Graco Inc 308972 User Manual
INSTRUCTIONS-PARTS LIST
308972
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
GH Series Roof Rigs
Gas-Hydraulic Airless Sprayers
GH5030
Model 687100
Maximum Working Pressure 4900 psi (337 bar, 33.8MPa)
GH3640
Model 687327
Maximum Working Pressure 3600 psi (245 bar, 24.5 MPa)
First choice when
quality counts.
t
Rev. A
GH2560
Model 965168
Maximum Working Pressure 2400 psi (166 bar, 16.6 MPa)
GH2075
Model 965171
Maximum Working Pressure 1800 psi (124 bar, 12.4 MPa)
GH1015
Model 965165
Maximum Working Pressure 1000 psi (70 bar, 0.70 MPa)
9089A
Model 687100
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1999 GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification 5. . . . . . . . . . . . . . . . . . . . . . . .
Setup 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
D This equipment is for professional use only.
Displacement Pump Service 16. . . . . . . . . . . . . . . . . . . .
Sprayer Parts Drawing 18. . . . . . . . . . . . . . . . . . . . . . . . .
Sprayer Parts List 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 27. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
equipment if you do not follow the instructions.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
D Do not alter or modify this equipment. Use only genuine Graco parts.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 27 for the maximum working pressure of this equipment.
D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
D Do not use hoses to pull equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
D Wear hearing protection when operating this equipment.
D Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
3089722
WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely
serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also
cause serious injury.
Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
Do not point the gun at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip.
Do not stop or deflect leaks with your hand, body, glove or rag.
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the gun when spraying.
Check the gun diffuser operation weekly. Refer to the gun manual.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 10 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
FUEL HAZARD
The fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire.
Do not fill the fuel tank while the engine is running or hot.
EXHAUST HAZARD
The exhaust contains poisonous carbon dioxide which is colorless and odorless.
Do not operate this equipment in a closed building.
3308972
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
If there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Disconnect all electrical equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not operate a gasoline engine in the spray area.
Ground the sprayer to a true earth ground with the ground wire and clamp (supplied).
Use only electrically conductive hoses.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the sprayer.
Before servicing the equipment, follow the Pressure Relief Procedure on page 10 to prevent the
equipment from starting unexpectedly.
NOTE: This is an example of the DANGER label on your sprayer. This label is available in other languages, free of
charge. See page 27 to order.
FIRE AND
EXPLOSION HAZARD
Spray painting, flushing or cleaning equipment with flammable
liquids in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground
equipment, hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic
drop cloths, open flames such as pilot lights, hot objects such as
cigarettes, arcs from connecting or disconnecting power cords
or turning light switches on and off.
Failure to follow this warning can result in death or serious injury.
READ AND UNDERST AND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
Liquids can be injected into the body by high pressure airless
spray or leaks – especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body . Drain all pressure before removing parts.Avoid accidental
triggering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical Treatment”.
Failure to follow this warning can result in amputation or serious
injury .
SKIN INJECTION
HAZARD
3089724
Component Identification
HYDRAULIC RETURN LINE TO MOT OR
MOTOR RESET BUTTON
HYDRAULIC MOTOR
FLUID
OUTLET
PRESSURE
DRAIN VALVE
HYDRAULIC SUPPLY LINE TO MOT OR
GASOLINE
FILL CAP
HYDRAULIC
RESERVOIR
HYDRAULIC
PUMP
DISPLACEMENT PUMP
SUCTION HOSE
Fig 1
1. Connect the Hose and Gun
a. Remove the plastic cap plug from the outlet
tee and screw an accessory, conductive or
grounded spray hose onto the 1/4 npsm(f) outlet nipple. See Fig 1.
b. Connect a small diameter, 3 ft (0.9 m) whip
hose between the main hose and a spray gun,
if desired, for more flexible gun movement.
See Fig 1.
Setup
NOTE: Use thread sealant on all male threads except at
2. Fill the Packing Nut/Wet Cup 1/3 full with Graco
SUCTION TUBE
c. Don’t use thread sealant on the swiveling nut
of the hose couplings, and
spray tip yet.
swivel unions. Swivel unions are made to self–
seal, and using thread sealant prevents the
swivel from turning freely.
Throat Seal Liquid (TSL), supplied. See Fig. 2.
don’ t install the
5308972
Setup
3. Check the Hydraulic Oil Level
a. Unscrew the hydraulic oil fill cap. See Fig 2.
The dipstick is attached to the cap. The oil
should be up to the full line on the dipstick.
CAUTION
To prevent damage to the cooling system and
hydraulic pump, use
169236 (5 gal./20 liter) or 207428 (1 gal/3.8 liter).
Other types of hydraulic oil may damage the hydraulic components.
b. Add oil as needed to the proper level. A
completely full hydraulic system contains
about 5 gallons (20 liters) of oil.
P ACKING
NUT/ WET
CUP
only
Graco Hydraulic Fluid,
HYDRAULIC OIL
FILL CAP
OIL DIPSTICK
GASOLINE
FILL CAP
FUEL
SHUTOFF
VALVE
ENGINE OIL
FILL PLUG
Fig 3
4. Check the Engine Oil Level
a. Remove the dipstick. See Fig 3.
b. Check to be sure the oil is up to the full mark
on the dipstick.
7872A
Fig 2
7871A
c. If oil is needed, see the chart below for the
recommended oil type and weight.
d. Crank case capacity: 1.5 quarts (1.4 liters)
RECOMMENDED LUBRICATION OIL:
Use a high
quality detergent oil of American Petroleum Institute
(API) service class SG or SH for regular use and for
breaking in a new engine.
GRADE OF OIL CHART
SEASON OR TEMPERA TURE GRADE OF OIL
Spring, Summer, Autumn SAE 10W–30
30F to 0, Winter SAE 5W–20 or 10W–20
3089726
Setup
5. Fill the Fuel Tank
WARNING
FIRE AND EXPLOSION HAZARD
Fuel spilled on a hot surface can cause
a fire or explosion and serious bodily
injury and property damage. Shut off
engine and let it cool before filling the
tank. Carefully follow steps 5.a. to 5.c.,
below, being sure not to spill any fuel.
a. Close the fuel shutoff valve. See Fig 3.
b. Use only clean, fresh, well-known brands of
unleaded regular grade gasoline
minimum octane requirements are 87 octane
in the U.S.A. and 96 octane elsewhere.
c. Remove the gasoline fill cap and fill the tank.
Be sure the air vent in the fill cap is not
plugged so gasoline can flow to the carburetor,
then replace the cap. See Fig 3.
. The
6. Grounding
WARNING
FIRE AND EXPLOSION HAZARD
To reduce the risk of static sparking, fire
or explosion which can result in serious
bodily injury and property damage,
ground the sprayer, all system components, and
the object being sprayed as instructed under FIRE
OR EXPLOSION HAZARD on page 3.
Connect the ground wire and clamp (provided) to a
true earth ground. See Fig 4.
CLAMP
d. Fuel tank capacity: 1.7 gallons (6.5 liters)
e. Gasoline consumption at the maximum oper-
ating speed of 2900 RPM is about 1.3 gallons/
hour (4.9 liters/hour).
Fig 4
7. Flush the sprayer to remove the oil which was left
in the pump after factory testing to protect the
pump from corrosion. See Flushing .
7873A
7308972
Flushing
When to Flush
1. New sprayer. Your new sprayer was factory tested
with lightweight oil which was left in to protect
pump parts from corrosion.
Before using oil–base paint,
spirits only.
Before using water–base paint,
mineral spirits, followed by soapy water, then a
clean water rinse.
2. Changing colors. Flush with a compatible solvent
such as mineral spirits.
3. Changing from water–base to oil–base paint.
Flush with soapy water, then mineral spirits.
How to Flush
flush with mineral
flush with
WARNING
INJECTION HAZARD
Follow the Pressure Relief Procedure
Warning on page 10. Remove the spray
tip before flushing.
1. Engage the gun safety latch. Remove the spray tip
from the gun.
2. Pour enough clean, compatible solvent to fill the
pump and hoses into a large, grounded metal pail.
3. Place the suction tube into the pail or tilt the
sprayer back (it will support itself) and place the
pail under the pump. Then tilt the sprayer forward
to lower the pump into the pail.
4. Changing from oil–base to water–base paint.
Flush with mineral spirits, followed by soapy water,
then a clean water flush.
5. Storage.
Water–base paint:
spirits and leave the pump, hose and gun filled
with mineral spirits. Follow the Pressure Relief
Procedure Warning, page 10.
Oil–base paint:
the Pressure Relief Procedure Warning, page
10.
6. Startup after storage.
Before using water–base paint,
spirits with soapy water and then clean water.
When using oil–base paint,
spirits with fluid to be sprayed.
8. Turn and hold the ignition key to START until you
hear the engine “catch”, then release the key to RUN.
See Fig 5. If the engine does not start, open the
choke a little (push in on head). If the engine floods,
open the choke all the way and try again.
FUEL
SHUTOFF
VALVE
PRESSURE
CONTROL
KNOB
flush with water, then mineral
flush with mineral spirits. Follow
flush out mineral
flush out mineral
AIR FILTER
CHOKE
4. Turn the pressure control knob
until all spring tension is relieved. You will be able
to feel it. The sprayer is now set at the lowest
pressure setting. Turning the knob further will
remove it. Tighten the knob locknut to set. See Fig
5.
5. Open the bypass valve. The valve lever will be
parallel to the body of the valve. See Fig 5.
6. Open the fuel shutoff valve by turning it to horizontal. See Fig 5.
7. Close the choke by pulling out on the choke head.
See Fig 5.
counterclockwise
CAUTION
The bypass valve must be opened when starting the
sprayer to prevent damaging the starter.
3089728
ON/OFF
BYPASS
VALVE
Fig 5
9. After the engine is warm, gradually open the choke
lever (push choke head in completely) and close
the bypass valve. See Fig 5.
10. Point the gun into the grounded metal pail and hold
a metal part of the gun firmly against the pail.
NOTE: To save the fluid in the pump and hose, trigger
the gun into the paint container or a separate
clean container . At the same time, slowly turn the
pressure control knob clockwise just enough to
start the pump. When solvent appears, release
the trigger and continue as below.
SWITCH
7874A
WARNING
Flushing
12. Circulate the solvent until the system is thoroughly
flushed.
FIRE AND EXPLOSION HAZARD
To reduce the risk of static sparking and
splashing when flushing, always remove
the spray tip from the gun and hold a
metal part of the gun firmly to the side of a
grounded metal pail.
11. Making firm metal-to-metal contact, hold the gun
firmly to the side of the grounded solvent pail.
Trigger the gun. At the same time, slowly turn the
pressure control knob clockwise just enough to
start the pump.
13. Release the trigger and engage the gun safety
latch.
14. If you are going to start spraying, place the
pump or suction tube into the supply container.
Follow the Pressure Relief Procedure on page
10. Engage the gun safety latch until you are ready
to prime the pump. See Step 3, page 9.
15. If you are going to store the sprayer, be sure
your final flush is with an oil–based solvent, such
as mineral spirits. Remove the suction tube or
pump from the solvent pail. Follow the Pressure
Relief Procedure on page 10. Engage the gun
safety latch, but leave the drain valve open.
9308972
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