Graco 311797J User Manual

Repair

GH™ 130, GH 200, GH 230, GH 300 Hydraulic Sprayers

- Use with Architectural Coatings and Paints -

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

List of models provided on page 2.

IMPORTANT SAFETY INSTRUCTIONS.

Read all warnings and instructions in this manual. Save these instructions. Contact Graco Customer Service, your local Graco distributor or our website: www.graco.com, to obtain a manual in your language.

311797J

ENG

ti5380a

Models

GH130 GH200 GH230 GH300

253957 253959 253980 253962 253963 253981 255095 253965 253966 253982 253968

✔✔ ✔✔✔ ✔✔✔

✔✔ ✔✔✔ ✔✔✔ ✔✔

Electric Motor Kit Options

Kit Number Sprayer Model Description

288474 288473 248950 248949 248946

GH130 120VAC, 60Hz, 20A, CAS/UL approved

GH130 120VAC, 60Hz, 15A

GH200/GH230 120VAC, 60Hz, 20A, CSA/UL approved

GH200/GH230 120 VAC, 60Hz, 15A

EH200/HD1200 240VAC, 50Hz, 13.4A

120 Vac

60 Hz

ETL/CSA/UL

120 Vac

60 Hz

✔✔ ✔✔ ✔ ✔✔✔

✔✔

2 311797J

Models

Warnings

The following Warnings are for the 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. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

WARNINGWARNINGWARNING

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.

• 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 all equipment in the 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.

• Keep a working fire extinguisher in the work area.

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.

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.

• Do not expose to rain. Store indoors.

311797J 3

Models

WARNING

WARNINGWARNINGWARNING

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.

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 311797J

Component Identification

10.

ti9126a

off

bar/MPa

PSI

ti9167a

11.12.

ti8714a

OFF

ti9166a

13.

ti8691a

ti8844a

Item No. Component

1 Hydraulic pump valve 2 Pressure control 3 Hydraulic Oil Cap 4Drain valve 5 Engine ON/OFF switch 6 Engine controls 7 Electric motor On/Off Switch 8 Gun trigger Lock 9 Displacement pump

11 Inlet strainer (standard) 12 Inlet strainer (option) 13 Serial number tag

ProConnect

ti5381b

™

311797J 5

General Repair Information

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.

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

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 when using solvent-based materials. Fig. 1.

6250

IG. 1

ti5416a

5 Tighten lock nut to indicated torque.

(Make sure washer is seated properly without pinching o-ring).

ti5417a

6 311797J

Maintenance

Pressure Relief Procedure

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.

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 counter clockwise.

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.

NOTICE

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

Maintenance

DAILY: Check and fill the gas tank.

DAILY: Check that displacement pump is tight.

DAILY: Check level of Throat Seal Liquid (TSL) in dis-

placement pump packing 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.

W EE KLY / DA ILY: 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 with Graco hydraulic oil 169236 (5 gallon/20 liter) or 207428 (1 gallon/3.8 liter) and filter 116909.

Replace belt.

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.

DAILY: Check pressure drain valve for proper operation.

311797J 7

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 does not start Switch OFF, low oil, no gasoline Consult engine manual, supplied. Gas engine doesn't work properly Faulty engine Consult engine manual, supplied.

Elevation Refer to Engine Repair Kit.

4.0 hp - 288678 / 5.5 hp - 248943 /

6/5 hp - 248944 / 9.0 hp - 248945 Gas engine operates, but displacement

pump doesn't operate

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 wetcup Loosen wet-cup Tighten wet-cup enough to stop leakage.

Excessive leakage around hydraulic motor piston rod wiper

Fluid delivery is low Pressure setting too low Increase pressure.

The sprayer overheats Paint buildup on hydraulic components Clean. Spitting from gun Air in fluid pump or hose Check for loose connections on siphon

Excessive hydraulic pump noise Low hydraulic fluid level Turn sprayer OFF. Add fluid*. Electric motor does not operate Power switch is not ON Turn power switch to ON.

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

Hydraulic pump valve is OFF Set hydraulic pump valve ON. Pressure setting too low Increase pressure. Displacement pump outlet filter (if used)

is dirty or clogged Tip or tip filter (if used) is clogged Remove tip and/or filter and clean. Hydraulic fluid too low Shut off sprayer. Add fluid*. Belt worn or broken or off Replace, page 12. Hydraulic pump worn or damaged Bring sprayer to Graco distributor for repair. Dried paint seized paint pump rod Service pump. See manual 311845. Hydraulic motor not shifting Set pump valve OFF. Turn pressure down.

Piston ball check not seating properly Service piston ball check. See manual

Piston packings worn or damaged Replace packings. See manual 311845. Piston packings worn or damaged Tighten packing nut or replace packings.

Intake valve ball check not seating properly

Suction tube air leak

Throat packings worn or damaged Replace packings. See manual 311845. Piston rod seal worn or damaged Replace these parts.

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

Intake line to pump inlet is not tight Tighten. Hydraulic motor is worn or damaged Bring sprayer to Graco distributor for repair. Large pressure drop in fluid hose Use larger diameter or shorter hose.

Loose intake suction Tighten. Fluid supply is low or empty Refill supply container.

Tripped circuit breaker Check circuit breaker at power source.

Clean the filter.

Turn engine OFF. Pry rod up or down until

hydraulic motor shifts .

311845.

See manual 311845.

Service intake valve ball check. See man-

ual 311845.

Clean filter.

assembly, tighten, then reprime pump.

Reset motor switch.

8 311797J

Notes

311797J 9

Hydraulic Pump

(Figure 2)

Removal

Let hydraulic system cool before beginning service.

1 Relieve pressure, page 7. 2 Place drip pan or rags under sprayer to catch hydraulic oil

that leaks out during repair.

3 Remove drain plug (2) and oil filter (227) and allow

hydraulic oil to drain. 4 Fig. 2. Disconnect suction tube (114). 5 Disconnect pump (111), page 15. 6 Remove screw (172), nut (173) and belt guard (117). 7 Raise motor and remove belt (44). 8 Remove two set screws (176) and fan pulley (96). 9 Remove case drain tube (225). 10 Remove elbow (221). 11 Remove tube (276) from elbow (226). Remove elbow

(226) from hydraulic pump (220). 12 Remove eight screws (212) reservoir cover (209) filter

assembly (206) and gasket (203). 13 Remove four screws (277) and hydraulic pump (220) from

reservoir cover (209).

Installation

1 Install hydraulic pump (220) to reservoir cover (209) with

four screws (277); torque 90-110 in-lb (10.1-12.4 N·m). 2 Install gasket (203) and reservoir cover (209) with eight

screws (212); torque 110+/-5 in-lb (12.4 +/- 0.5 N·m). 3 Install elbow (226) in hydraulic pump (220). Install elbow

(226) in tube (276). Torque to 25 ft-lb (33.9 N·m). 4 Install elbow (221); torque to 15 ft-lb (20.3 N·m). 5 Install case drain tube (225); torque to 15 ft-lb (20.3 N·m). 6 Install fan pulley (96) with two set screws (176). 7 Raise motor and install belt (44). 8 Install belt guard (117) with screw (172) and nut (173). 9 Connect pump (111), page 15. 10 Fig. 2. Connect suction tube (114). 11 Install drain plug (2); torque to 110 in-lb (12.4 N·m). Install

oil filter (227); tighten 3/4 turn after gasket contacts base.

Fill hydraulic pump with Graco hydraulic oil, page 6,

through elbow (221) 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.

10 311797J

Hydraulic Pump

172

117

173

96 44

176

266

276

277

227

222

221

225

226

220

211

209

212

207

206

111

FIG. 2

114

203

ti8821b

311797J 11

+ 25 hidden pages