Graco 307847K GM 5000 Airless Paint Sprayer Owner's Manual

INSTRUCTIONS–PARTS LIST
307–847
Rev. K
Supersedes J
and PCN K
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
5 HORSEPOWER, GASOLINE–POWERED
GM 5000 Airless Paint Sprayer
3000 psi (210 bar) Maximum Working Pressure
Sprayers with Upright Carts
Model 220–886, Series C
Basic sprayer, without hose or gun
Model 231–052
Complete sprayer, with hose and Contractor gun,
RAC IV DripLess Tip Guard,
and 517 size SwitchTip
Sprayers with Lo–Boy Carts
Model 222–488, Series A
Basic sprayer, without hose or gun
Model 231–085
Complete sprayer, with hose and Contractor gun,
RAC IV DripLess Tip Guard,
and 517 size SwitchTip
0136
NOTE: This is an example of the DANGER label on your sprayer.
This label is available in other languages, free of charge. See page 42 to order.
FIRE AND
EXPLOSION HAZARD
Spray painting, flushing or cleaning equipment with flammable liquids in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground equipment, hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic
drop cloths, open flames such as pilot lights, hot objects such as
cigarettes, arcs from connecting or disconnecting power cords or
turning light switches on and off.
Failure to follow this warning can result in death or serious injury.
SKIN INJECTION
HAZARD
Liquids can be injected into the body by high pressure airless
spray or leaks – especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts. Avoid accidental
triggering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate “Surgical
Treatment”.
Failure to follow this warning can result in amputation or serious
injury.
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN
COPYRIGHT 1987, GRACO INC.
55440–1441
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings
English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
French (Avertissement) . . . . . . . . . . . . . . . . . . . . . . . 6
Spanish (Advertencia) . . . . . . . . . . . . . . . . . . . . . . . . 8
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Flushing Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . 16
Repair
Bearing Housing & Connecting Rod . . . . . . . . . . . 18
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Field and Wiring Harness . . . . . . . . . . . . . . . . . . . . . 24
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Replacement . . . . . . . . . . . . . . . .
Pressure Control Adjustment . . . . . . . . . . . . . . . . .
Displacement Pump Repair . . . . . . . . . . . . . . . . . . .
25
25
26
28
30
31
Parts Lists and Drawings
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . .
Complete Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
220–886, Basic Sprayer with Upright cart . . . . . . .
222–488, Basic Sprayer with Lo-Boy cart . . . . . . .
Pressure Control Assembly . . . . . . . . . . . . . . . . . . .
34
35
35
36
38
40
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Important Phone Numbers . . . . . . . . . . . . . . . . . . . . 43
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
Introduction
GM5000 BASIC COMPONENTS
NOTE: Refer to Fig.1.
Your new GM5000 Sprayer functions and operates differently than other airless paint sprayers. This section will
help you become familiar with the sprayer before operating it.
Pressure Control
The pressure control includes an ON/OFF switch for the
sprayer, the pressure adjusting knob, and a pressuresensing device. The pressure control engages and disengages the clutch to control pressure.
Engine
The engine is a 5 horsepower, four stroke, gasoline engine. Its function is to drive the displacement pump to
supply paint. An adjustable throttle allows you to adjust
engine speed for large or small orifice spray tips. When
the oil level is too low, the engine shuts off automatically.
If you try to start the engine without refilling the oil, a light
illuminates to alert you to the problem, and to protect the
engine from damage.
Clutch
The clutch is engaged by the electric power generated by
the gasoline engine. The power is controlled by the pressure switch.
Drive Assembly
The permanently greased drive assembly transfers power from the gasoline engine to the displacement pump.
Displacement Pump
The positive–displacement, volume-balanced pump provides equal fluid delivery on both the up and down pump
strokes. The pump has a wetcup which, when filled with
Graco Throat Seal Liquid, helps prevent damage to the
throat packings and piston rod.
Fluid Filter
The fluid filter strains the paint to help avoid clogs in the
hose and spray tip. The filter includes a reusable element, and a pressure drain valve for relieving fluid pressure.
Hoses
The grounded, nylon spray hoses have spring guards on
both ends. The 50 ft. (15.2 m) hose has a 1/4 in. ID. The
3 ft. (0.9 m), 3/16 in. ID whip hose provides more flexible
gun movement. The nylon hose material acts as a pulsation dampener to absorb pressure fluctuations.
Spray Gun & RAC IV DripLess Tip Guard
Graco high pressure spray guns have a trigger safety
which prevents accidental triggering when the safety is
engaged. See Fig. 1. The gun provided with the sprayer
also has a filter for final paint straining. The Reverse-AClean IV (RAC IV) SwitchTip uses high pressure fluid
to remove clogs from the spray tip without removing the
spray tip from the gun. The Reverse-A-Clean IV DripLess tip guard is a safety feature which helps reduce
the risk of a fluid injection injury.
A
B
C
M
D
0138
L
0015
4
K
J
51
0016
20
H
47
G
71
F
0136
E
28
202
53
KEY
A
Pressure Control ON/OFF
switch
B
Pressure adjusting knob
C
Air cleaner
D
Fuel Tank
E
Muffler
F
Engine
G Spark plug cable
H
Fuel shutoff lever
J
Choke
K
Throttle
L
Engine ON/OFF switch
M Engine oil light
N
Trigger safety latch
(shown engaged)
4
Clutch
20 Drive assembly
28 Displacement pump
47 Grounding wire and clamp
51 Fluid filter
53 Pressure drain valve
71 Pail hanger
202 Main hose
203 Whip end hose
204 “Contractor” gun with RAC
IV Dripless tip guard and
517 size SwitchTip
203
204
N
0137
Fig. 1
WARNINGS
High Pressure Spray Can Cause Serious Injury. For Professional Use Only.
Observe All Warnings. Read and understand all instruction manuals before operating equipment.
FLUID INJECTION HAZARD
General Safety
This equipment generates very high fluid pressure. Spray from
the gun, leaks or ruptured components can inject fluid through
your skin and into your body, and cause extremely serious injury, including the need for amputation. Also, fluid injected or
splashed into the eyes or on the skin can cause serious damage.
NEVER point the spray gun at any one or at any part of the body.
NEVER put your hand or fingers over the spray tip. NEVER try
to “blow back” paint; this is NOT an air spray system.
ALWAYS have the tip guard in place on the spray gun when
spraying.
ALWAYS follow the Pressure Relief Procedure, below, before
cleaning or removing the spray tip or servicing any system
equipment.
NEVER try to stop or deflect leaks with your hand or body.
Be sure equipment safety devices are operating properly before
each use.
Medical Alert––Airless Spray Wounds
If any fluid appears to penetrate your skin, get EMERGENCY
MEDICAL CARE AT ONCE. DO NOT TREA T AS A SIMPLE
CUT. Tell the doctor exactly what fluid was injected.
Note to Physician: Injection in the skin is a traumatic injury. It
is important to treat the injury surgically as soon as possible. Do
not delay treatment to research toxicity. Toxicity is a concern
with some exotic coatings injected directly into the blood
stream. Consultation with a plastic surgeon or reconstructive
hand surgeon may be advisable.
Spray Gun Safety Devices
Be sure all gun safety devices are operating properly before
each use. Do not remove or modify any part of the gun; this can
cause a malfunction and result in serious injury.
Safety Latch
Whenever you stop spraying, even for a moment, always set
the trigger safety latch in the closed or “safe” position, making
the gun inoperative. Failure to set the safety latch can result in
accidental triggering of the gun.
Diffuser
The gun diffuser breaks up spray and reduces the risk of fluid
injection when the tip is not installed. Check diffuser operation
regularly. Follow the Pressure Relief Procedure, below, then
remove the spray tip. Aim the gun into a metal pail, holding the
gun firmly to the pail. Using the lowest possible pressure, trigger
the gun. If the fluid emitted is not diffused into an irregular
stream, replace the diffuser immediately.
Tip Guard
ALWAYS have the tip guard in place on the spray gun while
spraying. The tip guard alerts you to the fluid injection hazard
and helps reduce, but does not prevent, the risk of accidentally
placing your fingers or any part of your body close to the spray
tip.
Trigger Guard
Always have the trigger guard in place on the gun when spraying to reduce the risk of accidentally triggering the gun if it is
dropped or bumped.
Spray Tip Safety
Use extreme caution when cleaning or changing spray tips. If
the spray tip clogs while spraying, engage the trigger safety
latch immediately. ALWAYS follow the Pressure Relief Procedure, below, and then remove the spray tip to clean it.
NEVER wipe off build–up around the spray tip until the pressure
is fully relieved and the gun safety is engaged.
PRESSURE RELIEF PROCEDURE
To reduce the risk of serious injury , including fluid injection,
splashing fluid or solvent in the eyes or on the skin, or injury from
moving parts or electric shock, always follow this procedure
whenever you shut off the sprayer, when checking or servicing
any part of the spray system, when installing, cleaning or changing spray tips, and whenever you stop spraying.
1 Engage the trigger safety latch.
2 Turn the engine ON/OFF switch to OFF.
3 Flip the pressure control switch to OFF.
4 Disengage the trigger safety latch. Hold a metal part of the
gun firmly to the side of a grounded metal pail, and trigger the
gun to relieve pressure.
1,5
2
3
5 Engage the trigger safety latch.
6 Open the pressure drain valve. Leave the valve open until
you are ready to spray again.
7 Disconnect the spark plug cable.
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 the tip guard retaining nut
or hose end coupling to relieve pressure gradually, then loosen
completely. Now clear the tip or hose.
4
6
0139
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers or other body
parts. KEEP CLEAR of moving parts when starting or operating
the sprayer. Follow the Pressure Relief Procedure above be-
fore checking or servicing any part of the sprayer, to prevent it
from starting accidentally.
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the spray equipment or accessories, such as
overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them
to rupture and result in fluid injection, splashing in eyes or on
skin, or other serious injury, or fire, explosion or property damage.
NEVER alter or modify any part of this equipment; doing so
could cause it to malfunction.
CHECK all spray equipment regularly and repair or
worn or damaged parts immediately.
replace
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.
Noise
Ear protection is recommended when the sprayer is operating.
Refer to the Sound Level in the Technical Data on page 43.
System Pressure
This sprayer can develop 3000 psi (210 bar) Maximum Working
Pressure. Be sure all spray equipment and accessories used
are rated to withstand the this pressure. DO NOT exceed the
maximum working pressure of any component or accessory
used in the system.
Fluid and Solvent Compatibility
All chemicals used in the sprayer must be chemically compatible with the wetted parts shown in the Technical Data on page
43. Consult your chemical supplier to ensure compatibility.
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in this equipment, which contains aluminum and/or zinc
parts. Such use could result in a serious chemical reaction, with
the possibility of explosion, which could cause death, serious injury and/or substantial property damage.
HOSE SAFETY
High pressure fluid in the hoses can be very dangerous. If the
hose develops a leak, split or rupture due to any kind of wear,
damage or misuse, the high pressure spray emitted from it can
cause a fluid injection injury or other serious injury or property
damage.
All fluid hoses must have strain reliefs on both ends! The strain
reliefs help protect the hose from kinks or bends at or close to
the coupling which can result in hose rupture.
TIGHTEN all fluid connections securely before each use. High
pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coupling.
NEVER use a damaged hose. Before each use, check the entire hose for cuts, leaks, abrasion, bulging cover, or damage or
movement of the hose couplings. If any of these conditions exist, replace the hose immediately. DO NOT try to recouple high
pressure hose or mend it with tape or any other device. A repaired hose cannot contain the high pressure fluid.
Handle and route hoses carefully. Do not pull on hoses to move
equipment. Keep hoses clear of moving parts and hot surfaces
of the pump and gas engine. Do not use fluids or solvents which
are not compatible with the inner tube and cover of the hose. DO
NOT expose Graco hoses to temperatures above 180 F (82
C) or below –40 F (–40 C).
Hose Grounding Continuity
Proper hose grounding continuity is essential to maintaining a
grounded spray system. Check the electrical resistance of your
fluid hoses at least once a week. If your hose does not have a
tag on it which specifies the maximum electrical resistance,
contact the hose supplier or manufacturer for the maximum resistance limits. Use a resistance meter in the appropriate range
for your hose to check the resistance. If the resistance exceeds
the recommended limits, replace it immediately
. An ungrounded or poorly grounded hose can make your system hazardous. Also read Fire Or Explosion Hazard, below.
FLUID INJECTION HAZARD
Static electricity is created by the flow of fluid through the pump
and hose. If every part of the spray equipment is not properly
grounded, sparking may occur , and the system may become
hazardous. Sparking may also occur when plugging in or unplugging a power supply cord or using a gasoline engine.
Sparks can ignite fumes from solvents and the fluid being
sprayed, dust particles and other flammable substances,
whether you are spraying indoors or outdoors, and can cause
a fire or explosion and serious injury and property damage.
If you experience any static sparking or even a slight shock
while using this equipment, STOP SPRAYING IMMEDIATELY.
Check the entire system for proper grounding. Do not use the
system again until the problem has been identified and corrected.
Grounding
To reduce the risk of static sparking, ground the sprayer and all
other spray equipment used or located in the spray area.
CHECK your local electrical code for detailed grounding instructions for your area and type of equipment. BE SURE to ground
all of this spray equipment:
1. Sprayer: connect a ground wire and clamp (supplied) to a
true earth ground.
2. Fluid hoses: use only grounded hoses with a maximum f
500 ft (150 m) combined hose length to ensure grounding
continuity. See Hose Grounding Continuity, above.
3. Spray gun: obtain grounding through connection to a properly grounded fluid hose and sprayer.
4 Object being sprayed: according to local code.
5. Fluid supply container: according to local code.
6. All solvent pails used when flushing, according to local code.
Use only metal pails, which are conductive. Do not place the
pail on a non–conductive surface, such as paper or cardboard, which interrupts the grounding continuity.
7. To maintain grounding continuity when flushing or relieving
pressure, always hold a metal part of the gun firmly to the side
of a grounded metal pail, then trigger the gun.
Flushing Safety
Reduce the risk of fluid injection injury , static sparking, or
splashing by following the flushing procedure given on page 15
of this manual. Follow the Pressure Relief Procedure on page
4, and remove the spray tip before flushing. Hold a metal part
of the gun firmly to the side of a grounded metal pail and use the
lowest possible fluid pressure during flushing.
GASOLINE ENGINE HAZARD
NEVER fill the fuel tank while the engine is running or hot. Fuel
spilled on a hot surface can ignite and cause a fire.
ALWAYS pour fuel in slowly to avoid spilling. Also read Fire Or
Explosion Hazard, above, and Fueling on page 11.
NEVER operate the engine in a closed building unless the engine exhaust is piped outside. The exhaust contains carbon
monoxide, a poisonous, odorless and invisible gas which can
cause serious illness and even death of inhaled.
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards – particularly the
General Standards, Part 1910, and the Construction Standards, Part 1926 – should be consulted.
307-847
5
Avertissement
La pulvérisation à haute pression peut causer des blessures très graves.
Réservé exclusivement à l’usage professionnel. Observer toutes les consignes de sécurité.
Bien lire et bien comprendre tous les manuels d’instructions avant d’utiliser le matériel.
RISQUES D’INJECTION
Consignes générales de sécurité
Cet appareil produit un fluide à très haute pression. Le fluide pulvérisé par le pistolet ou le fluide sous pression provenant de fuites ou de ruptures peut pénétrer sou la peau ou à l’intérieur du
corps et entraîner des blessures très graves, voir même une amputation. Même sans être sous pression, le fluide éclaboussant ou
entrant dans les yeux peut aussi entraîner des blessures graves.
Ne jamais pointer le pistolet vers quelqu’un ou vers une partie
quelconque du corps. Ne jamais mettre le main ou les doigts
sur l’ajutage du pulvérisateur. Ne jamais essayer de “refouler”
la peinture. Cet appareil N’est PAS un compresseur pneumatique.
TOUJOURS garder la protection de l’ajutage en place sure le
pistolet pendant la pulvérisation.
TOUJOURS observer la Marche à Suivre Pour Détendre la
Pression donnée plus loin, avant de nettoyer ou d’enlever l’ajutage du pulvérisateur, ou d’effectuer un travail quelconque sur
une partie de l’appareil.
NE JAMAIS essayer d’arrêter ou de dévier le fuites avec la main
ou le corps.
Avant chaque utilisation, bien s’assurer que les dispositifs de
sécurité fonctionnent correctement.
Soins médicaux
En cas de pénétration de fluide sous la peau: DEMANDER IMMEDIATEMENT DES SOINS MÉDICAUX D’URGENCE. Ne
pas soigner cette blessure comme une simple coupure.
Avis au médecin: La pénétration des fluides sous la peau est
un traumatisme. Il est important de traiter chirurgicalement
cette blessure immédiatement. Ne pas retarder le traitement
pour effectuer des recherches sur la toxicité. Certains revêtements exotiques sont dangereusement toxiques quand ils sont
injectés directement dans le sang. Il est souhaitable de consulter un chirurgien esthétiques ou un chirurgien spécialisé dans
la reconstruction des mains.
Dispositifs de sécurité du pistolet
Avant chaque utilisation, bien s’assure que tous les dispositifs
de sécurité du pistolet fonctionnent correctement. Ne pas enlever ni modifier une partie quelconque du pistolet; ceci risquerait
d’entraîner un mauvais fonctionnement et des blessures graves.
Verrou de sécurité
A chaque fois que l’on s’arrête de pulvériser , même s’il s’agit
d’un court instant, toujours mettre le verrou de sécurité du pistolet sur la position, “fermée” ou “sécurité” (“safe”), pour empêcher
le pistolet de fonctionner. Si le verrou de sécurité n’est pas mis,
le pistolet peut se déclencher accidentellement.
Diffuseur
Le diffuseur du pistolet sert à diviser le jet et à réduire les risques
d’injection accidentelle quand l’ajutage n’est pas en place. Vérifier le fonctionnement du diffuseur régulièrement. Pour cette vérification, détendre la pression en observant la Marche à Suivre
Pour Détendre la Pression donnée plus loin enlever l’ajutage du
pulvérisateur. Pointer le pistolet dans un seau en métal, en le
maintenant fermement contre le seau. Puis, en utilisant la pression la plus faible possible, appuyer sur la gâchette du pistolet.
Si le fluide projeté n’est pas diffusé sous forme de jet irrégulier,
remplacer immédiatement le diffuseur.
Protection de l’ajutage
TOUJOURS maintenir la protection de l’ajutage en place sur le
pistolet du pulvérisateur pendant la pulvérisation. La protection
de l’ajutage attire l’attention sur les risques d’injection let contribue à réduire, mai n’évite pas le risque, que les doigts ou une
partie quelconque du corps ne passent accidentellement à
proximité immédiate de l’ajutage du pulvérisateur.
Consignes de sécurité concernant l’ajutage
du pulvérisateur
Faire extrêmement attention à l’occasion du nettoyage ou due
remplacement des ajutages du pulvérisateur . Si l’ajutage se
bouche pendent la pulvérisation, mettre immédiatement le verrou de sécurité du pistolet. TOUJOURS bien observe la Marche
à Suivre Pour Détendre la Pression puis enlever l’ajutage du
pulvérisateur pour le nettoyer.
NE JAMAIS essuyer ce qui s’est accumulé autour de l’ajutage
du pulvérisateur avant que la pression ne soit complètement
tombée et que le verrou de sécurité du pistolet ne soit engagé.
Pour réduire les risques de blessures graves, y compris les blessures par projection de fluide ou celles causées par de éclaboussures dans les yeux ou sur la peau, par des pièces en mouvement, toujours bien observe cette marche à suivre chaque
fois que l’on arrête le pulvérisateur, à l’occasion de la vérification,
du Égale ou du nettoyage du système ou lors du changement
des ajutages.
4 Désengager le verrou de sécurité du pistolet. Tout en maintenant une partie métallique du pistolet fermement appuyé
contre le côte d’un seau en métal, actionner le pistolet pour
libérer la pression.
5 Engager le verrou de sécurité du pistolet.
6 Ouvrir la soupape de sécurité et la laisser ouverte jusqu’à ce
que l’on soit prêt à se servir de nouveau du pulvérisateur.
7 Débrancher le fil de la bougie.
Si l’on soupconne que le tuyau ou l’ajutage est complètement
bouché ou que la pression n’a pas été complètement libérée
après avoir procédé aux opérations ci–dessus, desserrer Tres
lentement un raccord de bout de tuyau ou l’écrou de retenue de
la protection de l’ajutage et libérer progressivement la pression.
MARCHE A SUIVRE POUR DÉTENDRE LA PRESSION
1. Engager le verrou de sécurité du pistolet.
2 Mettre le levier d’arrêt du moteur sur ARRET (OFF).
3 Basculer l’interrupteur de commande de pression sur ARRET (OFF).
1,5
6
307-847
2
3
4
6
0139
RISQUES EN CAS DE MAUVAISE UTILISATION DU MATERIAL
Consignes générales de sécurité
Toute utilisation anormale de l’appareil du pulvérisation ou des
accessoires comme, par exemple, la mise sous une pression
excessive, les modifications de pièces, l’utilisation de produits
chimiques et de matières incompatibles et l’utilisation de pièces
usées ou abîmées peut causer des dégâts à l’appareil ou des
ruptures de pièces et entraîner une injection de liquide ou d‘autres blessures sérieuses, un incendie, une explosion ou d’autres dégâts.
Tous les tuyaux flexibles doivent avoir des ressorts spirale de
protection aux 2 bouts! Les spirales de protection contribuent
à éviter la formation de pliures, de boucles ou de nœuds sur les
tuyaux qui pourraient entraîner la rupture du tuyau à l’endroit du
raccord ou à son voisinage.
Serrer fermement tous les raccords avant chaque utilisation. Le
fluide sous pression peut faire sauter un raccord desserré ou
produire un jet à haute pression s’échappant par le raccord.
Toujours porter une protection pour les yeux, de gants, des vêtements protecteur et un dispositif pour la respiration correspondant
aux recommandations des fabricants de fluides et solvants.
NE JAMAIS utiliser un tuyau endommagé. NE PAS essayer de
refaire le raccord d’un tuyau haute pression ni de réparer le
tuyau avec du ruban adhésif ou par tout autre moyen. Un tuyau
réparé ne peut pas résister au fluide sous pression.
Pression
Ce pulvérisateur peut produire une PRESSION MAXIMUM DE
TRAVAIL 210 bar (3000 lb/po. @) S’assurer que tous les éléments du pulvérisateur et ses accessoires sont conçus pour résister à la pression maximum de travail de ce pulvérisateur. NE
PAS dépasser la pression maximum de travail d’aucun des éléments ou accessoires utilisés avec cet appareil.
Manipuler les tuyaux avec precaution et choisir soigneusement
leur chemin. Ne pas déplacer le fluide en tirant sur le tuyau. Ne
pas utiliser de fluides ou de solvants que ne sont pas compatibles avec l’enveloppe intérieur ou extérieure de tuyau. NE PAS
exposer le tuyau à fluides des températures supérieures à 82_C
(180_F) ou inférieures à –40_C (–40_F).
Compatibilité chimique des corps
BIEN S’ASSURER que tous les corps des solvants utilisés sont
chimiquement compatibles avec les parties mouillées indiquées
dans les “Données techniques”, à page 43. Toujours lire soigneusement les documents et brochures du fabricant des fluides et solvants utilisés avant de s’en servir dans ce pulvérisateur.
Le fluide à haute pression circulant dans les tuyaux peut être
très dangereux. En cas de fuite sur le tuyau, de fissure, déchirure ou rupture à la suite de l’usure, de dégâts ou d’une mauvaise
utilisation, les projections de fluide haute pression qui en proviennent peuvent entraîner des blessures graves par pénétration sous la peau ou par contact, ainsi que des dégâts matériels.
Continuité de la mise à la terre des tuyaux
Une bonne continuité de la mise à la terre des tuyaux est essentielle pour maintenir la mise à la terre de l’ensemble de vaporisation. Vérifiez la résistance électrique de vos tuyaux à fluides et
à air, au moines une fois par semaine. Si votre tuyau ne comporte pas d’étiquette qui précise la résistance électrique maximum,
prenez contact avec le fournisseur de tuyaux ou la fabricant
pour avoir les limites de résistance maximum. Utilisez un mètre
de résistance de la gamme appropriée pour votre tuyau et vérifiez la résistance. Si celle–ci dépasse les limites recommandées, remplacez le tuyau immédiatement. Un tuyau sans mise
à la terre ou avec une mise à la terre incorrecte peut entraîner
des risques pour votre système. Lisez aussi LES RISQUES
D’INCENDIE OU D’EXPLOSION.
RISQUES D’INCENDIE OU D’EXPLOSION
De l’électricité statique est produite par le passage du fluide à
grande vitesse dans la pompe et dans les tuyaux. Si toutes les
pièces de l’appareil de pulvérisation ne sont pas convenablement reliées ou à la masse ou à la terre, des étincelles peuvent
se produire et l’appareil risques d’être dangereux. Des étincelles peuvent Également se produire à l’occasion du branchement ou du débranchement du cordon d’alimentation ou de l’utilisation d’un moteur à essence. Les étincelles sont suffisantes
pour allumer les vapeurs de solvants et le fluide pulvérisé, les
fines particules de poussière ainsi que d’autres substances inflammables, quand on pulvérisé à l’intérieur ou à l’extérieur, et
elles peuvent causer un incendie ou une explosion, ainsi que
des blessures graves et des dégâts matériels.
2 Pistolet:Réaliser la mise à la terre en le raccordant à une
tuyau flexible et à une pulvérisateur déjà convenablement
reliés à la terre.
S’il se produit des étincelles d’électricité statique, ou si vous ressentez la moindre décharge, ARRETEZ IMMEDIATEMENT LA
PULVERISATION. Vérifiez que le système avant que le problème soit identifié et corrigé.
6 Tous le seaux de solvant utilisés pour le rinçage: observer le
code ou les réglementations locales.
N’utiliser que des
seaux métallique conducteurs de l’électricité. Ne pas mettre
le seau sur une surface non conductrice comme sur du papier ou du carton car cela interromprait la continuité de la
mise à la terre.
Mise à la terre ou à la masse
Pour réduire les risques de production d’étincelles d’électricité
statique, le pulvérisateur et tous les équipement utilisés ou se
trouvant dans la zone de pulvérisation doivent être reliés à la
terre ou à la masse. Pour connaître le détail des instructions de
mise à la terre dans la région et le type particulier d’équipement,
CONSULTER le code ou les réglementations électriques locales. S’ASSURER que tous le équipements de pulvérisation suivants sont bien reliés à la terre:
3 Tuyaux flexibles: Afin d’assurer la continuité de la mise à la
terre, n’utiliser que des tuyaux comportant une mise à la terre
et ayant une longueur maximum combinée de 150 m (500
pieds). Se reporter également au paragraphe, “Continuité
du circuit de mis à la terre des tuyaux”.
4 Récipient d’alimentation: observer le code ou les réglementations locales.
5 Objets, matériel ou surfaces recevant la pulvérisation: observer le code ou les réglementations locales.
7 Pour conserver la continuité de la mise à la terre quand on
rincé le matériel ou quand on libère la pression, toujours
maintenir une partie métallique du pistolet fermement appuyée contre le côté d’un seau en métal puis appuyer sur la
détente du pistolet.
1 Pulvérisateur: Relier le file de masses et le collier (fourni) à
une bonne terre.
Mesures de Sécurité concernant le Rinçage
Pour réduire les risques de blessures par pénétration de la
peau et les risques dûs aux étincelles d’électricité statique ou
aux éclaboussures, observe la marche à suivre pour le rinçage
donnée à la page 15 de ce manuel.
NE JAMAIS remplir le réservoir de carburant quand le moteur
tourne ou quand il est chaud. Le carburant renversé sur une surface chaude peut s’enflammer et causer un incendie. T OUJOURS verse le carburant lentement pour éviter d’en renverser.
Lire RISQUES D’INCENDIE OU D’EXPLOSION.
NE JAMAIS faire tourner un moteur dans un bâtiment fermé à
moins que les gaz d’échappement ne soient dirigés au dehors.
Les gaz d’échappement contiennent de l’oxyde de carbone, un
gaz toxique, inodore et invisible qui peut entraîner des malaises
graves ou même la mort se l’on le respiré.
MESURES DE SECURITE CONCERNANT LES TUYAUX FLEXIBLES
ADVERTENCIA
EL ROCIADO a ALTA PRESIÓN PUEDE CAUSAR GRAVES LESIONES.
SOLO PARA USO PROFESIONAL. RESPETE LOS AVISOS DE ADVERTENCIA.
Lea y entienda todo el manual de instrucciónes antes de manejar el equipo.
PELIGRO DE INYECCION DE FLUIDO
Seguridad general
Este equipo general un fluido a una presión muy alta. El rociado
de la pistola, los escapes de fluido o roturas de los componentes pueden inyectar fluido en la piel y el cuerpo y causar lesiones extremadamente graves, incluyendo a veces la necesidad
de amputación. También, el fluido inyectado o salpicado en los
ojos puede causar graves daños.
NUNCA apuntar la pistola hacia alguien o alguna parte del cuerpo. NUNCA colocar la mano o los dedos encima de la boquilla.
NUNCA tratar de “hacer retornar la pintura”; este NO es un sistema de rociado de aire.
SIEMPRE tener colocado el protector de la boquilla en la pistola
mientras se está pulverizando.
SIEMPRE seguir el procedimiento de descarga de presión,
dado más abajo, antes de limpiar o sacar la boquilla o de dar
servicio a cualquier del sistema.
NUNCA tratar de parar o desviar los escapes con la mano o el
cuerpo.
Asegurar que todos los aparatos de seguridad del equipo están
funcionando bien antes de cada uso.
Tratamiento médico
Si pareciera que un poco de fluido penetró la piel, conseguir
TRATAMIENTO MEDICO DE URGENCIA DE INMEDIA TO.
NO TRATAR LA HERIDA COMO UN SIMPLE CORTE. Decir
al
médico exactamente cua fluido fue.
Aviso al médico: Si se llega a inyectar este fluido en la piel
se causa una lesión traumática. Es importante tratar quirúrgicamente la lesión a la brevedad posible. No demorar el
tratamiento para investigar la toxicidad. La toxicidad es algo
de sumar importancia en algunas pinturas exóticas cuando
se inyectan directamente al torrente sanguíneo. Sirá conveniente consultar a un especialista en cirugía plástica o reconstructiva de las manos.
Aparatos de seguridad de la pistola pulverizadora
Asegurar que todos los aparatos protectores de la pistola están
funcionando bien antes de cada uso. No sacar ni modificar ninguna pieza de la pistola pues podría causar el malfuncionamiento de la misma con las consiguientes lesiones personales.
Pestillo de seguridad
Cada vez que se deje de pulverizar, aunque sea por un breve
momento, siempre colocar el pestillo de seguridad en la posición “cerrada”, lo que deja la pistola inoperante. El no hacerlo
puede llevar al disparo imprevisto de la pistola.
Difusor
El difusor de la pistola dispersa el chorro pulverizado y reduce
el riesgo de inyección cuando no está instalada la boquilla. Revisar con regularidad el funcionamiento del difusor . Seguir el
procedimiento de descarga de presión, dado más abajo, y después sacar la boquilla. Apuntar la pistola a un balde metálico,
sosteniéndola bien firme contra él. Utilizando la presión más
bajo posible, disparar la pistola. Si el fluido emitido no sale disperso en un chorro irregular, reemplazar de inmediato el difusor.
Protector de la boquilla
SIEMPRE tener el protector de la boquilla colocado en la pistola
mientras se está pulverizando. Este protector llama la atención
contra el peligro de inyección y ayuda a reducir, pero no evita,
la colocación accidental de los dedos o cualquier otra parte del
cuerpo cerca de la boquilla.
Seguridad de la boquilla pulverizadora
Tener mucho cuidado al limpiar o cambiar las boquillas. Si llegara a obstruirse mientras está pulverizando, enganchar el pestillo de la pistola de inmediato. SIEMPRE seguir el procedimiento
de descarga de presión y después sacar la boquilla para limpiarla
NUNCA limpiar la acumulación de pintura alrededor de la boquilla antes de que se haya descargado por completo la presión
y el pestillo esté enganchado.
PROCEDIMIENTO DE DESCARGA DE PRESION
Para reducir el riesgo de sufrir graves lesiones corporales, incluyendo la inyección de fluidos, salpicaduras en los ojos o la
piel, o lesiones causadas por piezas en movimiento, siempre
seguir este procedimiento al apagar la máquina pulverizadora,
al revisar, ajustar o limpiar el sistema, o al cambiar las boquillas.
1 Enganchar el pestillo de seguridad de la pistola.
2 Mover el interruptor de parada del motor a OFF.
3 Mover el interruptor de control de presión a OFF.
4 Desenganchar el pestillo de seguridad de la pistola. Mantener una parte metálica de la pistola firmemente contra el lado
de un balde de metal y activar la pistola para descargar la
presión.
1,5
2
3
5 Volver a enganchar el pestillo de seguridad de la pistola.
6 Abrir la válvula de alivio de presión y dejarla abierta hasta
que se esté nuevamente listo para pulverizar.
7 Desconectar el cable de la bujía.
Si se sospecha que la boquilla o la manguera esté completamente obstruida, o que no se ha descargado por completo la
presión después de haber seguido el procedimiento anterior,
aflojar MUY LENTAMENTE un adaptador de extremo de la
manguera o la tuerca de renención del protector de lay punta
y descargar gradualmente la presión.
4
6
0139
PELIGRO POR MAL USO DEL EQUIPO
Seguridad general
Cualquier mal uso del equipo pulverizador o los accesorios, tal
como sobre presurización, modificación de piezas, uso de materiales y productos químicos incompatibles, o utilización de
piezas dañadas o desgastadas, puede hacen que se rompan
y causen la inyección de fluido u otras lesiones corporales graves, incendio, explosión o daños a la propiedad.
Siempre usar gafas, guantes, vestimentas protectoras y un respiradero, tal como recomiendan los fabricantes del fluido y del
solvente.
Presión del sistema
Esta pulverizadora puede desarrollar 210 barías (3000 psi) de
PRESION DE TRABAJO MAXIMA. Asegurar que todo el equipo pulverizador y sus accesorios tienen la capacidad para
aguantar la presión máxima de trabajo de ningún componente
o accesorio de este sistema.
Compatibilidad de fluido
Siempre leer las instrucciones del fabricante del fluido y solvente antes de usarlos en esta pulverizadora en la página 43.
SEGURIDAD EN EL USO DE LAS MANGUERAS
El fluido que escapa a alta presión por las mangueras puede
ser muy peligroso. Si en la manguera se desarrola un escape,
una rotura o rajadura debido a cualquier tipo de desgaste, daño
o maltrato, el chorro a alta presión emitido por allí puede causar
una lesión por inyección u otras lesiones corporales graves o
daños a la propiedad.
¡Todas las mangueras para fluidos tienen que tener guardas de
resorte en ambos extremos! Estas protegen las mangueras
contra dobleces o retorceduras en los acoplamientos o cerca
de ellos, los que podrían traducirse en roturas de la manguera.
Antes de usarlas, APRETAR bien firmes todas las conexiones.
El fluido a lata presión puede desalojar un acoplamiento suelto
o dejar que pro él escape un chorro a alta presión.
NUNCA usar una manguera que está dañada. Siempre revisarla en busca de cortaduras, escapes, abrasión, cubierta abultada, o acoplamientos sueltos o dañados. Si llegara a encontrarse cualquiera de estas condiciones, reemplazar de inmediato
la manguera. NO intentar reacoplar una manguera de alta presión o enmendarla con cinta adhesiva u otro material similar .
Una manguera que ha sido remendada no aguante el fluido al
alta presión.
Manejar y pasar cuidadosamente las mangueras. No tirar de
las mangueras para mover el equipo. No usar fluidos o solventes que sean incompatibles con el tubo interno y la cubierta de
la manguera. NO exponer las mangueras a temperaturas sobre
82) C (180_F) o bajo -40_C (-40_ F).
Continuidad del circuito de puesta a tierra de la
manguera
La continuidad del circuito de puesta a tierra apropiado es esencial
para mantener conectado a tierra el sistema pulverizador. Es indispensable revisar la resistencia eléctrica máxima de las mangueras
de aire y de fluido por lo menos una vez a la semana. Si la manguera no tiene una etiqueta en la cual se especifica la resistencia
eléctrica máximum, ponerse en contacto con el proveedor o fabricante de la manguera para la información sobre los límites de resistencia. Usar un metro de resistencia en la gama apropiada para
comprobar la resistencia; si excede los lites recomendados, reemplazarla de inmediato. Es muy arriesgado tener una manguera sin
puesta a tierra o con la puesta a tierra en malas condiciones. Leer
también la información sobre RIESGO DE INCENDIO O EXPLOSION, más arriba.
PELIGRO DE INCENDIO O EXPLOSION
El flujo a alta velocidad del fluido al pasar por la bomba y manguera crea electricidad estática. Si todas las partes del equipo
pulverizador no tienen buena tierra, pueden ocurrir chispas,
convirtiéndo al sistema en algo peligroso. T ambién, pueden
producirse chispas al enchufar o desenchufar el cordón eléctrico o al usar un motor de gasolina. Estas chispas pueden inflamar los vapores de los solventes y el chorro de fluido pulverizado, partículas de polvo y otras sustancias inflamables, sea al
aire libre o bajo techo, lo que podría causar una explosión o incendio y graves lesiones corporales y daños a la propiedad.
Si ocurre una chispa de electricidad estática o incluso un ligero
choque eléctrico mientras se usa el equipo, DEJAR DE PULVERIZAR DE INMEDIATO. Revisar todo el sistema en busca de
una tierra apropiado. No usar de nuevo el sistema hasta haber
identificado y solucionado el problema.
Puesta a tierra
Para reducir el riesgo de chispas estáticas, conectar a tierra la
pulverizadora y todo el otro equipo de pulverizar que se use o
se encuentre en el lugar que se va a rociar. CONSULTAR el código eléctrico de la localidad para las instrucciones sobre las
conexiones a tierra exigidas para la zona y tipo de equipo. ASEGURAR de conectar a tierra todo este equipo pulverizador:
1 Pulverizadora: Conectar el alambre de tierra y la abrazadera
(suministrada) a una buena conexión a tierra.
2 Mangueras para fluidos: usar solamente mangueras con
puesta a tierra de una longitud combinada de 150 m (500
pies), para asegurar buena continuidad a tierra. Referirse
también al párrafo sobre continuidad a tierra de la manguera.
3 Pistola: hacer la puesta a tierra conectándola a una manguera de fluido y pulverizadora bien conectadas a tierra.
4 Suministrar un recipiente: de acuerdo al código local. Usar
solamente baldes de metal, que sean conductivos. No colocar el balde en una superficie no conductiva, como papel o
cartón, que interrumpe la continuidad a tierra.
5 Objeto que se está rociando: de conformidad con el código
local.
6 Todos los baldes de solvente usados durante el lavado, de
conformidad con el código local.
7 Para mantener la continuidad a tierra durante el lavado o
descarga de presión, siempre apoyar una parte metálica de
la pistola bien firme contra el costado de balde de metal, después apretar el gatillo.
Seguridad durante el lavado
Para reducir el riesgo de que se inyecte o salpique fluido en la
piel, o que ocurra una descarga de electricidad estática, siempre seguir las INSTRUCCIONES PARA EL LAVADO, dadas en
la página 15. Seguir el procedimiento de descarga de presión
en la página 8, y quitar la boquilla de metal y usar le presión más
baja posible de fluido durante el lavado.
PRECAUCIONES PARA LOS MOTORES DE GASOLINA
NUNCA llenar el tanque de combustible mientras el motor está
funcionando o caliente. El combustible derramado en una superficie caliente puede encenderse y provocar un incendio.
SIEMPRE verter el combustible lentamente para evitar derrames. Leer PELIGRO DE INCENDIO O EXPLOSION.
NUNCA hacer funcionar el motor en un edificio cerrado sin en–
caminar los gases de escape hacia el aire libre. Los gases de
escape contienen monóxido de carbono, un gas venenoso, sin
olor e invisible que podría causar enfermedades graves, incluso la muerte, al inhalarse.
307-847
9
Setup
1. Connect hose and gun. (Refer to Fig. 2.)
a. Remove the plastic cap plug from the filter outlet
nipple (57) and screw the 50 ft. (15.2 m) main
fluid hose (202) onto the nipple.
b. Connect the whip end hose (203) between the
main fluid hose and the gun (204) inlet adapter.
c.
DO NOT use thread sealant, and DO NOT install
the spray tip yet!
KEY
53 Pressure drain valve
56 Secondary hose cap
57 Outlet nipple
71 Pail hanger
202 Main hose
203 Whip end hose
204 “Contractor” gun with RAC IV
Dripless tip guard and 517
size SwitchTip
416 Wetcup
56
WARNING
If you are supplying your own hoses and spray gun,
be sure the hoses are electrically conductive, that the
gun has a tip guard, and that each part is rated for at
least 3000 psi (210 bar) Maximum Working Pressure.
This is to reduce the risk of serious injury caused by
static sparking, fluid injection or over-pressurization
and rupture of the hose or gun.
57
2. Two gun hookup. (Refer to Fig. 2.) Remove the cap
(56) from the secondary hose outlet and attach an
accessory hose and gun to the 1/4 npsm(m) nipple.
416
CAUTION
71
To avoid damaging the pressure control, which may
result in poor equipment performance and component damage, follow these precautions.
53
1. Always use nylon spray hose at least 50 ft.
(15.2 m) long.
2. Never use a wire braid hose; it is too rigid to act
as a pulsation dampener.
3. Never install any shutoff device between the filter
(51) and the main hose (202). See Fig. 2.
4. Always use the main filter outlet (57) for one gun
operation. Never plug this outlet.
3. Fill packing nut/wetcup. (See Fig. 2.) Fill the packing nut/wetcup (416) 1/3 full with Graco Throat Seal
Liquid (TSL), supplied.
4. Check the engine oil level. Refer to the Honda engine manual, supplied. This is a summary of the information: Remove one of the oil fill plugs; the oil
should be almost overflowing. See Fig. 3. Add oil as
necessary.
Recommended lubrication oil: Use a high–quality ,
detergent oil, SAE 10W–40, classified “FOR SERVICE SE or SF”, for regular use and for breaking–in
a new engine.
10
307-847
204
202
204
Fig. 2
0140
Setup
5. Be sure your system is properly grounded before operating it. Read and follow the warning section, FIRE OR EXPLOSION HAZARD, on page 5.
M
L
6. Fill the gas tank. See the Fueling section, below.
7. Flush the pump to remove the lightweight oil which
was left in the pump to protect it from rust.
0015
P
a. Before using water–base paint, flush with mineral spirits, followed by soapy water, and then flush
with clean water.
b. Before using oil–base paint, flush with mineral
spirits, only.
c.
See Flushing on page 15 for the flushing procedure.
8. Prepare the paint according to the manufacturer ’s
recommendations.
a. Remove any skin that may have formed.
b. Stir the paint to mix pigments.
c.
47
Strain the paint through a fine nylon mesh bag
(available at most paint dealers) to remove particles that could clog the filter or spray tip. This
is probably the most important step toward trouble–free spraying.
9. Keep the sprayer upright and level during operation and whenever it is being moved. See the last
CAUTION on page 12.
Fig. 3
Q
0141
Fueling
WARNING
Gasoline is extremely flammable and explosive under certain conditions.
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.
Do not overfill the tank. Make sure the gas fill cap is
securely closed after refueling.
Be careful not to spill fuel when fueling. Fuel vapor or
spilled fuel can ignite. If any fuel is spilled, make sure
the area is dry before starting the engine.
1. Fuel specifications. Use automotive gasoline with
a pump octane number [(R + M)/2] of 86 or higher ,
or a research octane number of 91 or higher
.
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 containing alcohol. See the HONDA engine manual for more information.
3. General. Do not use oil and gasoline mixtures or
contaminated gasoline. A void getting dirt, dust or
water in the fuel tank.
4. Tank Capacity. 0.95 gallons (3.6 liter). Always leave
at least 1/2 in. at the top of the tank for expansion.
5. Shut off the engine before refueling.
6. After refueling, tighten the fuel tank cap firmly.
307-847
11
Startup
Before you start the sprayer
f.
1. See Flushing on page 15 to determine if you should
flush the sprayer.
Open the choke as soon as the engine starts, except in cold weather. In cold weather, leave the
choke closed for 10 to 30 seconds before opening it to keep the engine running.
2. Be sure the gas tank is full.
7. Disengage the trigger safety latch (N).
3. Check the engine oil level.
8. To start the pump:
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. Be sure the spark plug cable (G) is firmly pushed
onto the plug.
Startup
NOTE: Refer to Fig. 4 as you start the sprayer.
1. When starting a sprayer that IS NOT PRIMED, remove the spray tip.
2. If a secondary hose and gun is not installed, be
sure the cap (56) is securely plugging the secondary
outlet fitting.
3. Place the suction tube into the paint, water or
solvent container, depending on whether you are
flushing or are ready to spray.
4. Open the black fuel shutoff lever (H) by pushing
it in the direction of the arrow.
CAUTION
Never try to start the engine unless fluid pressure is
relieved and the pressure control switch (A) is OFF.
Trying to start the engine when it is pressurized could
damage the recoil system.
5. Turn the pressure control switch (A) to OFF.
6. To start the engine:
a. Turn the pressure adjusting knob (B) fully counterclockwise to the lowest pressure setting.
b. Slide the metal throttle lever (K) away from the
fuel tank to maximum position (fully left).
c.
If the engine is cold, close the choke by moving
the gray lever (J).
If the engine is warm, close the choke by moving
the gray lever only half way or not at all.
a. Open the pressure drain valve (53).
b. Turn the pressure control switch (A) to ON.
c.
Turn the pressure control knob (B) about 1/4 turn
from minimum pressure. Run the pump until fluid
is flowing smoothly from the pressure drain
valve, indicating the pump is fully primed.
d. Close the pressure drain valve (53). Hold a metal
part of the gun firmly against a grounded metal
pail and squeeze the trigger until fluid flows from
the gun.
e. Release the trigger . Engage the trigger safety
latch (N).
9. If you have not primed the sprayer with paint yet,
move the suction tube to the paint container. Release
the trigger safety latch. Trigger the gun into the water/solvent pail just until paint appears. Release the
trigger and engage the trigger safety latch. Repeat
for the second gun if two guns are used.
WARNING
To reduce the risk of serious injury from fluid injection,
NEVER operate the spray gun with the tip guard removed.
10. Install the spray tip in the gun. See the separate
tip instruction manual, 307–848, supplied.
11. Adjust the engine speed and pump pressure. Release the trigger safety latch (N). Trigger the gun onto
test paper to check the spray pattern and atomization. Turn the pressure adjusting knob (B) until you
get a good pattern. Then slowly lower the throttle (K)
setting as far as you can without changing the spray
pattern.
CAUTION
Always use the lowest needed fluid pressure and the
lowest needed throttle setting, to increase the life of
the sprayer. Higher settings cause excessive clutch
cycling and premature tip and pump wear.
d. Turn the engine switch (L) to ON.
WARNING
A rope which recoils too quickly may hit someone and
cause serious injury. The rope could also jam in recoil
assembly.
e. 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 return the rope until the engine starts.
12
307-847
CAUTION
Close the black fuel shutof f lever (H) whenever you
are transporting the sprayer to prevent fuel from
flooding the engine.
Keep the sprayer upright and level when operating it
and when transporting it. This prevents crankcase oil
from leaking into the combustion chamber , which
makes startup very difficult.
A
B
C
M
D
0138
L
0015
4
K
J
51
0016
H
56
47
G
F
0136
E
28
202
53
KEY
A
Pressure Control ON/OFF
switch
B
Pressure adjusting knob
C
Air cleaner
D
Fuel Tank
E
Muffler
F
Engine
G Spark plug cable
H
Fuel shutoff lever
J
Choke
K
Throttle
L
Engine ON/OFF switch
M Engine oil light
N
Trigger safety latch
(shown engaged)
4
Clutch
28 Displacement pump
47 Grounding wire and clamp
51 Fluid filter
53 Pressure drain valve
56 Secondary hose outlet cap
202 Main hose
203 Whip end hose
204 “Contractor” gun with RAC
IV Dripless tip guard and
517 size SwitchTip
203
204
N
0137
Fig. 4
307-847
13
Maintenance
WARNING
CAUTION
To reduce the risk of serious injury, including fluid injection or splashing in the eyes or on the skin, or injury
from moving parts, always follow the Pressure Relief Procedure W arning, below , before checking,
adjusting, cleaning or shutting down the sprayer. Disconnect the spark plug!
For detailed engine maintenance and specifications,
refer to the separate engine manual, supplied.
DAILY: Check the engine oil level and fill as necessary.
WEEKLY: Check the level of the TSL in the displacement pump packing nut. Fill the nut, if necessary . Keep
TSL in the nut to help lubricate the pump packings.
DAILY: Check and fill the gas tank.
AFTER THE FIRST 20 HOURS OF OPERATION
Drain the oil and refill with clean oil.
WEEKLY: Remove the cover of the air filter and clean
the element. Replace the element, if necessary. If operating in an unusually dusty environment, check the filter
daily and replace it, if necessary.
Replacement elements can be purchased from your local
HONDA dealer.
AFTER EACH 100 HOURS OF OPERATION:
Change the oil.
SPARK PLUG: Use only an (NGK) BP6ES or BPR6ES
plug. Gap the plug to 0.025 to 0.030 in. (0.7 to 0.8 mm).
Use a spark plug wrench when installing and removing
the plug.
WARNING
Pressure Relief Procedure
To reduce the risk of serious injury, including fluid injection, splashing fluid or solvent in the eyes or on the skin,
or injury from moving parts or electric shock, always follow this procedure whenever you shut of f the sprayer,
when checking or servicing any part of the spray system, when installing, cleaning or changing spray tips,
and whenever you stop spraying.
1. Engage the trigger safety latch.
2. Turn the engine ON/OFF switch to OFF.
3. Turn the pressure control switch to OFF.
1,5
14
307-847
2
4. Disengage the trigger safety latch. Hold a metal part
of the gun firmly to the side of a grounded metal pail,
and trigger the gun to relieve pressure.
5. Engage the trigger safety latch.
6. Open the pressure drain valve. Leave the valve
open until you are ready to spray again.
7. Disconnect the spark plug cable.
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
the tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now
clear the tip or hose.
3
4
6
0139
Flushing
When to Flush
WARNING
1. New Sprayer. This unit was factory tested in lightweight oil, which was left in to protect the pump.
Before using water–base paint, flush with mineral
spirits, followed by a soapy water flush, and then a
clean water flush.
To reduce the risk of static sparking and splashing
when flushing, always remove the spray tip from the
gun, and hold a metal part of the gun firmly to the side
of, and aimed into, a grounded metal pail .
Before using oil–base paint, flush with mineral spirits.
2. Changing Colors. Flush with a compatible solvent
such as mineral spirits or water.
3. Changing from water–base to oil–base paint. Flush
with warm, soapy water, then mineral spirits.
4. Changing from oil–base to water–base paint. Flush
with mineral spirits, followed by warm, soapy water,
and then a clean water flush.
CAUTION
NEVER leave water in the sprayer if there is the
slightest chance it could freeze. Push the water out
with mineral spirits. Water frozen in the pressure control tube prevents the sprayer from being started, and
causes serious damage to the pressure control.
5. Storage.
Water base paint: flush with water, then mineral spirits and leave the pump, hose and gun filled with mineral spirits. Shut of f the sprayer, remove the spark
plug cable, and open the pressure drain valve to relieve pressure. Leave the drain valve open.
Oil base paint: flush with mineral spirits and leave the
pump, hose and gun filled with mineral spirits. Shut
off the sprayer , remove the spark plug cable, and
open the pressure drain valve to relieve pressure.
Leave the drain valve open.
6. Startup after storage.
Before using water–base paint , flush out mineral
spirits with soapy water, and then with clean water.
When using oil–based paint, flush out the mineral
spirits with the paint to be sprayed.
Maintain firm
metal-to-metal
contact when
flushing
6. Follow Startup on page 12. Keep the gun triggered
until clean solvent comes from the nozzle. Release
the trigger and engage the trigger safety latch.
NOTE: For two guns, release the trigger safety latch on
the second gun and trigger that gun until clean solvent
comes from the nozzle. Flush the first gun and then the
second gun at least one more time.
7. Check all fluid connections for leaks. Relieve pressure before tightening any connections. Start the
sprayer. Recheck the connections for leaks.
8. Remove the suction tube from the solvent pail. Disengage the trigger safety latch. T rigger the gun to
force solvent from the hose. Do not let the pump run
dry for more than 30 seconds, to avoid damaging the
pump packings. Relieve pressure.
9. Remove the strainer, suction tube and suction hose
and clean them separately to be sure all paint sediment is removed. Dried paint can build up in these
parts and later cause performance problems.
10. Unscrew the filter bowl and reinstall the clean
screen. Reinstall the bowl, hand tight only.
11. Follow Storage or Changing Colors, to the left. Relieve pressure.
R
How to Flush
NOTE: “Solvent” refers to water or oil-based solvent.
S
1. Relieve pressure. See page 14.
2. Remove the filter bowl (R) and screen (S); see instruction manual 307–273, supplied. Install the bowl
and support (T), without the screen, to flush. Clean
the screen separately. See Fig. 5.
T
3. Close the pressure drain valve (53).
4. Put the suction tube in a grounded pail of solvent.
5. Remove the spray tip from the gun(s).
Fig. 5
53
0142
Troubleshooting Guide
WARNING
Pressure Relief Procedure
To reduce the risk of serious injury, including fluid injection, splashing in the eyes or on the skin, or injury from
moving parts, always follow this procedure when you
shut off the sprayer, when checking, adjusting or cleaning the system, and when changing spray tips.
1. Engage the trigger safety latch.
2. Turn the engine ON/OFF switch to OFF.
3. Turn the pressure control switch to OFF.
4. Disengage the trigger safety latch. Hold a metal
part of the gun firmly to the side of a grounded
metal pail, and trigger the gun.
5. Engage the trigger safety latch.
6. Open the fluid pressure drain valve and leave it
open until you start the sprayer again.
7. Disconnect the spark plug.
If you suspect the hose or spray tip is
completely
clogged or that pressure is not fully relieved after following the steps above, VERY SLOWLY loosen the tip
guard or hose end coupling to relieve pressure gradually. Now clear the tip or hose obstruction.
Check everything in the chart before disassembling the sprayer.
PROBLEM
CAUSE
SOLUTION
Engine/sprayer won’t start
Engine switch not on
Turn on.
Out of gas
Replenish
Engine oil level low
Try starting engine. If light on rear of engine glows, replenish oil.
Spark plug cable disconnected or
spark plug damaged
Connect cable on top of engine or replace
spark plug.
Water frozen in pressure control
Return pressure control to authorized
Graco dealer for repair.
Oil seepage into combustion
chamber
Remove spark plug. Pull starter rope 3 or
4 times. Clean or replace plug. Try to
start. Keep sprayer upright to avoid oil
seepage.
Engine won’t “pull over”
Engine operates, but displace- Pressure control switch turned OFF
ment pump doesn’t
Turn on.
Pressure setting too low
Increase pressure.
Displacement pump outlet filter dirty
Clean filter.
Tip or tip filter clogged
Clean tip or tip filter.
Displacement pump rod seized by
dry paint
Service pump. See page .
Connecting rod worn or damaged
Replace. See page 18.
Drive housing worn or damaged
Replace. See page 19.
Electrical power not energizing field
Check wiring connections. See Fig. 13,
page 23.
With pressure control switch ON and
pressure turned to MAXIMUM, use a test
light to check for power at black and white
wires from pressure control.
Have pressure control checked by authorized Graco dealer.
Clutch worn or damaged
Service. See page 22.
Pinion assembly worn or damaged
Service. See page 20.
PROBLEM
CAUSE
SOLUTION
Displacement pump output
low on upstroke
Pump inlet screen clogged
Clean.
Piston ball check not seating
Service piston ball check. See page 31.
Piston packings worn or damaged
Replace packings. See page 31.
Sleeve gasket in displacement
pump worn or damaged
Replace. See page 31.
Pump inlet screen clogged
Clean.
Piston packings worn or damaged
Replace packings. See page 31.
Intake valve ball check not seating
properly
Clean and service. See page 31.
Engine RPM too low
Increase throttle setting. See Startup,
Step 11, page 12.
Clutch worn or damaged
Replace. See page 22.
Loose wet–cup
Tighten just enough to stop leakage.
Throat packings worn or damaged
Replace packings. See page 31.
Displacement rod worn or damaged
Replace rod. See page 31.
Pump inlet screen clogged.
Clean.
Pressure setting too low
Increase pressure. See Startup,
Step 11, page 12.
Engine RPM too low
Increase throttle setting. See Startup,
Step 11, page 12.
Dirty outlet filter, tip filter or tip
Clean.
Large pressure drop in hose
Use larger diameter hose.
Air in fluid pump or hose
Check for loose connections at pump intake and tighten. Then prime the pump.
See page 12.
Tip partially clogged
Clear.
Fluid supply is low or empty
Refill and prime the pump. See Startup,
page 12. Check fluid supply often to prevent running the pump dry.
Air leak
Check all hose connections and tighten as
needed.
Reduce RPM and cycle pump as slowly
as possible during priming.
Intake valve is leaking
Shut off pump and relieve pressure. Disassemble and clean intake valve. Be sure
ball seat is not nicked or worn and that the
ball seats well. Reassemble.
Worn packings
Repack the pump. See page 31.
Fluid is too thick
Thin fluid according to supplier’s
recommendations.
Displacement pump output
low on downstroke or both
strokes
Paint leaks into wet–cup
Low fluid delivery
Spitting from gun
Pump is difficult to prime
307-847
17
Bearing Housing & Connecting Rod
WARNING
CAUTION
To reduce the risk of serious injury, including fluid injection always follow the Pressure Relief Procedure
Warning on page 14 before checking, adjusting,
cleaning or shutting of f the sprayer. Disconnect the
spark plug!
DO NOT use the bearing housing screw (73) to align
or seat the bearing housing with the drive housing.
These parts must be aligned using the locating pins
(F), to help avoid premature bearing wear.
NOTE: Steps 1 to 13 refer to Fig. 6.
1. Remove the front cover and screws (23,68).
13. Install the screws (73) and lockwashers (74) on the
bearing housing. T ighten evenly to 300 in–lb (34
N.m).
14. Refer to Installing the Pump on page 31.
2. For upright models only: Remove the spring clips
(112, 114) and the drain hose (1 13). Unscrew the
suction tube (30) from the pump, holding a wrench on
the pump intake valve (B) to keep the pump from
loosening.
20
D
3. Disconnect the pump outlet hose (59) from the displacement pump outlet nipple (92).
73
74
C
E
A
22
4. Use a screwdriver to push aside the retaining spring
(26) at the top of the pump. Push the pin (25) out the
rear.
5. Loosen the jam nut (27) with an adjustable wrench.
Unscrew and remove the displacement pump.
F
6. Use a hex key wrench to remove the four screws (73)
and lockwashers (74) from the bearing housing (21).
21
26
7. While pulling the connecting rod (22) with one hand,
lightly tap the lower rear of the bearing housing (21)
with a plastic mallet to loosen it from the drive housing (20). Pull the bearing housing and the connecting
rod assembly (22) off the drive housing.
25
23
68
8. Inspect the crank (A) for excessive wear and replace
parts as needed.
9. Evenly lubricate the inside of the bronze bearing (C)
in the bearing housing (21), and the inside of the connecting rod link (D), with high–quality motor oil. Liberally pack the roller bearing (E) in the connecting rod
assembly (22) with bearing grease.
307-847
92
B
113
11. Clean the mating surfaces of the bearing and drive
housings.
18
27
112
10. Assemble the connecting rod (22) and bearing housing (21).
12. Align the connecting rod with the crank (A) and carefully align the locating pins (F) in the drive housing
(20) with the holes in the bearing housing (21). Push
the bearing housing onto the drive housing or tap it
into place with a plastic mallet.
Torque to
300 in–lb
(34 N.m)
59
30
114
Fig. 6
0149
Drive Housing
WARNING
CAUTION
To reduce the risk of serious injury, including fluid injection always follow the Pressure Relief Procedure
Warning on page 14 before checking, adjusting,
cleaning or shutting of f the sprayer. Disconnect the
spark plug!
DO NOT drop the gear cluster (18) when removing
the drive housing (20). The gear cluster is easily damaged. The gear may stay engaged in the drive housing or pinion housing.
NOTE: Refer to Fig. 7 for this procedure.
1. Remove the front cover and screws (23,68).
2. Disconnect the pump outlet hose from the displacement pump nipple. For the upright carts only, remove
the spring clips (112, 114) and the drain hose (113)
from the pump.
3. Remove the four screws (73) and lockwashers (74)
from the bearing housing (20).
4. Lightly tap the back of the bearing housing (21) with
a plastic mallet. Pull the pump, bearing housing and
connecting rod away from the drive housing as one
assembly.
5. Remove the two screws (24) and lockwashers (11).
Remove the four screws (10) and lockwashers (11).
6. Lightly tap around the drive housing (20) to loosen
the drive housing. Pull the drive housing straight off
the pinion housing. Be prepared to support the gear
cluster (18), which may also come out.
20b
20a
DO NOT lose the thrust balls (20c or 19d) located at
each end of the gear cluster, or allow them to fall between the gears. The ball, which is heavily covered
with grease, usually stays in the shaft recesses, but
could be dislodged. If the balls are caught between
the gears and not removed, they will seriously damage the drive housing. If the balls are not in place, the
bearings will wear prematurely.
7. Liberally apply bearing grease to the gear cluster
(18). A tube of grease is supplied with each replacement gear cluster . Use a full 6 oz. (160 grams) of
grease. Be sure the thrust balls (20c and 19d) are in
place.
8. Place the bronze colored washer (20a) and then the
silver–colored washer (20b) on the shaft protruding
from the big bearing of the drive housing (20). Align
the gears and push the new drive housing straight
onto the pinion housing and locating pins (B).
9. Starting at Step 4, work backwards to reassemble
the sprayer. Or, move ahead to the next section in
this manual if further service is needed.
10
11
B
19
20
11
24
23
73
74
21
19d
68
20c
10
11
18
112
113
114
Fig. 7
0170
Pinion, Clutch, Clamp, Field & 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 19, and then continue with
the procedure below.
If starting from the clutch, see page 22.
Pinion
Pinion Housing
2. Pull the pinion housing away from the clutch housing.
The armature (4a) will come with it.
WARNING
To reduce the risk of serious injury, including fluid injection always follow the Pressure Relief Procedure
Warning on page 14 before checking, adjusting,
cleaning or shutting of f the sprayer. Disconnect the
spark plug!
NOTE: Refer to Fig. 8 for Steps 1 to 3.
1. Remove the two bottom screws (10) and lockwashers (11) first, and then remove the top three screws
(10) and lockwashers (11).
3. Pull the armature (4a) off the hub (19j – see Fig. 9)
of the pinion housing.
CAUTION
Do not lose the thrust ball (19d). Refer to the CAUTION on page 19 for more information.
NOTE: To disassemble the pinion, go to page 21. To disassemble more of the sprayer , go to page 22. T o reassemble the sprayer from this point, skip ahead to Reassembly, page 27, Step 7.
See page 21
2
11
10
4a
19
19d
11
10
0171
Fig. 8
Pinion Housing
1
Lubricate exterior
4
Press pinion assembly in here
2
Lubricate inner and outer diameters
5
Back of pinion housing (19a)
3
Lubricate teeth
19k
**Included in Repair Kit 221–032
19b
19a
CUTAWAY VIEW OF
PINION HOUSING (19a)
19m**
5
19j**
4
19h**
19g**
1
0041
19c
19f**
19d
19e
2
3
2
1
Fig. 9
0169
Repairing the Pinion
NOTE: Refer to Fig. 9 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.
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 (19j).
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. Remove the snap ring (19k) from the bearing recess
of the pinion housing (19a).
2. Push on the front of the shaft (19g**) to force the
bearing and hub assembly out of the housing (19a).
3. Push on the front of the shaft (19g) to force the bearing (19h) and hub (19j) assembly out of the housing.
3. Install the new shaft assembly into the pinion housing, pushing it to the shoulder of the housing (19a).
4. Install the rings (19k and 19m**).
5. Go to Reassembly, 27, Step 7, or continue on page
22.
5. Apply lubricant to the parts as shown in Fig. 9.
Placement of steel blocks when
pressing off large bearing (19h)
1
Round bar to push
on shaft (19g)
2
Hydraulic press
3
Two steel bars (
front bar not shown)
4
Two steel bars
5
Press platform
Fig. 10
2
19j
1
19h
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
5
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
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. 10.
3
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).
4
8. Install the snap ring (19k). Install the small ring
(19m).
0043
9. Go to Reassembly, 27, Step 7, or continue on page
22.
307-847
21
Clutch
NOTE: The clutch assembly (4) includes the armature
(4a) and rotor (4b). The armature and rotor must be replaced together so they wear evenly.
5. The armature (4a) was removed with the pinion
housing. Remove the armature from the pinion hub.
NOTE: If the pinion assembly (19) is not yet separated
from the clutch housing (2), follow Steps 1 to 4. Otherwise, start at Step 5.
6. There are two ways to remove the rotor (4b).
a. Remove the four socket head capscrews (16)
and lockwashers (11). Install two of the screws
in the threaded holes in the rotor . Alternately
tighten the screws until the rotor comes off. See
Fig. 11.
NOTE: Refer to Fig. 11 for this procedure.
1. Follow the Pressure Relief Procedure Warning on
page 14.
2. Disconnect the hose (59) from the displacement
pump. For the upright cart only , remove the spring
clips (112, 114) and drain hose (113).
b. You can use a standard steering wheel puller (A).
However, two 1/4–22– x 3 or 4 in. long screws (B)
are also needed. Replace the short screws of the
steering wheel puller with the longer screws (B).
Turn the screws (B) into the threaded holes of
the rotor (4b). T ighten the capscrew (C) of the
tool until the rotor comes off. See Fig. 11.
3. Remove the bottom two screws and lockwashers
(10, 11) from the front of the clutch housing (2) and
then the remaining three of them.
4. Tap lightly on the back of the bearing housing (21)
with a plastic mallet to loosen the assembly (D) from
the clutch housing. Pull the assembly away.
7. Skip ahead to Reassembly, page 27, Step 6, or continue on the next page.
2
4a
16
11
11
10
4b
D
1
Threaded holes
2
Pinion shaft located
in back
1
2
19
A
B
C
59
112
113
114
Fig. 11
Using a steering wheel
puller to remove rotor
Engine
NOTE: The engine must be removed before the Field,
Clamp and Clutch Housing can be removed.
1. Working under the mounting plate (A) of the cart, remove the screw (15), lockwasher (80) and washer
(99) which hold the clutch housing (2) to the cart. See
Fig. 13.
2. Still working under the mounting plate, remove the
two locknuts (111) and then pull the screws (14) out
of the base of the engine. Disconnect the red wire
from the engine lead (B). Disconnect the black and
white wires from the field. For the upright cart only ,
loosen the clamp (97). Pull the wires carefully
through the grommets (66) before removing the engine. See Fig. 12 and 13.
10
11
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 24 and 25.
5. Skip ahead to Reassembly, page 27, Step 5.
NOTE: All service to the engine must be performed by
an authorized HONDA dealer.
2
66
A
99
80
B
15
111
Fig. 12
62,9,61
66
1
To field
1
2
To engine
66
1
66
2
97
2
RED
97
WHITE
BLACK
66
RED
WHITE
BLACK
Fig. 13
View from under engine mounting
plate on upright cart
0154
View from under engine mounting
plate on lo-boy cart
0147
Field and Wiring Harness
NOTE: Refer to Fig. 14.
1. Remove the engine from the cart. See page 23.
2. Pull the plastic caps (B) of f the wire screws (98) in
both places on the field. Loosen the screws and release the wires (96).
3. Loosen the four setscrews (12) holding the field (6)
to the clutch housing (2).
4. Pull off the field.
5. Skip ahead to Reassembly, page 26, Step 4 or continue on page 25.
12
2
6
96
B
98
Fig. 14
0046
Clamp
NOTE: A standard steering wheel puller and two 1/4–28
x 3 or 4 in. long screws are required to remove the clamp.
NOTE: Refer to Fig. 15.
1. Loosen the two screws (16) on the clamp (3), working through the slot at the bottom of the clutch housing (2).
2. Install two screws (B) of the tool (A) in two of the
threaded holes in the clamp (3). T ighten the screw
(C) until the clamp comes off.
3. Skip ahead to Reassembly, page 26, Step 3, or continue to the right.
2
A
B
C
3
16
Fig. 15
0155
Clutch Housing
NOTE: Refer to Fig. 16.
1. Remove the four capscrews (8) and lockwashers (9)
which hold the clutch housing (2) to the engine.
2. Remove the capscrew (15), lockwasher (80) and
washer (99) from beneath the mounting plate (D).
9
3. Remove the engine key (13).
4. Pull off the clutch housing (2).
13
2
8
5. Skip ahead to Reassembly, page 26, Step 1.
D
99
80
15
Fig. 16
0156
Reassembly
1. Install the clutch housing (2) , capscrews (8) and
lockwashers (9) on the engine. See Fig. 17.
1
2. Install the engine shaft key (13). See Fig. 17.
3. Press the clamp (3) onto the engine shaft. Maintain
the 1.99 in. +/– 0.01 (50.55 mm) dimension shown in
Fig. 18.
To check the dimension, place a rigid, straight steel
bar (B) across the face of the clutch housing (2). Use
an accurate measuring device to measure the distance between the bar and the face of the clamp. Adjust the clamp as necessary. Torque the two screws
(16) to 120 in–lb (14 N.m).
4. Install the field (6) in the clutch housing (2). Working
through the slot in the clutch housing, connect the
wires of the harness (96) to the screws (98) in both
places on the field. Pull the plastic caps (C) up and
snap them over the screws. With the setscrew holes
in the field and the clutch housing (2) aligned, tighten
the setscrews (12) oppositely and evenly, to 27 in–lb
(3.2 N.m). See Fig. 17.
1
Torque oppositely
and evenly to
27 in–lb (3.2 N.m)
2
Slot
13
1
12
9
8
3
A
2
2
16
6
96
Fig. 17
98
0049
2
B
1
Face of housing
2
Torque to
120 in–lb
(14 N.m)
3
1.99” (50.55 mm)
Fig. 18
3
16
2
0050
Reassembly
5. Place the engine (1) assembly on the cart. Align the
mounting holes. Carefully guide the engine wire (D)
and wiring harness (96) from the field, through the
appropriate grommets (66) in the mounting plate (E).
Install the flange screws (14) and locknuts (1 11).
Torque to 15 ft–lb (20.4 N.m). Install the capscrew
(15), lockwasher (80) and washer (99) from under
the engine mounting plate to the clutch housing (2).
Connect the engine wire (D) to the red wire, and connect the black and white wires as shown in the Detail
drawing in Fig. 19.
friction between the rotor (4b) and the field (6). If
there is friction, loosen the setscrews (12) and reposition the field. Tighten the setscrews oppositely and
evenly to 27 in–lb (3.2 N.m).
Be sure the face of the armature (4a) is clean. Assemble the armature to the shaft in the pinion housing (19). A retaining ring located within the armature
makes it difficult to assemble these parts. Follow this
procedure for the best results. First, engage a few
splines of both parts. While they are engaged, use a
screwdriver to gently push the retaining ring into the
armature, and finish engaging the splines. Push the
armature onto the shaft until it contacts the ring
(19m). See Fig. 19.
6. Be sure the face of the rotor (4b) and the field is free
of all oil and contaminants. Remove any burrs on the
outside edge of the rotor. Install the rotor, lockwashers (11) and capscrews (16). Torque the capscrews
to 7 ft–lb (9.5 N.m). See Fig. 19.
7. Assemble the pinion housing (19) to the clutch
housing, using the capscrews (10) and lockwashers
(11). See Fig. 19.
After installing the rotor (4b), pull the engine recoil
rope to assure the engine turns freely, and there is no
1
1
Torque to 7 ft–lb 99.5 N.m)
2
Spline
3
Face must be clean
4
Torque to 15 ft–lb (20.4 N.m)
5
To field (ref. 96)
6
To engine (ref. D)
11
12
10
2
1
4b
11
16
4a
14
2
3
4
E
6
96
99
80
D
15
111
19
0157
View from under engine mounting plate on Lo–Boy cart
View from under engine mounting plate on upright cart
66
5
66
5
97
Ref 14,111
6
6
RED
WHITE
BLACK
WHITE
Fig. 19
BLACK
0147
RED
0146
Pressure Control Replacement
WARNING
2. Working under the engine mounting plate of the cart,
disconnect the red, black and white wires.
To reduce the risk of serious injury, including fluid injection always follow the Pressure Relief Procedure
Warning on page 14 before checking, adjusting,
cleaning or shutting of f the sprayer. Disconnect the
spark plug!
For the upright cart, remove the three nuts (61) and
lockwashers (9) from the capscrews (62). See Fig.
21.
1. Disconnect both hoses at the pressure control (63).
while holding the elbows (317 or 320) firmly. See the
CAUTION, below. Note the original location of each
hose to be sure you reassemble them correctly at the
end of this procedure. See Fig. 20.
For the lo-boy cart, remove the three screws (62) and
washers (9). See Fig. 21.
3. Remove the wire clamp (97). See Fig. 21. Remove
the pressure control.
CAUTION
DO NOT allow the elbow (317 or 320) to turn when
removing or connecting the hoses. T urning the elbows can damage the sensitive bourdon tube.
4. Remove the pressure control cover (76) and the
mounting bracket (67 or 107). See Fig. 20.
63
106
106
76
67
76
63
64
62
64
107
319
317
66
316
320
1
1
2
2
UPRIGHT CART
Fig. 20
66
1
To pump
2
To filter
9
62
LO-BOY CART
0144
1
To field
2
To engine
0145
66
97
1
2
2
1
WHITE
61,9,62
BLACK
66
RED
RED
97
Fig. 21
View from under engine mounting
plate on upright cart
0146
BLACK
WHITE
View from under engine mounting
plate on lo-boy cart
0147
Pressure Control Replacement
5. Disconnect the black, red and white wires from the
rectifier (307) and switch (302), which are sheathed
with the conductor (314). See Fig. 22.
10. For the upright carts, guide the new pressure control
wires through the wire clamps (97). Fasten the wireclamps to the cart with the same screws, lockwashers, and nuts (61, 9, 62) which hold the bracket
(76) to the cart. See Fig. 20.
6. Unscrew the connector (318 or 108) from the control
box, pulling the conductor and wires out with it.
11. For the lo-boy carts, guide the pressure control wires
through the single wire clamp (97), and install the
screws and washers (62, 9) to hold the bracket (107)
to the cart. See Fig. 20.
7. For the upright cart, remove the nipple (316) from the
elbow (317). See Fig. 22.
8. Use a wrench to hold the hex of the adapters (A)
while removing the elbows (317, or 320 and 319).
12. Perform the Pressure Control Adjustment on
page 30 before regular operation of the sprayer.
9. Reassemble in the reverse order.
For Upright cart sprayers
307
302
RED
RED
A
317
h
316
WHITE
BLACK
313
314
RED
GROUND
315,305
318
0151
Rectifier (307) connections
0148
For Lo-Boy cart sprayers
302
107
307
320
108
RED
0150
A
RED
315,305
BLACK
WHITE
Top view
319
Ref 320
313
RED
GROUND
Fig. 22
0165
Pressure Control Adjustment
WARNING
USE EXTREME CAUTION WHEN PERFORMING THIS CALIBRATION PROCEDURE to reduce the risk of a
fluid injection injury or other serious injury, which can result from component rupture, electric shock, fire, explosion or moving parts.
NEVER EXCEED 3000 psi (210 bar) MAXIMUM
This procedure sets the sprayer to 2600–3000 psi
WORKING PRESSURE. Normal operation of the
(182–210 bar) MAXIMUM WORKING PRESSURE.
sprayer at higher pressures could result in component
This procedure must be performed when the pressure
rupture,
fire or explosion.
control assembly is removed and reinstalled, or replaced, to be sure the sprayer is properly calibrated.
Improper calibration can cause the sprayer to over–
pressurize and result in component rupture, fire or explosion. It may also prevent the sprayer from obtaining
the maximum working pressure, resulting in poor
sprayer performance.
NEVER attempt to increase the fluid outlet pressure by
performing these calibrations in any other way
.
Service Tools Needed
NEW 50 foot (15.2 m), 3000 psi (210 bar), flexible nylon,
airless spray hose, p/n 223–541
0–5000 psi (0–350 bar) fluid–filled pressure gauge, p/n
102–814
NEW spray tip, size 0.025 to 0.029
3/8 in. ignition wrench or nut driver
5 gallon pail and water or mineral spirits
Swivel, p/n 156–823
Nipple, p/n 162–453
Tee, p/n 104–984
ALWAYS use a new 50 foot (15.2 m) spray hose, rated
for at least 3000 psi (210 bar) MAXIMUM WORKING
PRESSURE, when performing this procedure. A used,
under–rated hose could develop a high pressure leak
or rupture.
AVOID touching the wires in the pressure control assembly when the control box cover is removed, to reduce the risk of electric shock.
b. Slowly tighten the nut just until another click is
heard. STOP.
4. Replace the plug (326) and pressure control cover.
Connect to
fluid outlet
102–814
156–823
104–984
162–453
223–541
Set Up
1. Follow the Pressure Relief Procedure Warning on
page 14.
2. Set up the system as shown in Fig. 23.
Set the Dead Band (Pressure Differential)
NOTE: Do not alter this adjustment if the wheel is already set as shown in Fig. 24.
Fig. 23
0474
A
1. Remove the pressure control cover.
2. Set the white dif ferential wheel (A) on the microswitch. Turn the wheel so the letter F is concealed behind the switch and the letter A is the first letter seen.
Pressure Up
1. Start the sprayer and prime it.
2. Adjust the pressure to 2600 psi (180 bar).
Fig. 24
0475
A
3. Shut off the engine. If the pressure drops, replace
pump packings before proceeding. See page 31.
B
Adjust the Pressure
See Fig. 25.
1. Remove the pressure control plug (326).
2. Turn and hold the pressure control knob (B) at the
maximum pressure setting.
h
3. Engage the nut (C): insert the nut driver through the
pressure control hole, or use the ignition wrench from
the front of the pressure control.
a. Loosen the nut just until you hear a click. STOP.
C
Fig. 25
326
0151
Removing and Installing the Pump
WARNING
Installing the pump
To reduce the risk of serious injury, including fluid injection always follow the Pressure Relief Procedure
Warning on page 14 before checking, adjusting,
cleaning or shutting of f the sprayer. Disconnect the
spark plug!
Removing the pump
See Fig. 26.
1. Flush the pump. Relieve pressure. See page 14.
2. Hold the intake valve (423) with a wrench and unscrew the suction tube (30). Remove the hose (59).
For upright carts, remove the spring clips (112,114)
and drain hose (113).
3. Push the retaining spring (26) up. Push the pin (25)
out the rear.
4. Loosen the locknut (27). Unscrew the pump. See below for how to repair the pump.
1. Screw the pump about 3/4 of the way into the bearing
housing (21). Hold the pin (25) up to the pin hole on
the connecting rod (22) and continue screwing in the
pump until the pin slides easily into the hole.
2. Back off the pump until the top threads of the pump
cylinder are flush with the face of the bearing housing
and the outlet nipple faces back.
3. Push the retaining spring (26) into the groove all the
way around the connecting rod. Tighten the locknut
(27) to 79 ft–lb (97 N.m) using a 2 1/4 in. open end
wrench and a light hammer.
4. Install the front cover and screws. Connect the pump
outlet hose. Install the suction tube parts. For Upright
carts, install the spring clips and drain hose.
1
Face of bearing housing
2
Torque to 79 ft–lb (97 N.m)
25
26
22
59
25
See Fig. 27.
26
27
112
21
1
113
27
2
114
30
Fig. 27
Fig. 26
0031
0477
Displacement Pump Repair
Disassembly procedure
1. Remove the pump from the sprayer. See above.
2. Disassemble the intake valve. See Fig. 28.
1
419
Torque to
110 ft–lb
(146 N.m)
420
3. Clean and inspect the parts. Replace any worn or
damaged parts. Use a new o–ring (401* ). If no further sevice is needed, reassemble the intake valve
and torque it into the cylinder to 110 ft–lb (146 N.m).
*404
421*
*401
1
423
Fig. 28
307-847
31
Displacement Pump Repair
4. To disassemble the rest of the pump, remove the
packing nut (416) and plug (405). See Fig. 33.
5. Use a plastic mallet to tap the piston rod (424) down.
Pull the rod out through the bottom of the cylinder.
6. Remove the throat packings. See Fig. 33.
WARNING
Always use the special sleeve removal tool,
P/N
220–991, to remove the sleeve. Other removal methods could cause the pump to rupture, resulting in serious injury. If the sleeve cannot be removed easily using the tool, return the sleeve and cylinder to your
Graco distributor for removal.
7. Remove the sleeve. Screw the large nut (B) of the
tool into the top of the cylinder (419). Screw down the
rod (A) to push the sleeve out. Remove the tool. See
Fig. 29.
8. Clamp the flats of the piston rod (424) in a vise. Loosen the retaining nut (411). Unscrew the piston valve
(422). See Fig. 30.
9. Disassemble the piston valve (422). See Fig. 30.
3. Alternate leather and plastic packings as shown in
Fig. 30. The lips of the throat “V” packings must face
down. The lips of the piston “V” packings must face
up. The lips of the U–cup seal (403) face down. Incorrect installation damages the packings and causes
the pump to leak.
4. Soak leather packings in oil before reassembling the
pump.
Reassembly Procedure
1. Stack the backup washer (414), seal (403*), female
gland (415*), alternate the packings (412*,406*), and
then male gland (410*) onto the piston valve (422).
See Fig. 30.
2. Tighten the packing retaining nut (411) onto the piston valve (22) to the torque specified in Fig. 30.
3. Put the ball (425*) on the piston valve (422). See
Fig. 30.
CAUTION
Step 5, tightening the piston valve into the rod, is critical. Follow the procedure carefully to avoid damaging
the packings by overtightening.
4. Apply one drop of adhesive, supplied, to the threads
of the piston valve. Then hand tighten the valve assembly into the piston rod just until the nut (411) contacts the rod. See Fig. 30.
A
B
NOTE: Note the alignment of the piston (422) to the nut
(411). Maintain this alignment through Steps 5, 6 and 7.
5. Place the flats at the top of the rod (424) in a vise.
419
Fig. 29
0028
Reassembly Notes
1. Pump Repair Kit, P/N 220–877, is available. For the
best results, use all the new parts in the kit, even if
the old ones still look good. Parts included in the kit
are shown with an asterisk, e.g., (410*) in the text
and drawings.
2. Check the outside of the piston rod (424) and the inside of the sleeve (418) for scoring or scratches. If
the parts are damaged, new packings will not seal
properly. Replace these parts if needed.
1
Torque to
4 in-lb (0.35 N.m)
2
Apply one drop
of sealant to
these threads
3
Lips face up
4
Lips face down
1
424
425*
2
411
410*
3
*406
*412
414
Fig. 30
415*
403*
4
422
0029
Displacement Pump Repair
1
Torque nut
against rod to
19 ft–lb (26 N.m)
2
Do not allow nut (411) to
move when installing piston
onto rod
424
2
411
1
2
Fig. 31
6. Use a wrench to CAREFULLY tighten the nut (411)
against the piston rod to 19 ft–lbs (26 N.m). See Fig.
31.
1
Leather
2
Polyethylene
3
Lips must face DOWN
4
Lips must face UP
5
U–cup seal
6
Torque to
110 ft–lb
(146 N.m)
405
416
*409
27
*407
413*
NOTE: Use two wrenches to maintain the alignment
mentioned in the NOTE following Step 4, page 32.
1
7. Put a new o–ring (417*) firmly in the cylinder groove.
See Fig. 33.
*408
8. One at a time stack the male gland (408*), alternate
the packings (413*,407*), and then install the female
gland (409*), into the top of the cylinder (419). See
Fig. 33.
*417
3
2
3
419
418
9. Install the packing nut (416) and plug (405), but leave
loose for now. See Fig. 33.
NOTE: The tapered end of the sleeve is the bottom of it.
Do not install it upside down. See Fig. 32.
10. Coat the piston rod and packings with oil. Carefully
slide the assembly (A) INTO THE T OP OF THE
SLEEVE (418). Then slide the sleeve/piston rod assembly INTO THE BOTT OM OF THE CYLINDER
(419). This procedure helps prevent damaging the
packings during reassembly. See Fig. 32.
410*
*406
1
4
*403
3
5
412*
4
2
415*
414*
*401
1
Tapered end
6
419
Fig. 33
418
A
Fig. 32
11. Screw down the cylinder locknut (27) until it is finger
tight at the bottom of the external cylinder threads.
12. Put the flats of the intake valve (423) in a vise. Install
a new o-ring (401*) and screw the intake valve into
the pump cylinder. See Fig. 33. Torque the valve to
110 ft–lb (146 N.m).
1
0030
13. Reinstall the pump. See page 31.
Parts – Displacement Pump
Model 220–872, Series A
Includes items 401 to 425
REF
NO.
PART NO. DESCRIPTION
401*
403*
404*
405*
406*
407*
408*
409*
410*
411
412*
413*
414*
415*
416
417*
418
419
420
421*
422
423
424
425*
107–098
108–690
108–775
183–171
183–174
183–175
183–176
183–177
183–178
183–179
183–182
183–183
186–653
183–185
183–186
183–172
183–361
183–181
183–180
183–173
220–631
220–629
220–630
101–947
PACKING, o–ring, PTFE SEAL, u–cup, polyurethane
BALL; sst
PLUG 1
V–PACKING, leather
V–PACKING, leather
GLAND, male
GLAND, female
GLAND, male
NUT, hex, retaining
V–PACKING, polyurethane
V–PACKING, polyurethane
WASHER, backup
GLAND, female
NUT, packing
O–RING, PTFE SLEEVE, cylinder
CYLINDER
GUIDE, ball
PIN, ball stop
VALVE, piston
VALVE, intake
ROD, piston
BALL
*405
QTY
416
1
1
1
*409
2
2
1
1
1
1
3
3
1
1
1
1
1
1
1
1
1
1
1
1
*417
* These parts are also included in Repair Kit 220–877,
which may be purchased separately. Keep an extra kit on
hand to reduce down time.
418
*413
424
425*
411
407*
410*
412*
*408
419
*406
415*
403*
414*
422
420
421*
404*
401*
Accessories
224–788
Sleeve Removal Tool
220–877
Packing Repair Kit
See contents in parts list, above
423
Parts – Complete Sprayers
Model 231–052 Sprayer with Upright cart
Includes items 201 to 204
202
Model 231–085 Sprayer with Lo-Boy cart
Includes items 202 to 205
Ref
No.
Part No.
Description
201
220–886
202
223–541
203
214–701
204
220–955
205
222–488
GM5000 Upright Basic Sprayer
See parts list on page 37
1
HOSE, grounded, nylon; 1/4” ID;
cpld 1/4 npsm(fbe); 50 ft (15 m);’
spring guards both ends
1
HOSE, grounded, nylon; 3/16” ID;
cpld 1/4 npsm(m) x 1/4 npsm(f) swivel;
3 ft (0.9 m); spring guards both ends 1
“CONTRACTOR” SPRAY GUN
Includes RAC IV DripLess Tip Guard
and 517–size SwitchTip
See 307–614 for parts
1
GM5000 Lo-Boy Basic Sprayer
See parts list on page 39
1
Qty
204
203
0160
Parts – Pinion Assembly
Ref No. 19
Pinion Housing Assembly 220–920
Includes items 19a to 19m
Ref
No.
Part No.
Description
19a
19b
19c
19d
19e
19f**
19g**
183–394
105–489
108–692
100–069
107–088
108–797**
183–395**
.HOUSING, pinion
.PIN, dowel
.BEARING
.BALL, sst
.BEARING
.BEARING, ball, small
.SHAFT, pinion
Qty
1
2
1
1
1
1
1
Ref
No.
Part No.
Description
19h**
19j**
19k
19m**
108–798**
183–396**
108–799
108–796**
.BEARING, ball, large
.HUB, armature
.RING, retaining, internal, large
.RING, retaining, small
Qty
1
1
1
1
**Included in Repair Kit No. 221–032.
19k
19b
19a
19m**
19c
19j**
19h**
19e
19d
19g**
19f**
0169
307-847
35
Parts – Basic Sprayer with Upright Cart
Model 220–886, Series C
1
22
74
73
21
11
102
20
20b
20a
11
18
Detail
Ref 36
10
40
45
24
Ref 19
37
46
3
10
11
Ref 19d
23
68
39
20c
72
26
92
69
1
101
Ref 59
106
76
63
77,100
71
25
27
1
67
64
28
4
62
Ref 113
30
11
9
114
59
31
7
16
1
Label
2
See Detail above
3
See page 35
4
See page 34
57
1
36
112
56
1
3
2
10
13
2
47
8
11
14
49
50
11
58
12
55
51
98
4b 6
4a
66
16
61
96
111
9
97
99
80
15
87
111
57
54
Ref 59
118
41
117
44
53
93
113
121
35
38
36
307-847
42
43
0158
Parts – Basic Sprayer with Upright Cart
Model 220–886, Series C
Ref
No.
Part No.
Description
1
2
3
4
108–802
183–397
183–517
236–568
4a
4b
6
7
8
9
10
183–400
108–800
108–842
100–214
100–644
11
12
13
14
105–510
108–801
183–401
110–837
15
16
18
19
100–469
108–803
220–919
220–920
20
220–879
20a
20b
20c
20d
21
22
23
24
25
26
27
28
106–227
183–209
100–069
110–293
220–639
220–640
183–168
108–849
183–210
183–169
183–170
220–872
30
31
35
36
37
38
39
183–423
181–072
236–788
220–918
183–350
108–794
108–795
ENGINE, gasoline
1
HOUSING, clutch
1
1
CLAMP, mounting, rotor
CLUTCH ASSEMBLY
Includes items 4a and 4b
1
.ARMATURE
1
.ROTOR
1
FIELD
1
PIN, dowel, spring, 5/16 x 1”
1
4
CAPSCREW, hex hd, 5/16–24 x 3/4”
7
LOCKWASHER, 5/16”
CAPSCREW, socket head, 1/4–20
x 3/4”
9
17
LOCKWASHER, spring, 1/4”
4
SETSCREW, 1/4–20
1
KEY, parallel, 3/16” sq x 7/8”
FLANGE SCREW, hex hd, 5/16–18
x 1-1/2”
2
1
CAPSCREW, hex hd, 3/8–16 x 3/4”
CAPSCREW, socket head, 1/4–28 x 1” 6
GEAR REDUCER
1
PINION HOUSING ASSEMBLY
See parts on page 35
1
DRIVE HOUSING KIT
Includes items 20a to 20d
1
.WASHER, bronze
1
.WASHER, silver
1
.BALL, sst
1
.TUBE, grease
1
BEARING HOUSING
1
CONNECTING ROD
1
COVER, housing
1
CAPSCREW, socket head, 1/4–20 x 3” 2
PIN, straight, 3/8 x1/8”
1
SPRING, retaining
1
1
NUT, hex, 1 13/16–16
DISPLACEMENT PUMP
See page 34 for parts
1
TUBE, intake
1
STRAINER
1
CART FRAME
1
CART HANDLE & HOSE RACK
1
2
WASHER, plain
PLUG, tubing
2
SCREW, mach, pan head,
10–32 x 5/16”
4
SLEEVE
2
WHEEL, semi–pneumatic
2
RING, retaining
2
HUBCAP
2
4
WASHER, 5/8”
BUTTON, snap
2
PIN, spring, straight, 3/16” x 1-1/4”
2
GROUNDING CLAMP & WIRE
1
SCREW, mach, hex washer head,
No. 8 x 3/8”
1
1
LOCKWASHER, internal, No. 8
40
41
42
43
44
45
46
47
49
185–188
179–811
101–242
104–811
154–636
179–777
108–068
222–011
100–078
50
157–021
Qty
Ref
No.
Part No.
Description
51
214–570
53
54
55
56
57
224–775
178–034
100–040
220–285
162–453
58
59
100–840
220–849
61
62
63
100–188
101–344
222–369
64
106–078
66
67
68
69
71
72
73
108–805
183–392
108–850
183–414
186–227
110–814
110–141
74
76
77
80
86
106–115
183–995
183–415
100–133
206–994
87
162–485
92
93
183–461
110–997
96
97
98
99
100
101
102
106
220–980
108–868
108–860
108–851
177–762
181–867
185–953
110–037
111
112
113
114
117
118
110–838
186–490
186–495
181–102
186–638
110–963
121
122
108–982
187–189
FLUID FILTER
See 307–273 for parts
VALVE, pressure drain
TAG, warning
PLUG, pipe, sq hd, 3/8 npt
CAP
NIPPLE, hex, 1/4 npsm x 1/4 npt,
1–3/16” long
ELBOW, street, 1/4–18 npt (m x f)
HOSE, 3/8” ID, cpld 3/8 npsm (fbe),
29” (737 mm), spring guard both ends
NUT, heavy hex, 5/16–18
CAPSCREW, hex hd, 5/16–18 x 7/8”
PRESSURE CONTROL KIT
See page 40 for parts
SCREW, mach, flat head, thd frmg,
10–24 x 3/8” 4
BUSHING, snap
BRACKET, mounting
SCREW, mach, filh, 8–32 x 1-1/4”
LABEL, identification
HANGER, pail
NUT, retainer
CAPSCREW, socket head, 3/8–16
x 1-1/2”
LOCKWASHER, spring, 3/8”
COVER, pressure control
LABEL, identification, outside cover
LOCKWASHER, spring, 3/8”
THROAT SEAL LIQUID,
8 oz (0.27 liter)
NIPPLE, pipe, 3/8 npt(m) x
3/ npsm(m)
8
NIPPLE, 3/8–18 npsm x 1/4–18 npt
FLANGE SCREW, hex hd,
1/4–20 x 5/8”
HARNESS, wiring
CLAMP, wire
SCREW, mach, bdgh, 8–32 x 1/4”
WASHER, plain, 3/8”
LABEL, Warning
LABEL, Warning
LABEL, Danger
SCREW, mach, pan head, thread
forming, 10–24 x 1/2”
LOCKNUT, heavy hex, 5/16–18
CLIP, spring
TUBE, bypass
CLIP, spring
BRACKET, filter mounting
FLANGE SCREW, hex
hd, 5/16–18 x 3/4”
CONNECTOR, tube
NIPPLE, reducing
Qty
1
1
1
1
1
2
1
2
3
3
1
2
1
4
1
1
2
4
4
1
1
1
1
1
1
2
1
2
2
1
1
1
1
4
5
1
1
1
1
3
1
1
Replacement Danger and Warning labels, tags and cards
are available at no cost.
Parts – Basic Sprayer with Lo–Boy Cart
Model 222–488, Series A
1
Ref 19
1
22
21
11
20
102
11
18
20b
20a
63
107
108
66
Ref
319
64
24
10
11
Ref 19d
1
9
20c
69
62
101
26
3
76
2
10
74
73
23
68
106
77,100
25
31e
27
31j
28
92
Ref 59
16
6
11
7
3
8
9
2
10
11
1
13
12
1
14
66
97
11
16
50
49
31c
47
31d
98
96
4b
35
1
Label
2
See page 35
3
See page 34
4a
99
80
15
65
79
9
111
41
55
78
79
30
51
58
56
57
57
54
43
31c
59
87
53
31a
31b
93
42
31e
31g
10
Ref 31h
88
44
31f
31h
0159
Parts – Basic Sprayer with Lo–Boy Cart
Model 222–488, Series A
Ref
No.
Part No.
Description
1
2
3
4
108–802
183–397
183–517
236–568
4a
4b
6
7
8
9
10
183–400
108–800
108–842
100–214
100–644
11
12
13
14
105–510
108–801
183–401
110–837
15
16
100–469
108–803
18
19
220–919
220–920
20
220–879
20a
20b
20c
20d
21
22
23
24
25
26
27
28
106–227
183–209
100–069
110–293
220–639
220–640
183–168
108–849
183–210
183–169
183–170
220–872
30
31
109–059
222–517
31a
31b
31c
31d
31e
31f
31g
31h
31j
35
41
42
43
44
170–957
181–072
110–964
110–960
103–473
181–102
185–381
805–077
176–450
222–612
179–811
101–242
104–811
154–636
ENGINE, gasoline
1
HOUSING, clutch
1
1
CLAMP, mounting, rotor
CLUTCH ASSEMBLY
Includes items 4a and 4b
1
.ARMATURE
1
.ROTOR
1
FIELD
1
PIN, dowel, 5/16 x 1”
1
4
CAPSCREW, hex hd, 5/16–24 x 3/4”
9
LOCKWASHER, 5/16”
CAPSCREW, socket head, 1/4–20
x 3/4”
13
17
LOCKWASHER, spring, 1/4
4
SETSCREW, 1/4–20”
1
KEY, parallel, 3/16” sq x 7/8”
FLANGE SCREW, hex hd,
5/ –18 x1-1/2”
2
16
1
CAPSCREW, hex hd, 3/8–16 x 3/4”
CAPSCREW, socket head, 1/4–28
x 1.0”
6
GEAR REDUCER
1
PINION HOUSING ASSEMBLY
See parts on page 35
1
DRIVE HOUSING KIT
Includes items 20a to 20d
1
.WASHER, bronze
1
.WASHER, silver
1
.BALL, sst
1
.TUBE, grease
1
BEARING HOUSING
1
CONNECTING ROD
1
COVER, housing
1
CAPSCREW, socket head, 1/4–20 x 3” 2
PIN, straight, 3/8 x 11/8”
1
SPRING, retaining
1
1
NUT, hex, 1 13/16–16
DISPLACEMENT PUMP
See page 34 for parts
1
BUMPER
2
SUCTION TUBE
Includes items 31a to 31j
1
.TUBE, suction
1
.STRAINER
1
2
.CLAMP, hose
.UNION, adapter
1
2
.STRAP, tie
2
.CLIP, spring
.HOSE, suction
1
.TUBE, bypass
1
.GUARD, HOSE
1
CART
1
WHEEL, semi–pneumatic
2
RING, retaining
4
HUBCAP
2
6
WASHER, 5/8”
Qty
Ref
No.
Part No.
Description
47
49
222–011
100–078
50
51
157–021
214–570
53
54
55
56
57
222–198
178–034
100–040
220–285
162–453
58
59
100–840
222–516
62
63
100–001
222–369
64
106–078
65
66
68
69
73
100–333
109–099
108–850
183–414
110–141
74
76
77
78
79
80
86
106–115
183–995
183–415
100–015
100–016
100–133
206–994
87
162–485
88
92
93
222–469
183–461
110–997
96
97
98
99
100
101
102
106
220–980
108–868
108–860
108–851
177–762
181–867
185–953
110–037
107
108
111
183–765
109–078
110–838
GROUNDING CLAMP & WIRE
1
SCREW, mach, hex washer hd, No. 8
x 3/8”
1
1
LOCKWASHER, internal, No. 8
FLUID FILTER
See manual 307–273 for parts
1
1
VALVE, pressure drain
1
TAG, warning
PLUG, pipe, sq hd, 3/8
1
CAP
1
NIPPLE, hex, 1/4 npsm x 1/4 npt,
13/16” long
2
1
ELBOW, street, 1/4–18 npt (m x f)
HOSE, 3/8” ID, 2’4” long,
cpld 3/8–18 npt(m) x 3/8 npsm(f) swivel;
spring guards both ends
2
3
CAPSCREW, hex hd, 5/16–18 x 5/8”
PRESSURE CONTROL KIT
See page 40 for parts
1
SCREW, mach, flat head,
thread forming, 10–24 x 3/8”
4
4
CAPSCREW, hex hd. 1/4–20 x1/2”
BUSHING, snap
2
4
SCREW, mach, filh, 8–32 x 1.25”
LABEL, identification
1
CAPSCREW, socket head, 3/8–16
x 1.5”
4
4
LOCKWASHER, spring, 3/8”
COVER, pressure control
1
LABEL, identification, outside cover
1
4
NUT, hex, 1/4–20
8
LOCKWASHER, spring, 1/4”
1
LOCKWASHER, spring, 3/8”
THROAT SEAL LIQUID,
8 oz (0.27 liter)
1
NIPPLE, pipe, 3/8 npt(m) x
3/ npsm(m)
1
8
1
SUPPORT, foot
1
NIPPLE, 3/8–18 npsm x 1/4–18 npt
FLANGE SCREW, hex head,
1/4–20 x 5/8
2
HARNESS, wiring
1
1
CLAMP, wire
2
SCREW, mach, bdgh, 8–32 x 1/4”
1
WASHER, plain, 3/8”
LABEL, Warning
1
LABEL, Warning
1
LABEL, Danger
1
SCREW, mach, pan head, thread frmg,
10–24 x 1/2”
4
1
BRACKET, mounting
BUSHING, strain relief
1
2
LOCKNUT, heavy hex, 5/16–18
Qty
Replacement Danger and Warning labels, tags and cards
are available at no cost.
307-847
39
Parts – Pressure Control
Part No. 222–369 – Basic Pressure Control for the GM5000 Sprayers
Includes items 300 to 313,315, 325 and 326. Does not includes items 314,316 to 320.
For Upright Cart Sprayers,
Order the Basic Pressure Control 222–369, and item 314 and/or 316 to 318 as required
For Lo–Boy Cart Sprayers,
Order the Basic Pressure Control 222–369, and item 314 and/or 319 and 320 as required
Ref
No.
Part No.
Description
300{
222–380
301Y{
302{
303{
304{
305{
306{
307{
308{
309{
310{
311{
312{
313{
183–466
105–679
105–659
107–255
157–021
100–284
108–219
108–783
222–352
107–070
100–072
103–181
220–979
PRESSURE CONTROL
Includes items 302 to 304
LABEL, warning
ON/OFF SWITCH
BOOT, switch
GUARD, locking
LOCKWASHER, No. 8, internal
NUT, hex, msc 8–32
RECTIFIER, bridge
SCREW, mach, frhd 8–32 x 13/16”
TRIAC ASSEMBLY
SCREW, flat head; csk hd
NUT, hex
LOCKWASHER
CONDUCTOR, red
Qty
1
1
1
1
1
2
1
1
1
1
2
2
2
2
Ref
No.
Part No.
Description
314
315{
220–978
100–035
316
317
318
319
183–461
100–840
108–852
156–823
320
325{
326{
110–195
108–814
101–754
CONDUCTOR, red, white, black
SCREW, mach, slotted pan head;
No. 8 x 5/16”
NIPPLE, hex; 3/8–18 npsm x 1/4–18
ELBOW, str, 1/4–18 npt (m x f)
CONNECTOR, 45_
UNION, swivel, 1/4 npt (f) swivel x
1/4 npt(m)
UNION, swivel, 45_
PLUG, pipe
PLUG, pipe
Qty
1
1
2
2
1
1
2
1
1
Y Replacement Danger and Warning labels, tags and cards
are available at no cost.
{Parts marked with a dagger are supplied with the basic
pressure control. See Parts Drawing on page 41.
Wiring Schematic – Pressure Control
WHITE
CLUTCH
FIELD
RECTIFIER
MAIN
SWITCH
MT1
RED
RED
RED
G
RED
RED
ENGINE
MT2
R
C
ADJUSTABLE
PRESSURE
SWITCH
40
307-847
GROUND
NO
WHITE
BLACK
CLUTCH
FIELD
0054
Parts – Pressure Control
For Upright Cart Sprayers
Parts marked with a dagger are supplied
304
303
with the basic pressure control.
308,305,306
302
307
300
RED
313
RED
310
311
312
317
316
309
313
WHITE
RED
GROUND
BLACK
315,305
RECTIFIER (307) CONNECTIONS
326
318
314
0148
0151
For Lo–boy Cart Sprayers
Parts marked with a dagger are supplied
314
with the basic pressure control.
303
302
304
301
320
308,305,306
307
RED
313
RED
TOP VIEW
300
319
0150
310
311
312
309
Ref 320
313
RED
GROUND
315,305
WHITE
325
326
BLACK
0165
307-847
41
Accessories
USE ONLY GENUINE GRACO PARTS AND ACCESSORIES
DANGER LABELS
The English language DANGER label shown on
page 1 is also on your sprayer. If you have painters
who do not read English, order one of the following
labels to apply to your sprayer. The drawing below
shows the best placement of these labels for good
visibility.
Order the labels directly from Graco, free of
charge. Toll Free: 1–800–328–0211
Apply other
language here
French
Spanish
German
Greek
Korean
English
5 Gallon (19 Liter) Suction Tube Kit
Includes:
Ref
No.
Part No.
Description
1
2
3
4
5
6
101–818
160–327
170–705
170–706
170–957
181–072
CLAMP, hose
UNION, 90 swivel; 3/4 npt(m x f)
ADAPTER, intake
HOSE, 1” ID x 48”; nylon
TUBE, suction
STRAINER
5
Sleeve Removal Tool 224–788
Required for removing the displacement pump sleeve.
55 Gallon (200 Liter) Suction Tube Kit
Includes:
2
214–961
3
4
5
6
7
8
9
10
156–591
156–593
100–220
176–684
156–592
159–100
161–377
159–101
208–259
Description
Qty
UNION, 90 ADAPTER, 3/4 npt(f) x
3/4 npsm(f) swivel
1
HOSE, coupled 3/4 npt(mbe)
3/4” ID; nylon, 6 ft (1.8 m);
spring guard one end
1
ELBOW, 90; 3/4 npt x 1–1/2 – 24 NS 1
1
PACKING, o–ring, nitrile rubber
1
THUMBSCREW, 5/16–18 x 1”
ADAPTER, bung
1
TUBE, riser
1
RETAINER, screen
1
SCREEN, filter
1
1
NUT, screen retainer
6
2
3
1
0161
Heavy Duty 5 Gallon (19 Liter) Suction Tube Kit
223–934
Includes:
Ref
No.
Part No.
Description
1
2
3
4
5
6
7
8
9
10
183–770
110–962
110–964
186–245
170–706
110–960
805–077
108–982
103–473
176–450
STRAINER
SUCTION TUBE
HOSE CLAMP
SPRING CLIP
SUCTION HOSE
UNION
DRAIN TUBE
TUBE CONNECTOR
PLASTIC TIE
HOSE GUARD
Qty
1
1
2
2
1
1
1
1
1
1
9
2
3
9
10
4
6
5
3
7
7
3
8
8
9
10
2
1
1
1
1
1
4
0162
Displacement Pump Repair Kit 220–877
Parts included in the kit are shown on page 34. Repair instructions are on page 31 of this manual and are also included with the kit.
Part No.
156–589
Qty
1
185–956
185–961
186–041
186–045
186–049
185–593
Ref
No.
1
208–920
ÄÄ
4
6
5
2
1
1
0162
0164
Technical Data
Dimensions
Engine . . . . . . . . . . . . . . . . . . . . . . 5 Horsepower, Honda
Maximum Working Pressure . . . . . . 3000 psi (210 bar)
Noise – Sound Power . . . . . . . . . . . . . . . . . . . . . 105 dBa
measured at 3.1 ft (1 m)
Cycles/Gallon (liter) . . . . . . . . . . . . . . . . . . . . . 104 (27.5)
Maximum Delivery . . . . . . . . . . 1.25 GPM (4.7 liter/min)
Fuel Tank Capacity . . . . . . . . . . . 0.95 gallons (3.6 liter)
Maximum Tip Size . . . . . . . . . . . . . . 1 gun with 0.035 tip
2 guns with 0.025 tip
3 guns with 0.019 tip
Inlet Paint Strainer . . . . . . . . . . . 16 mesh (1190 micron)
Stainless Steel screen, reusable
Outlet Paint Filter . . . . . . . . . . . . . 60 mesh (250 micron)
Stainless Steel screen, reusable
Pump inlet Size . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt (m)
Fluid Outlet Size . . . . . . . . . . . 1/4 npsm from fluid filter
Wetted Parts
Displacement Pump . Stainless Steel, Carbon Steel,
Polyurethane, UHMW polyethylene,
Delrin, Leather
Filter . . . . . Aluminum, Carbon Steel, Stainless Steel
Model 220–886
Upright cart without hose or gun
Weight (dry, without packaging) . . . . . . . 135 lb (61 Kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 31.6 in. (803 mm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . 30.5 in. (775 mm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 in. (572 mm)
Model 222–488
Lo-Boy cart without hose or gun
Weight (dry, without packaging) . . . . . 130 lb (58.5 Kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 in. (673 mm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 in. (914 mm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 in. (483 mm)
NOTE: Delrin
Graco Phone
Numbers
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
FOR TECHNICAL ASSISTANCE, service repair
information or assistance regarding the application of
Graco equipment: 1–800–543–0339 Toll Free
Manual Change
Summary
Old and new parts are interchangeable. Added and
Deleted parts are not interchangeable.
Assembly
Changed
Part
Status
Ref
No.
Part No.
Name
220–886
g
Upright
Sprayer
Delete
Add
4
4
221–031
236–568
Clutch Kit
Clutch Kit
Delete
(2)
9
100–214
Lockwasher
Old
New
35
35
224–002
236–788
Frame
Frame
Add (3)
111
110–838
Locknut
Delete
119
110–996
Nut
Delete
Add
4
4
221–031
236–568
Clutch Kit
Clutch Kit
222–488
Lo–Boy
Sprayer
The Graco Warranty and Disclaimers
WARRANTY
Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on
the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this
warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defective, with the exception of defects in parts on the drive train/gear box on EM and GM sprayers or power train on EH and GH
sprayers, which will be repaired or replaced for twenty-four months from the date of sale for Gas–Hydraulic (GH) and GasMechanical (GM) sprayers and for thirty-six months from the date of sale for Electric-Mechanical (EM), Electric-Hydraulic (EH),
390st and 490st sprayers. 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, 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 with Graco
equipment of 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 claim. 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 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.
DISCLAIMERS AND LIMITATIONS
The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or
implied), including warranty of merchantability or warranty of fitness for a particular purpose, and of any non–contractual
liabilities, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential damages or loss is expressly excluded and denied. In no case shall Graco’s liability exceed the amount of the purchase price.
Any action for breach of warranty must be brought within two (2) years of the date of sale.
EQUIPMENT NOT COVERED BY GRACO WARRANTY
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with
respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not
manufactured by Graco (such as electric motor, 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.
Sales Offices: Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.)
Foreign Offices: Canada; England; Korea; Switzerland; France; Germany; Hong Kong; Japan
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN
PRINTED IN U.S.A.
55440–1441
307–847 June, 1987; Revised January, 1995