e 19h Lubricate exterior 19b Lubricate inner and Ma outer diameters Lubricate teeth Lubricate inner and outer diameters 19k 19j Lubricate exterior 0042 308 125 33 N Parts Complete Sprayer COMPLETE SPRAYER Model 231 148 Includes items 101 to 104 Ref Ref No Part No Description Qty No Part No Description Qty 101 224 439 HOSE coupled 3 4 npt m x 104 224 483 BASIC SPRAYER 3 4 nspm f swivel 3 4 ID Includes items 104a 104c 1 50 ft 15 m long 1 104a 224 442 55 GALLON SUCTION KIT 102 224 472 MASTIC FLOW VALVE See parts on page 35 1 See manual 308 124 for parts 1 104b 224 528 ROOFING PUMP and 103 224 440 HOSE coupled 3 4 npt x 1 2 npt mbe PRESSURE CONTROL KIT 5 8 ID 40 ft 12 m long 1 See parts on page 35 1 104c 224 482 SPRAYER DRIVE ASSEMBLY See parts on page 36 1 See parts2. SPRAYER DRIVE ASSEMBLY Model 224 482 Series A Includes items 1 to 69 REF NO O CO NO okRONM ss O CO Ooohwnh Od SD i O N N 20a 20b 20c 20d 21 22 23 24 25 26 27 28 29 PART NO 220 919 105 510 100 644 108 803 100 469 100 133 108 851 108 805 221 031 183 399 108 806 183 400 108 842 100 214 108 800 183 401 183 517 108 801 183 397 220 920 220 638 106 227 183 209 100 069 110 293 183 168 224 560 224 484 101 242 154 636 179 811 104 811 108 068 183 350 DESCRIPTION QTY GEAR REDUCER LOCKWASHER 1 4 1 CAPSCREW hex sch 1 4 20 x 3 4 CAPSCREW hex sch 1 4 28 x 1 CAPSCREW hex hd 3 8 16 X 3 4 LOCKWASHER 3 8 WASHER plain 3 8 BUSHING snap CLUTCH ASSEMBLY Includes items 9a and 9b ROTOR ARMATURE FIELD CAPSCREW sch 5 16 24 x 3 4 LOCKWASHER 5 16 PIN dowel 5 16 x 1 KEY shaft CLAMP mounting rotor SETSCREW 1 4 20 x 5 16 long cone point HOUSING clutch PINION HOUSING See parts on page 33 DRIVE HOUSING Includes items 20a 20d WASHER bronze colored WASHER silver colored BALL TUBE grease not shown COVER drive housing CONNECTING ROD BEARING HOUSING RETAINING RING ext WASHER WHEEL HUBCAP PIN spring straight 3 16 x 1 25 WASHER pRpmppNNNN AA SS k k REF NO PART NO 31 112 798 32 237 686 33 179 777 34 224 002 35 108 7
3. Do not overfill the tank Make sure the filler cap is securely closed after refueling Fuel vapor or spilled fuel can ignite If any fuel is spilled during refueling make sure the are is dry before starting the engine 1 Fuel specifications Use automotive gasoline with a pump octane number of 86 or higher If the engine knocks or pings use a higher octane fuel Unleaded fuel minimizes combustion chamber deposits 2 Gasolines containing alcohol gasohol Do not use gasohol which contains methanol if the gasohol does not contain cosolvents and corrosion inhibitors for methanol Even if it does contain such additives do not use the gasohol if it contains more than 5 methanol NOTE The HONDA engine warranty does not cover damage resulting from the use of gasolines con taining alcohol See the HONDA engine manual for more information 3 General Do not use oil and gasoline mixtures or contaminated gasoline Avoid getting dirt dust or water in the fuel tank 4 Tank capacity 0 95 gallons 3 6 liter Leave 1 2 in 13 mm at the top of the tank for gas expansion 5 Shut off the engine switch before refueling 6 After refueling tighten the fuel tank cap firmly FILL CAP OFF N Fr z ENGINE W ENGINE ON OFF SWITCH 0015 0141D 308 125 9 Start Up Before You Start The Sprayer 1 See FLUSHING GUIDELINES page 12 to deter mine if the unit should be flushed 2 Be sure the gas tank
4. gage the gun safety latch Trigger the gun to force water or solvent from the hose Do not let the pump run dry for more than 30 seconds to avoid damaging the pump packings Relieve pressure position Fig 5 0553 Maintain firm metal to metal contact when flushing to reduce the chance of static sparking and splashing Fig 6 0406 Spray Tip and Tip Guard A WARNING To reduce the risk of fluid injection or splashing in the eyes or on the skin completely relieve the fluid pressure before installing cleaning or changing tips See the Pressure Relief Procedure on page 8 Installation 1 Insert the housing through the back of the retaining nut and pull it forward See Fig 7 2 Install the metal seal in the housing flat side first See Fig 8 3 Install the cylinder tip in the housing so its small ori fice faces front See Fig 9 4 Snap on the tip guard Install the screw and the white gasket See Fig 10 Operation Be sure the tip arrow handle is in the FULL SPRAY posi tion before operating the gun See Fig 10 A WARNING Keep clear of the nozzle High pressure fluid from leaks or spray can penetrate the skin and cause extremely serious injury including the need for amputation The tip guard provides extra protection against injection but does not prevent it Never cut off the tip guard Clearing a clogged spray tip See Fig 11 1 Engage the trigger safety latch 2 Turn the
5. 50 ft 15 m AG AIR CLEANER MAIN HOSE lt SPARK PLUG CABLE GROUNDING CLAMP MUFFLER PRESSURE CONTROL KNOB PRESSURE CONTROL ON OFF SWITCH PRESSURE RELIEF VALVE shown in closed position DISPLACEMENT PUMP QUICK DISCONNECT ELBOW SIPHON TUBE Fig 1 0394A 308 125 7 Setup General Information Pressure Relief Procedure NOTE Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing 71 WARNING A WARNING INJECTION HAZARD Fluid under high pressure can be in FIRE AND EXPLOSION HAZARD jected through the skin and cause seri ous injury To reduce the risk of an injury Before operating the pump ground the from injection splashing fluid or moving parts fol system as explained below Also read low the Pressure Relief Procedure whenever you the section FIRE OR EXPLOSION HAZ ARD on page 3 are instructed to relieve the pressure stop spraying check or service any of the system equipment or install or clean the spray tips Grounding 1 Sprayer plug the power supply cord or extension cord into a properly grounded outlet Do not use an adapter All extension cords must have three wires 1 Engage the gun safety latch and be rated for 15 amps 2 Turn the ON OFF switch to OFF 2 Fluid hoses use only grounded hoses with a maximum of 150 m combined hose length to 3 Unplug the power supply cord ensure
6. These parts must be aligned using the locating pins B to help avoid prema ture bearing wear Fig 18 0400 22 308 125 Drive Housing A WARNING CAUTION Do not drop the gear cluster 1 when removing the drive housing 20 The gear cluster is easily damaged The gear may stay engaged in either the drive housing or the pinion housing To reduce the risk of serious injury always follow the Pressure Relief Procedure on page 8 before repairing the sprayer NOTE Refer to Fig 19 for this procedure Do not lose the thrust balls 20c and 19k located at each end of the gear cluster The balls which are heavi 1 Disconnect the suction hose A Disconnect the ly covered with grease usually stay in the shaft re pressure control cord 62 Remove the front cover cesses but they could be dislodged If they are caught 21 between the gears and not removed the balls will seri ously damage the drive housing If the balls are not in 2 Disconnect the pump outlet hose place the bearings will wear prematurely 3 Remove the four screws 48 and lockwashers 49 from the bearing housing 23 7 Liberally apply bearing grease 20d supplied to the gear cluster 1 Be sure the thrust balls 20c and 4 Lightly tap the back of the bearing housing 23 with 19k are in place a plastic mallet Pull the pump bearing housing and connecting rod away from the drive housing 20 as one assembly 8 Place the br
7. 308 125 27 Field and Wiring Harness NOTE Refer to Fig 26 3 Pull the caps A off the wire screws 57 in both 1 Remove the engine See page 27 places on the field Loosen the screws and release the wires of the harness 69 2 Loosen the setscrews 16 Unplug the wiring har ness 69 from under the engine mounting plate Pull the field out to expose the black and white wires 4 Goto Reassembly page 30 Step 4 0046 Fig 26 28 308 125 Clamp NOTE A standard steering wheel puller and two1 4 28 x 3 or 4 in long screws are required to remove the clamp NOTE Refer to Fig 27 1 Loosen the two screws 4 on the clamp 15 work ing through the slot at the bottom of the clutch hous ing 17 2 Install two screws B of the tool A in two of the threaded holes in the clamp Tighten the screw C until the clamp comes off 3 Go to Reassembly page 30 Step 3 or continue below 4 TORQUE TO 125 in Ib 14 N m 0155 Fig 27 Clutch Housing NOTE Refer to Fig 29 2 1 Remove the capscrews 11 and lockwashers 12 which hold the clutch housing 17 to the engine 45 2 Remove the engine key 14 3 Pull off the clutch housing 17 4 Goto Reassembly page 30 Step 1 Fig 28 ___ o om0m0M0MoOyJyJ JD DODODDES 0 308 125 29 TORQUE OPPOSITELY Fig 29 30 Reassembly Install the clutch housing 17 capscrews 11 and lockwashers 12 on the engine See
8. Gra doesn t start pump co dealer for repair Engine won t fire or pull over Oil seepage into combustion chamber Remove spark plug Pull starter rope 3 or 4 times Clean and replace plug Try to start Keep sprayer upright to avoid oil seepage Engine operates but Pressure control switch turned OFF Turn on pressure control switch displacement pump doesn t Also see manual 308 126 Pressure setting too low Increase pressure Tip clogged Clean tip Tecogsed Scant i dry coating Electrical power not energizing field Check wiring connections See page 28 With pressure control switch ON and pres sure turned to MAXIMUM use a test light to check continuity across black and white wires from pressure control Have pressure control checked by autho rized Graco dealer Clutch worn or damaged Service clutch See page 26 Pinion assembly worn or damaged Service pinion assembly See page 24 16 308 125 PROBLEM CAUSE SOLUTION Engine starts but dies Oil level drops below oil sensor Add oil Displacement pump output low Siphon hose strainer is clogged Clean strainer on upstroke Piston ball check not seating Service piston ball check See page 19 Piston packings worn or damaged Replace packings See page 19 Sleeve o ring in displacement pump Replace o ring gasket See page 19 worn or damaged Displacement pump output low Siphon hose strainer is clogged Clean straine
9. ON the engine switch A WARNING A starter rope that recoils too quickly may hit someone and cause serious injury The rope could also jam in the recoil assembly Hold the frame of the sprayer with one hand and pull the starter rope rapidly and firmly Continue holding the rope as you let it return Pull and re turn the rope until the engine starts Open the choke as soon as the engine starts ex cept in cold weather In cold weather leave the choke closed for 10 to 30 seconds before open ing it to keep the engine running 5 Engage the gun trigger safety latch by tipping the gun forward ENGINE ON OFF THROTTLE CHOKE shown in choked position FUEL SHUTOFF LEVER shown in off position SPARK PLUG CABLE 0394A Start Up 6 To start the pump A WARNING a Place a container under the pressure drain valve and open the valve To reduce the risk of serious injury from fluid injec b Reduce the engine speed by moving the metal tion never operate the spray gun with the tip guard throttle lever away from the fuel tank about half removed way ECN 8 Install the tip guard and spray tip See page 13 c Turn the pressure control knob to minimum d Turn ON the pressure control switch e Turn the pressure control knob 1 4 turn from A CAUTION minimum pressure Run the pump until fluid Use the lowest fluid pressure and the lowest throttle flows smoothly from the pressure drain valve setting neede
10. and Installing a Displacement Pump 18 Roofing Pump and Pressure Control Kit 35 Displacement Pump 1 s 1 2 22222 22 19 Drive Assembly c scee coe eee ota woe es 36 Bearing Housing and Connecting Rod 22 Accessories xb de ee n 38 Drive Housing lt 158 sade04 nd toa taweed eee ws 23 Technical Data tins cs 2nben wets deen oN ee eee 39 Pinon HOUSING as baka a ar eel 24 WA IMY gecesine taet edd aie s ki 40 TEILE ene rene et eee E eee ee ee ng 26 Phone NUMBER ts pereira a nee eee aes 40 NOTE This is an example of the English language DANGER label on your sprayer This label is supplied with the sprayer in other languages Before operating the sprayer apply a DANGER label in the appropriate language for your operators according to the separate instructions supplied with it oO 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 Avoid all ignition sources such as static electricity from plastic drop ing of gun by always setting safety latch whe
11. both ends rated for at least 3000 psi 21 0 MPa 210 bar working pressure HIGH PRESSURE SPRAY HOSES 3000 psi 21 0 MPa 210 bar MAXIMUM WORKING PRESSURE 214 705 3 8 ID cpld 3 8 npt m 50 ft 15 m spring guards both ends 223 541 1 4 ID cpld 1 4 npsm f 50 ft 15 m spring guards both ends 214 701 1 4 ID cpld 1 4 npsm f 3 ft 0 9 m spring guards both ends ADAPTERS 157 705 Union 1 4 npt m x 3 8 npsm f 150 287 Adapter 1 4 npt m x 3 8 npt f 156 173 Union 3 8 npt f x 3 8 nosm f Technical Data BNGING s a bugAgi 5 Horsepower Honda Maximum Working Pressure 1200 psi 8 3 MPa 83 bar Cycles Gallon liter 00 0000 cee ee 42 11 Maximum Delivery 3 GPM 11 liter min Fuel Tank Capacity 0 97 gallons 3 7 liter Pump Inlet Size 2 quick disconnect Weight dry without packaging 140 Ib 63 kg Fela b ba bb albubb s t nan 32 in 813 mm EEE 11 R 33 in 838 mm WW oss tt See Hs goi Pope H ba 23 in 584 mm Fluid Outlet Size 2 2 2 3 4 npsm f Wetted Parts Displacement Pump Zinc Plated Carbon Steel Stainless Steel Chrome Plated Stainless Steel Polyethylene Tungsten Carbide Leather Polyurethane 308 125 39 Graco Standard Warranty Graco warrants all equipment manufactured by Graco and bearing its name t
12. 4 on the piston seat 422 Hand tighten the nut very firmly NOTE If you disassembled the piston rod 401 and pis ton housing 416 clean the threads thoroughly Apply red Loctite and torque to 35 50 ft lb 47 68 N m 5 Apply Loctite green supplied in the repair kit to the piston seat 422 threads Install the ball 415 CAUTION Before assembling the piston not that the top of the piston seat 422 has four flutes B and that the piston housing 416 has four holes A Together these flutes and holes provide the fluid flow path Failure to align the parts properly as instructed in Step 6 will result in poor pump performance 6 Back off the piston housing just until the holes and flutes B mentioned in the CAUTION are perfectly aligned and the tips B are not visible when you look through the holes A See Fig 20 1 Screw the pis ton housing 416 down to the nut 414 and torque to 90 125 ft lb 122 170 N m 20 308 125 7 From the top of the pump housing 417 install the male gland 403 With the lips of the v packings fac ing down alternately install the leather packings 418 and poly packings 402 Install the female gland 419 8 Screw in the packing nut 420 loosely It will be tight ened after the pump is installed and operating 9 Grease the o rings on the cylinder 405 Slide the cylinder into the bottom of the pump housing 417 10 Grease the piston r
13. 95 36 185 188 37 220 918 38 181 867T 39 185 953T 40 108 850 41 108 849 42 110 837 43 110 838 44 108 794 45 108 802 48 110 616 49 106 115 56 187 120 57 108 860 59 187 121 60 187 111 61 183 169 62 224 538 63 111 348 64 108 868 65 187 182 66 110 963 67 110 996 68 187 240 69 220 980 T Replacement Warning and Danger Labels and tags avail able at no charge DESCRIPTION SCREW mach hex washer hd No 8 32 x 3 8 GROUNDING CLAMP w 25 ft 7 6 m wire BUTTON snap CART SCREW mach pnh 10 32 x 0 312 BUSHING HANDLE w hose rack LABEL WARNING on engine LABEL DANGER on drive housing SCREW mach filh 8 32 x 1 1 4 CAPSCREW hex sch 1 4 20 x 3 SCREW serrated flange hex hd 5 16 18 x 1 1 2 LOCKNUT 5 16 PLUG tubing ENGINE gasoline 5 HP CAPSCREW sch 3 8 16 x 1 1 5 special LOCKWASHER 3 8 high collar LABEL ID SCREW mach slotted bdgh 8 32 x 1 4 LABEL ID SCREW quick disconnect SPRING retaining CORD SET BUSHING strain relief CLAMP wire BRACKET power cord SCREW serrated flange hex hd 5 16 18 x 3 4 NUT flanged hex hd LABEL warning ELECTRICAL HARNESS QTY N N N AR NAN NARA HANMRHDY VD N 308 125 37 Accessories USE ONLY GENUINE GRACO PARTS AND ACCESSORIES DANGER LABELS The English language DANGER label shown on page 1 is also on your sprayer lf you have painters who do not read English order o
14. Fig 29 Install the engine shaft key 14 See Fig 29 Install the clamp 15 onto the engine shaft A Maintain the 1 99 in 0 01 50 54 mm dimension shown in Fig 30 To check the dimension place a rigid straight steel bar B across the face of the clutch housing 17 Use an accurate measuring device to measure the distance between the inside of the bar and the face of the clamp Adjust the clamp as necessary Torque the two screws 4 to 125 in Ib 14 N m AND EVENLY TO 25 in Ib 2 8 N m 16 TORQUE TO 125 in Ib 14 N m CONNECT WIRING HARNESS 69 HERE BEFORE SLIDING FIELD 10 INTO HOUSING 17 0049 308 125 4 FACE OF HOUSING Connect the wires of the harness 69 to the screws 57 in both places on the field Pull the plastic caps C up and snap them over the screws Guide the wires of the harness 69 through the slot in the clutch housing Slide the field 10 into the clutch Align the setscrew chamfers in the field and the clutch housing 17 Tighten the setscrews 16 oppositely and evenly to 25 in Ib 2 8 N m See Fig 29 177 M 1 99 s 50 54 mm L Vd B OB 4 TORQUE TO 125 in Ib 14 N m SIDE CUTAWAY VIEW OF CLUTCH HOUSING Fig 30 0050 Reassembly F NOTE Refer to Fig 31 for Steps 5 9 5 Place the engine 45 on the cart Align the mount ing holes Guide t
15. INSTRUCTIONS PARTS LIST gt 308 125 Rev D 9 This manual contains important GRACO S des R B KJ warnings and information Ba uperse if ape an READ AND KEEP FOR REFERENCE quality counts INSTRUCTIONS Roof Rigs GM 1230 GASOLINE POWERED AIRLESS SPRAYER B 1200 psi 8 3 MPa 83 bar MAXIMUM GLUDE WORKING PRESSURE Model 231 148 With one gun Heavy Duty RAC IV DripLess Tip Guard and 861 size tip 90 foot 28 m hose Model 224 483 Series A Without hose or gun 0394A GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 http www graco com COPYRIGHT 1991 GRACO INC Graco Inc is registered to I S EN ISO 9001 Table of Contents VV ARMING Sass nana as ska h a ra 3 EMONG AR 27 SEUD R a a a Sue ate 8 Field and Wiring Harness 28 PUGHIAO 2 va eect ete a 9 GIAO AV ote Meter het ee hee ee 29 Slalt UD ee tie rR teehee 10 CIUtCh HOUSING v 438o bass s See g H be a a lb 29 Flushing Guidelines s1 s ss2sssssana a 12 Reassembly vas skrb lusgbasas asug bank ba 30 Spray Tip and Tip Guard 13 Parts Lists and Drawings Spray Techniques sssssssssssssana a 14 Displacement Pump 1 1 1 22222 2 2 32 MAINLENANG Cet ote a a ewe bea 15 Pinion Assembly 0 000 e cece ees 33 Troubleshooting 00 0 c eee 16 Complete Sprayer 0 00 0 annann 34 Service SUCHOM KiE eessen eiae ae a rikur a 35 Removing
16. a compatible solvent fol lowed by an oil base solvent such as mineral spirits Leave the drain valve open Startup after storage Before using water base coating flush out the com patible solvent with warm soapy water and then with clean water When using oil based coating flush out the compat ible solvent with the coating to be sprayed How To Flush The Pump Only 1 Relieve pressure Leave the drain valve open See Fig 5 Disconnect the siphon assembly Put the pump in a grounded metal pail of water or compatible solvent Start the sprayer see page 10 Flush until the ball in the foot valve is clean and moves up and down easily How To Flush The Entire Fluid System 1 12 Relieve pressure Leave the drain valve open See Fig 5 308 125 PRESSURE DRAIN VALVE shown in closed Put the siphon tube in a grounded metal pail of water or compatible solvent Start the sprayer Trigger the gun into the coating container just until water or solvent comes from the nozzle Release the trigger Move the gun to the grounded flushing container Trigger the gun until clean water or solvent comes from the it See Fig 6 Release the trigger and en gage the safety latch Open the drain valve to clean it Check all fluid connections for leaks Relieve pres sure before tightening any connections Start the sprayer Recheck the connections for leaks Remove the siphon tube from the solvent pail Disen
17. ail in Fig 23 7 Skip ahead to Reassembly page 31 Step 6 or con tinue on page 27 17 S L J lt 9 ih My S gt N S 7 eae 2 N N gt ay SEI LL L GE d S 2 D THREADED HOLES PINION SHAFT INSIDE THIS HOUSING Ref 9a USE A STEERING WHEEL PULLER TO REMOVE ROTOR 0402 Engine 1 Working under the mounting plate A of the cart re move the screw 5 lockwasher 6 and washer 7 See Fig 24 2 Remove the engine mounting locknuts 43 and screws 42 Disconnect the mating black white and green wires Pull the wires carefully through the grommets 8 before removing the engine See Fig 24 and 25 3 Lift the engine carefully and place it on a work bench 4 Remove the Field and Wiring Harness Clamp and Clutch Housing as instructed on pages 28 and 29 5 Goto Reassembly page 30 Step 1 NOTE All service to the engine must be performed by an authorized HONDA dealer Fig 24 0153 RED FROM ENGINE GREEN W RED COVER TO FIELD WHITE P Ha d ea i oo O 62 RR BLACK O Fig 25 VIEW FROM UNDER ENGINE MOUNTING PLATE 0405
18. and when transporting it This prevents crankcase oil from leaking into the combustion chamber which makes startup very difficult Maintenance DAILY Check the engine oil level and fill as necessary DAILY Check and fill the gas tank AFTER THE FIRST 20 HOURS OF OPERATION AND EACH 100 HOURS THEREAFTER Change the oil WEEKLY Remove the air filter cover and clean the ele ment In very dusty environments check the filter daily Replace the element as needed Replacement elements can be purchased from your local HONDA dealer SPARK PLUG Use only a NGK BP6ES or BPR6ES plug Gap the plug to 0 025 to 0 030 in 0 7 to 0 8 mm Always use a spark plug wrench 308 125 15 Troubleshooting Check everything in the guide before disassembling A WARNING the sprayer To reduce the risk of serious injury whenever you Relieve the pressure before disassembling the spray are instructed to relieve pressure always follow the er Pressure Relief Procedure on page 8 CAUSE SOLUTION Engine switch not on Turn on engine switch Engine sprayer won t start Outofgas o0o00o0o0000 of Outofgas o0o00o0o0000 Refill gas tank Refill gas tank tank Engine oil level low Try starting engine If light on rear of engine glows replenish oil Spark plug cable disconnected or Connect cable on top of engine or replace spark plug damaged spark plug Adjusting the pressure control knob Return pressure control to authorized
19. ap ring 19k Install the small ring 19m 9 Goto Reassembly page 31 Step 7 or continue on page 26 308 125 25 Clutch NOTE The clutch assembly 9 includes the armature 9b and rotor 9a The armature and rotor must be replaced together so they wear evenly NOTE If the pinion assembly 19 is not yet separated from the clutch housing follow Steps 1 to 4 Otherwise start at Step 5 1 Relieve the pressure 2 Disconnect the hose from the displacement pump Disconnect the cord set 62 from the pressure control 3 Remove the bottom two screws 3 from the clutch housing 17 and then remove the remaining three screws 3 4 Tap lightly on the back of the bearing housing 23 with a plastic mallet to loosen the assembly D from the clutch housing 17 Pull the assembly away the armature 9b will come with it Fig 23 26 308 125 5 Remove the armature from the pinion 6 There are two ways to remove the rotor 9a a Remove the capscrews 4 and lockwashers 2 Install two of the screws in the threaded holes in the rotor 9a Alternately tighten the screws until the rotor comes off See Fig 23 b Use a standard steering wheel puller A with two 1 4 28 x 3 or 4 in long screws B Replace the short screws of the steering wheel puller with the longer screws Turn the screws B into the threaded holes of the rotor 9a Tighten the cap screw C of the tool until the rotor comes off See Det
20. arrow handle to the FULL CLEAN position 3 Disengage the trigger safety latch and trigger the gun into the waste container 4 Engage the trigger safety latch Return the arrow handle to the FULL SPRAY position Maintenance Replace the gasket and seal whenever you replace a tip these parts wear at about the same rate HOUSING RETAINING NUT ag V Yr Fig 7 0464 RETAINING NUT HOUSING Fig 8 0465 HOUSING N od CYLINDER TIP SMALL ORIFICE 0466 Fig 9 V E GASKET TIP GUARD Fig 10 0467 GUN NOZZLE N RAC IV DripLess TIP GUARD FULL SPRAY POSITION FULL CLEAN POSITION Fig 11 0093 308 125 13 Spray Techniques HOLD THE GUN PERPENDICULAR TO AND 24 610 MM ABOVE THE SURFACE MOVE HORIZONTALLY AT A STEADY RATE Sour EACH STROKE BY 50 Fig 12 0551 Start the spray stroke 24 610 mm above the target sur 1 Type ol Goalng mo face and pull the trigger as the gun is moving Then while the gun is still moving and as you approach the other Primers NA 0 031 or larger edge release the trigger This method avoids excess Aluminum Solvent Base OoN 0 041 or larger material build up at the end of each stroke Aluminum Emulsion No 0 051 or larger Do not try to increase coverage by increasing the fluid pressure Use a slower stroke Use the lowest pressure Asphalt ONONE Pase me ee ne
21. ays follow the Pressure Relief Procedure on page 8 before 10 Refer to Installing the pump on page 18 repairing the sprayer NOTE Steps 1 to 10 refer to Fig 18 1 Refer to Removing the pump on page 18 2 Remove the screws 48 and lockwashers 49 from the bearing housing 23 Le Nha 10 3 While pulling the connecting rod assembly 22 with ep one hand lightly tap the lower rear of the bearing housing 23 with a plastic mallet to loosen it from the drive housing 20 Pull the bearing housing and the connecting rod assembly off the drive housing i S 4 Inspect the crank A for excessive wear and replace the drive housing See page 23 5 Evenly lubricate the inside of the bronze bearing C in the bearing housing 23 and the inside of the con necting rod link D with high quality motor oil do not use grease Liberally pack the roller bearing E in the connecting rod assembly 22 with bearing grease 20d supplied 6 Assemble the connecting rod 22 and bearing hous ing 23 7 Clean the mating surfaces of the bearing 23 and drive 20 housings 8 Align the connecting rod with the crank A and care fully align the locating pins B in the drive housing 20 with the holes in the bearing housing 23 Push the bearing housing onto the drive housing or tap it into place with a plastic mallet CAUTION DO NOT use the bearing housing screws 48 to align or seat it with the drive housing
22. cessary to get the results you want this helps prolong Asphalt Emulsion No 0 051 the life of your sprayer and minimizes coating lost by Aluminum Solvent Base Yes 0 061 ovelepray Aluminum Emulsion Yes 0 061 If there is a wind angle the spray pattern into the wind to minimize drifting Asphalt Emulsion 0 061 The best way to control the rate of coverage is with the 1 Roof coatings vary greatly The formulas batch gun tip size A small tip orifice applies less coating A larg temperature and age of the coating all affect its vis er tip orifice applies more coating The width of the pat cosity If the sprayer does not atomize the coating tern depends on the fan pattern of the tip you choose well thinning and or agitating it should help Apply thinned coating more heavily to get an equal dry film thickness For example coating that is thinned 10 should be applied about 10 thicker 2 A0 061 tip is standard with the sprayer 14 308 125 A WARNING To reduce the risk of serious injury always follow the Pressure Relief Procedure on page 8 before checking adjusting cleaning or shutting down the sprayer A CAUTION For detailed engine maintenance and specifications refer to the HONDA engine manual A CAUTION Close the black fuel shutoff lever whenever you are transporting the sprayer to prevent fuel from flooding the engine Keep the sprayer upright and level when operating it
23. crankcase oil from leaking into the combustion chamber which makes start up very difficult TRIGGER LOCK shown in engaged or safe position THROTTLE CHOKE shown in choked ti TRIGGER LOCK position shown in disengaged or off safe position FUEL SHUTOFF LEVER shown in off position PRESSURE CONTROL KNOB TTS AV Dan oa TV ASSSSS ERLE KE X WEAN as sy N Veo ce i 4 im Na G VAAS y 4 ECE E ji SANA gt J I i ENG xK EXE see vy 5 ee ae Siz awt PRESSURE CONTROL ON OFF SWITCH PRESSURE DRAIN VALVE 0394A Fig 4 308 125 11 Flushing Guidelines A WARNING To reduce the risk of serious injury including fluid injection always follow the Pressure Relief Proce dure Warning on page 8 before checking adjust ing cleaning or shutting down the sprayer When To Flush 1 Flush a new sprayer to remove the protective oil Before using water base coating flush with a com patible solvent then warm soapy water and then clean water Before using oil base coating flush with a compat ible solvent Changing coatings Use a compatible solvent Changing from water base to oil base coating Flush with warm soapy water and then a compatible solvent Changing from oil base to water base coating Flush with a compatible solvent then warm soapy water and then clean water Storage Flush the pump only with
24. d Higher settings cause excessive f Close the pressure drain valve clutch cycling and premature tip and pump wear A WARNING 9 Adjust the engine speed and pump pressure be fore transporting the hoses to the roof Trigger Hold the handle of the wand firmly when triggering the gun onto a test paper to check the spray pattern the gun to reduce the risk of it kicking back from and atomization Turn the pressure adjusting knob the surge of pressure which could cause serious until you get a good pattern Then slowly lower the ahi throttle setting as far as you can without changing the spray pattern the clutch does not cycle g Disengage the gun safety latch Hold a metal part of the gun firmly against a grounded metal 10 Read SPRAY TECHNIQUES on page 14 container Holding the gun firmly with both hands squeeze the trigger until fluid flows from the gun A CAUTION h Release the trigger Engage the safety latch Close the black fuel shutoff lever whenever you are transporting the sprayer to prevent fuel from flooding 7 If you have not primed the unit with the coating the engine yet move the siphon tube to the coating container Release the trigger safety latch Trigger the gun into the water solvent pail just until coating appears Tip the gun forward and fully release the trigger to en gage the trigger safety latch Keep the sprayer upright and level when operating it and when transporting it This prevents
25. der or the furnishing performance or use of any products or other goods sold 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 reconnais sent 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 procedures concern es Graco Phone Number TO PLACE AN ORDER contact your Graco distributor or call this number to identify the distributor closest to you 1 800 367 4023 Toll Free 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 308 125 May 1991 Revised October 1997 40 308 125
26. displacement pump repairing the sprayer 2 Pull the displacement rod out of the pump 2 to 3 in 1 Flush the sprayer Remove the suction hose if used 50 75 mm A WARNING 3 Align the flats of the pump piston rod and the pump outlet Lift the pump into position and gently push on the pin while moving the pump slightly until the pin slips into the hole Be sure the retaining ring snaps down over the end of the pin To reduce the risk of pinching or amputating a finger keep your fingers away from the area of the connection rod and pin while jogging the engine 2 Start the engine Jog the pressure control ON OFF A WARNING switch until the connecting link stops near the bottom of the stroke and is fully exposed See Fig 13 Shut off the engine Be sure the retaining spring is firmly in the groove of the connecting link all the way around to pre vent it from working loose due to vibration See Fig 3 Unscrew the collar of the power supply cord and un 13 plug the cord from the pressure control See Fig 14 If the pin work loose it or other parts could break off due to the force of the pumping action and 5 Remove the outlet hose Slightly loosen the two result in serious injury or property damage includ mounting screws See Fig 13 ing damage to the pump connecting link or bearing 6 Use a small screwdriver to push in the connecting housing link pin just until you can gently pry the retaining ring up from
27. grounding continuity 4 Disengage the gun safety latch Hold a metal part 3 Spray gun obtain grounding through connection to of the gun firmly to the side of a grounded metal a properly grounded fluid hose and sprayer pail and trigger the gun to relieve pressure 4 Object being sprayed according to local code 5 Engage the gun safety latch 5 Fluid supply container according to local code 6 Open the pressure drain valve having a container ready to catch the drainage Leave the valve open 6 All solvent pails used when flushing according to until you are ready to spray again local code Use only metal pails which are con ductive Do not place the pail on a non conductive 7 Disconnect the spark plug cable surface such as paper or cardboard which inter rupts the grounding continuity If you suspect that the spray tip or hose is completely clogged or that pressure has not been fully relieved 7 To maintain grounding continuity when flushing or after following the steps above wrap a rag around the relieving pressure always hold a metal part of the tip guard retaining nut or hose end coupling and very gun firmly to the side of a grounded metal pail slowly loosen the part to relieve pressure gradually then trigger the gun Now clear the tip or hose 8 308 125 Setup 1 Read and follow the warnings on pages 3 3 before setting up or operating this sprayer Install the hoses and gun Clamp the siphon hose to the pump Be sure
28. he engine wire A and wiring har ness 69 through the mounting plate grommets 8 Install the screws 42 and nuts 43 and torque to 15 ft lb 20 N m Install the capscrews 5 lockwash ers 6 and washer 7 from under the engine mount ing plate to secure the clutch housing 17 Connect the like colored wires as shown in the Detail A Be sure the face of the rotor 9a and the field 10 is free of all oil and contaminants Install the rotor lockwashers 2 and capscrews 4 Torque the cap screws to 7 ft lb 9 5 N m After installing the rotor 9a pull the engine recoil rope to assure that the engine turns freely and there is no friction between the rotor 9a and the field 10 If there is friction loosen the setscrews 16 and re position the field 10 as necessary Tighten the setscrews oppositely and evenly to 25 in Ib 2 8 N m Also make sure there are no burrs on the outside edge of the rotor TORQUE TO 4 7 ft Ib 9 5 N m 19n 19k Be sure the face of the armature 9b is clean As semble the armature to the shaft in the pinion hous ing C A retaining ring located within the armature makes it difficult to assemble these parts For the best results first engage a few splines of both parts then use a screwdriver to gently push the retaining ring into the armature and then engage the remain ing splines Push the armature onto the shaft until it contacts the ring Assemble the drive pinion housi
29. he gun trigger safety operates before spraying Lock the gun trigger safety when you stop spraying Follow the Pressure Relief Procedure on page 8 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 Hazardous 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 308 125 5 Notes 6 308 125 Setup lime AN TRIGGER yd SHOWN IN ENGAGED OR SAFE POSITION ENGINE 0015 OIL LIGHT ENGINE ON OFF SWITCH ENGINE SW TRIGGER LOCK SHOWN IN DISENGAGED OR OFF SAFE POSITION 40 ft 12 m HOSE THROTTLE CHOKE SPRAY GUN FUEL SHUTOFF K LEVER 40 ft 12 m HOSE N y Wes Ss WAND HANDLE
30. inion housing 4 CAUTION Do not lose the thrust ball 19k Refer to the CAUTION on page 23 for more information NOTE To disassemble the pinion go to Repairing the Pinion page 25 To disassemble more of the sprayer go to page 27 To reassemble the spray er from this point go to Reassembly page 31 Step 7 SEE PAGE 26 FOR PINION 0171 Pinion Housing CUTAWAY VIEW OF PINION HOUSING 19a PRESS PINION ASSEMBLY IN HERE 19 19c O X Lubricate exterior Pa 19d 19c BACK OF PINION HOUSING 19a ig hS O 5 19h Lubricate inner and outer diameters 199 a 33 Lubricate teeth 19f Lubricate inner and outer diameters Lubricate exterior Fig 21 Repairing the Pinion NOTE Refer to Fig 21 except where noted NOTE A hydraulic press is required if you purchase the pinion parts individually Otherwise use Repair Kit No 221 032 which includes the shaft and bearings pre assembled and lubricated If using Repair Kit 221 032 follow Steps 1 to 5 below 1 Remove the small ring 19m from the hub 19j and the large ring 19k from the bearing recess of the pinion housing 19a 2 Push on the front of the shaft 199 to force the bearing and hub assembly out of the housing 19a 3 Install the new shaft assembly into the pinion hous ing pushing it to the shoulder of the housing 19a Install the rings 19
31. is full 3 Check the engine oil level NOTE The engine stops automatically or will not start if it is low on oil If you try to start it again without adding more oil a red light near the engine on off switch glows as you pull the starter rope 4 Push the spark plug cable firmly onto the spark plug 5 If the sprayer in not primed remove the spray tip Refer to Fig 3 as you start the sprayer Start Up 1 Place the siphon tube into the coating water or solvent container depending on whether you are flushing or are ready to spray 2 Open the black fuel shutoff lever by pushing it in the direction of the arrow Never start the engine unless fluid pressure Is re lieved and the pressure control switch is turned OFF Attempting to start the engine when it is pressurized could damage the recoil system ENGINE OIL LIGHT TRIGGER LOCK shown in engaged or safe position TRIGGER LOCK shown in disengaged or off safe position PRESSURE CONTROL KNOB Fig 3 10 308 125 3 Turn OFF the pressure control switch 4 To start the engine a b Turn the pressure adjusting knob all the way counterclockwise to the lowest pressure setting Slide the metal throttle lever away from the fuel tank to the maximum position fully left If the engine is cold close the choke by moving the gray lever If the engine is warm close the choke by moving the gray lever only half way or not at all Turn
32. k and 19m Go to Reassembly page 31 Step 7 or continue on page 26 PLACEMENT OF STEEL BLOCKS WHEN PRESSING OFF LARGE BEARING 19h HYDRAULIC PRESS ROUND STEEL ON SHAFT 19g eee STEEL BAR STOCK LARGE 7 BEARING TWO STEEL 19h a BLOCKS only one shown Fig 22 PRESS PLATFORM 0043 Included in Repair Kit 221 032 dies If purchasing parts separately use these instructions Disassemble as far as needed for the parts being replaced NOTE The old bearings 19h and 19f will be damaged when removed Have extra ones on hand if you need to remove them for any reason 1 Remove the small ring 19m from the hub 19 2 Remove the snap ring 19k from the bearing recess of the pinion housing 19a 3 Push on the front of the shaft 19g to force the bear ing 19h and hub 19j assembly out of the housing 4 Using a hydraulic press place pieces of steel bar stock on the inner race of the large bearing 19h and press the shaft through the hub and bearing Then turn over the shaft and press out the small bearing 19f See Fig 22 5 Apply lubricant to the parts as shown in Fig 21 6 Press fit the following parts Large bearing 19h to the large shoulder of the shaft 19g Small bearing 19f to the shoulder of the shaft 19g Hub 19j onto the shaft 19g all the way to the large bearing 19h 7 Install the shaft assembly pushing it to the shoulder of the housing 19a 8 Install the sn
33. moke 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 Ground the sprayer to a true earth ground with the ground wire and clamp supplied Use only electrically conductive hoses 308 125 3 4 WARNING EQUIPMENT MISUSE HAZARD Le Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury INSTRUCTIONS 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 Graco 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 39 for the maximum working pressure of this equipment Use fluids and solvents which are compatible 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 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 Co
34. mply with all applicable local state and national fire electrical and safety regulations Wear hearing protection when operating this equipment 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 MOVING PARTS HAZARD a Moving parts can pinch or amputate your fingers Keep clear of all moving parts when starting or operating the sprayer e Before servicing the equipment follow the Pressure Relief Procedure on page 8 to prevent the equipment from starting unexpectedly 4 308 125 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 Fluid injected into the skin may look like just a cut but it is a serious injury Get immediate medi cal 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 t
35. n not spraying cloths open flames such as pilot lights hot objects such as cigarettes Never spray without a tip guard arcs from connecting or disconnecting power cords or turning light In case of accidental skin injection seek immediate switches on and off Surgical Treatment Failure to follow this warning can result in death or serious injury Failure to follow this warning can result in amputation or serious injury READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE 2 308 125 Symbols Warning Symbol Caution Symbol This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions equipment if you do not follow the instructions A 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 fthere 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 Disconnect all electrical equipment in the spray area Extinguish all open flames or pilot lights in the spray area Do not s
36. ne of the following labels to apply to your sprayer The drawing below shows the best placement of these labels for good visibility Order the labels directly from Graco free of charge 1 800 328 0211 Apply other language here Toll Free S S ig AZT 185 956 185 961 186 041 186 045 186 049 185 953 French Spanish German Greek Korean English 2 GPM PUMP KIT 238 053 1900 psi 13 2 MPa 132 bar Maximum Working Pressure S REPLACEMENT KIT 238 115 1900 psi 13 2 MPa 132 bar Maximum Working Pressure Installation instructions are included with the kit DISPLACEMENT PUMP REPAIR KIT 224 523 See contents on page 30 Repair instructions are in cluded with the kit SPRAY ROLLER 4050 psi 27 6 MPa 276 bar MAXIMUM WORKING PRESSURE For rolling roofing coatings that require back rolling or for use in high wind conditions to minimize overspray Instal lation and and repair instructions included 224 470 38 308 125 HIGH PRESSURE DISPLACEMENT PUMP PRESSURE CONTROL AND FILTER KIT 224 524 3000 psi 21 0 MPa 210 bar MAXIMUM WORKING PRESSURE Up to 1 25 GPM Quickly convert your Roof Rig to a system that will spray architectural paints acrylics urethanes and bonding adhesives Maximum recommended tip size is 0 035 Contact your distributor for help in determining when to use this kit Installation and repair instructions included Requires gun and hose with spring guards on
37. ng C to the clutch housing using the capscrews 3 and lock washers 2 Connect the cord set 62 to the pressure control WT 42 K TORQUE TO 15 ft lb 20 4 N m DETAIL A VIEW FROM UNDER ENGINE MOUNTING PLATE FROM ENGINE neocon TO FIELD RED COVER WHITE 0403 Fig 31 308 125 31 Parts Displacement Pump Model 224 527 Series A Includes items 401 423 Ref No 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 Part No 187 067 187 071 187 069 111 486 187 066 187 074 187 072 187 102 187 064 224 407 102 973 187 073 187 078 187 077 101 859 187 076 186 951 187 079 187 070 187 068 187 065 224 408 183 210 Description ROD piston V PACKING poly GLAND male steel O RING CYLINDER GLAND male V PACKING poly U CUP SEAL GUIDE ball HOUSING pump intake BALL intake GLAND female V PACKING leather NUT 1 1 4 18 BALL piston HOUSING piston HOUSING outlet V PACKING leather GLAND female PACKING NUT LUG NUT PISTON SEAT PIN These parts also included in Packing Repair Kit 224 523 Keep a kit on hand to reduce down time 32 308 125 Qty ss b St PD SS Ss i Ss i St NS SS ai i eS i eS St S SH HSH MOM 0412 Parts Pinion Assembly Ref No 19 Pinion Housing Includes items 19a to 19f
38. o 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 accor dance 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 sub stitution 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 defective parts The equipment will be returned to the original purchaser tran
39. od 401 and piston packings Slide the piston rod assembly into the bottom of the cylinder so it extends out of the piston housing 2 3 in 50 75 mm Be careful not to damage any pack ings 11 Align the holes in the top of the piston rod with the pump outlet NOTE If you push the piston rod too far out of the pump housing using a hard rubber mallet ONLY to tap it down If the piston rod does not extend out far enough remove the foot valve and tap the piston up 12 Install the intake valve housing and tighten firmly 13 Install the pump and prime it Check the packing nut 20 and tighten it just enough to prevent leakage HOLE FLUTE TIP Fig 16 _ O O O MMj MyW om3 Displacement Pump V 20 19 2 POLY 18 LIPS OF LEATHER LIPS OF V PACKINGS MUST FACE DOWN V PACKINGS MUST FACE DOWN 3 4 Ww 1 TORQUE ROD 1 TO 5 p HOUSING 16 TO 15 34 50 FT LB a 44 68 N m 13 r 16 TORQUE NUT 14 TO HOUSING 16 LEATHER 14 TO 110 FT LB LIPS OF 150 N m V PACKINGS 6 MUST FACE UP 12 POLY LIPS OF V PACKINGS MUST FACE UP 21 8 U CUP SEAL LIPS MUST FACE DOWN 4 Fig 17 mn 308 125 21 Bearing Housing and Connecting Rod 9 Install the screws 48 and lockwashers 49 on the bearing housing Tighten the screws evenly to 25 ft lb 84 N m A WARNING To reduce the risk of serious injury alw
40. on page 36 104b See parts on page 32 and 35 104a See parts on page 35 0395A 34 308 125 SUCTION KIT Model 224 442 Parts Suction Kit and Roofing Pump Includes items 301 to 306 Ref No 301 302 303 304 305 306 Part No 111 338 187 123 187 131 187 119 111 340 Description COUPLER 90 quick disconnect HOSE 2 ID SUCTION TUBE STRAINER CLAMP clamp supplied with sprayer requires special tool use radiator clamp as alternative GASKET 305 303 ROOFING PUMP AND PRESSURE CONTROL KIT Model 224 528 Includes items 201 to 212 Ref No 201 202 203 203a 204 205 206 209 210 211 212 Part No 187 181 187 184 224 711 155 463 110 885 224 527 183 210 157 785 111 337 100 505 224 441 Description Qty LABEL ON OFF amp PRES ADJ 1 COVER PLATE PRESSURE CONTROL 1200 PSI Includes replaceable part 203a 1 O RING 1 SCREW mach pnh 10 24 x 3 8 8 ROOFING PUMP 3 GPM See parts on page 32 PIN straight UNION swivel 3 4 npt m x 3 4 npsm f TEE 3 4 npt m X 3 4 npt f x 3 4 npt f BUSHING 3 4 npt m x 3 8 npt f BALL VALVE See 306 861 for parts l 1 i 1 1 201 LABEL 204 p 203 0396 308 125 35 Parts Drive SEE PARTS pe 3 ON PAGE 33 Ref 34 M 38 WARNING LABEL WARNING 68 LABEL SEE PARTS ON PAGE 33 60 36 308 125 Parts Drive
41. onze colored washer 20a and then the silver colored washer 20b on the shaft protruding from the big bearing of the drive housing 20 Align 5 Remove the bearing housing screws 41 and the the gears and push the new drive housing straight pinion housing screws 3 onto the pinion housing and locating pins B 6 Lightly tap around the drive housing 20 with a plas 9 Reassemble the sprayer Or go to the next section tic mallet to loosen it from the pinion housing 19p in this manual if further service is needed 48 TORQUE TO 25 ft lb 40 34 N m 0401 Fig 19 308 125 23 Pinion Clutch Clamp Field and Engine Disassembling these parts can start from the pinion housing or from the clutch if no pinion service is needed If starting from the pinion housing first follow Steps 1 to 6 of DRIVE HOUSING on page 23 and then contin ue with the procedure below If starting from the clutch see page Pinion Housing Removing the Pinion Housing A WARNING To reduce the risk of serious injury always follow the Pressure Relief Procedure on page 8 before repairing the sprayer NOTE Refer to Fig 20 for Steps 1 to 3 1 Remove the two bottom screws 3 first and then re move the top three screws 3 2 Pull the pinion housing 19p away from the clutch housing 17 The armature 9b will come with it Fig 20 24 308 125 3 Pull the armature 9b off the hub 19j see Fig 21 of the p
42. r on downstroke or both strokes Piston packings worn or damaged Replace packings See page 19 Intake valve ball check not seating Clean and service intake valve See page properly 19 Clutch worn or damaged Replace clutch See page 26 Coating leaks into wet cup Loose wet cup Tighten wet cup just enough to stop leakage Throat packings worn or damaged Replace packings See page 19 Displacement rod worn or damaged Replace displacement rod See page 19 Pressure setting too low Increase pressure See Startup Step 9 page 11 Engine RPM too low Increase throttle setting See Startup Steps 4b and 9 pages 10 and 11 Large pressure drop in hose Use larger diameter hose Low fluid delivery Spitting from gun Air in fluid pump or hose Change gasket in siphon hose quick discon nect coupling if worn or missing Replace pump cylinder o ring Then prime the pump See Startup page 10 Fluid supply is low or empty Refill and prime the pump See Startup page 10 Check fluid supply often to prevent running the pump dry 308 125 17 Removing and Installing a Displacement Pump Removal 7 Remove the two mounting screws while supporting 17 the weight of the pump with your free hand A WARNING Installation To reduce the risk of serious injury always follow 1 Push the pin just barely into the connecting link but the Pressure Relief Procedure on page 8 before not into the mating hole of the
43. sportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE 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 hereun
44. the gasket is in the quick disconnect elbow air leaks will prevent priming 4 Check the engine oil level Refer to the Honda en gine manual supplied In summary remove one oll fill plug the oil should be almost overflowing See Fig 1 Add oil as necessary Also read the MAINTE NANCE section on page 15 Recommended engine oil Use a high quality deter gent oil SAE 10W 40 classified FOR SERVICE SE or SF 5 Ground the sprayer before operating it Connect the grounding clamp 32 to a true earth ground Fol low the FIRE OR EXPLOSION HAZARD on page 3 6 Fill the gas tank See FUELING below 7 Flush the pump to remove the protective light weight oil See FLUSHING GUIDELINES on page 12 8 AGITATE OR MIX THE MATERIAL THOROUGH LY Make sure the heavier material on the bottom of the container is completely mixed in 9 Start the sprayer See page 10 CAUTION To avoid damaging the pressure control follow these precautions 1 Always use spray hose at least 90 ft 27 m long Do not allow water or water base material to freeze in the pressure control Fueling A WARNING Gasoline is extremely flammable and explosive under certain conditions To reduce the risk of a fire or explosion Always shut off the engine before refueling Refuel in a well ventilated area Do not smoke or allow flames or sparks in the area where the engine is refueled or where the gasoline is stored
45. the back of the connecting link Then push the pin in so it falls out the back Procedure continued on page 19 4 Relieve the pressure CUTAWAY VIEW SHOWS HOW PIN GOES THROUGH CONNECTING ROD BACK OF PUMP 2 PUMP PISTON ROD A WARNING WARN Bhi CONNECTING LINK P Ke lear BEARING HOUSING F tll a S RETAINING RING FRONT OF PUMP RETAINING RING CONNECTING LINK MOUNTING SCREWS oo a Torque to 20 ft lb 27 N m FRONT VIEW OF PUMP AND SPRAYER CONNECTING LINK Fig 13 S 18 308 125 Removing and Installing A Displacement Pump 4 Check the back of the bearing housing to be sure the parts are installed properly PRESSURE CONTROL 5 Lift the pump to align the mounting holes and install the mounting screws IMPORTANT torque the screws to 20 ft lb 27 N m See Fig 13 6 Plug in the power cord so the notch in the collar and the tab in the socket align Screw on the collar See Fig 14 COLLAR Fig 14 808 A WARNING To reduce the risk of serious injury always follow the Pressure Relief Procedure on page 8 before repairing the sprayer Disassemble the pump 1 See page 18 for how to remove the pump 2 Usea hard rubber mallet on the tabs of the lug nut 421 to loosen the foot val
46. ve housing 3 Disassemble the pump but do not disassemble the piston rod 401 from the piston housing 416 unless one of those needs to be replaced Due to the high strength Loctite used at the joint of these two parts the joint must be heated before disassembly Refer to Fig 15 Clean and inspect all parts 1 Use a compatible solvent to thoroughly clean all parts and remove all traces of sealant 2 Inspect the parts including seats for nicks and scratches Replace worn or damaged parts as they cause the packings to wear more quickly and or re sult in poor pump performance Continued on page 20 Fig 15 0412 308 125 19 Displacement Pump Repair Kit 1 A Packing Repair Kit Part No 224 523 is available Use all the parts in the kit for the best results 2 Parts included in the kit are marked with an asterisk in the text and drawings For example 408 Reassemble the pump NOTE Refer to Fig 13 for reassembly except where noted NOTE Grease all packings and o rings before installing them 1 Install the ball guide 409 ball 411 and intake housing 410 in the lug nut 421 2 Place new o rings 4047 on the cylinder 405 3 On the piston seat 422 install the u cup seal 408 lips down Install the female gland 412 With the lips of the v packings facing up alternately install the leather 407 and poly packings 413 In stall the male gland 406 4 Install the nut 41
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