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 symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the
body of this manual where applicable.
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 (SPRAY GUN)
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.
SKIN INJECTION HAZARD (APPLICATOR)
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.
•Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
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.
313889B3
Warning
WARNING
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
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
•Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure in this manual when equipment is not in use.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
•Do not alter or modify equipment.
•Use equipment only for its intended purpose. Call your distributor for information.
•Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Do not kink or over bend hoses or use hoses to pull equipment.
•Keep children and animals away from work area.
•Comply with all applicable safety regulations.
4313889B
Component Identification - Sprayer
1
2
3
Component Identification - Sprayer
Top Coat Kit
8
9
10
8
4
1ON/OFF Switch
2Prime Switch (used with Base Coat Pump)
3Pump Control
4Heavy Texture Material Hose (used with Base Coat Pump)
5Applicator Switch (used with Base Coat Pump--on Hose 5)
6Applicator (Base Coat)
7Pump (Base Coat)
8Over Pressure Relief Valve
9Pump (Top Coat)
10Spray Gun (Top Coat)
11Paint/Texture Material Hose (used with Top Coat Pump)
12Prime/Drain Valve
5
12
6
7
11
ti14415a
313889B5
Component Identification - Base Coat Applicator
Component Identification - Base Coat Applicator
8
1
7
2
3
1Applicator
2Air Hose Adapter and Air Adjustment Valve
3Airless Filter or Air Passage Plug
4Filter Support
5Airless Spray Assembly
6Airless Spray Tip
E=XX is displayedFault condition existsDetermine fault correction from Digital Display Mes-
sages table, see manual 313888.
Engine will not startEngine switch is OFFTurn engine switch ON
Engine is out of gasolineRefill gas tank. Honda Engines Owner's Manual.
Engine oil level is lowTry to start engine. Replenish oil, if necessary.
Honda Engines Owner's Manual.
Spark plug is disconnected or damaged Connect spark plug cable or replace spark plug
Cold engineUse choke
Fuel shutoff lever is OFFMove lever to ON position
Oil is seeping into combustion chamber Remove spark plug. Pull starter 3 to 4 times. Clean
or replace spark plug. Start engine. Keep sprayer
upright to avoid oil seepage
Engine operates, but displacement pump does not operate
Error code displayedReference Pressure Control repair, page 18.
Applicator switch is OFF
(Base Coat Only)
Pump setting is OFFTurn pressure adjusting knob clockwise to increase
Tip or tip filter is cloggedClean tip or tip filter, see manual 313537/313603.
Displacement pump piston rod is stuck
due to dried paint or texture
Connecting rod is worn or damagedReplace connecting rod. Page 10.
Drive housing is worn or damagedReplace drive housing. Page 12.
Electrical power is not energizing clutch
field
Clutch is worn, damaged, or incorrectly
positioned
Pinion assembly is worn or damagedRepair or replace pinion assembly. Page 13.
Base Coat Pump: Applicator switch on
material hose and/or Prime Switch on
Pressure Control are damaged.
Top Coat Pum p: Pump is not correctly
aligned to pump sensor or sensor is
damaged.
Turn applicator switch ON
pressure.
Repair pump, see manual 310894 or page 22.
Check wiring connections. Page 24.
Reference Digital Display Messages, manual
313888.
Reference Wiring Diagram. Page 24.
With applicator switch ON and pressure turned to
MAXIMUM, use a test light to check for power
between clutch test points on control board.
Remove clutch wires from control board and mea-
sure resistance across clutch coil. At 70° F (21° C),
the resistance must be between 1.2 +0.2Ω; if not,
replace pinion housing.
Have pressure control checked by authorized Graco
dealer
Adjust or replace clutch. Page 17.
See page 22.
Rotate pump to align transducer port toward back of
sprayer. Replace damaged pump sensor.
313889B7
Troubleshooting
ProblemCauseSolution
Pump output is low
(Base Coat Pump see pages
22.
Top Coat Pump see manual
310894)
Excessive paint leakage into
throat packing nut
Fluid is spitting from gunAir in pump or hoseCheck and tighten all fluid connections. Reprime
Pump is difficult to primeAir in pump or inlet tubeCheck and tighten all fluid connections.
Strainer (82) is cloggedClean strainer.
Piston ball is not seatingService piston ball.
Piston packings are worn or damagedReplace packings.
O-ring in pump is worn or damagedReplace o-ring.
Intake valve ball is not seating properlyClean intake valve.
Intake valve is packed with materialClean intake valve.
Engine speed is too lowIncrease throttle setting.
Clutch is worn or damagedAdjust or replace clutch. Page 17.
Pressure setting is too lowIncrease pressure.
Tip filter or tip is clogged or dirtyClean filter.
Large pressure drop in hose with heavy
Throat packings are worn or damagedReplace packings.
Displacement rod is worn or damagedReplace rod.
Tip is partially cloggedClear tip.
Fluid supply is low or emptyRefill fluid supply. Prime pump. Check fluid supply
Use larger diameter hose and/or reduce overall
length of hose.
packing nut just enough to stop leakage.
pump.
often to prevent running pump dry.
Reduce engine speed and cycle pump as slowly as
possible during priming.
Intake valve is leaking or contaminatedClean intake valve. Be sure ball seat is not nicked or
worn and that ball seats well. Reassemble valve.
Pump packings are wornReplace pump packings.
Paint is too thickThin the paint according to the supplier's recommen-
dations
Engine speed is too highDecrease throttle setting before priming pump.
Prime/Drain valve is pluggedMaterial hardened in valveOperate drain valve at least once per hour when
spraying.
Flush valve more thoroughly when cleaning sprayer.
Aggregate packed up in valveValve is opened too slowly and/or aggregate is too
large.
Over pressure relief valve
actuates
Clutch squeaks each time clutch
engages
High engine speed at no loadMisadjusted throttle settingReset throttle to 3300 engine rpm at no load.
No display, sprayer operatesDisplay damaged or has bad connec-
Clutch is worn out or damaged. Pressure transducer or control board are
damaged.
Valve is damaged or worn.Clean out debris and replace valve.
Clutch surfaces are not matched to
each other when new and may cause
noise
Worn engine governorReplace or service engine governor
tion
Check and replace worn or damaged component.
Clutch surfaces need to wear into each other. Noise
will dissipate after a day of run time.
Check connections. Replace display.
8313889B
Pressure Relief Procedure
Pressure Relief Procedure
Applicator (Base Coat Pump)
1.Turn engine OFF.
2.Turn on/off switch OFF and turn pressure control
knob fully counterclockwise.
ti6208b
ti13050a
3.Turn prime/drain valve down to DRAIN position.
Fluid from drain valve can splash in eyes or skin and
cause serious injury. Keep hands clear of pressure
relief valve and always wear safety glasses.
Spray Gun (Top Coat Pump)
1.Lock gun trigger safety and turn engine OFF.
ti13131a
2.Turn on/off switch to OFF and turn pressure control
knob fully counterclockwise.
ti13050a
ti10796b
3.Unlock trigger safety. Hold metal part of gun firmly
to side of grounded metal pail and trigger gun to
relieve pressure.
ti14632a
NOTE: If you suspect spray tip nozzle or hose is completely clogged or that pressure has not been fully
relieved after following the previous steps, cover the
connection at end of hose with a heavy rag and very slowly loosen connection.
ti13130a
ti13128a
4.Lock gun trigger safety. Open pressure prime/drain
valve. Leave valve open until ready to spray again.
ti13131a
ti14632a
NOTE: If you suspect that the spray tip nozzle or hose is
completely clogged, or that pressure has not been fully
relieved after following the previous steps, VERY
SLOWLY loosen the tip guard retaining nut or hose end
coupling to relieve pressure gradually, then loosen completely. Then clear tip nozzle or hose.
313889B9
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