Graco Inc 310778N User Manual

Repair

™

200, GH 230,

GH 300; Series A & B

™

200, Series A

Hydraulic Sprayers

ti5380a

Korean Patent:10-0647761

310778N

- Use with Architectural Coatings and Paints -

3300 psi (2.8 MPa, 228 bar) Maximum Working Pressure

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

GH200 GH230 GH300

ti5380a

248559 ✓✓

248560 ✓✓ ✓

248565 ✓✓ ✓

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248949 ✓

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248943 ✓

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248567 ✓ ✓

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120 Vac

60 Hz

CSA/UL 120 Vac

60 Hz

240 Vac

50 Hz

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

Table of Contents

WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

General Repair Information . . . . . . . . . . . . . . . . . . 5

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Hydraulic Motor Rebuild . . . . . . . . . . . . . . . . . . . . 12

Hydraulic Oil/Filter Change . . . . . . . . . . . . . . . . . 14

Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . 15

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

GH 200 Sprayers with Spray Gun and Hoses . . . 22 GH 230 Sprayers with Spray Gun and Hoses . . . 22 GH 300 Sprayers with Spray Gun and Hoses . . . 23

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 26

2 310778N

The following Warnings are for the safe setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. Refer back to these Warnings.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and can ignite or explode if spilled on hot surface.

• When flammable liquid is sprayed or used for flushing or cleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground equipment and conductive objects in work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on sprayer and extension cords.

RECOIL HAZARD

Brace yourself; gun may recoil when triggered and cause you to fall, which could cause serious injury.

310778N 3

WARNING

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings.

• Check equipment daily. Repair or replace worn or damaged parts immediately.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your Graco distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.

SUCTION HAZARD

Never place hands near the pump fluid inlet when pump is operating or pressurized. Powerful suction could cause serious injury.

CARBON MONOXIDE HAZARD

Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon monoxide can cause death. Do not operate in an enclosed area.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

4 310778N

General Repair Information

WAR NING

MOVING PARTS HAZARD

To reduce risk of serious injury, do not touch moving parts with fingers or tools while testing repair. Shut off sprayer when repairing. Install all covers, gaskets, screws and washers before operating sprayer.

1. Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts are not normally provided with replacement assemblies.

2. Test repair after problem is corrected.

3. If sprayer does not operate properly, review repair procedure to verify procedure was done correctly. If necessary, see Troubleshooting Guide, page 7, for other possible solutions.

WAR NING

HOT SURFACES HAZARD EXPLOSION HAZARD

Hydraulic system and engine may be very hot during operation and could burn skin if touched.

SAE O-Ring Installation

1. Unscrew lock nut to touch fitting.

2. Lubricate o-ring (A).

3. Screw in fitting hand tight.

4. Unscrew fitting until oriented properly.

ti5415a

ti5414a

Flammable materials spilled on hot engine could cause fire or explosion.

4. Install belt guard before operation of sprayer and replace if damaged. Belt guard reduces risk of pinching and loss of fingers; see preceding WARNING.

Grounding

Ground sprayer with grounding clamp to earth ground for safe sprayer operation. Fig. 1.

6250

IG. 1

5. Tighten lock nut to indicated torque. (Make sure washer is seated properly without pinching o-ring).

ti5417a

310778N 5

Maintenance

DAILY: Check pressure drain valve for proper operation.

Maintenance

WAR NING

SKIN INJECTION HAZARD

The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:

• are instructed to relieve the pressure,

• stop spraying,

• check or service any of the system equipment,

• or install or clean the spray tip.

Pressure Relief Procedure

1. Lock gun trigger safety.

2. Turn engine ON/OFF switch to OFF.

3. Move pump valve to OFF (down) and turn pressure control knob fully counterclockwise.

4. Unlock trigger safety. Hold metal part of gun firmly to side of grounded metal pail, and trigger gun to relieve pressure.

5. Lock gun trigger safety.

6. Open pressure drain valve. Leave valve open until ready to spray again.

If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen

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

CAUTION

For detailed engine maintenance and specifications, refer to separate Honda Engines Owner's Manual, supplied.

DAILY: Check and fill the gas tank.

DAILY: Check that displacement pump is tight.

DAILY: Check level of TSL in displacement pump pack-

ing nut. Fill nut, if necessary. Keep TSL in nut to help prevent fluid buildup on piston rod and premature wear of packings and pump corrosion.

AFTER THE FIRST 20 HOURS OF OPERATION:

Drain engine oil and refill with clean oil. Reference Honda Engines Owner's Manual for correct oil viscosity.

WEEKLY: Remove engine air filter cover and clean element. Replace element, if necessary. If operating in an unusually dusty environment: check filter daily and replace, if necessary.

Replacement elements can be purchased from your local HONDA dealer.

WEEKLY/DAILY: Remove any debris or media from hydraulic rod.

AFTER EACH 100 HOURS OF OPERATION:

Change engine oil. Reference Honda Engines Owner's Manual for correct oil viscosity.

SEMI-ANNUALLY:

Check belt wear, page 10; replace if necessary.

YEARLY OR 2000 HOURS:

Replace hydraulic oil and filter element with Graco hydraulic oil 169236 (5 gallon/20 liter) or 207428 (1 gallon/3.8 liter) and filter element 246173; page 6.

DAILY: Check engine oil level and fill as necessary.

DAILY: Check hydraulic oil level and fill as necessary.

DAILY: Check hose for wear and damage.

DAILY: Check gun safety for proper operation.

6 310778N

Replace belt.

SPARK PLUG: Use only BPR6ES (NGK) or W20EPR-U (NIPPONDENSO) plug. Gap plug to 0.028 to 0.031 in. (0.7 to 0.8 mm). Use spark plug wrench when installing and removing plug.

Troubleshooting

Problem Cause Solution

Gas engine pulls hard (won't start) Hydraulic pressure is too high Turn hydraulic pressure knob counter-

clockwise to lowest setting Gas engine will not start Switch OFF, low oil, no gasoline Consult engine manual, supplied Gas engine doesn't work properly

Gas engine operates, but displacement pump doesn't operate

Elevation Pump valve is OFF

Pressure setting too low

Consult engine manual, supplied.

Refer to 6.5 HP Engine Repair Kit 246311.

Set pump valve ON

Increase pressure. See manual 310765

Displacement pump outlet filter (if used) is dirty or clogged

Tip or tip filter (if used) is clogged

Hydraulic fluid too low

Belt worn or broken

Hydraulic pump worn or damaged

Dried paint seized paint pump rod

Hydraulic motor not shifting

Displacement pump operates, but output is low on upstroke

Displacement pump operates but output is low on downstroke and/or on both strokes

Paint leaks and runs over side of wet-cup

Excessive leakage around hydraulic motor piston rod wiper Fluid delivery is low

The sprayer overheats

Spitting from gun Air in fluid pump or hose

Excessive hydraulic pump noise Low hydraulic fluid level

*Check hydraulic fluid level often. Do not allow it to become too low. Use only Graco approved hydraulic fluid, page 6.

Piston ball check not seating properly. Piston packings worn or damaged. Piston packings worn or damaged.

Intake valve ball check not seating properly.

Suction tube air leak Loose wet-cup

Throat packings worn or damaged Piston rod seal worn or damaged Replace these parts

Pressure setting too low Displacement pump outlet filter (if used) is dirty or clogged Intake line to pump inlet is not tight Hydraulic motor is worn or damaged Large pressure drop in fluid hose Paint buildup on hydraulic components Oil level is low

Loose intake suction Fluid supply is low or empty

Clean filter

Remove tip and/or filter and clean

Shut off sprayer. Add fluid*. See page 6.

Replace

Bring sprayer to Graco distributor for

repair

Service pump. See manual 309277.

Set pump valve OFF. Turn pressure

down. Turn engine OFF. Pry rod up or

down until hydraulic motor shifts

Service piston ball check. See manual

309277.

Replace packings. See manual 309277.

Tighten packing nut or replace pack-

ings. See manual 309277.

Service intake valve ball check. See

manual 309277.

Tighten suction tube

Tighten packing nut enough to stop leakage

Replace packings. See manual 309277

Increase pressure. See manual 310765.

Clean filter

Tighten

Bring sprayer to Graco distributor for repair

Use larger diameter or shorter hose

Clean

Fill with oil. See page 6.

Check for loose connections on siphon

assembly, tighten, then reprime pump

Tighten

Refill supply container

Shut off sprayer. Add fluid*. See page 6.

310778N 7

Hydraulic Pump

Removal

WAR NING

Relieve pressure; page 6.

Let hydraulic system cool before beginning service.

1. Place drip pan or rags under sprayer to catch hydraulic oil that leaks out during repair.

2. Remove drain plug (40) and oil filter (47) and allow hydraulic oil to drain.

3. Fig. 2. Disconnect suction tube (114).

4. Disconnect paint pump (111), page 15.

5. Remove screw (172), nut (173) and belt guard (117).

6. Raise motor and remove belt (44).

7. Remove two set screws (133) and fan pulley (96).

8. Remove case drain tube (97).

9. Remove elbow (22).

10. Remove tube (94) from elbow (37). Remove elbow (37) from hydraulic pump (98).

11. Remove eight screws (27) reservoir cover (68) filter assembly (46) and gasket (62).

12. Remove four screws (5) and hydraulic pump (98) from reservoir cover (68).

Installation

1. Install hydraulic pump (98) to reservoir cover (68) with four screws (5); torque 100 in-lb (11 N·m).

2. Install gasket (62) and reservoir cover (68) with eight screws (27); torque 90 in-lb (10 N·m).

3. Install elbow (37) in hydraulic pump (98). Install elbow (37) in tube (94). Torque to 15 ft-lb (20.3 N·m).

4. Install elbow (22); torque to 15 ft-lb (20.3 N·m).

5. Install case drain tube (97); torque to 25 ft-lb (33.9 N·m).

6. Install fan pulley (96) with two set screws (133).

7. Raise motor and install belt (44).

8. Install belt guard (117) with screw (172) and nut (173).

9. Connect paint pump (111), page 15.

10. Fig. 2. Connect suction tube (114).

11. Install drain plug (40); torque to 110 in-lb (12.4 N·m). Install oil filter (47); tighten 3/4 turn after gasket contacts base. Fill hydraulic pump with Graco hydraulic oil, page 6, through elbow (22) port until full. Fill reservoir with remaining hydraulic oil.

12. Start up and allow pump to operate at low pressure for approximately 5 minutes to purge all air.

13. Check oil hydraulic oil and top off, if required.

8 310778N

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