Graco GM 5000, 220-886, 231-052, 222-488, 231-085 Instructions And Parts List

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Page 1

INSTRUCTIONS–P

This manual contains important warnings and information. READ AND RETAIN FOR REFERENCE

ARTS LIST

5 HORSEPOWER, GASOLINE–POWERED

307–847

Rev. L

Supersedes K

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 RAC IV DripLess and 517 size SwitchT

sprayer

, with hose and Contractor gun,

 T

ip Guard,

ip

Sprayers with Lo–Boy Carts Model 222–488, Series A

Basic

sprayer

, without hose or gun

Model 231–085

Complete RAC IV DripLess and 517 size SwitchT

sprayer

, with hose and Contractor gun,

 T

ip Guard,

ip

NOTE: This This label is available in other languages, free of charge. See page 42 to order

Spray

in confined areas can result in fire or explosion.

uids Use

outdoors or

ment, Avoid all ignition sources such as static electricity from plastic

cloths, open flames such as pilot lights, hot objects such as

drop cigarettes, turning

Failure

is an example of the DANGER label on your sprayer

painting, flushing or cleaning equipment with flammable liq

in extremely well ventilated areas. Ground equip

hoses, containers and objects being sprayed.

arcs from connecting or disconnecting

light switches on and off.

to follow this warning can result in death or serious injury

READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE

GRACO INC. P.O. BOX 1441

FIRE

AND

EXPLOSION HAZARD

power cords or

COPYRIGHT

SKIN INJECTION

HAZARD

Liquids can be injected into the body by high pressure airless

MINNEAPOLIS, MN

1987, GRACO INC.

or leaks – especially hose leaks.

spray Keep

body clear of the nozzle. Never stop leaks with any part of the

body.

Drain

triggering Never In case of accidental skin injection, seek immediate “Surgical

Treatment”. Failure

injury.

all pressure before removing parts. A

of gun by always setting safety latch

spray without a tip guard.

to follow this warning can result in amputation or serious

void accidental

when not spraying.

55440–1441

0136

Page 2

Table

of Contents

Introduction 2. Warnings

English 4 French Spanish

Setup 10 Fueling 11 Startup 12 Maintenance 14 Flushing Guidelines 15. Troubleshooting Guide 16. Repair

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearing Drive

Housing Pinion 20 Clutch 22 Engine 23 Field

and Wiring Harness

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vertissement) 6.

(Advertencia)8. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Housing & Connecting Rod

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

18.

19.

24.

Introduction

GM5000 BASIC COMPONENTS

NOTE: Refer to Fig.1.

Your

new GM5000 Sprayer functions and operates dif ently than other airless paint sprayers. This section will help

you become familiar with the sprayer before operat

ing

it.

Pressure Control

The

pressure control includes sprayer, the pressure adjusting knob, and a pressuresensing device. The pressure control engages and disengages

the clutch to control pressure.

an ON/OFF switch for the

fer-

Clamp 25 Clutch Reassembly 26 Pressure Pressure Displacement

Parts

Displacement Pump Complete Pinion 35 220–886, 222–488, Pressure

Accessories 42 Technical Dimensions 43 Graco Warranty Back

Displacement Pump

The vides strokes. Graco Throat Seal Liquid, helps prevent damage to the

throat

Fluid Filter

The hose and spray tip. The filter includes a reusable element, sure.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Housing

Control Replacement Control Adjustment

Lists and Drawings

Sprayers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic Sprayer with Upright cart Basic Sprayer with Lo-Boy cart

Control Assembly

Data

Phone Number

. . . . . . . . . . . . . . . . . . . . . . . . . . .

positive–displacement, volume-balanced pump pro

equal fluid delivery on both the up

The pump

packings and piston rod.

fluid filter strains the paint to help avoid clogs in

and a pressure drain valve for relieving fluid pres

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

Pump Repair

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

has a wetcup which, when filled with

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

and down pump

. . . . . .

Cover

25.

28.

30.

31.

34.

35.

36.

38.

40.

43.

the

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

you try to start the engine without refilling the oil, a

If illuminates engine

Clutch

The

clutch is engaged by the electric power generated by the

gasoline engine.

switch.

sure

Drive Assembly

The

permanently greased drive assembly transfers pow er

from the gasoline engine to the displacement pump.

too low

to alert you to the

from damage.



, the engine shuts of

problem, and to protect the

The power is controlled by the pres

f automatically

light

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

ft. (0.9 m), 3/16

gun

movement. The

tion

dampener to absorb pressure fluctuations.

Spray Gun & RAC IV DripLess

Graco high pressure spray guns have a trigger safety which prevents accidental triggering when the safety is engaged. also has a filter for final paint straining. The Reverse-A-

Clean

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

See Fig. 1. The gun provided with the sprayer

IV (RAC IV) SwitchT

risk of a fluid injection injury

in. ID whip hose provides more flexible

nylon hose material acts as a pulsa

 T

ip Guard

ip

uses high pressure

fluid

Page 3

202

0138

0015

0016

0136

KEY

A Pressure

switch

Pressure adjusting knob

Air cleaner

Fuel T E Muffler F Engine G

Spark plug cable H

Fuel shutof J Choke K Throttle L

Engine ON/OFF switch M

Engine oil light NT

(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”

IV Dripless tip guard and

517 size SwitchT

Control ON/OFF

ank

f lever

rigger safety latch

gun with RAC

Fig. 1

203

204

0137

 

Page 4

High

Observe All W

WARNINGS

Pressure Spray Can Cause Serious Injury

arnings. Read and understand all instruction manuals before operating equipment.

. For Professional Use Only.

FLUID

General

This the your ry, including the need for amputation. Also, fluid injected or splashed into the eyes or on the skin can cause serious damage.

NEVER NEVER 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 cleaning or removing the spray tip or servicing any system equipment.

NEVER Be

each

Medical

If any fluid appears to penetrate your skin, get EMERGENCY MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE CUT.

Note

important to treat the injury surgically as soon as possible.

not

with some exotic coatings injected directly into the blood stream. Consultation with a plastic surgeon or reconstructive hand

Spray

Be sure all gun safety devices are operating properly before each cause

Safety

equipment generates very high fluid pressure. Spray from

gun, leaks or ruptured components can inject fluid through

skin and into your body

point the spray gun at any one or at any part of the body put your hand or fingers over the spray

follow the

try to stop or deflect leaks with your hand or body

sure equipment safety devices are operating properly before

use.

Pressure Relief Procedure

Alert––Airless Spray W

ell the doctor exactly what fluid was injected.

to Physician:

delay treatment to research toxicity

surgeon may be advisable.

, and cause extremely serious inju

ounds

Injection in the skin is a traumatic injury

oxicity is a concern

Gun Safety Devices

use. Do not remove or modify any part of the gun; this can

a malfunction and result in serious injury

PRESSURE

To reduce the risk of serious injury, including fluid injection, splashing moving parts or electric shock, always follow this procedure whenever any ing

1 2 Turn the engine ON/OFF switch to OFF 3 4 Disengage the trigger safety latch. Hold a metal part of the

fluid or

solvent in the eyes or on the skin, or injury from

you shut of

part of the spray system, when installing, cleaning or chang

spray tips, and whenever you stop spraying.

Engage the trigger safety latch.

Flip the pressure control switch to OFF gun

firmly to the side of a grounded metal pail, and trigger the

gun

to relieve pressure.

f the sprayer

, when

checking or servicing

INJECTION HAZARD

, before

tip. NEVER try

, below

RELIEF

Safety Latch

Whenever you stop spraying, even for a moment, always set the

trigger safety latch in the closed or

the

gun inoperative. Failure to set the safety latch can result

accidental

Diffuser

The gun diffuser breaks up spray and reduces the risk of fluid injection regularly remove gun the gun. If the fluid emitted stream,

ip 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 placing tip.

Trigger

Always ing to reduce the risk of accidentally triggering the gun if it is dropped

Spray T

Use extreme caution when cleaning or changing spray tips. If the spray tip clogs while spraying, engage the trigger safety latch

dure,

NEVER is

fully relieved and the gun safety is engaged.

triggering of the gun.

when the tip is not installed. Check dif

. Follow the

the spray tip. Aim the gun into a metal pail, holding the

firmly to the pail. Using the lowest possible pressure, trigger

replace the dif

helps reduce, but does not prevent, the

your

fingers or any part of your body close to the spray

Guard

have the trigger guard in place on the gun when spray

or bumped.

Pressure Relief Procedure

is not

fuser immediately

ip Safety

immediately

below, and then remove the spray tip to clean it.

wipe of

. AL

WAYS

follow the

f build–up around the spray tip until the pressure

“safe” position, making

fuser operation

, below

diffused into an irregular

risk of accidentally

Pressure Relief Proce

, then

PROCEDURE

Engage the trigger safety latch.

6 Open the pressure drain valve. Leave the valve open until

you

are ready to spray again.

Disconnect the spark plug cable.

you suspect that the spray tip or hose

or that pressure has not been fully relieved after following the steps

above,

VER

hose end coupling to relieve pressure gradually

completely.

Y SLOWL

Now clear the tip or hose.

Y loosen

is completely clogged,

the tip guard retaining nut

, then loosen

1,5

23 4

MOVING PARTS HAZARD

Moving

parts parts. the

sprayer

can pinch or amputate your fingers or other body

KEEP CLEAR of moving parts when starting or

. Follow the

Pressure Relief Procedure



operating

above be

checking or servicing any part of the sprayer

fore from

starting accidentally

, to prevent it

0139

Page 5

EQUIPMENT MISUSE HAZARD

General

Any misuse of the spray equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals to rupture and result in fluid injection, splashing in eyes or on skin, age.

NEVER alter or modify any part of this equipment; doing so could

CHECK all spray equipment regularly and repair or replace worn

Always tor

Noise

Ear Refer

Safety

and fluids, or using worn or

other serious injury

cause it to malfunction.

or damaged parts immediately

wear protective eyewear

as recommended by the fluid and solvent manufacturer

protection is recommended when the sprayer is operating.

to the Sound Level in the Technical Data

damaged parts, can cause them

, or fire, explosion or property dam

, gloves, clothing and respira

on page 43.

HOSE SAFETY

High

pressure fluid in the hoses can hose develops a leak, split or rupture due to any kind of wear, damage cause damage.

All reliefs the coupling which can result in hose rupture.

TIGHTEN pressure sure

NEVER tire movement of the hose couplings. If ist, replace the hose immediately pressure hose or mend it with tape or any other device. A repaired

or misuse, the high pressure spray emitted from it

a fluid injection injury or other serious

fluid hoses must have strain reliefs on both

help protect the hose from kinks or bends at or close to

all fluid connections securely before each use. High

fluid can dislodge a loose coupling or allow high pres

spray to be emitted from the coupling.

use a damaged hose. Before each use, check the en

hose for cuts,

hose cannot contain the high pressure fluid.

leaks, abrasion, bulging cover

be very dangerous. If the

can

injury or property

ends! The strain

, or damage or

any of these conditions ex

. DO NOT try to recouple high

System

This

Pressure.

are rated to withstand the this pressure. DO NOT exceed the maximum working pressure of any component or accessory used

Pressure

sprayer can develop 3000 psi (210 bar)

Be sure all spray equipment and accessories used

in the system.

Maximum Working

Fluid and Solvent Compatibility

All

chemicals used

ible

with the wetted parts shown in the Technical Data

43.

Consult your chemical supplier to ensure compatibility

not use 1,1,1-trichloroethane, methylene chloride, other ha

logenated hydrocarbon solvents or fluids containing such solvents in this equipment, which contains aluminum and/or zinc parts.

Such

the

possibility of explosion, which could cause death, serious in

jury

and/or substantial property damage.

Handle

and route hoses carefully equipment. of

the pump and gas engine. Do not use fluids or solvents which

are

not compatible with

NOT

expose Graco hoses to temperatures above 180 F

or below –40 F (–40

in the sprayer must be chemically compat

use could result in a serious chemical reaction, with

. Do not pull on hoses to move

Keep hoses clear of moving parts and hot

the inner tube and cover of the hose. DO

 C).

Hose Grounding Continuity

Proper

hose grounding continuity is essential to maintaining a

grounded

fluid tag on it which specifies the maximum electrical resistance, contact

sistance

for your hose to check the resistance. If the resistance exceeds the recommended limits, replace it immediately. An ungrounded ardous.

spray system. Check the electrical resistance of your

hoses at least once a week. If your hose does not have a

the hose supplier or manufacturer for the maximum re

limits. Use a resistance meter in the appropriate range

or poorly grounded hose can make

Also read

Fire Or Explosion Hazard

your system haz

, below

on page

surfaces

(82



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

Check the entire system for proper grounding. Do not use the

this equipment, ST

system again until the problem has been identified and corrected.

OP SPRA

Grounding

reduce the risk of static sparking, ground the sprayer and other spray equipment used or located in the spray area. CHECK tions all

NEVER spilled

ALWAYS

Explosion Hazard

United General Standards, Part 1910, and the Construction Standards, Part 1926 – should be consulted.

your local electrical code for

for your area and type of equipment. BE SURE to ground

of this spray equipment:

Sprayer:

true

connect a ground wire and clamp (supplied) to a

earth ground.

fill the fuel tank while the engine is running or hot. Fuel

on a hot surface can ignite and cause a fire.

pour fuel in slowly

, above, and

States Government safety standards have been adopted under the Occupational Safety and Health Act.

to avoid spilling. Also read

Fueling

FLUID

YING IMMEDIA

detailed grounding instruc

GASOLINE

on page 1

INJECTION HAZARD

TELY.

all

ENGINE HAZARD

Fire Or

IMPORTANT

Fluid hoses:

500 ft (150 m) combined hose length to ensure grounding continuity.

Spray gun:

3. erly

grounded fluid hose and sprayer

Object being sprayed:

Fluid supply container:

All

solvent pails used when flushing,

Use

only metal pails, which are conductive. Do not place the pail on a non–conductive surface, such as paper or cardboard,

To maintain grounding continuity when flushing or relieving

pressure

a grounded metal pail, then trigger the gun.

Flushing

Reduce the risk of fluid injection injury, static sparking, or

splashing of

this manual. Follow the 4, and remove the spray tip before flushing. Hold a metal part of

the gun firmly to the side of lowest

possible fluid pressure during flushing.

NEVER gine 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.

use only grounded hoses with a maximumf

See

Hose Grounding Continuity, above.

obtain grounding through connection to a prop-

according to local code.

which interrupts the grounding continuity

always hold a metal part of the gun firmly to the side

according to local code.

Safety

by following the flushing procedure given on page 15

operate the engine in a closed building unless the en

Pressure Relief Procedure

a grounded metal pail and use the

These standards – particularly the

307-847 5

on page

Page 6

Avertissement

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

Cet

appareil produit un fluide à très haute pression. Le fluide pul vérisé tes

ou de ruptures peut pénétrer sou la peau ou à l’intérieur du corps putation. ou

entrant dans les yeux peut aussi entraîner des blessures gra

ves.

jamais

quelconque du corps. Ne jamais mettre le main ou les doigts sur

l’ajutage du pulvérisateur. Ne jamais la

peinture. Cet appareil que. TOUJOURS garder la protection de l’ajutage en place sure le pistolet TOUJOURS observer la Marche à Suivre Pour Détendre la

Pression donnée plus

tage une

partie de l’appareil.

JAMAIS essayer d’arrêter ou de dévier le fuites avec la main

le corps. Avant chaque utilisation, bien s’assurer que les dispositifs de sécurité

Soins médicaux

cas de pénétration de fluide sous la peau: MEDIATEMENT DES SOINS MÉDICAUX D’URGENCE. Ne pas

soigner cette blessure comme une simple coupure.

Avis

traumatisme.

cette

pour effectuer des recherches sur la toxicité. Certains revêtements

injectés directement dans le sang. Il est souhaitable de consul

ter un chirurgien esthétiques ou un chirurgien spécialisé

la reconstruction des mains.

Dispositifs de sécurité du pistolet

Avant de

sécurité du pistolet fonctionnent correctement.

ver

ni modifier une partie quelconque du pistolet; ceci risquerait d’entraîner un mauvais fonctionnement et des blessures graves.

Pour sures par projection de fluide ou celles causées par de éclaboussures vement, toujours bien observe cette marche à suivre chaque fois

que l’on arrête le pulvérisateur

Égale ou du nettoyage du système ou lors du

des ajutages.

Engager le verrou de sécurité du pistolet.

Mettre le levier d’arrêt du moteur sur ARRET (OFF).

3 Basculer l’interrupteur de commande de pression sur AR-

RET (OFF).

4 Désengager

nant une partie métallique du pistolet fermement appuyé contre libérer

générales de sécurité

par le pistolet ou le fluide sous pression provenant de fui

et entraîner des

Même

pointer le pistolet vers

pendant la pulvérisation.

du pulvérisateur

fonctionnent correctement.

médecin:

blessure immédiatement.

exotiques sont

blessures très graves, voir même une am

sans être sous pression, le fluide éclaboussant

quelqu’un ou vers une partie

N’est P

loin,

avant

, ou d’ef

AS un compresseur pneumati

fectuer un travail quelconque sur

essayer de “refouler”

de nettoyer ou d’enlever l’aju

DEMANDER

La pénétration des fluides sous la peau est

Il est important de traiter chirurgicalement

Ne pas retarder le traitement

dangereusement toxiques quand ils sont

dans

chaque utilisation, bien s’assure que

tous les dispositifs

Ne pas enle

MARCHE A SUIVRE POUR DÉTENDRE LA PRESSION

réduire les risques de blessures graves, y compris les bles

dans les yeux ou sur la peau, par des pièces en mou

le verrou de sécurité

le côte d’un seau en la pression.

, à l’occasion de la vérification,

du pistolet. T

métal, actionner le pistolet pour

changement

out en mainte

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 pisto

let

sur la position, “fermée” ou “sécurité” (“safe”), pour empêcher

pistolet de fonctionner

pistolet peut se déclencher accidentellement.

. Si le verrou de sécurité n’est pas mis,

Diffuseur

dif

fuseur du pistolet sert à diviser le jet et à réduire les risques d’injection fier rification, Pour pulvérisateur. Pointer le pistolet dans un seau en métal, en le maintenant sion Si le fluide projeté remplacer

accidentelle quand l’ajutage

le fonctionnement du

détendre la pression en observant la Marche à Suivre

Détendre la Pression donnée plus loin enlever l’ajutage du

fermement contre le seau. Puis, en utilisant la pres

la plus faible possible, appuyer sur la gâchette du pistolet.

immédiatement le dif

dif

n’est pas

fuseur régulièrement. Pour cette vé

dif

fusé sous forme de jet irrégulier

n’est pas en place. Véri

fuseur.

Protection de l’ajutage

TOUJOURS pistolet de

l’ajutage attire l’attention sur les risques d’injection let contri

bue

à réduire, mai n’évite pas le risque, que les doigts ou une partie quelconque du corps ne passent accidentellement à proximité

Consignes de sécurité concernant l’ajutage du pulvérisateur

Faire remplacement des ajutages du pulvérisateur. Si l’ajutage se bouche rou

de sécurité du pistolet. T à Suivre Pour Détendre la Pression puis enlever l’ajutage du pulvérisateur NE

JAMAIS essuyer du pulvérisateur avant que la pression ne soit complètement tombée

Engager le verrou de sécurité du pistolet.

6 Ouvrir

que

Débrancher le fil de la bougie.

Si l’on soupconne que le tuyau ou l’ajutage est

maintenir la protection de l’ajutage en place sur le

du pulvérisateur pendant la

immédiate de l’ajutage du pulvérisateur

extrêmement attention à l’occasion du

pendent la pulvérisation, mettre immédiatement le ver

pour le nettoyer

ce qui s’est accumulé autour de l’ajutage

et que le verrou

la soupape de

l’on soit prêt à se servir de nouveau du pulvérisateur

de sécurité du pistolet ne soit engagé.

sécurité et la laisser ouverte jusqu’à ce

pulvérisation. La protection

nettoyage ou due

OUJOURS bien observe la Marche

complètement

bouché ou que la pression n’a pas été complètement libérée

après

avoir procédé aux opérations

lentement

protection

un raccord de bout de tuyau ou l’écrou de retenue de

de l’ajutage et libérer progressivement la pression.

ci–dessus, desserrer

Tres

1,5

23 4 6

307-8476

0139

Page 7

RISQUES EN CAS DE MAUVAISE UTILISATION DU MATERIAL

Consignes

Toute accessoires comme, par exemple, la mise sous une pression excessive, chimiques usées ruptures tres blessures sérieuses, un incendie, une explosion ou d’autres

dégâts.

Toujours tements protecteur et un dispositif pour la respiration correspondant vants.

Pression

pulvérisateur peut

TRAVAIL 210 bar (3000 lb/po.@)

ments sister PAS ments

Compatibilité chimique des corps

BIEN chimiquement compatibles avec les parties mouillées indiquées soigneusement les documents et brochures du fabricant des fluides sateur.

Le fluide à haute pression circulant dans les tuyaux peut être

dangereux. En cas de

très re

ou rupture à la suite de l’usure, de dégâts utilisation, les projections de fluide haute pression qui en proviennent tion

sous la peau ou par contact, ainsi que des dégâts matériels.

générales de sécurité

utilisation anormale de l’appareil du

les modifications de pièces, l’utilisation de produits

de matières incompatibles et l’utilisation de pièces

ou abîmées peut causer des dégâts à

de pièces et entraîner une

porter une protection pour les yeux, de

aux recommandations des fabricants de

produire une

du pulvérisateur et ses accessoires sont conçus pour ré

à la pression maximum de travail de ce pulvérisateur

dépasser la pression maximum de travail d’aucun des élé

ou accessoires utilisés avec cet appareil.

S’ASSURER que tous les corps des solvants utilisés sont

dans les “Données techniques”, à page 43. T

et solvants utilisés avant de s’en servir dans ce pulvéri

fuite sur le tuyau, de fissure, déchiru

peuvent entraîner des blessures graves par pénétra

pulvérisation ou des

l’appareil ou des

injection de liquide ou d‘au

gants, des vê

fluides et sol

PRESSION MAXIMUM DE

S’assurer que tous les élé-

. NE

oujours lire

ou d’une mauvaise

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 Serrer

fluide sous pression peut faire sauter un raccord desserré ou

produire NE

refaire le raccord d’un tuyau haute pression ni de réparer le tuyau

réparé

Manipuler leur pas

bles exposer

(180_F)

Continuité de la mise à la terre des tuyaux

Une tielle tion. à te pas d’étiquette qui précise

prenez contact avec le fournisseur de tuyaux ou la fabricant pour de

fiez la résistance. Si celle–ci dépasse les limites recommandées, à

des risques pour votre système. Lisez aussi LES RISQUES D’INCENDIE OU D’EXPLOSION.

ou à son voisinage.

fermement tous les raccords avant chaque utilisation. Le

un jet à haute pression s’échappant par le raccord.

JAMAIS utiliser un tuyau endommagé. NE P

avec du ruban adhésif

ne peut pas résister au fluide sous pression.

les tuyaux avec precaution

chemin. Ne pas déplacer le fluide en tirant sur le tuyau. Ne

utiliser de fluides ou de solvants que ne sont pas compati

avec l’enveloppe intérieur ou extérieure de tuyau. NE P

le tuyau à fluides des températures

ou inférieures à –40_C (–40

bonne continuité de la mise à la terre des tuyaux est

pour maintenir la mise à la terre de l’ensemble de vaporisa

Vérifiez la résistance électrique de vos tuyaux à fluides et

air

, au moines

avoir les limites de résistance maximum. Utilisez un mètre

résistance de la gamme appropriée pour votre tuyau et véri

remplacez le tuyau immédiatement. Un tuyau sans mise

la terre ou avec une mise à la terre incorrecte peut entraîner

une fois par semaine. Si votre tuyau ne compor

ou par tout autre moyen. Un tuyau

et choisir soigneusement

supérieures à 82

_F).

résistance électrique maximum,

AS essayer de

essen

RISQUES D’INCENDIE OU D’EXPLOSION

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

produire et l’appareil risques d’être dangereux. Des étincel les peuvent Également se produire à l’occasion du branchement

ou du débranchement du cordon d’alimentation

lisation

d’un moteur à essence. Les

pour

allumer les vapeurs de solvants et le

fines

particules de poussière ainsi que d’autres substances in flammables, elles peuvent causer un incendie ou une explosion, ainsi que des

blessures graves et des dégâts matériels.

S’il

se produit des étincelles d’électricité statique, ou si vous res sentez PULVERISATION. me

soit identifié et corrigé.

Mise à la terre ou à la masse

Pour statique, trouvant dans la zone de pulvérisation doivent être reliés à la terre mise CONSULTER les.

S’ASSURER que tous le équipements de pulvérisation sui

vants 1

Pulvérisateur:

une bonne terre.

quand on pulvérisé à l’intérieur ou à l’extérieur

la moindre décharge, ARRETEZ IMMEDIA

Vérifiez que le système avant que le problè

réduire les risques de production d’étincelles d’électricité

le pulvérisateur et tous les équipement utilisés ou

ou à la masse. à la terre dans la région et le type particulier d’équipement,

le code

sont bien reliés à la terre:

Relier le file de masses et le collier (fourni) à

ou à la terre, des étincelles peuvent

étincelles sont suf

fluide pulvérisé, les

Pour connaître le détail des instructions de

ou les réglementations électriques loca

ou de l’uti

fisantes

, et

TEMENT LA

2 Pistolet:

tuyau flexible et à une pulvérisateur déjà convenablement reliés

Tuyaux

terre, et ayant une longueur maximum combinée de 150 m (500 pieds).

du circuit de mis à la terre des tuyaux”.

Récipient

tations

Objets,

ver

Tous

code ou les réglementations locales.

seaux

le pier ou du carton car cela interromprait la continuité de la mise

Pour conserver la continuité de la mise à la terre quand on

Réaliser la mise à la terre en le raccordant à une

à la terre.

flexibles:

n’utiliser que des tuyaux comportant

Se reporter également au paragraphe,

locales.

matériel ou surfaces recevant

le code ou les réglementations locales.

le seaux de solvant

Afin d’assurer la continuité

d’alimentation:

observer le code ou les réglemen

utilisés pour le rinçage: observer le

une mise à la terre

la pulvérisation:

N’utiliser que des

métallique

seau sur une surface non conductrice comme sur du pa

à la terre.

conducteurs de l’électricité. Ne pas mettre

rincé le matériel ou quand on libère la pression,

maintenir une partie métallique du pistolet fermement appuyée

contre le côté d’un seau

détente

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 donnée

du pistolet.

éclaboussures, observe la marche

à la page 15 de ce manuel.

métal

puis appuyer sur la

à suivre pour le rinçage

de la mise à la

“Continuité

obser

toujours

MESURES DE SECURITE CONCERNANT LES TUYAUX FLEXIBLES

JAMAIS remplir le réservoir de carburant

tourne

ou quand face chaude peut s’enflammer et causer un incendie. TOUJOURS

Lire RISQUES D’INCENDIE OU D’EXPLOSION.

verse le carburant

il est chaud. Le carburant renversé sur une sur

lentement pour éviter d’en renverser

quand le moteur

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,

gaz

toxique, inodore et invisible qui peut entraîner des malaises

graves

ou même la mort se l’on le respiré.

 

Page 8

ADVERTENCIA

ROCIADO a ALTA PRESIÓN PUEDE CAUSAR GRA

SOLO P

ARA USO PROFESIONAL. RESPETE LOS A

VISOS DE ADVERTENCIA.

Lea y entienda todo el manual de instrucciónes antes de manejar el equipo.

PELIGRO DE INYECCION DE FLUIDO

VES LESIONES.

Seguridad

Este

equipo general un fluido a una presión muy alta. El rociado

la pistola, los escapes de fluido o roturas de los componen

tes

pueden inyectar fluido en la piel y el cuerpo y causar lesio

nes

extremadamente graves, de amputación. T ojos

puede causar graves daños.

NUNCA po.

NUNCA colocar la mano o los dedos encima de la boquilla. NUNCA tema

SIEMPRE mientras

SIEMPRE dado más abajo, servicio

NUNCA cuerpo.

Asegurar funcionando

Tratamiento

Si pareciera que un poco de fluido penetró la piel, conseguir

TRATAMIENTO MEDICO DE URGENCIA DE INMEDIATO. NO

TRATAR LA HERIDA COMO UN SIMPLE CORTE.

al médico

Aviso

causa una lesión traumática.

gicamente

tratamiento para investigar

de sumar importancia en algunas pinturas exóticas cuando se

inyectan directamente al torrente sanguíneo. Sirá conve

niente consultar a un especialista en cirugía plástica o reconstructiva

general

ambién, el

apuntar la pistola tratar de “hacer retornar la pintura”; este NO es un sis

de rociado de aire.

tener

colocado el protector de la boquilla en la pistola

se está pulverizando.

seguir el procedimiento de descarga de presión,

a cualquier del sistema.

tratar de parar o desviar los escapes

que todos los aparatos de seguridad del equipo están

antes

bien antes de cada uso.

incluyendo a veces la necesidad

fluido

inyectado o salpicado en los

hacia alguien o alguna parte del cuer

de limpiar o sacar la boquilla o de dar

con la mano o el

médico

exactamente cua fluido fue.

al médico:

Si se llega a inyectar este fluido en la piel

la lesión a la

de las manos.

Es importante tratar quirúr

brevedad posible.

toxicidad. La toxicidad es algo

No demorar el

Decir

Aparatos

Asegurar

funcionando

guna pieza de la pistola pues podría causar el malfuncionamiento

Pestillo

Cada

momento, siempre colocar el pestillo de seguridad en la posición

puede llevar al disparo imprevisto de la pistola.

Difusor

difusor de la pistola dispersa el chorro pulverizado y reduce

riesgo visar con regularidad el funcionamiento del difusor. Seguir el procedimiento pués sacar la boquilla. Apuntar la pistola a un balde metálico, sosteniéndola bien firme contra él. Utilizando la presión más bajo

perso Protector

SIEMPRE mientras contra la

colocación accidental de los dedos o cualquier otra parte del cuerpo

Seguridad

Tener ra

a obstruirse mientras está pulverizando, enganchar el

llo

de la de descarga de presión y después sacar la boquilla para limpiarla

NUNCA limpiar la acumulación de pintura alrededor de la boquilla y

el pestillo esté enganchado.

de seguridad de la pistola pulverizadora

que todos los aparatos protectores de la pistola están

bien antes de cada uso. No sacar ni modificar nin

la misma con las consiguientes lesiones personales.

de seguridad

vez que se deje de pulverizar

“cerrada”, lo que deja la pistola inoperante. El no hacerlo

de inyección cuando no está instalada la boquilla. Re

de descarga de presión, dado más abajo, y des

posible, disparar la pistola. Si el fluido emitido

en un

chorro irregular

de la boquilla

tener

el protector de la boquilla colocado en la pistola

se está pulverizando.

el peligro de inyección

cerca de la boquilla.

, reemplazar de inmediato el difusor

, aunque sea por un breve

Este protector llama la atención

y ayuda a reducir

de la boquilla pulverizadora

mucho cuidado al limpiar o cambiar las

pistola de inmediato. SIEMPRE seguir el procedimiento

antes de que se haya descargado por completo la presión

boquillas. Si llega

no sale dis

, pero no evita,

pesti

PROCEDIMIENTO

Para

reducir el cluyendo la inyección de piel, o lesiones causadas por piezas en movimiento, siempre seguir

este procedimiento al apagar la máquina pulverizadora,

revisar 1 Enganchar 2

Mover el interruptor de parada del motor a OFF Mover el interruptor de control de presión a OFF

3 4 Desenganchar

ner

una parte metálica de la pistola firmemente contra el de un balde de metal y activar la pistola para descargar la presión.

riesgo de sufrir graves lesiones corporales, in

, ajustar o limpiar el sistema, o al cambiar las boquillas.

el pestillo de seguridad de la pistola.

fluidos, salpicaduras en los ojos o la

el pestillo de seguridad de la pistola.

1,5

23 4 6



DE DESCARGA DE

5 Volver

6 Abrir la válvula de alivio de presión y dejarla abierta hasta

que

se esté nuevamente listo para pulverizar

Desconectar el cable de la bujía.

Mante

lado

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.

PRESION

a enganchar el pestillo de seguridad de la pistola.

0139

Page 9

PELIGRO POR MAL USO DEL EQUIPO

Seguridad

Cualquier como sobre presurización, modificación de piezas, teriales 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

ves,

incendio, explosión o daños a la propiedad.

Siempre piradero, solvente.

general

mal uso del equipo pulverizador o los accesorios, tal

usar gafas, guantes, vestimentas protectoras

tal como recomiendan los fabricantes del fluido y del

uso de ma

gra

y un res

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 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, APRET El fluido a lata presión puede desalojar un acoplamiento suelto o

dejar que pro él escape un chorro a alta presión.

NUNCA la da, o acoplamientos sueltos o dañados. Si llegara a encontrar se cualquiera de estas condiciones, reemplazar de inmediato la sión o enmendarla con cinta adhesiva u otro material similar. Una alta

usar una manguera que está dañada. Siempre revisar

en busca de cortaduras, escapes, abrasión, cubierta

manguera. NO intentar reacoplar una manguera de alta pre

manguera que ha sido remendada no aguante

presión.

AR bien firmes

todas las conexiones.

causar

abulta

el fluido al

Presión

Esta

PRESION

po pulverizador y sus accesorios tienen la capacidad para aguantar

accesorio de este sistema.

Compatibilidad de fluido

Siempre te

Manejar y pasar cuidadosamente las mangueras. No tirar de las tes la

82) C

Continuidad

del sistema

pulverizadora puede desarrollar 210 barías (3000 psi) de

TRABAJO MAXIMA.

la presión máxima de trabajo

leer las instrucciones del fabricante del fluido y solven

antes de usarlos en esta pulverizadora en la página 43.

mangueras para mover el equipo. No usar fluidos o solven que sean

manguera. NO exponer las mangueras a temperaturas sobre

incompatibles con el tubo interno y la cubierta de

(180_F) o bajo -40

_C (-40_

Asegurar que todo el equi

de ningún componente

F).

del circuito de puesta a tierra de la

manguera

La continuidad del circuito de puesta a tierra apropiado es esencial dor las mana. Si la manguera no tiene una etiqueta en la cual se espe cifica la resistencia eléctrica máximum, ponerse en contacto con ción

cia

cede los lites recomendados, reemplazarla de inmediato. Es

muy arriesgado tener una manguera sin puesta a tierra o con la

mación sobre RIESGO DE INCENDIO O EXPLOSION, más arriba.

para mantener conectado a tierra el sistema pulveriza

. Es indispensable revisar la resistencia eléctrica máxima de

mangueras de aire y de fluido por lo menos una vez

el proveedor o

sobre los límites

en la gama apropiada para

puesta a tierra en malas condiciones. Leer también la infor

fabricante de la manguera para la informa

de resistencia. Usar un metro de resisten

comprobar la resistencia; si ex

a la se

PELIGRO DE INCENDIO O EXPLOSION

flujo a alta velocidad del fluido al pasar por la bomba y man

guera

crea electricidad estática. Si todas las partes del pulverizador no tienen buena tierra, pueden ocurrir chispas, convirtiéndo al sistema en algo peligroso. También, pueden producirse co

o al usar un motor de gasolina. Estas chispas pueden infla mar do, partículas de polvo y otras sustancias inflamables, sea al aire cendio

ocurre una chispa de electricidad estática o incluso un ligero choque RIZAR DE INMEDIATO. Revisar todo el sistema en busca de una identificado

Puesta

Para pulverizadora se

encuentre en el lugar que se va a rociar digo eléctrico de la localidad para las instrucciones sobre las conexiones GURAR

Pulverizadora:

(suministrada)

chispas al enchufar o desenchufar el cordón eléctri

los vapores de los solventes y el chorro de fluido pulveriza

libre o bajo techo, lo que podría causar una explosión o in

y graves lesiones corporales y daños a la propiedad.

eléctrico mientras se usa el equipo, DEJAR DE PUL

tierra apropiado. No usar de nuevo el sistema hasta haber

y solucionado el problema.

a tierra

reducir el riesgo de chispas estáticas, conectar a tierra la

y todo el otro equipo de pulverizar que se use o

a tierra exigidas para la zona y tipo de equipo. ASE

de conectar a tierra todo este equipo pulverizador:

Conectar el alambre de tierra a una buena conexión a tierra.

. CONSULTAR el

y la abrazadera

equipo

VE-

có

Mangueras para fluidos:

puesta a tierra de una longitud combinada de 150 m (500 pies), para asegurar buena continuidad a tierra. Referirse

también

Pistola:

Suministrar un recipiente: solamente

car cartón, que interrumpe la continuidad a tierra.

Objeto

local.

Todos los baldes de solvente

conformidad con el código local.

Para mantener la continuidad a tierra durante el lavado o descarga

la pués

Seguridad durante el lavado

Para

piel, o que ocurra una descarga de electricidad estática, pre

seguir las INSTRUCCIONES P

página 15. Seguir el procedimiento de descarga de presión

baja

al párrafo sobre continuidad a tierra de la manguera.

hacer la puesta a

de fluido y pulverizadora bien conectadas a tierra.

baldes de metal,

el balde en una superficie no conductiva, como papel o

que se está rociando:

pistola bien firme contra el costado

reducir el riesgo

página 8, y quitar la

posible de fluido durante el lavado.

presión,

apretar el gatillo.

usar solamente mangueras con

tierra conectándola a una mangue

de acuerdo al código local. Usar

que sean conductivos. No colo

de conformidad con el código

usados durante

siempre apoyar una parte metálica de

de que se inyecte o salpique fluido en la

ARA EL LAVADO, dadas

boquilla de metal

el lavado, de

balde de metal

y usar le presión más

, des

siem

PRECAUCIONES PARA LOS MOTORES DE GASOLINA

NUNCA funcionando o caliente. El combustible derramado en una superficie caliente puede encenderse y provocar un incendio. SIEMPRE verter el combustible lentamente para evitar derra-

mes. Leer PELIGRO DE INCENDIO O EXPLOSION.

llenar el tanque de combustible mientras el motor está

NUNCA caminar escape olor so

hacer funcionar el motor en un edificio cerrado sin en– los gases de escape hacia el aire libre. Los gases

contienen monóxido de carbono, un

e invisible que podría causar enfermedades graves, inclu

la muerte, al inhalarse.

gas venenoso, sin

307-847 9

Page 10

Setup

1. Connect hose and gun. a. Remove

the plastic cap plug from

(Refer to Fig. 2.)

the filter outlet

nipple (57) and screw the 50 ft. (15.2 m) main

hose (202) onto the nipple.

fluid

b. Connect the whip end hose (203) between the

main

c. DO

the

fluid hose and

NOT use thread sealant, and DO NOT install

spray tip yet!

the gun (204) inlet adapter

WARNING

If you are supplying your own hoses and spray gun, be

sure the hoses are electrically conductive, that

gun

has a tip guard, and that each part is

least

3000 psi (210 bar) Maximum Working Pressure

This

is to reduce the risk

of serious injury caused by

rated for at

static sparking, fluid injection or over-pressurization and

rupture of the hose or gun.

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.

CAUTION

To avoid damaging the pressure control, which may result in poor equipment performance and component

damage, follow these precautions.

1. Always use nylon spray hose at least 50 ft. (15.2 m)

long.

the

KEY

53 Pressure 56

Secondary hose cap

Outlet nipple

Pail hanger

202

Main hose

203

Whip end hose

204

“Contractor” gun with RAC IV

Dripless tip guard and 517 size SwitchT

416 Wetcup

drain valve

416

Never use a wire braid hose; it is too rigid to act as a pulsation dampener

3. Never

4. Always

3. Fill ing Liquid

4. Check

install any shutof

(51)

and the main hose (202). See Fig. 2.

use the

operation.

Never plug this outlet.

packing nut/wetcup.

nut/wetcup (416) 1/3 full with

(TSL), supplied.

the engine oil level.

main filter outlet (57) for one gun

f device between the filter

(See Fig. 2.) Fill the pack

Graco Throat Seal

Refer to the Honda en gine 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

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

new engine.

204

202

Fig. 2

204

0140

307-84710

Page 11

Setup

5. Be sure your system is properly grounded be-

fore

operating it.

tion,

FIRE OR EXPLOSION HAZARD

6. Fill the gas tank.

7. Flush

8. Prepare the paint according to the manufacturer’s

9. Keep the sprayer upright and level during opera-

the pump

was

left in the pump to protect it from rust.

a. Before

b. Before using oil–base paint, flush with mineral

c. See

recommendations. a. Remove

b. c. Strain the paint through a fine nylon mesh bag

tion and whenever it is being moved. See the last

CAUTION

using water–base paint,

spirits, followed by soapy water, and then flush

al with

clean water

only

spirits,

Flushing

dure.

Stir the paint to mix pigments.

(available ticles that could clog the filter or spray tip. This is

probably the

ble–free

on page 12.

Read and follow the warning sec

, on page 5.

See the

to remove the lightweight oil which

on page 15 for the flushing proce

any skin that may have formed.

at most paint dealers) to remove par

most important step toward trou

spraying.

Fueling

section, below

flush with miner

Fig. 3

0015

0141

Fueling

WARNING

Gasoline is extremely flammable and explosive under

certain conditions. Always shut of Refuel in a well–ventilated area. Do not smoke or allow flames or sparks in the area

where

the engine is refueled or where

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 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.

f the engine before refueling.

the gasoline is

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 do not use the gasohol if it contains more than 5% methanol.

NOTE: The HONDA engine warranty does not cover damage cohol. tion.

3. General. Do not use oil and gasoline mixtures or

4. Tank

5. Shut off the engine before refueling.

6. After refueling, tighten the fuel tank cap firmly.

resulting from the use of gasolines containing al

See the HONDA engine manual for more informa

contaminated gasoline. Avoid getting dirt, dust or

in the fuel tank.

water

Capacity. 0.95 gallons (3.6 liter). Always leave

least 1/2 in. at the top of the tank for expansion.

additives,

307-847 11

Page 12

Startup

Before you start the sprayer

1. See Flushing flush

the sprayer

Be sure the gas tank is full.

3. Check the engine oil level.

NOTE: The 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.

on page 15 to determine if you should

engine stops automatically

, or will not start,

Startup

NOTE:

1. When

2. If a secondary hose and gun is not installed, be

3. Place the suction tube into the paint, water or

4. Open the black fuel shutoff lever (H) by pushing

Refer to Fig. 4 as you start the sprayer

starting a sprayer that IS

move

the spray tip.

the cap (56) is securely plugging the secondary

sure outlet

fitting.

solvent container, depending on whether you are flushing

or are ready to spray

in the direction of the arrow

NOT PRIMED,

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.

f. Open

7. Disengage the trigger safety latch (N).

8. To start the pump: a. b. T c. Turn

d. Close

e. Release the trigger. Engage the trigger safety

9. If

you have not primed the sprayer with paint

move 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.

the choke as soon as the engine starts, ex cept in cold weather. In cold weather, leave the choke

closed for 10 to 30

it to keep the engine running.

ing

Open the pressure drain valve (53).

urn the pressure control switch (A) to ON.

the pressure control knob (B) about 1/4 turn from minimum pressure. Run the pump until is flowing smoothly from the pressure drain valve,

indicating the pump is fully primed.

the pressure drain valve (53). Hold a metal part of the gun firmly against a grounded metal pail

and squeeze the trigger until

the

gun.

latch (N).

the suction tube

to the paint container

seconds before open

fluid flows from

WARNING

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 instruction manual, 307–848, supplied.

tip

fluid

yet,

. Release

5. Turn the pressure control switch (A) to OFF.

6. To start the engine: a. Turn

b. Slide the metal throttle lever (K) away from the

c. If

d. T

the pressure adjusting knob (B) fully coun

terclockwise

fuel

tank to maximum position (fully left).

the engine is cold, close the

the

gray lever (J).

the engine is warm, close the

the

gray lever only half way or not at all.

urn the engine switch (L) to ON.

to the lowest pressure setting.

choke by moving

WARNING

rope which recoils too quickly may hit someone and

cause

serious injury

assembly.

e. Hold

the frame of the sprayer with one hand

pull

the starter rope rapidly holding turn

the rope until the engine starts.

307-84712

. The rope

the rope as you let it return.

could also jam in recoil

and firmly

and

. Continue

Pull and re

11. Adjust lease test paper to check the spray pattern and atomization. Turn the pressure adjusting knob (B) until you get setting pattern.

the engine speed and pump pressure.

the trigger safety latch (N). T

a good pattern. Then slowly lower the throttle (K)

as far as you

can without changing the spray

rigger the gun onto

CAUTION

Always lowest needed throttle setting, to increase the life of the sprayer. Higher settings cause excessive clutch cycling

use the lowest needed fluid pressure and

and premature tip and pump wear

CAUTION

Close the black fuel shutoff lever (H) whenever you are transporting the sprayer to prevent fuel from flooding

Keep and from leaking into the combustion chamber, which makes

the engine.

the sprayer upright

when transporting it. This prevents crankcase oil

startup very dif

and level when operating it

ficult.

the

Page 13

202

0138

0015

0016

0136

KEY

A Pressure

switch

Pressure adjusting knob

Air cleaner

Fuel T E Muffler F Engine G

Spark plug cable H

Fuel shutof J Choke K Throttle L

Engine ON/OFF switch M

Engine oil light NT

(shown engaged) 4 Clutch 28

Displacement pump 47

Grounding wire and clamp 51

Fluid filter 53

Pressure drain valve 56 Secondary 202 Main 203

Whip end hose 204 “Contractor”

IV Dripless tip guard and

517 size SwitchT

Control ON/OFF

ank

f lever

rigger safety latch

hose outlet cap

hose

gun with RAC

Fig. 4

203

204

0137

307-847 13

Page 14

Maintenance

WARNING

reduce the risk of

jection

or splashing in the eyes or on the skin, or injury from moving parts, always follow the Pressure Re- lief Procedure Warning, below, before checking, adjusting,

connect

DAILY: Check DAILY: Check AFTER THE FIRST 20 HOURS OF OPERA

Drain the oil and refill with clean oil.

WEEKLY:

the

element. ing in an unusually dusty environment, check the filter daily

Replacement HONDA

cleaning or

the spark plug!

Remove the cover of the air Replace the element, if necessary

and replace it, if necessary

elements can be purchased from your

dealer

serious injury

shutting down the sprayer

the engine oil level and and fill the gas tank.

, including fluid in

Dis-

fill as necessary

TION

filter and clean

. If operat

local

WARNING

Pressure Relief Procedure

reduce the

tion,

splashing fluid or solvent in the eyes or on the skin, or injury from moving parts or electric shock, always fol low 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.

risk of serious injury

, including fluid injec

CAUTION

For

detailed engine maintenance and specifications,

refer

to the separate engine manual, supplied.

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.

AFTER EACH 100 HOURS OF OPERA

Change the oil.

SPARK

plug. Use a spark plug wrench when installing and removing the

4. Disengage

6. Open the pressure drain valve. Leave the valve

PLUG:

Gap the plug to 0.025 to 0.030 in. (0.7 to 0.8

plug.

the gun firmly to the side of a grounded metal pail,

and

trigger the gun to relieve pressure.

Engage the trigger safety latch.

open

until you are ready to spray again.

Disconnect the spark plug cable.

Use only an (NGK)

the trigger safety latch. Hold

TION:

BP6ES or BPR6ES

mm).

a metal part

Engage the trigger safety latch.

2. T

urn the engine ON/OFF switch to OFF

3. T

urn the pressure control switch to OFF

1,5 2 3

If you suspect that the spray tip or hose is completely clogged,

ter following the steps above,

the tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear

or that pressure has not been fully relieved af

VERY SLOWLY loosen

the tip or hose.

0139

307-84714

Page 15

Flushing

When to Flush

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.

Before using oil–base paint,

flush with mineral spir-

its.

2. Changing Colors. as mineral spirits or water

such

3. Changing from water–base to oil–base paint.

with

warm, soapy water, then mineral spirits.

Flush with a compatible solvent

Flush

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 trol tube prevents the sprayer from being started, and causes

spirits. W

ater frozen in the pressure con

serious damage to the pressure control.

WARNING

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

of,

and aimed into, a grounded metal pail .

Maintain



metal-to-metal contact when flushing



6. Follow Startup until clean solvent comes from the nozzle. Release the

trigger and engage the trigger safety latch.

NOTE: For

two guns, release the trigger 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.

on page 12. Keep the gun triggered

safety latch on

side

firm

5. Storage.

Water

base paint:

its and leave

flush with water

the

pump, hose and gun filled with min

, then mineral spir

eral spirits. Shut off the sprayer, remove the spark plug

cable, and open the pressure drain

lieve

pressure. Leave the drain valve open.

Oil

base paint:

flush with mineral spirits and leave

valve to re

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.

Startup after storage.

Before using water–base paint

spirits

with soapy water

, and then with clean water

When using oil–based paint,

spirits

with the paint to be sprayed.

, flush out mineral

flush out the mineral

How to Flush

NOTE: “Solvent”

Relieve pressure. See page 14.

refers to water or oil-based solvent.

the

7. Check all fluid connections for leaks. Relieve pres-

sure before tightening any connections. Start the

sprayer.

8. Remove the suction tube from the solvent pail. Dis-

Recheck the connections for leaks.

engage the trigger safety latch. Trigger the gun to

force

solvent from the hose. Do not let the pump run

dry

for more than 30 seconds, to avoid damaging

pump

packings. Relieve pressure.

9. Remove

the strainer

, suction tube and suction 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.

the

hose

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

Close the pressure drain valve (53).

Put the suction tube in a grounded pail of solvent.

Remove the spray tip from the gun(s).

. See Fig. 5.

Fig. 5

014

 

Page 16

Troubleshooting

WARNING

Pressure

reduce the risk of serious injury, including fluid injec tion, moving parts, always follow this procedure when you shut ing

Relief Procedure

splashing in the eyes or on the skin, or injury from of

f the sprayer

the system, and when changing spray tips.

Engage the trigger safety latch. T

urn the engine ON/OFF switch to OFF

urn the pressure control switch to OFF

, when checking, adjusting or clean

Guide

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.

Engage the trigger safety latch. Open the fluid pressure drain valve and leave it

open until you start the sprayer again. Disconnect the spark plug.

If you suspect the hose or spray tip is completely clogged ing the steps above, VERY SLOWLY

guard ly.

or that pressure is not fully

or hose end coupling to

Now clear the tip or hose obstruction.

relieved after follow

relieve pressure gradual

loosen the tip

Check everything in the chart before disassembling the sprayer

PROBLEM CAUSE SOLUTION

Engine/sprayer won’t start

Engine won’t “pull over”

Engine operates, but displace ment pump doesn’t

Engine switch not on Out of gas Engine oil level low

Spark plug cable disconnected or spark plug damaged

ater frozen in pressure control

Oil seepage into combustion chamber

Pressure control switch turned OFFTurn on.

Pressure setting too low Displacement pump outlet filter dirty

urn on. Replenish T

ry starting engine. If light on rear of en gine glows, replenish oil.

Connect cable on top of engine or replace spark plug.

Return pressure control to authorized Graco dealer for repair

Remove spark plug. Pull starter rope 3 or 4 times. Clean or replace plug. T start. Keep sprayer upright to avoid oil seepage.

Increase pressure. Clean filter

ry to

ip or tip filter clogged

Displacement pump rod seized by dry paint

Connecting rod worn or damaged Drive housing worn or damaged Electrical power not energizing field

Clutch worn or damaged Pinion assembly worn or damaged



Clean tip or tip filter Service pump. See page .

Replace. See page 18. Replace. See page 19. 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 autho rized Graco dealer

Service. See page 22. Service. See page 20.

Page 17

PROBLEM

CAUSE SOLUTION

Displacement pump output low on upstroke

Displacement pump output low on downstroke or both strokes

Paint leaks into wet–cup

Pump inlet screen clogged

Piston ball check not seating Piston packings worn or damaged Sleeve gasket in displacement

pump worn or damaged Pump inlet screen clogged

Piston packings worn or damaged Intake valve ball check not seating

properly Engine RPM too low

Clutch worn or damaged Loose wet–cup Throat packings worn or damaged Displacement rod worn or damaged

Clean.

Service piston ball check. See page 31. Replace packings. See page 31. Replace. See page 31.

Clean.

Replace packings. See page 31. Clean and service. See page 31.

Increase throttle setting. See Step 1

1, page 12.

Startup,

Replace. See page 22. T

ighten just enough to stop leakage. Replace packings. See page 31. Replace rod. See page 31.

Low fluid delivery

Pump inlet screen clogged. Pressure setting too low

Engine RPM too low

Dirty outlet filter

, tip filter or tip

Large pressure drop in hose

Clean. Increase pressure. See

Step 1

1, page 12.

Startup,

Increase throttle setting. See Step 1

1, page 12. Clean. Use larger diameter hose.

Startup,

Spitting from gun Air in fluid pump or hose Check for loose connections at pump in

take and tighten. Then prime the pump. See page 12.

ip partially clogged

Fluid supply is low or empty Refill and prime the pump. See

Clear.

Startup,

page 12. Check fluid supply often to pre

Pump is dif

ficult to prime

Air leak

vent running the pump dry Check all hose connections and tighten as

needed. Reduce RPM and cycle pump as slowly

as possible during priming.

Intake valve is leaking

Shut of

f pump and relieve pressure. Dis assemble and clean intake valve. Be sure ball seat is not nicked or worn and that the ball seats well. Reassemble.

orn packings

Fluid is too thick

Repack the pump. See page 31. Thin fluid according to supplier

recommendations.

307-847 17

’s

Page 18

Bearing

Housing & Connecting Rod

WARNING

reduce the risk of

jection

always follow the Warning on page 14 before checking, adjusting, cleaning or shutting off the sprayer.

spark

plug!

NOTE:

2. For upright models only: Remove the spring clips

3. Disconnect the pump outlet hose (59) from the dis-

4. Use

5. Loosen the jam nut (27) with an adjustable wrench.

6. Use a hex key wrench to remove the four screws (73)

7. While

8. Inspect

9. Evenly

10. Assemble

Steps 1 to 13 refer to Fig. 6.

Remove the front cover and screws (23,68).

(112, 114) and the drain hose (113). Unscrew the suction the pump intake valve (B) to keep the pump from loosening.

placement

(26) rear.

Unscrew

and

lightly with ing rod

parts

in necting ally assembly

ing (21).

tube (30) from the pump, holding a wrench on

pump outlet nipple (92).

a screwdriver to push aside the retaining

at the top of the pump. Push the pin (25) out the

and remove the displacement pump.

lockwashers (74) from the bearing housing (21).

pulling the connecting rod (22) with one tap the lower rear of the

a plastic mallet to loosen it from the drive hous

(20). Pull the bearing housing and the connecting

assembly (22) of

the crank (A) for excessive

as needed.

lubricate the inside of the bronze bearing

the bearing housing (21), and the inside of the con

rod link (D),

pack the roller bearing (E) in the connecting

(22) with bearing grease.

the connecting rod (22)

serious injury

Pressure Relief Procedure

, including fluid in

Disconnect the

spring

hand,

bearing housing (21)

f the drive housing.

wear and replace

(C)

with high–quality motor oil. Liber

rod

and bearing hous

CAUTION

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

13. Install the screws (73) and lockwashers (74) on the bearing housing. Tighten evenly to 300 in–lb (34 N.m).

14. Refer



Installing the Pump



Torque 300 in–lb (34 N.m)

on page 31.

112

113

11. Clean the mating surfaces of the bearing and drive housings.

12. Align

the connecting rod with the crank (A) and care fully 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.

307-84718

Fig. 6

114

0149

Page 19

Drive

Housing

WARNING

reduce the risk of

jection

always follow the Warning on page 14 before checking, adjusting, cleaning or shutting off the sprayer.

spark

plug!

NOTE:

2. Disconnect

3. Remove the four screws (73) and lockwashers (74)

4. Lightly

5. Remove the two screws (24)

6. Lightly tap around the drive housing (20) to loosen

Refer to Fig. 7 for this procedure.

Remove the front cover and screws (23,68).

ment

pump the spring clips (112, 114) and the drain hose (113) from

the pump.

from

the bearing housing (20).

tap the back of the bearing a plastic mallet. Pull the pump, bearing housing and connecting rod away from the drive housing as one assembly.

Remove

the drive housing. Pull the drive housing straight off the cluster

the four screws (10) and lockwashers (1

pinion housing. Be prepared to support the gear

(18), which may also come out.

serious injury

Pressure Relief Procedure

, including fluid in

Disconnect the

the pump outlet hose from the displace

nipple. For the upright carts only

housing (21) with

and lockwashers (1

, remove

1).

20a

CAUTION

DO NOT drop the gear cluster (18) when removing the

drive housing (20). The gear cluster is easily dam

aged.

The gear may stay engaged in the drive hous

or pinion housing.

ing DO

NOT lose the thrust balls

each

end of the gear cluster tween 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

20b

the gears and not removed, they age

the drive housing. If the balls are not in place, the

bearings

7. Liberally apply bearing grease to the gear cluster

9. Starting at Step 4, work backwards to reassemble

will wear prematurely

(18).

A tube ment gear cluster. Use a full 6 oz. (160 grams) of grease. place.

Place the bronze colored washer (20a) 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).

the sprayer. Or, move ahead to the next section in this

manual if further service is needed.

of grease is supplied with each replace

Be sure the thrust balls (20c and 19d) are in

(20c or 19d) located at

, or allow them to fall be

will seriously dam

and then the

Fig. 7

19d

20c

112

113

114

0170

 

Page 20

Pinion,

Clutch, Clamp, Field & Engine

Disassembling these parts can start from the pinion housing, needed.

or from the clutch if no pinion service is

Pinion

Pinion Housing

WARNING

reduce the risk of

jection

always follow the Warning on page 14 before checking, adjusting, cleaning or shutting off the sprayer.

spark

plug!

NOTE:

Refer to Fig. 8 for Steps 1 to 3.

Remove the two bottom screws (10) and lockwash ers (11) first, and then remove the top three screws (10)

and lockwashers (1

serious injury

Pressure Relief Procedure

1).

, including fluid in

Disconnect the

starting from the pinion housing, first follow Steps 1 to

If 6

Drive Housing

the

procedure below

If starting from the clutch

2. Pull

3. Pull the armature (4a) off the hub (19j –

the pinion housing away from

The

armature (4a) will come with it.

the pinion housing.

, on page

, see page 22.

19, and then continue with

the clutch housing.

CAUTION

Do not lose the thrust ball (19d). Refer to the CAUTION

on page 19 for more information.

NOTE: To

assemble more of the sprayer, go to page 22. To reassemble sembly,

disassemble the

the sprayer from this point, skip ahead to

page 27, Step 7.

pinion, go to page 21. T

see Fig. 9)

o dis

Reas-

Fig. 8

See

page 21



19d



0171



Page 21

Pinion

Housing

Lubricate exterior

Lubricate inner and outer diameters

Lubricate teeth

CUTAWAY PINION HOUSING (19a)

Fig.

VIEW OF

0041

19c

19d

Press pinion assembly in here

Back of pinion housing (19a)

**Included in Repair Kit 221–032

19e

19b

19a

Repairing the Pinion

NOTE: Refer NOTE: A

pinion parts individually.Otherwise, use Repair Kit No. 221–032, sembled

to Fig. 9 except where noted.

hydraulic press is required if you purchase the which includes the shaft and bearings pre–as

and lubricated.

19k

19h**

19g**

19f**

If purchasing parts separately, use these instructions. Disassemble as far as needed for the parts being replaced.

NOTE: The when remove

old

bearings (19h and 19f) will be damaged

removed. Have extra

them for any reason.

ones on hand if you need to

19m**

19j**

0169

If using Repair Kit 221–032, follow Steps 1 to 5, below

1. Remove

the small ring (19m**) from the hub (19j) and the large ring (19k) from the bearing recess of the pinion

housing (19a).

2. Push on the front of the shaft (19g**) to force the bearing

and hub assembly out of the housing (19a).

3. Install the new shaft assembly into the pinion housing,

pushing it to the shoulder of the housing (19a).

Install the rings (19k and 19m**).

5. Go

Reassembly

, 27, Step 7, or continue on page

22.

Round bar to push

on shaft (19g)

Hydraulic press T

wo steel bars (

front bar not shown) T

wo steel bars

Press platform

Placement pressing off large bearing (19h)

19h

of steel blocks when

19j

Remove the small ring (19m) from the hub (19j).

2. Remove of

3. Push ing

Using a hydraulic press,

stock

the snap ring (19k) from the bearing recess

the pinion housing (19a).

on the front of the shaft (19g) to force the bear

(19h) and hub (19j) assembly out of the housing.

place pieces of steel bar

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.

Apply lubricant to the parts as shown in Fig. 9.

6. Press fit the following parts: Large bearing (19h) to large shoulder of the shaft (19g).

the

 Small (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

the housing (19a).

, pushing it

to the shoulder

bearing

Fig.

8. Install the snap ring (19k). Install the small ring (19m).

0043

9. Go

22.

Reassembly

, 27, Step 7, or continue on page

307-847 21

Page 22

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

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.

NOTE:

1. Follow

Refer to Fig. 1

the

page

14.

1 for this procedure.

Pressure Relief Procedure W

arning

2. Disconnect the hose (59) from the displacement pump. For the upright cart only

12, 1

clips (1

14) and drain hose (1

, remove the spring

13).

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)

a plastic

with the

clutch housing. Pull the assembly away

mallet to loosen the assembly (D) from

5. The armature (4a) was removed with the pinion housing.

6. There

Remove the armature from the pinion

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.

b. You

can use a standard steering However are also needed. steering

, two 1/4–22– x 3

Replace

wheel puller with the longer screws (B).

wheel puller (A).

4 in. long screws (B)

the short screws of the

Turn the screws (B) into the threaded holes of the rotor (4b). Tighten the capscrew (C) of the tool

7. Skip tinue

until the rotor comes of

ahead to

Reassembly, page 27, Step 6, or con

on the next page.

f. See Fig. 1

hub.

Fig. 11

Threaded holes

Pinion

shaft located

in back

A B

Using

112

a steering wheel

puller to remove rotor

113

114



Page 23

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, re move 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 locknuts (111) and then pull the screws (14)

two

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 gine.

3. Lift

4. Remove

Clutch

5. Skip

the grommets (66) before removing the en

See Fig. 12 and 13.

the

engine carefully and place it on a work bench.

the

Field

Housing

ahead to

and W

, as instructed

Reassembly, page 27, Step 5.

iring Harness, Clamp

on pages 24 and 25.

and

NOTE: All service to the engine must be performed by an

authorized HONDA dealer

62,9,61

WHITE

BLACK

Fig. 13

View

from under engine mounting

plate on upright cart

RED

99 80

Fig. 12

o field

o engine

WHITE

BLACK

iew from under engine mounting

0154 0147

plate on lo-boy cart

111

RED

 

Page 24

Field

and W

iring Harness

NOTE: Refer

Remove the engine from the cart. See page 23.

2. Pull the plastic caps (B) off the wire screws (98) in both places on the field. Loosen the screws and release

to Fig. 14.

the wires (96).

3. Loosen the four setscrews (12) holding the field (6) to

the clutch housing (2).

Pull of

f the field.

5. Skip

ahead to

tinue

on page 25.

Reassembly, page 26, Step

4 or con

Fig. 14



0046

Page 25

Clamp

NOTE: A

3 or 4 in. long screws are required to remove the

NOTE: Refer

1. Loosen

2. Install two screws (B) of the tool (A) in two of the

3. Skip

standard steering wheel puller and two 1/4–28

clamp.

to Fig. 15.

the two screws (16) on the clamp (3), work

ing

through the slot at the bottom of the clutch hous

ing (2).

threaded holes in the clamp (3). Tighten the screw (C)

until the clamp comes of

ahead to

tinue

to the right.

Reassembly, page 26, Step 3, or con

Fig. 15

3 16

0155

Clutch

NOTE: Refer

1. Remove which

2. Remove the capscrew (15), lockwasher (80) and washer

Remove the engine key (13).

Pull of

Skip ahead to

to Fig. 16.

the four capscrews (8) and lockwashers (9)

hold the clutch housing (2) to the engine.

(99) from beneath the mounting plate (D).

f the clutch housing (2).

Reassembly, page 26, Step 1.

Housing

Fig. 16

D 99

80 15

0156

 

Page 26

Reassembly

1. Install the clutch housing (2), capscrews (8) and lockwashers

Install the engine shaft

3. Press the

1.99 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. Ad

the clamp as necessary

just (16)

to 120 in–lb (14 N.m).

4. Install 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 field and the clutch housing (2) aligned, tighten

the

setscrews (12) oppositely

(3.2

N.m). See Fig. 17.

Torque

and evenly to 27 in–lb (3.2 N.m)

Slot

(9) on the engine. See Fig. 17.

the clamp (3)

key (13).

onto the engine shaft. Maintain

See Fig. 17.

+/– 0.01 (50.55 mm) dimension shown in

. T

orque the two screws

the

field

(6)

in the clutch housing (2). W

the setscrew holes

and evenly

oppositely

, to 27 in–lb

orking

Face of housing

Fig.

orque to 120 in–lb (14 N.m)

1.99”

(50.55 mm)

0050

Fig. 17

004



Page 27

Reassembly

5. Place

the

mounting

engine (1)

assembly on the cart. Align the

holes. Carefully guide the engine wire and wiring harness (96) from the field, through the appropriate

grommets (66)

in the mounting plate (E). Install the flange screws (14) and locknuts (111). 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 Connect nect drawing

6. Be

the engine wire (D) to the red wire, and con

the black and

white wires as shown in the Detail

in Fig. 19.

sure the face of the

rotor (4b)

and the

field is free of all oil and contaminants. Remove any burrs on the outside ers (11) and capscrews (16). T

edge of the rotor

. Install the rotor

orque the capscrews

, lockwash

to 7 ft–lb (9.5 N.m). See Fig. 19. After installing the rotor (4b), check the clearance-

between

the outside diameter of the rotor and the in

orque to 7 ft–lb 99.5 N.m) Spline Face must be clean T

orque to 15 ft–lb (20.4 N.m)

o field (ref. 96)

T T

o engine (ref. D)

(D)

(2).

side

diameter of the field. The clearance must be at least 0.010 in. (0.25 mm) all the way around. Use shim

stock or feeler gauge. If necessary setscrews (12) and reposition the field. Tighten the setscrews

evenly to 27 in–lb (3.2 N.m).

Be sure the face of the armature (4a) is clean. Assemble

ing makes

the armature to the shaft in

(19). A retaining ring located within the armature

it dif

ficult to assemble these parts. Follow this

the pinion hous

procedure for the best results. First, engage a few splines screwdriver armature,

armature onto the shaft until it contacts the ring (19m).

of both

parts. While they are engaged, use a

to gently push the retaining ring into the

and finish engaging the splines. Push the

See Fig. 19.

7. Assemble the pinion housing (19) to the clutch housing,

(11).

using the capscrews (10) and

See Fig. 19.

, loosen

the

lockwashers

View

from under engine mounting plate on Lo–Boy cart

WHITE

Fig. 19

BLACK

96 99

80 15

111

0157

iew from under engine mounting plate on upright cart

RED

WHITE

BLACK

Ref 14,1

RED

014601460147

 

Page 28

Pressure

Control Replacement

WARNING

reduce the risk of

jection

always follow the

serious injury

, including fluid in

Pressure Relief Procedure

Warning on page 14 before checking, adjusting,

cleaning or shutting off the sprayer.

spark

plug!

Disconnect both hoses at the pressure control (63). while

holding the elbows (317 or 320) CAUTION, hose end

of this procedure. See Fig. 20.

below

. Note the original

to be sure you

reassemble them correctly at the

Disconnect the

firmly

. See the

location of each

CAUTION

DO NOT allow the elbow (317 or 320) to turn when removing or connecting the hoses. Turning the elbows

can damage the sensitive bourdon tube.

106

317

2. Working

disconnect

For

under the engine mounting plate of the cart,

the red, black and white wires.

the upright cart

, remove the three

nuts (61) and

lockwashers (9) from the capscrews (62). See Fig.

21.

For

the lo-boy cart

washers

(9). See Fig. 21.

, remove the three screws (62) and

3. Remove the wire clamp (97). See Fig. 21. Remove the

pressure control.

4. Remove the pressure control cover (76) and the mounting

bracket (67 or 107). See Fig. 20.

106

319

107

316

Fig. 20

WHITE

BLACK

320

o pump

o filter

UPRIGHT

CART

0144 0145

o field

o engine

LO-BOY CART

61,9,62

RED

WHITE

RED

BLACK

View

from under engine mounting

Fig.

plate on upright cart



0146

iew from under engine mounting

plate on lo-boy cart

0147

Page 29

Pressure

Control Replacement

5. Disconnect the black, red and white wires from the rectifier with

6. Unscrew box,

7. For elbow

(307) and switch (302),

which are sheathed

the conductor (314). See Fig. 22.

the connector (318 or 108) from the control

pulling the conductor and wires out with it.

the upright

cart

, remove the nipple (316) from the

(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).

Reassemble in the reverse order

For Upright cart sprayers

307

302

RED

10. For wires

the upright carts

through the wire clamps (97).

, guide the new pressure control

Fasten the wire clamps to the cart with the same screws, lockwashers, (76)

11. For

and nuts (61, 9, 62) which hold the bracket

to the cart. See Fig. 20.

the lo-boy carts

, guide the pressure control wires through the single wire clamp (97), and install the screws to

and washers (62, 9) to hold the bracket (107)

the cart. See Fig. 20.

12. Perform the Pressure Control Adjustment on 30 before regular operation of the sprayer

page

317

316

WHITE

BLACK

For

Lo-Boy cart sprayers

RED

315,305

302

314

307

318

313

RED GROUND

107

108

0150

Ref 320

Top

Rectifier

view

0151

(307) connections

0148

320

319

315,305

Fig.

BLACK

WHITE

313

RED

GROUND

0165

 

Page 30

Pressure

Control Adjustment

WARNING

USE

EXTREME CAUTION WHEN PERFORMING THIS CALIBRA fluid injection injury or other serious injury sion or moving parts.

This procedure sets the sprayer to 2600–3000 psi (182–210

This

bar) MAXIMUM WORKING PRESSURE.

procedure must be performed when the pressure 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 plosion.

and result in component rupture, fire or

It may also prevent the sprayer from the maximum working pressure, resulting in poor sprayer

NEVER

performance.

attempt

to increase the fluid outlet pressure by

performing these calibrations in any other way.

, which can result from component rupture, electric shock, fire, explo

obtaining

TION PROCEDURE to reduce the risk of a

NEVER EXCEED 3000 psi (210 bar) MAXIMUM WORKING PRESSURE. Normal operation of the sprayer rupture,

ALWAYS

at higher pressures could result in component

fire or explosion.

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.

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      T

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

ee, p/n 104–984

Set Up

1. Follow

the

Pressure Relief Procedure W

page

14.

Set up the system as shown in Fig. 23.

arning

Set the Dead Band (Pressure Differential)

NOTE: Do not alter this adjustment if the wheel is al-

ready

set as shown in Fig. 24.

Remove the pressure control cover

2. Set the white differential wheel (A) on the microswitch.

urn the wheel so the letter F is concealed be

hind

the switch and the letter A is the

first letter seen.

b. Slowly tighten the nut just until another click is

heard.

OP.

Replace the plug (326) and pressure control cover



Connect fluid outlet

102–814

104–984 162–453 223–541

Fig. 23

156–823



0474

Pressure Up

1. Start

3. Shut off the engine. If the pressure drops, replace

Adjust the Pressure See

2. Turn and hold the pressure control knob (B) at the

3. Engage

the sprayer and prime it.

Adjust the pressure to 2600 psi (180 bar).

pump

packings before proceeding. See page 31.

Fig. 25.

Remove the pressure control plug (326).

maximum

pressure setting.

the nut (C): insert the nut driver through the pressure the

a. Loosen

control

hole, or use the ignition wrench from

front of the pressure control.

the nut just until you hear a click. ST



OP.

Fig.

Fig. 25

0475

326

0151

Page 31

Removing

and Installing the Pump

WARNING

reduce the risk of

jection

always follow the Warning on page 14 before checking, adjusting, cleaning or shutting off the sprayer.

spark

plug!

Removing the pump See

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 For upright carts, remove the spring clips (112,114) and

drain hose (1

Push the retaining spring (26) up. Push the pin (25) out the rear

4. Loosen low

the locknut (27). Unscrew the pump. See be

for how to repair the pump.

serious injury

Pressure Relief Procedure

, including fluid in

Disconnect the

Fig. 26.

13).

(59).

Installing the pump See

1. Screw

3. Push

4. Install

the

pump about 3/4 of the way into the bearing housing the pump

Back of cylinder and

way around the connecting rod. Tighten the locknut (27) wrench

outlet carts,

Face T

(21). Hold the pin (25) up to the pin hole on

connecting rod (22) and continue screwing in

until the pin slides easily into the hole.

f the pump until the top threads of the pump

are flush with the

the outlet nipple faces back.

the retaining spring (26)

to 90 ft–lb (1

and a light hammer

the

front cover and screws. Connect the pump hose. Install the suction tube parts. For Upright install the spring clips and drain hose.

of bearing housing

orque to 90 ft–lb (1

Fig. 27.

the

face of the bearing housing

into the groove all the

10 N.m) using a 2 1/4 in. open end

10 N.m)

Fig. 26

112 113

114

0477

Displacement

Disassembly procedure

1. Remove

Disassemble the intake valve. See Fig. 28.

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

the pump from the sprayer

torque

it into the cylinder to 1

. See above.

10 ft–lb (146 N.m).

22 26

Fig. 27

Pump Repair

Torque

10 ft–lb

(146 N.m)

*404 *401

419

420 421*

0031

Fig.

423

307-847 31

Page 32

Displacement

Pump Repair

4. To disassemble the rest of the pump, remove the packing

5. Use Pull

Remove the throat packings. See Fig. 33.

nut (416) and plug (405). See Fig. 33.

a plastic mallet to tap the piston rod (424) down.

the rod out through the bottom of the cylinder

WARNING

Always use the special sleeve removal tool, P/N 220–991, ods ous ing the tool, return the sleeve and cylinder to your Graco

7. Remove the sleeve. Screw the large nut (B) of the tool rod Fig.

8. Clamp en (422).

Disassemble the piston valve (422). See Fig. 30.

to remove the sleeve. Other removal meth could cause the pump to rupture, resulting in seri injury

. If the sleeve cannot be removed easily us

distributor for removal.

into

the top of the cylinder (419). Screw down the

(A) to push the sleeve out. Remove the tool. See

29. the flats of the piston rod (424) in a vise. Loos

the retaining nut (41

1). Unscrew the piston valve

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

The

up.

lips of the U–cup seal (403) face down. Incor rect installation damages the packings and causes the

pump to leak.

4. Soak

leather packings in oil

before reassembling the

pump.

Reassembly Procedure

1. Stack

2. Tighten

3. Put the ball (425*) on the piston valve (422). See

the backup washer (414), seal (403*),

gland

(415*), alternate the

packings (412*,406*), and

then male gland (410*) onto the piston valve (422).

Fig. 30.

See

the packing retaining ton

valve (22) to the torque specified in Fig. 30.

Fig.

30.

nut (41

1) onto the pis

CAUTION

Step

5, tightening the piston valve into the rod, is criti

cal.

Follow the procedure carefully to avoid damaging

the

packings by overtightening.

female

419

Fig. 29

Reassembly Notes

1. Pump

2. Check

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.

the outside of the piston rod (424) and the in side of the sleeve (418) for scoring or scratches. If the parts are damaged, new packings will not seal properly.

Replace these parts if needed.

0028

4. Apply

one drop of

adhesive, supplied, to the threads of the piston valve. Then hand tighten the valve assembly tacts

NOTE:

(411).

5. Place

into the piston rod just

until the nut (41

the rod. See Fig. 30.

Note the alignment

of the

piston (422) to the nut

Maintain this alignment through Steps 5,

the flats at the top of the rod (424) in a vise.

Torque

4 in-lb (0.35 N.m) Apply

one drop of sealant to these threads

Lips face up Lips face down

411

424

425*

410* 415*

403*

422

Fig.

*406

*412

414

1) con

6 and 7.

0029



Page 33

Displacement

Pump Repair

orque nut

T against rod to

19 ft–lb (26 N.m) Do

not allow nut (41

move when installing piston onto rod

Fig.

1) to

424

411

1 2

6. Use a wrench to CAREFULLY tighten the nut (411) against

the piston rod to 19 ft–lbs (26 N.m). See Fig.

31.

NOTE: Use two wrenches to maintain the alignment mentioned

7. Put

8. One

in the NOTE following Step 4, page 32.

a new o–ring (417*) firmly in the cylinder groove.

See

Fig. 33.

at a time stack the male

the

packings (413*,407*), and then

gland (408*), alternate

install the female

gland (409*), into the top of the cylinder (419). See

33.

Fig.

Leather

Polyethylene

Lips

must face DOWN

Lips must face UP

U–cup seal

orque to

10 ft–lb

(146 N.m)

*409

*407

1 3

*408

*417

405

416

413*

419

418

9. Install

NOTE: The Do

not install it upside down. See Fig. 32.

loose

the packing

for now

nut (416) and plug (405), but leave

. See Fig. 33.

tapered end of the sleeve is the bottom of

it.

10. Coat the piston rod and packings with oil. Carefully slide the assembly (A) INTO THE TOP OF THE

SLEEVE

(418)

. Then slide the sleeve/piston rod

as sembly INTO THE BOTTOM OF THE CYLINDER (419). This procedure helps prevent damaging the packings

during reassembly

Tapered

end

. See Fig. 32.

419

418

*406

1 4

*403

*401

Fig.

11. Screw tight

at the bottom of the external cylinder threads.

down the cylinder locknut (27) until

410*

412*

415* 414*

it is finger

Fig. 32

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).

0030

13.

Reinstall the pump. See page 31.

 

Page 34

Model

220–872, Series A

Parts

– Displacement Pump

Includes items 401 to 425

REF NO. PART NO. DESCRIPTION QTY

401* 107–098 P 403* 108–690 404* 108–775 BALL; sst 1 405* 183–171 PLUG 1 406* 183–174 V–P 407* 183–175 V–P 408* 183–176 409* 183–177 410* 183–178 411 412* 183–182 V–P 413* 183–183 V–P 414* 186–653 WASHER, backup 1 415* 183–185 416 183–186 NUT 417* 183–172 O–RING, PTFE 418 183–361 SLEEVE, cylinder 1 419 183–181 CYLINDER 1 420 183–180 421* 183–173 422 220–631 VAL 423 220–629 VAL 424 220–630 ROD, piston 1 425* 101–947

183–179

These parts are also included in Repair Kit 220–877,

which may be purchased separately

hand to reduce down time.

ACKING, o–ring, PTFE

SEAL, u–cup, polyurethane

ACKING, leather

ACKING, leather GLAND, male GLAND, female GLAND, male NUT

, hex, retaining ACKING, polyurethane ACKING, polyurethane

GLAND, female

, packing

 1

GUIDE, ball 1 PIN, ball stop

VE, piston VE, intake

BALL

 1

. Keep an extra kit on

*405

416

*409

424

425*

2 2 1 1 1 1 3 3

1 1

*413

*408

407*

*406

419

411 410*

412*

415* 403*

1 1 1

*417

414* 422

420 421*

418

404*

Accessories

224–788 Sleeve 220–877

Packing Repair Kit See contents in parts list, above

Removal T

401*

423

ool



Page 35

Parts

Model

231–052

Includes items 201 to 204

Sprayer with Upright cart

– Complete Sprayers

202

Model 231–085

Sprayer with Lo-Boy cart

Includes items 202 to 205

Ref No.

201 220–886 GM5000 Upright Basic Sprayer 202 223–541

203 214–701

204 220–955 “CONTRACTOR” SPRAY GUN

205 222–488

Ref

Part No.

No. 19

Description Qty

See parts list on page 37 HOSE, grounded, nylon; 1/4” ID; cpld 1/4 npsm(fbe); 50 ft (15 m);’ spring guards both ends 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

Includes RAC IV and 517–size SwitchT See 307–614 for parts GM5000 Lo-Boy Basic Sprayer See parts list on page 39

Parts

 DripLess

ip

– Pinion Assembly

Pinion Housing Assembly 220–920

Includes items 19a to 19m

ip Guard

204

1 1

203

0160

Ref No. Part No. Description Qty

19a 183–394 .HOUSING, pinion 1 19b 105–489 19c 108–692 .BEARING 1 19d 100–069 .BALL, sst 1 19e 107–088 .BEARING 1 19f** 108–797** 19g** 183–395** .SHAFT

.PIN, dowel

.BEARING, ball, small

, pinion

19b

19a

19c

19e

Ref No. Part No. Description Qty

19h** 108–798**

19j** 183–396** 19k 108–799 19m** 108–796**

**Included in Repair Kit No. 221–032.

.BEARING, ball, large .HUB, armature .RING, retaining, internal, large .RING, retaining, small

19k

19j**

19h**

19g**

1 1 1 1

19m**

19d

19f**

0169

307-847 35

Page 36

Parts

– Basic Sprayer with Upright Cart

Model 220–886, Series C

102

Ref

25 27 28

112 113

114

20a

20b

72 26 92

Ref 59

77,100

Detail

Ref 36

Ref

Ref 19d

20c

101

106

Label

See See page 35

See page 34

Detail above

57 54

117

121

113

307-84736

118

111

Ref 59

80 15

111

0158

Page 37

Parts

Model

220–886, Series C

– Basic Sprayer with Upright Cart

Ref No. Part No. Description Qty

1 108–802 2 183–397 HOUSING, clutch 1 3 183–517 CLAMP 4 236–568 CLUTCH ASSEMBLY

4a .ARMATURE 1 4b .ROTOR 1 6 183–400 FIELD 1 7 108–800 8 108–842 CAPSCREW 9 100–214 LOCKWASHER, 10 100–644 CAPSCREW

11 105–510 LOCKW 12 108–801 SETSCREW 13 183–401 KEY 14 110–837 FLANGE SCREW

15 100–469 CAPSCREW 16 108–803 CAPSCREW 18 220–919 GEAR REDUCER 1 19 220–920 PINION HOUSING ASSEMBLY

20 220–879 DRIVE HOUSING KIT 20a 106–227 .WASHER, bronze 1

20b 183–209 .WASHER, silver 1 20c 100–069 .BALL, sst 1 20d 110–293 21 220–639 BEARING HOUSING 1 22 220–640 CONNECTING ROD 1 23 183–168 COVER, housing 1 24 108–849 CAPSCREW 25 183–210 26 183–169 27 183–170 NUT 28 220–872 DISPLACEMENT PUMP

30 183–423 31 181–072 STRAINER 1 35 236–788 CART FRAME 1 36 220–918 CART HANDLE & HOSE RACK 1 37 183–350 W 38 108–794 39 108–795 SCREW

40 185–188 SLEEVE 2 41 179–811 42 101–242 43 104–811 HUBCAP 2 44 154–636 WASHER, 45 179–777 BUTTON, snap 2 46 108–068 47 222–011 GROUNDING CLAMP & WIRE 1 49 100–078 SCREW

50 157–021 LOCKW

ENGINE, gasoline

, mounting, rotor

Includes items 4a and 4b

PIN, dowel, spring, 5/16 x 1” 1

, hex hd, 5/16–24 x 3/4”

/16”7

, socket head, 1/4–20

x 3/4”

ASHER, spring, 1/4”

, 1/4–20

, parallel, 3/16” sq x 7/8”1

, hex hd, 5/16–18

x 1–1/2”

, hex hd, , socket head, 1/4–28 x 1”

See parts on page 35 Includes items 20a to 20d

.TUBE, grease

, socket head, 1/4–20 x 3” PIN, straight, 3/8 x1/8”1 SPRING, retaining

, hex, 1 13/16–16

See page 34 for parts TUBE, intake

ASHER, plain

PLUG, tubing

, mach, pan head,

10–32 x 5/16”4 WHEEL, semi–pneumatic

RING, retaining

/8”4

PIN, spring, straight, 3/16” x 11/4” 2

, mach, hex washer head,

No. 8 x 3/8”1

ASHER, internal, No. 8

–16 x 3/4”

Ref No. Part No. Description Qty

51 214–570

1 1

53 224–775 VAL 54 178–034 T

55 100–040 56 220–285 CAP 1 57 162–453

58 100–840 ELBOW

59 220–849 HOSE, 61 100–188 NUT

62 101–344 CAPSCREW 63 222–369 PRESSURE CONTROL KIT

64 106–078 SCREW

66 108–805 BUSHING, snap 2

67 183–392 BRACKET

68 108–850 SCREW 69 183–414 71 186–227 HANGER, pail 1

72 110–814 NUT 73 110–141 CAPSCREW

74 106–115 LOCKWASHER, spring, 76 183–995 COVER, pressure control 1 77 183–415

80 100–133 LOCKWASHER, spring, 86 206–994 THROAT SEAL LIQUID,

87 162–485

92 183–461 NIPPLE,

93 110–997 FLANGE SCREW

96 220–980 HARNESS, wiring 1

97 108–868 CLAMP

98 108–860 SCREW 99 108–851 W 100 177–762 101 181–867

102 185–953

106 110–037 SCREW 111 110–838 LOCKNUT

112 186–490 CLIP

113 186–495 TUBE, bypass 1

114 181–102 CLIP 117 186–638 BRACKET 118 110–963 FLANGE SCREW

121 108–982 CONNECT 122 187–189

Replacement Danger and W



are available at no cost.

FLUID FIL See 307–273 for parts

AG, warning

PLUG, pipe, sq hd, 3/8 npt NIPPLE, hex, 1/4 npsm x 1/4 npt,

1–3/16” long

29” (737 mm), spring guard both ends

See page 40 for parts 10–24 x 3/8” 4

LABEL, identification

x 1–1/2”

LABEL, identification, outside cover

8 oz (0.27 liter) NIPPLE, pipe, 3/8 npt(m) x

/8 npsm(m)

1/4–20 x 5/

ASHER, plain, 3/8”1 LABEL, W LABEL, W LABEL, Danger

forming, 10–24 x 1/2”

hd, 5/16–18 x 3/4”3 NIPPLE, reducing

TER

VE, pressure drain

, street, 1/4–18 npt (m x f)

/8” ID, cpld 3/8 npsm (fbe),

, heavy hex, 5/16–18

, hex hd, 5/16–18 x 7/

, mach, flat head, thd frmg,

, mounting

, mach, filh, 8–32 x 1–1/4”

, retainer

, socket head, 3/8–16

/8–18 npsm x 1/4–18 npt

, hex hd,

8”

, wire

, mach, bdgh, 8–32 x 1/4”

arning 1 arning 1

, mach, pan head, thread

, heavy hex, 5/16–18 5

, spring , spring

, filter mounting

, hex

OR, tube

arning labels, tags and cards

1 1 1 1

2 1

2 3 3

8”

1 4 1

/8”4

/8”1

1 1

1 2 2

1 4 1 1

1 1

 

Page 38

Parts

– Basic Sprayer with Lo–Boy Cart

Model 222–488, Series A

31e

31j

31c

102

20a

20b

Ref 59

20c

Ref

Ref 19d

77,100

Ref

319

106

101

107

108

14 66

31d

Label

See

See page 34

page 35

59 87

Ref 31h



78 79 30

65 79

31b

31f

31h

99 80

9 111

31a

31g

31c

31e

0159

Page 39

Parts

Model

222–488, Series A

– Basic Sprayer with Lo–Boy Cart

Ref No.

1 108–802 ENGINE, 2 183–397 HOUSING, clutch 1 3 183–517 CLAMP 4 236–568 CLUTCH ASSEMBLY

4a .ARMATURE 1 4b .ROTOR 1 6 183–400 FIELD 1 7 108–800 8 108–842 CAPSCREW 9 100–214 LOCKWASHER, 10 100–644 CAPSCREW

11 105–510 LOCKW 12 108–801 SETSCREW 13 183–401 KEY 14 110–837 FLANGE SCREW

15 100–469 CAPSCREW 16 108–803 CAPSCREW

18 220–919 GEAR REDUCER 1 19 220–920 PINION HOUSING ASSEMBLY

20 220–879 DRIVE HOUSING KIT 20a 106–227 .WASHER, bronze 1

30 109–059 BUMPER 2 31 222–517 SUCTION TUBE

31a 170–957 .TUBE, suction 1 31b 181–072 .STRAINER 1 31c 110–964 .CLAMP 31d 110–960 31e 103–473 .STRAP 31f 181–102 .CLIP 31g 185–381 .HOSE, suction 1 31h 805–077 .TUBE, bypass 1 31j 176–450 .GUARD, HOSE 1 35 222–612 CART 1 41 179–811 42 101–242 43 104–811 HUBCAP 2 44 154–636 WASHER,

Part No.

Description Qty

gasoline

, mounting, rotor

Includes items 4a and 4b

PIN, dowel, 5/16 x 1” 1

, hex hd, 5/16–24 x 3/4”

/16”9

, socket head, 1/4–20

x 3/4”

ASHER, spring, 1/4

, 1/4–20”

, parallel, 3/16” sq x 7/8”1

/16–18 x1–1/2”

x 1.0”

See parts on page 35 Includes items 20a to 20d

.TUBE, grease

PIN, straight, 3/8 x 11/8”1 SPRING, retaining

, hex, 1 13/16–16

See page 34 for parts

Includes items 31a to 31j

, hose

.UNION, adapter

, tie

, spring

WHEEL, semi–pneumatic RING, retaining

, hex hd,

, hex hd, 3/8–16 x 3/4”1 , socket head, 1/4–28

, socket head, 1/4–20 x 3”

/8”6

13 17

Ref No.

47 222–011 GROUNDING CLAMP & WIRE 1 49 100–078 SCREW

50 157–021 LOCKW

51 214–570 53 222–198 VAL

54 178–034 T 55 100–040

56 220–285 CAP 1 57 162–453

58 100–840 ELBOW 59 222–516

62 100–001 CAPSCREW

63 222–369 PRESSURE CONTROL KIT 64 106–078 SCREW

65 100–333 CAPSCREW 66 109–099 BUSHING, snap 2

68 108–850 SCREW 69 183–414

73 110–141 CAPSCREW 74 106–115 LOCKWASHER, spring,

76 183–995 COVER, pressure control 1

77 183–415 78 100–015 NUT 79 100–016 LOCKW 80 100–133 LOCKWASHER, spring,

86 206–994 THROAT SEAL LIQUID,

87 162–485

88 222–469 SUPPORT

92 183–461 NIPPLE, 93 110–997 FLANGE SCREW

96 220–980 HARNESS, wiring 1 97 108–868 CLAMP 98 108–860 SCREW

99 108–851 W

100 177–762

101 181–867

102 185–953 106 110–037 SCREW

107 183–765 BRACKET 108 109–078 BUSHING, strain relief 1

111 110–838 LOCKNUT



Part No.

Description Qty

, mach, hex washer hd, No. 8

x 3/8”1

ASHER, internal, No. 8 FLUID FIL See manual 307–273 for parts

VE, pressure drain

AG, warning

PLUG, pipe, sq hd, 3/ NIPPLE, hex, 1/4 npsm x 1/4 npt,

13/16” long

, 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

See page 40 for parts

, mach, flat head,

thread forming, 10–24 x 3/8”4

, mach, filh, 8–32 x 1.25”

LABEL, identification x 1.5”

LABEL, identification, outside cover

, hex, 1/4–20

ASHER, spring, 1/4”

8 oz (0.27 liter) NIPPLE, pipe, 3/8 npt(m) x

/8 npsm(m)

1/4–20 x 5/

, wire

, mach, bdgh, 8–32 x 1/4”

ASHER, plain, 3/8” LABEL, W LABEL, W LABEL, Danger

, mach, pan head, thread frmg,

10–24 x 1/2”

Replacement Danger and W are available at no cost.

TER

, hex hd, 5/16–18 x 5/8”

, hex hd. 1/4–20 x1/2”

, socket head, 3/8–16

, foot

/8–18 npsm x 1/4–18 npt

, hex head,

arning 1 arning 1

, mounting

, heavy hex, 5/16–18

arning labels, tags and cards

1 1

1 1 1

2 1

2 3

4 4

/8”4

/8”1

1 4 8

1 1

2 1

1 4

1 2

307-847 39

Page 40

Parts

Part

No. 222–369 – Basic Pressure Control for the GM5000 Sprayers

– Pressure Control

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 Qty

300

{ 222–380 PRESSURE CONTROL

Includes items 302 to 304 301Y{ 183–466 302

{ 105–679 ON/OFF SWITCH 1

303{ 105–659 BOOT, switch 1 304

{ 107–255 GUARD, locking 1 { 157–021 LOCKW

305 306

{ 100–284 NUT { 108–219

307 308

{ 108–783 SCREW

309{ 222–352 TRIAC ASSEMBLY 1 310

{ 107–070 SCREW

{ 100–072 NUT

311 312

{ 103–181 LOCKWASHER 2

313{ 220–979 CONDUCTOR, red 2

LABEL, warning

ASHER, No. 8, internal

, hex, msc 8–32

RECTIFIER, bridge

, mach, frhd 8–32 x 13/16”1

, flat head; csk hd

, hex

Ref No. Part No. Description Qty

314 220–978 CONDUCT 315{ 100–035 SCREW

1 1

316 183–461 317 100–840 ELBOW, str 318 108–852 CONNECTOR, 45 319 156–823 UNION, swivel, 1/4 npt (f) swivel x

2 1

320 110–195 UNION, swivel, 45

325{ 108–814

{ 101–754

326

2 2

Replacement Danger and W

are available at no cost.

{

Parts marked with a dagger are supplied with the basic

pressure control. See Parts Drawing on page 41.

No. 8 x 5/16” NIPPLE, hex; 3/8–18 npsm x 1/4–18

1/4 npt(m)

PLUG, pipe PLUG, pipe

, mach, slotted pan head;

OR, red, white, black

, 1/4–18 npt (m x f)

_ 1

_ 2

arning labels, tags and cards

1 2 2

1 1

ENGINE

Wiring

MAIN SWITCH

RED

Schematic – Pressure Control

RED

ADJUSTABLE

PRESSURE

SWITCH

MT2 MT1

RED

CNO

RECTIFIER

RED

WHITE

RED

GROUND

BLACK

CLUTCH FIELD

0054

307-84740

Page 41

For Upright Cart Sprayers

303

302

RED

313

RED

310 311 312

309

Parts – Pressure Control



304

308,305,306

307

Parts marked with a dagger are supplied

with the basic pressure control.

300

317

316

WHITE

BLACK

315,305

For

Lo–boy Cart Sprayers

Parts

marked with a dagger are supplied

with the basic pressure control.

303

302

RED

313

RED

310 311 312

304

318 314

308,305,306

307

326

300

313

RED GROUND

TOP

RECTIFIER (307) CONNECTIONS

314

301

VIEW

319

0148 0151

320

0150

309

315,305

WHITE

BLACK

325

326

313

RED

GROUND

Ref

320

0165

307-847 41

Page 42

Accessories

DANGER

USE ONL

LABELS

GENUINE

GRACO

The English language DANGER label shown on page

1 is also on your

who

do not read English, order one of the following

labels to apply to your sprayer.

sprayer

. If you have painters

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 185–956 Spanish 185–961 German 186–041 Greek 186–045 Korean 186–049 English 185–593

Displacement

Parts

included in the kit are shown on page 34. Repair in

structions

with the kit.

cluded

Sleeve Removal T

Pump Repair Kit

220–877

are on page 31 of this manual and are also in

ool 224–788

0162

Required for removing the displacement pump sleeve.

55 Gallon (200 Liter) Suction Tube Kit

208–259

Includes:

Ref No. Part No. Description Qty

1 156–589 UNION, 90

3/4 npsm(f) swivel 1

2 214–961

3 156–591 ELBOW 4 156–593 P 5 100–220 THUMBSCREW 6 176–684 7 156–592 TUBE, riser 1 8 159–100 RETAINER, screen 1 9 161–377 SCREEN, filter 1 10 159–101 NUT

HOSE, coupled 3/4 npt(mbe) 3/4” ID; nylon, 6 ft (1.8 m); spring guard one end

ACKING, o–ring, nitrile rubber

ADAPTER, bung

 ADAPTER, 3/4 npt(f) x

, 90; 3/4 npt x 1–1/2 – 24 NS

, 5/16–18 x 1”

, screen retainer

ARTS AND ACCESSORIES

5 Gallon (19 Liter) Suction Tube Kit

208–920

Includes:

Ref No. Part No. Description Qty

1 101–818 CLAMP 2 160–327 UNION, 90 3 170–705 ADAPTER, intake 1 4 170–706 HOSE, 1” ID x 48”; nylon 1 5 170–957 TUBE, suction 1 6 181–072 STRAINER 1

, hose



swivel; 3/4 npt(m x f)

Heavy Duty 5 Gallon (19 Liter) Suction Tube Kit 223–934

Includes:

Ref No. Part No. Description Qty

1 183–770 STRAINER 1 2 110–962 SUCTION TUBE 1 3 110–964 HOSE CLAMP 2 4 186–245 SPRING CLIP 2 5 170–706 SUCTION HOSE 1 6 110–960 UNION 1

7 805–077 DRAIN TUBE 1

8 108–982 TUBE CONNECTOR 1

9 103–473 PLASTIC TIE 1

10 176–450 HOSE GUARD 1

2 1

0161

2 3

4 6

8 9



0162

8 6

0164

Page 43

Technical

Data

Dimensions

Engine 5 Maximum Working Pressure Noise

Cycles/Gallon (liter) Maximum Fuel T Maximum T

Inlet Paint Strainer Outlet Paint Filter Pump inlet Size

Fluid Wetted

NOTE: Delrin

. . . . . . . . . . . . . . . . . . . . .

– Sound Power 105 dBa

Delivery

ank Capacity

ip Size

Outlet Size

Parts

Displacement Pump

Filter

Aluminum, Carbon Steel, Stainless Steel

. . . .

is a trademark of the DuPont Company

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . .

. . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . .

Stainless

. . . . . . . . . . . .

Stainless

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

Stainless Steel, Carbon Steel,

Polyurethane, UHMW polyethylene,

Horsepower

. . . . .

3000 psi (210 bar)

measured at 3.1 ft (1 m)

1.25 GPM (4.7 liter/min)

0.95 gallons (3.6 liter) 1 gun with 0.035 tip

guns with 0.025 tip

3 guns with 0.019 tip 16 mesh (1 Steel screen, reusable

60 mesh (250 micron)

Steel screen, reusable

1/4 npsm from fluid filter

Delrin

, Honda

104 (27.5).

190 micron)

3/4 npt (m).

, Leather

Model

220–886

Upright cart without hose or gun

eight (dry Height 31.6 in. (803 mm). Length 30.5 in. (775 mm). Width 22.5 in. (572 mm).

Model Lo-Boy cart without hose or gun

eight (dry Height 26.5 in. (673 mm). Length 36 in. (914 mm). Width 19 in. (483 mm).

, without packaging)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

222–488

, without packaging)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . .

135 lb (61 Kg)

130 lb (58.5 Kg)

Graco

Phone

Number

PLACE AN ORDER

utor

, or call this number to identify the distributor

closest to you:

1–800–367–4023 T

, contact your Graco distrib

oll Free

Manual

Change

Summary

Added a procedure to set the clearance between rotor

and

the field, on page 27.

 

Page 44

The

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 warranty, tive, 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’

This warranty does not cover 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, instal lation, 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), liabilities, including product liabilities, based on negligence or strict liability tial damages or loss is expressly excluded and denied. In no case shall Graco’ 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 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 Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defec

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

s written recommendations.

including warranty of merchantability or warranty of fitness for a particular purpose,

Graco Warranty and Disclaimers

by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this

, and Graco shall not be liable for

, and disclaims all implied

warranties of merchantability and fitness for a particular purpose

, switches, hose, etc.) are subject to the warranty

, any malfunction, damage or wear caused by faulty installation,

and of any non–contractual

. Every form of liability for direct, special or consequen

s liability exceed the amount of the purchase price.

, with

, if any

, of their manufacturer

Foreign Offices:

Belgium, Canada, England, Korea, Switzerland, France, Germany

Sales Offices:

GRACO INC. P.O. BOX 1441

PRINTED



IN U.S.A. 307–847 June 1987, Revised November 1995

Atlanta, Chicago, Detroit, Los Angeles

MINNEAPOLIS, MN

, Hong Kong, Japan

55440–1441

Page 45

3X7–847

Rev. N

Supersedes

and PCN M

Rev

. L

Parts

Change Notice

Some parts in Rev. L of manual 307–847 have changed but have not yet been changed in the instruction manual. Please note the changes below and mark them in your manual or keep this sheet with your manual.

Series

Assembly

Model 220–886 and 222–488

Other

Pages 36 and 38:

No.

Changes

Letter Change

– 222–198 53 VAL

Part That Changed

222–011 47 GROUNDING

100–078 49 SCREW

157–021 50 LOCKWASHER,

Ref No.

Part Description

VE, pressure

drain

CLAMP & WIRE

, mach, hex washer head, No. 8 x 3/8”

internal, No. 8

Description of Change

Replaced by 237–677

Replaced by 237–686

Replaced by 1

Deleted

12–798

06489

31 Jul 96

Page 46

Upright Cart:

LoBoy Cart:

Model 220–886, Basic sprayer Model 231–052, Complete sprayer*

Model 222–488, Basic sprayer Model 231–085, Complete sprayer*

Model

231–052 shown

0136

* Complete

and Contractor gun with RAC IV DripLess

sprayers include 50 ft (15 m) 1/4 in. I.D. hose, 3 ft (0.9 m) 3/16” I.D. whip hose,

Technical Data

Maximum Working Pressure Gasoline Sound

Fuel T Delivery 1.25 gpm (4.7 lpm). Cycles Tip

Pump Inlet Size Inlet

Fluid Filter Outlet Size Fluid

Pump Material

Engine

. . . . . . . . . . .

Data: Sound Power Level

measured at 3.1 ft. (1 m) per ISO 3744

ank Capacity

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

Per Gallon (Liter)

Size

. . . . . . . . . . . . . . . . . .

with latex at 2000 psi (138 bar)

. . . . . . . . . . . . . . . . . . . . . . .

Paint Strainer

. . . . . . . . . .

reusable

. . . . . . . . . . . . . . .

Filter Material

. . . . . . . . . . . .

steel,

carbon steel, 60 mesh (250 micron)

. . . . . . . . .

. . . . .

3000 psi (210 bar)

5.5 horsepower .

. . . . . . .

105 dB(A)*

, Honda

0.95 gal (3.6 liter)

. . . . . . . . . . . . . . .

104 (27.5).

1 gun with 0.035 in. tip

guns with 0.025 in. tip

3 guns with 0.019 in. tip

3/4 npt(m).

16 mesh (1

190 micron)

stainless steel screen

1/4 npsm(m).

aluminum, stainless

reusable SST screen

stainless steel, carbon steel

Delrin,

polyurethane



ip Guard and 517 SwitchT

Packing Material Spray

Hose Requirements

Application

Sprays a full range of architectural coatings, including heavy mastics. methylene chloride or other HHCs.

For information on converting your sprayer to one that can safely handle fluids containing HHCs, contact Graco Product Service at 1–800–328–021

U.S. patent pending.

Dimensions

Height Length 30.5 in. (775 mm) Width 22.5 in. (572 mm) Weight 135

. . . . . .

. . . . . . .

. . . . . .



leather

. . . . . .

ft (15 m) minimum, 1/4 in. I.D., non-wire

, UHMW polyethylene

. . . . . . . . . . . . . .

grounded,.

braid, spring guards on both ends

Do not

use with solvents such as

Upright Cart

LoBoy Cart

31.6 in. (803 mm) 26.5 in. (673 mm) 36 in. (914 mm) 19 in. (483 mm)

lb (61 kg)

130 lb (58.5 kg)

GRACO

INC.P.O. BOX 1441

MINNEAPOLIS, MN

1995, GRACO INC.

55440–1441

PLACE AN ORDER

1–800–367–4023 T

, call

oll Free

FOR TECHNICAL ASSIST

1–800–543–0339 T

oll Free

ANCE

, call

Page 47

3Z7–847

Rev B

Supplement

to manual 307–847

GM5000 Airless Paint Sprayer

WARNING

INJECTION

This is only a quick reference to the

INSTRUCTIONS

serious injury erating or repairing this sprayer ings and instructions in manual 307–847.

Model 220–886, Series C

Basic sprayer with upright cart

Model 231–052

Complete sprayer with upright cart

Model 222–488, Series A

Basic sprayer with LoBoy cart

Model 231–085

Complete sprayer with LoBoy cart

features and frequently ordered parts of this sprayer

, including fluid injection, while op

HAZARD

. T

o reduce the risk of

, follow the warn

15b



Ref Upright LoBoy

Part No. Part No.

No.

220–639 Same

220–640 Same

220–879 Same

Y185–953 Same

220–919 Same

220–849 222–516 Hose

222–369 Same

108–802 Same Engine

220–918 None

236–788 222–612 Cart Frame

224–775 222–198

1 12

108–982 None T

214–570 Same

236–568 Same

220–872 Same 15a 183–361 Same 15b 220–630 Same 15c 220–631 Same 15d 220–629 Same 16

183–423 170–957 17

181–072 Same Strainer 18

None 185–381 19

186–495 805–077

Extra danger labels are available for free.

Y

Description

Bearing Housing Connecting Rod Drive Housing Danger Label Gear Reducer

Pressure Control Handle & Hose Rack Pressure Drain V

ube Connector Fluid FIlter Clutch Assembly Displacement Pump .Cylinder Sleeve .Piston Rod .Piston V .Intake V Intake/Suction T

Suction Hose Bypass T

alve

ube

alve

ube

15a

15c

15d

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



0158







Packing Repair Kit

Includes parts marked with a

Sleeve Removal T

220–877

ool 224–788

Required for removing pump sleeve



0159