Graco 224483, GM 1230 User Manual
INSTRUCTIONS-PARTS
LIST
308–125
This
manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
Roof Rigs
GM 1230
GASOLINE-POWERED
1200
psi (8.3 MPa, 83 bar) MAXIMUM
WORKING PRESSURE
Model 231–148
With
one gun, Heavy Duty RAC IV
DripLess T
and 861 size tip,
90 foot (28 m) hose
ip Guard,
AIRLESS SPRA
YER
First
choice when
quality counts.
Supersedes Rev. B
and PCN D
Rev. D
Model 224–483, Series A
Without
hose or gun
0394A
GRACO INC. P.O. BOX 1441
http://www.graco.com
COPYRIGHT
Graco
Inc. is registered to I.S. EN ISO 9001
MINNEAPOLIS, MN
1991, GRACO INC.
55440–1441
Table
of Contents
Warnings 3.
Setup 8
Fueling 9
Start
Flushing
Spray T
Spray Techniques 14.
Maintenance 15
Troubleshooting 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Up
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guidelines
ip and T
. . . . . . . . . . . . . . . . . . . . . . . . . .
ip Guard
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.
12.
13.
Service
Removing
Displacement Pump
Bearing
Drive
Pinion
Clutch 26
and Installing a Displacement Pump
. . . . . . . . . . . . . . . . . . . . . .
Housing and Connecting Rod
Housing
Housing
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
19.
22.
23.
24.
Engine 27
Field
Clamp 29
Clutch
Reassembly 30
Parts
Lists and Drawings
Displacement Pump
Pinion
Complete
Suction
Roofing
Drive
Accessories 38
Technical
Warranty 40
Phone
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
and Wiring Harness
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
Assembly
Sprayer
Kit
Pump and Pressure Control Kit
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28.
29.
32.
33.
34.
35.
35.
36.
39.
40.
NOTE: This
sprayer in other languages. Before operating the sprayer
is an example of the English language DANGER label on your sprayer. This label is supplied with the
, apply a DANGER label in the appropriate language for
your operators, according to the separate instructions supplied with it.
FIRE
AND
EXPLOSION HAZARD
Liquids
Spray
painting, flushing or cleaning equipment with flammable liquids in
confined
Use outdoors or in extremely well ventilated areas. Ground equipment,
hoses,
A
cloths,
arcs
switches on and of
Failure to follow this warning can result in death or serious injury
areas can result in fire or explosion.
containers and objects being sprayed.
void all ignition sources such as static electricity from plastic drop
open flames
from connecting or disconnecting power cords or turning light
such as pilot lights, hot objects such as cigarettes,
f.
.
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
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.A
ing 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 T
Failure to follow this warning can result in amputation or serious
injury.
reatment”.
SKIN INJECTION
HAZARD
void accidental trigger
-
Symbols
Warning Symbol
WARNING
This
symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNING
FIRE AND EXPLOSION HAZARD
Improper
result in a fire or explosion and serious injury
grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
If there is any static sparking or you feel an electric shock while using this equipment,
ing immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Disconnect all electrical equipment in the spray area.
Caution Symbol
CAUTION
This
symbol alerts you to the possibility of damage to
equipment if you do not follow the instructions.
.
stop spray-
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or of
Do not operate a gasoline engine in the spray area.
Ground the sprayer to a true earth ground with the ground wire and clamp (supplied).
Use only electrically conductive hoses.
f any light switch in the spray area while operating or if fumes are present.
WARNING
EQUIPMENT MISUSE HAZARD
INSTRUCTIONS
Equipment
This equipment is for professional use only
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor
Do not alter or modify this equipment. Use only genuine Graco parts.
Check equipment daily
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
T
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
nical Data
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82C (180F) or below –40C (–40
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
misuse can cause the equipment to rupture or malfunction and result in serious injury
.
echnical Data
section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
. Repair or replace worn or damaged parts immediately
on page 39 for the maximum working pressure of this equipment.
.
F).
.
.
Tech-
W
ear hearing protection when operating this equipment.
Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
MOVING PARTS HAZARD
Moving
parts can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the sprayer
Before servicing the equipment, follow the
equipment from starting unexpectedly
Pressure Relief Procedure
.
.
on page 8 to prevent the
WARNING
INJECTION HAZARD
Spray
from the gun, leaks or ruptured components can inject fluid into your body and cause extremely
serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also
cause serious injury
Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediate medi
cal attention.
Do not point the gun at anyone or at any part of the body
Do not put your hand or fingers over the spray tip.
Do not stop or deflect leaks with your hand, body
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the gun when spraying.
Check the gun dif
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
.
fuser operation weekly
.
, glove or rag.
. Refer to the gun manual.
-
Follow the
checking or servicing the equipment.
T
ighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily
repair high pressure couplings; you must replace the entire hose.
Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
Pressure Relief Procedure
on page 8 if the spray tip clogs and before cleaning,
. Replace worn or damaged parts immediately
TOXIC FLUID HAZARD
Hazardous
inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container
state and national guidelines.
Always wear protective eyewear
solvent manufacturer
fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
. Dispose of hazardous fluid according to all local,
, gloves, clothing and respirator as recommended by the fluid and
.
. Do not
Notes
Setup
E
TRIGGER LOCK
SHOWN IN
ENGAGED OR
“SAFE” POSITION
TRIGGER LOCK
SHOWN IN
DISENGAGED OR
“OFF–SAFE” POSITION
40 ft (12 m) HOSE
WAND HANDLE
50 ft. (15 m)
MAIN HOSE
40 ft (12 m) HOSE
SPRAY GUN
ENGINE
OIL LIGHT
0015
ENGINE
ON/OFF
SWITCH
0016
FUEL
SHUTOFF
LEVER
AIR CLEANER
SP
ARK PLUG CABLE
THROTTL
CHOKE
PRESSURE
CONTROL KNOB
PRESSURE CONTROL
ON/OFF SWITCH
PRESSURE
RELIEF V
shown in closed
position
Fig.
1
0398
ALVE
SIPHON TUBE
GROUNDING CLAMP
MUFFLER
PRESSURE CONTROL
DISPLACEMENT PUMP
QUICK DISCONNECT ELBOW
0394A
Setup
General Information
NOTE:
in the text refer to the callouts in the figures and the
parts drawing.
Reference numbers and letters in parentheses
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below
the section
ARD
FIRE OR EXPLOSION HAZ
on page 3.
Grounding
1.
Sprayer
cord into a properly grounded outlet. Do not use an
adapter
and be rated for 15 amps.
2.
Fluid hoses:
maximum of 150 m combined hose length to
ensure grounding continuity
Spray gun:
3.
a properly grounded fluid hose and sprayer
: plug the power supply cord, or extension
. All extension cords must have three wires
use only grounded hoses with a
.
obtain grounding through connection to
. Also read
.
Pressure Relief Procedure
WARNING
INJECTION
Fluid under high pressure can be in
jected through the skin and cause seri
ous injury
from injection, splashing fluid, or moving parts, fol
-
low the
1.
2. T
3.
4.
Pressure Relief Procedure
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tips.
Engage the gun safety latch.
urn the ON/OFF switch to OFF
Unplug the power supply cord.
Disengage the gun 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.
HAZARD
. T
o reduce the risk of an injury
whenever you:
.
-
-
-
4.
Object being sprayed:
5.
Fluid supply container:
6.
All solvent pails used when flushing,
local code. Use only metal pails, which are con
ductive. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which inter
rupts the grounding continuity
T
o maintain grounding continuity when flushing or
7.
relieving pressure
gun firmly to the side of a grounded metal pail,
then trigger the gun.
according to local code.
according to local code.
according to
.
, always hold a metal part of the
5.
Engage the gun safety latch.
6.
Open the pressure drain valve, having a container
ready to catch the drainage. 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
tip guard retaining nut or hose end coupling and very
slowly loosen the part to relieve pressure gradually
Now clear the tip or hose.
, wrap a rag around the
.
Setup
1. Read and follow the warnings on pages 3–3
before setting up or operating this sprayer
2. Install the hoses and gun.
3. Clamp the siphon hose to the pump.
gasket
is in the quick
prevent
4. Check
gine manual, supplied. In summary: remove one oil
fill plug – the oil should be almost overflowing. See
Fig.
NANCE
Recommended
gent oil, SAE 10W–40, classified “FOR SERVICE
SE
5. Ground the sprayer before operating it. Connect
the
low the FIRE OR EXPLOSION HAZARD on page
3.
priming.
the engine oil level.
1. Add oil as necessary
section on page 15.
or SF”.
grounding clamp (32) to a true earth ground.
disconnect elbow; air leaks will
Refer to the Honda en
. Also read the MAINTE-
engine
oil: Use a high–quality
.
Be sure
, deter
the
Fol
Fueling
6. Fill the gas tank.
7. Flush the pump to remove the protective lightweight oil. See FLUSHING GUIDELINES on page
12.
8. AGITATE OR MIX THE MATERIAL THOROUGH-
Make sure the heavier material on the bottom of
LY!
-
the
container is completely mixed in.
9.
Start the sprayer. See page 10.
See FUELING, below
CAUTION
-
-
T
o avoid damaging the pressure control, follow these
precautions.
1.
Always use spray hose at least 90 ft. (27 m)
long.
2.
Do not allow water or water-base material to
freeze in the pressure control.
.
WARNING
Gasoline is extremely flammable and explosive
under certain conditions. T
or explosion:
1.
Always shut of
2.
Refuel in a well-ventilated area.
3.
Do not smoke or allow flames or sparks in the
area where the engine is refueled or where the
gasoline is stored.
4.
Do not overfill the tank. Make sure the filler cap
is securely closed after refueling.
5.
Fuel vapor or spilled fuel can ignite. If any fuel
is spilled during refueling, make sure the are is
dry before starting the engine.
1 Fuel specifications. Use automotive gasoline with
a
pump octane number of 86 or higher
knocks
fuel
2 Gasolines containing alcohol (gasohol). Do not
use
does
for
do not use the gasohol if it contains more than
5%
or pings, use a higher octane fuel.
minimizes combustion chamber deposits.
gasohol which contains methanol, if the gasohol
not contain cosolvents and corrosion inhibitors
methanol. Even if it does contain such
methanol.
f the engine before refueling.
o reduce the risk of a fire
. If the engine
Unleaded
additives,
3. General. Do not use oil and gasoline mixtures or
contaminated gasoline. Avoid getting dirt, dust or
in the fuel tank.
water
4. Tank
5. Shut off the engine switch before refueling.
6. After refueling, tighten the fuel tank cap firmly.
capacity:
(13
mm) at the top of the tank for gas expansion.
0.95 gallons (3.6 liter).
FILL
CAP
Leave 1/2 in.
ENGINE
ON/OFF
SWITCH
NOTE: The HONDA engine warranty does not cover
damage
taining
for
resulting from the use of gasolines con
alcohol.
more information.
See the HONDA engine manual
-
Fig.
2
0015
0141D
Start
Before You Start The Sprayer
1 See FLUSHING GUIDELINES, page 12, to deter-
mine
if the unit should be flushed.
2 Be sure the gas tank is full.
3 Check the engine oil level.
NOTE: The
4 Push the spark plug cable firmly onto the spark
plug.
5 If
Refer
engine stops automatically
if
it is low on oil. If you try to start it again without
adding
more oil,
switch
glows as you pull the starter rope.
a red light near the engine on/of
the sprayer in not primed, remove
to Fig. 3 as you start the sprayer
, or will not start,
the spray tip.
.
Up
3. T
urn OFF the pressure control switch.
4. To start the engine:
a. Turn the pressure adjusting knob all the way
counterclockwise
b. Slide the metal throttle lever away from the fuel
tank
c. If
f
the engine is cold, close the
the
the engine is warm, close the
If
the
d. T
urn ON the engine switch.
to the lowest pressure setting.
to the maximum position (fully left).
choke by moving
gray lever
.
choke by moving
gray lever only half way or not at all.
WARNING
Start Up
1. Place the siphon tube into the coating, water or
solvent container, depending on whether you are
flushing
or are ready to spray
.
2. Open the black fuel shutoff lever by pushing it in
direction of the arrow
the
.
CAUTION
Never start the engine unless fluid pressure is re
lieved and the pressure control switch is turned OFF
Attempting to start the engine when it is pressurized
could damage the recoil system.
ENGINE
OIL LIGHT
TRIGGER LOCK
shown in
engaged or
“safe” position
TRIGGER LOCK
shown in
disengaged or
“off–safe” position
.
A starter rope that recoils too quickly may hit
someone and cause serious injury
also jam in the recoil assembly
e. Hold
f. Open
the frame of the sprayer with one hand
pull
the starter rope rapidly
holding
turn
the rope as you let it return.
the rope until the engine starts.
the choke as soon as the engine starts, ex
. The rope could
.
and firmly
cept in cold weather. In cold weather, leave the
choke
5. Engage
gun
0015
closed for 10 to 30
it to keep the engine running.
ing
the gun trigger safety latch
forward.
ENGINE
ON/OFF
SWITCH
seconds before open
0016
FUEL SHUT
LEVER
shown in off position
and
. Continue
Pull and re
by tipping the
THROTTLE
CHOKE
shown in
choked position
OFF
-
-
-
PRESSURE
CONTROL KNOB
Fig.
3
0398
SP
ARK PLUG CABLE
0394A
6. To start the pump:
a. Place
b. Reduce the engine speed by moving the metal
c. T
d. T
e. Turn the pressure control knob 1/4 turn from
f.
a container under the pressure drain valve
and
open the valve.
throttle lever away from the fuel tank about half
way
to the left.
urn the pressure control knob to minimum.
urn ON the pressure control switch.
minimum pressure. Run the pump until fluid
flows
smoothly from the pressure drain valve.
Close the pressure drain valve.
Start
Up
WARNING
T
o reduce the risk of serious injury from fluid injec
tion, never operate the spray gun with the tip guard
removed.
8. Install the tip guard and spray tip.
CAUTION
Use the lowest fluid pressure and the lowest throttle
setting needed. Higher settings cause excessive
clutch cycling and premature tip and pump wear
See page 13.
-
.
WARNING
Hold the handle of the wand firmly when triggering
the gun to reduce the risk of it kicking back from
the surge of pressure, which could cause serious
injury.
g. Disengage the gun safety latch. Hold a metal
part of the gun firmly against a grounded metal
container. Holding the gun firmly with both
hands,
squeeze the trigger until
the gun.
h.
Release the trigger
7. If you have not primed the unit with the coating
yet, move the siphon tube to the coating container.
Release
the water/solvent pail just until coating appears. Tip
the gun forward and fully release the trigger to engage
the trigger safety
the trigger safety latch.
TRIGGER LOCK
shown in
engaged or
“safe” position
TRIGGER LOCK
disengaged or
“off–safe” position
. Engage the safety latch.
latch. T
shown in
fluid flows from
rigger the gun into
9. Adjust
fore transporting the hoses to the roof. Trigger
the
and atomization. Turn the pressure adjusting knob
until you get a good pattern. Then slowly lower the
throttle
spray
10.
Read SPRA
the engine speed and pump pressure be
gun onto a test paper to check the spray pattern
setting as far as
pattern (the clutch does not cycle).
Y TECHNIQUES on page 14.
you can without changing the
CAUTION
Close the black fuel shutof
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
makes start up very dif
f lever whenever you are
, which
ficult.
0016
THROTTLE
CHOKE
choked position
FUEL SHUT
LEVER
shown in off position
shown in
OFF
-
Fig.
PRESSURE
CONTROL KNOB
4
0398
PRESSURE CONTROL
ON/OFF SWITCH
PRESSURE DRAIN V
ALVE
0394A
Flushing
Guidelines
WARNING
To
reduce the risk of serious injury
injection, always follow the
dure W
ing, cleaning, or shutting down the sprayer
arning
on page 8 before checking, adjust
Pressure Relief Proce
When To Flush
1. Flush
2. Changing coatings.
3. Changing from water–base to oil–base coating.
4. Changing from oil–base to water–base coating.
a new sprayer
Before using water–base coating, flush with a compatible solvent, then warm, soapy water, and then
water
clean
Before using oil–base coating,
ible
solvent.
Flush
solvent.
Flush with a compatible solvent, then warm, soapy
water,
.
with warm, soapy water
and then clean water
to remove the protective oil.
Use a compatible solvent.
, including fluid
.
flush with a compat-
, and then a
.
compatible
-
-
2. Put
3. Start the sprayer. Trigger the gun into the coating
4. Move the gun to the grounded flushing container.
5. Check all fluid connections for leaks. Relieve pres-
6. Remove
the siphon tube in a grounded metal pail of water
or
compatible solvent.
just
container
nozzle.
Trigger the gun until clean water or solvent comes
from the it. See Fig. 6. Release the trigger and en-
the safety latch. Open the drain valve to clean
gage
it.
sure before tightening any connections. Start the
sprayer.
gage the gun safety latch. Trigger the gun to force
or solvent from the hose. Do not let the pump
water
run
dry for more than 30 seconds to avoid damaging
the
pump packings! Relieve pressure.
until water or solvent comes from the
Release the trigger
Recheck the connections for leaks.
the siphon tube from the solvent pail.
.
Disen
-
5. Storage.
Flush the pump only with a compatible solvent, fol-
lowed
by an oil–base solvent, such as mineral spirits.
Leave the drain valve open!
6.
Startup after storage.
Before
using water–base coating, flush out the com
solvent with warm, soapy water, and then with
patible
clean
water
.
using oil–based coating, flush out the compat
When
solvent with the coating to be sprayed.
ible
How To Flush The Pump Only
1. Relieve pressure. Leave the drain valve open. See
5.
Fig.
2.
Disconnect the siphon assembly
3. Put the pump in a grounded metal pail of water or
compatible
4. Start the sprayer – see page 10. Flush until the ball
in the foot valve is clean and moves up and down
easily.
solvent.
.
How To Flush The Entire Fluid System
-
-
PRESSURE
DRAIN VALVE
shown in closed
position
Fig.
5
0553
Maintain
metal-to-metal
when
reduce the chance of
static sparking and
splashing.
firm
flushing to
contact
1. Relieve pressure. Leave the drain valve open. See
Fig.
5.
Fig.
6
0406
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