Graco Inc 687327, 965171, 687100, 308972R, 965165 User Manual

...

Instructions -- Parts List

GH Series Roof Rigs

Gas--Hydraulic Airless Sprayers

Important Safety Instructions

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

GH5030

Model 687100, Series C

4900 psi (33.8 MPa, 337 bar) Maximum Working Pressure

GH3640

Model 687327, Series D

3600 psi (24.5 MPa, 245 bar) Maximum Working Pressure

GH2560

Model 965168, Series B

2400 psi (16.6 MPa, 166 bar) Maximum Working Pressure

308972R

GH2075

Model 965171, Series B

1800 psi (12.4 MPa, 124 bar) Maximum Working Pressure

GH1015

Model 965165, Series C

1000 psi (0.70 MPa, 70 bar) Maximum Working Pressure

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440--1441

9089c

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 34.............................

Accessories 37..................................

Technical Data 37................................

Graco Warranty 38...............................

Graco Information 38.............................

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 37 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

SKIN 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.

D Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediate surgi-

cal treatment.

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

D Do not put your hand or fingers over the spray tip.

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

D Do not “blow back” fluid; this is not an air spray system.

D Always have the tip guard and the trigger guard on the gun when spraying.

D Check the gun diffuser operation weekly. Refer to the gun manual.

D Be sure the gun trigger safety operates before spraying.

D Lock the gun trigger safety when you stop spraying.

D Follow the Pressure Relief Procedure on page 10 if the spray tip clogs and before cleaning,

checking or servicing the equipment.

D Tighten all fluid connections before operating the equipment.

D 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.

D 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.

D Know the specific hazards of the fluid you are using.

D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,

state and national guidelines.

D 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.

D 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.

D 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.

D 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.

D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid

being sprayed.

D Keep the spray area free of debris, including solvent, rags, and gasoline.

D Disconnect all electrical equipment in the spray area.

D Extinguish all open flames or pilot lights in the spray area.

D Do not smoke in the spray area.

D Do not turn on or off any light switch in the spray area while operating or if fumes are present.

D Do not operate a gasoline engine in the spray area.

D Ground the sprayer to a true earth ground with the ground wire and clamp (supplied).

D Use only electrically conductive hoses.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

D Keep clear of all moving parts when starting or operating the sprayer.

D 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 37 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 UNDERSTAND 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

DRAULIC RETURN LINE TOMOTOR

MOTOR RESET BUTTON

HYDRAULIC MOTOR

HYDRAULIC SUPPLY LINE TO MOTOR

HYDRAULIC RESERVOIR

SUCTION TUBE

Fig 1

CHECK VALVE

PRESSURE

DRAIN VALVE

DISPLACEMENT PUMP

SUCTION HOSE

GASOLINE FILL CAP

HYDRAULIC PUMP

9089d

PRESSURE CONTROL KNOB

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

c. Don’t use thread sealant on the swiveling nut

of the hose couplings, and don’t install the

spray tip yet.

NOTE: Use thread sealant on all male threads except at

swivel unions. Swivel unions are made to self-seal, and using thread sealant prevents the swivel from turning freely.

2. Fill the Packing Nut/Wet Cup 1/3 full with Graco Throat Seal Liquid (TSL), supplied. See Fig. 2.

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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 only Graco Hydraulic Fluid, 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.

Setup

GASOLINE FILL CAP

OIL DIPSTICK

ENGINE OIL FILL PLUG

PACKING NUT/ WET CUP

Fig 2

HYDRAULIC OIL FILL CAP

7871b

7872b

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.

c. If oil is needed, see the chart below for the

recommended oil type and weight.

d. Crank case capacity with filter: 2.1 quarts (2.0

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 TEMPERATURE GRADE OF OIL

Spring, Summer, Autumn SAE 10W--30

30_Fto0_,Winter SAE 5W--20 or 5W-- 30

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.The 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.

d. External fuel tank capacity: 6.0 gallons (22.7

liters)

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.

e. Gasoline consumption at the maximum oper-

ating speed of 2900 RPM is about 1.3 gallons/ hour (4.9 liters/hour).

CLAM

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.

7873B

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, flush with mineral spirits only. Before using water-base paint, flush with 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

WARNING

SKIN INJECTION HAZARD Follow the Pressure Relief Procedure Warning on page 10. Remove the spray

tip before flushing.

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: flush with water, then mineral spirits and leave the pump, hose and gun filled with mineral spirits. Follow the Pressure Relief Procedure Warning, page 10. Oil - base paint: flush with mineral spirits. Follow the Pressure Relief Procedure Warning, page

10.

6. Startup after storage. Before using water-base paint, flush out mineral spirits with soapy water and then clean water. When using oil- base paint, flush out mineral spirits with fluid to be sprayed.

8. Turn and hold the ignition key to START until you hear theengine “catch”, then release the key to RUN. See Fig 5. If the engine does not start, open the choke a little (move lever). If the engine floods, open the choke all the way and try again.

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. Turn the pressure control knob counterclockwise 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. Open the bypass valve. The valve lever will be parallel to the body of the valve. See Fig 5.

6. Attach fuel hose from tank to engine.

7. Close the choke by moving the choke lever. See Fig 5.

CHOKE

ON/OFF SWITCH

AIR FILTER

PRESSURE CONTROL KNOB

BYPASS VALVE

Fig 5

9. After the engine is warm, gradually open the choke lever (move lever) 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.

7874b

CAUTION

The bypass valve must be opened when starting the sprayer to prevent damaging the starter .

3089728

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.

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.

1 1. 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

Operation

Pressure Relief Procedure

WARNING

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:

D areinstructedtorelievethepressure, D st op spraying, D check or service any of the system equipment, D install or clean the spray tip.

1. Engage the gun safety latch.

2. Open the bypass valve.

2. Starting the Sprayer a. Open the bypass valve to make startup easier.

In the open position, the valve lever is parallel to the body of the valve. See Fig 6. Close the filter drain valve.

b. Turn the pressure control knob counterclock-

wise 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 fur-

ther will cause it to fall off. c. Attach fuel hose from tank. d. If the engine is cold, close the choke by mov-

ing the choke lever. See Fig 6.

3. Turn and hold the ignition key to START until you

hear the engine “catch”, then release the key to

RUN. See Fig 6. If the engine does not start,

open the choke a little (move choke lever). If the

engine floods, open the choke all the way and try

again. e. After the engine is warm, gradually open the

choke lever (move choke lever) and close the

bypass valve. See Fig 6.

3. Turn the ignition key to OFF.

4. Disengage the gun safety latch. Hold a metal part of the gun firmly to the side of a grounded metal pail, and trigger the gun to relieve pressure.

5. Engage the gun safety latch.

6. Open the pressure drain valve, having a container ready to catch the drainage. Leave the valve open until you are 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, wrap a rag around the tip

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

1. Prepare the Fluid

CHOKE

ON/OFF SWITCH

AIR FILTER

PRESSURE CONTROL KNOB

BYPASS VALVE

Fig 6

NOTE: In cold weather, run the engine for about 15

minutes with the bypass valve open before starting the displacement pump, to help avoid hydraulic motor stalling.

f. Follow the Pressure Relief Procedure

Warning on page 10, to shut off the sprayer.

7874b

a. Prepare the fluid according to the fluid manu-

facturer’s recommendations.

b. Place the pump or suction tube into the fluid

container.

30897210

WARNING

To stop the engine in an emergency, turn OFF

the ignition key. Close the bypass valve if possible. See Fig 6. Then follow the Pressure Relief Proce-

dure Warning on page 10.

Operation

If the motor stalls during operation, turn OFF the igni-

tion key. With your hand, firmly press straight down on the motor reset button. Now try to restart the sprayer. If it will not start, refer to the separate motor manual,

307158.

CAUTION

The engine throttle has been set to a maximum of 3000 RPM. The sprayer warranty will be voided and the hydraulic pump life shortened if this adjustment is changed.

Never use a hammer to depress the reset button, as it could cause serious internal motor damage.

4. Prime the Pump a. Be sure the gun safety latch is engaged.

b. Don’t install the spray tip yet! c. If the engine has not been started, follow the

procedure in Step 2., page 10. d. Disengage the gun safety latch. e. Point the gun into a grounded metal pail and

hold a metal part of the gun firmly against the

pail. See the WARNING below. f. Squeeze the trigger and slowly turn the pres-

sure control knob clockwise just enough to

start the pump. See Fig 6. g. Operate the pump until all air is purged from

the pump and hoses and the fluid is flowing

freely from the gun. h. Release the trigger and engage the safety

latch. i. Turn the pressure control knob counterclock-

wise until all spring tension is relieved. You will

be able to feel it. The sprayer is now at the

lowest pressure setting. Turning the knob

further will remove it. j. Follow the Pressure Relief Procedure on

page 10. Then install the spray tip in the gun

as instructed in the separate gun or tip instruc-

tion manual. If you are using the RAC IV

supplied with this sprayer, see manual 308644.

5. Adjusting the Pressure a. Turn the pressure control knob clockwise to

increase and counterclockwise to decrease the pressure. Tighten the knob locknut to set.

b. Always use the lowest pressure that is neces-

sary to completely atomize the fluid.

CAUTION

Operating the sprayer at a higher pressure than necessary wastes fluid, causes early tip wear, and shortens the sprayer life.

c. If more coverage is needed, use a larger tip

rather than increasing the pressure.

d. Check the spray pattern. The tip size and

angle determines the pattern width and flow rate. See the separate manual received with your gun.

6. Cleaning a Clogged Tip

WARNING

SKIN INJECTION HAZARD

To reduce the risk of a fluid injection injury , NEVER hold your hand, body or a

rag in front of the spray tip when cleaning or checking for a cleared tip. To reduce the risk of a fire or explosion, always hold the gun firmly against the side of a grounded metal waste container when checking to see if the tip was cleared or when using a self--clearing tip.

a. Follow the Pressure Relief Procedure

Warning on page 10.

b. Clean the front of the tip frequently during the

day to keep the fluid from building up and clogging the tip. To clean, and to clear a tip if it clogs, refer to your separate gun instruction manual. If you are using the RAC IV tip guard and SwitchT ip, refer to manual 308644.

7. Shutting Off the Sprayer

a. Whenever you stop spraying, even for a short

break, follow the Pressure Relief Procedure Warning on page 10.

b. Clean the tip and gun as recommended in your

separate gun or tip manual.

c. Flush the sprayer at the end of each work day

if using water--based fluid or if it could harden in the sprayer over night. See FLUSHING, page 8. Use a compatible solvent to flush, then fill the pump and hoses with solvent such as mineral spirits to help prevent pump corrosion. Relieve pressure!

d. For long term shutdown or storage, always fill

the sprayer with mineral spirits to prevent pump corrosion. Relieve pressure!

8. Adjusting the Intake Valve Ball Travel.

a. The pump is set to handle medium volume,

low viscosity fluid. To adjust the pump for higher flow or heavier viscosity fluid, disassemble the intake valve as instructed in the appropriate pump manual listed in the parts list and move the ball stop pin to a higher set of holes. This increases the ball travel.

11308972

Maintenance

1. Always stop the pump at the bottom of its stroke when you take a break and at the end of

the day. This helps keep fluid from drying on the rod and damaging the packings.

2. Keep the displacement pump packing nut/wet cup 1/3 full of TSL at all times. The TSL helps protect the packings and rod.

3. Check the tightness of the packing nut daily. It should be tight enough to stop leakage but no tighter.

CAUTION

Proper engine and hydraulic oil level is important to prevent costly damage to the sprayer. Check it as often as recommended in Steps 4 and 5., below.

4. Check the hydraulic oil level weekly. The oil must be up to the top mark on the dipstick. Use only Graco Hydraulic Oil.

5. Check the engine oil level at least weekly. The oil must be up to the FULL mark on the dipstick. The engine should not use more than one ounce of oil per hour of operation. Consult the engine manual, supplied, for additional recommended maintenance.

8. Change engine oil and filter every 100 hour of use. Use 30W detergent oil.

9. To change the hydraulic oil:

a. Follow the Pressure Relief Procedure

Warning on page 10.

b. Place a waste container under the drain plug

of the hydraulic reservoir. See Fig 7. Unscrew the plug and drain the reservoir . Reinstall the plug before proceeding.

c. Remove the nuts and reservoir cover.

d. Remove the return line filter and install a new

filter assembly.

e. Inspect the inlet filter and replace it if needed.

f. Install the reservoir cover and nuts. Then pour

in five gallons (19 liters) of Graco Hydraulic Oil through the intake filter. See Fig 7. Install the fill cap.

NUTS

HYDRAULIC OIL FILL CAP

COVER

INLET FILTER

ENGINE OIL FILL PLUG

6. Inspect the return line filter frequently for clogging. Replace it after every 500 hours of operation or every 6 months, whichever comes first. A clogged or worn out filter reduces filter capability and will damage the hydraulic pump.

7. Change the hydraulic oil after every 2000 hours of operation or every 12 months, whichever comes first. For continuous operation in temperatures above 85_F(30_C), change the oil after every 1000 hours or 6 months of use. See Step 9. for the procedure.

CAUTION

Cleanliness is essential when servicing the hydraulic system. Use special care to avoid getting dust or dirt into the hydraulic system to prevent damage to the hydraulic components.

RETURN LINE FILTER

Fig 7

HYDRAULIC OIL DRAIN PLUG LOCATED UNDER RESERVOIR

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