Graco PDW8800, 231-005, PDW9200 User Manual

INSTRUCTIONS-PARTS

This manual contains
WARNINGS

READ

AND

RETAIN

PORTABLE, AIRLESS

IMPORTANT

and

INSTRUCTIONS

FOR

REFERENCE

LIST

GRACO

307-293

Rev.

N

SUPERSEDES M

GH

3000

psi

(210 bar)

433

PAINT

MAXIMUM

WORKING PRESSURE

SPRAYER

Model 215-433, Series G

Includes Sprayer 231-005, Hose, Gun, Tip Guard and
Spray Tip

of

Choice.

Model 231-005, Series A

Sprayer only

INDEX

Warnings
Installation
Flushing Guidelines
Operation
Regular Maintenance
Troubleshooting
Repair
Parts Drawings
Accessories
How
Technical Data
Warranty ... ,

....................................

..................................

....................................

......................................

to

Order Replacement Parts

.......................

.......................

.............................

& List

...................................

......

...................

...................

'"

..... , ....

, ... Back Cover

2, 3
4, 5
6,
8, 9

10

11
12-15
16-19

20

........

Back Cover

21

7

~--------------------------------------WARNING-------------------------------------.

Aluminum and Zinc Material Hazard

Never

use
such solvents in this equipment.
plosion, which

Consult your

1,1, 1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing

could cause death, serious bodily injury

fluid suppliers

GRACO

INC.

Such

use

could result in a serious chemical reaction, with the possibility

to

ensure that the fluids being used are compatible

P.O.

BOX

©COPYRIGHT

1441

and/or

substantial property damage.

MINNEAPOLIS,

1985

GRACO INC.

with

aluminum and zinc parts.

MN

55440-1444

of

ex-

WARNING

HIGH PRESSURE

all

warnings.

SPRAY

Read

and

CAN

CAUSE SERIOUS

understand

all

instruction

FLUID INJECTION HAZARD

General
This equipment generates very high fluid pressure. Spray from
the gun,
through your skin and into your body and
serious bodily injury, including the need for amputation. Fluid
injected or splashed into the
serious damage.

NEVER
body.
try

ALWAYS have the tip guard on the spray
ALWAYS

Safety

leaks or ruptured components

eyes

or on the skin can cause

point the spray gun at anyone or at any part

to

NEVER

"blow

put hand or fingers over the spray tip.

back"

paint; this

follow

the Pressure Relief Procedure, below,

is

NOT

an

air spray system.

gu

can

inject fluid

cause

extremely

of

the

NEVER

n when spraying.

before cleaning or removing the spray tip or servicing any

system equipment.

NEVER

Be

before each use.

Medical

If

MEDICAL

SIMPLE CUT. Tell the doctor exactly what fluid was injected.

try

to

stop or deflect leaks with your hand

sure equipment safety devices

any fluid appears

Note

It
possible.

Alert-Airless

to

Phys/cilln:

is

important

CARE

Do

not

Spray

to

penetrate your skin, get EMERGENCY

AT

ONCE. DO

Injection in the skin is a traumatic injury.

to

treat

the

delay treatment to research toxicity. Tox-

Wound

injury

are

operating properly

NOT

TREAT

surgically

8S

or

soon

body.

AS

A

as

icity is a concern with some exotic coatings injected directly
into the blood stream. Consultation with a plastic surgeon or
reconstructive hand surgeon

Spray Gun
Be

sure all gun safety devices
each
can cause a malfunction and

use.

Safety

Do

Devices

not

remove or modify any part

may

be

advisable.

are

operating properly before

result in serious bodily injury.

of

the gun; this

INJURY.

manuals

For

professional

before

operating

use

only.

equipment.

Observe

Safety Latch

Whenever you stop spraying,
the gun safety
the gun inoperative.
accidental triggering

latch

in

Failure to set the safety latch

of

even

the closed or

the gun.

for a moment, always set

"safe"

position, making

can

result in

Diffuser

The gun diffuser breaks up spray and reduces the risk
injection when the tip
regularly. Follow the Pressure Relief
then remove the spray tip. Aim the gun into a metal pail,
holding
pressure, trigger the gun.
to

Tip

ALWAYS
spraying. The tip guard alerts you
and
your fingers

the gun firmly to the pail. Using the lowest possible

an

irregular stream, replace the diffuser immediately.

Guard

have the tip guard

helps reduce, but does not prevent, accidentally placing

or

is

any part

not

installed. Check diffuser operation

If

the fluid emitted is

in

place on the spray gun while

of

your body close

Procedure,

not

to

the fluid injection hazard

to

of

fluid

below,

diffused in-

the spray tip.

Trigger Guard

Always have the trigger guard in place on the gun when spray-

to

reduce the risk

ing
dropped or bumped.

Spray

Tip
Use
the spray tip clogs while spraying, engage the gun safety latch
immediately.
cedure

NEVER
fully relieved

Safety

extreme caution when cleaning or changing spray tips. If

ALWAYS

and then remove the spray tip

wipe

off

and

of

accidentally triggering the gun

follow the Pressure

build-up around the spray tip until pressure

the gun safety latch is engaged.

to

clean it.

Relief

if

Pro-

it

is

is

Relief

Pressure
To reduce the risk

always follow this procedure whenever you shut

parts,

installing, cleaning or changing spray tips, and whenever you stop spraying.

when
bypass

valve.
metal part
ty

latch. (7) Open the drain valve, having a container ready

ready to spray again.

If

you

suspect

steps above,

completely.

Procedure

of

serious bodily injury, including fluid injection, splashing in the

(3)

Depress the engine stop button.

of

the gun firmly

to

the side of-a grounded metal pail, and trigger the gun

off

the sprayer, when checking or servicing any part

(4)

Close the fuel shutoff valve.

to

catch the drainage.

that the spray tip or hose is completely clogged, or that pressure has

VERY SLOWLY loosen the tip guard retaining

Now

clear the tip

or

hose.

/4

nut

or hose end coupling and relieve pressure gradually, then loosen

eyes

or on the skin, or injury from moving

(1)

Engage the gun safety latch.

(5)

Disengage the gun safety latch and hold a

to

relieve pressure.

(8)

Leave

the drain valve open until you

not

been

fully

5

of

the spray system,

(2)

Open the

(6)

Engage the gun safe-

relieved after following the

are

2 307-293

EQUIPMENT MISUSE

General
Any

overpressurizing, modifying parts, using incompatible
chemicals and fluids, or using worn or damaged parts,
cause
serious bodily injury,

NEVER
could cause

CHECK

worn or damaged parts immediately.
Read

regarding the use

System

This sprayer

WORKING

accessories
pressure
ing pressure
system.

Fluid
BE
patible with the wetted parts shown
the back cover. Always
turer's literature before using them

HOSE

High pressure fluid in the hoses
hose develops a
damage or misuse, the high pressure spray emitted from

cause a fluid injection injury or other serious bodily injury or
property damage.

ALL

BOTH ENDSI

kinks or bends at or close
hose rupture.

TIGHTEN
pressure fluid can dislodge a loose coupling or
pressure spray

NEVER

hose
movement

exist, replace the hose immediately.

high pressure hose or mend

repaired hose cannot contain the high pressure fluid.

HANDLE AND

hoses

are

DO

or

Hose
Proper hose grounding continuity
grounded spray system. Check the electrical resistance
air and fluid hoses at least once a week.
have a tag on it which specifies the maximum electrical
resistance, contact the hose supplier or manufacturer
maximum resistance limits. Use a
propriate range for your hose to check the resistance.
resistance exceeds the recommended limits, replace
mediately. An ungrounded
your system hazardous. Also
HAZARD,

Safety

misuse

of

the spray equipment or accessories, such

them

to

rupture and result in fluid injection or other

alter

or

modify any part

it

to

all

spray equipment regularly and repair

and follow the fluid and solvent manufacturer's literature

Preb Jure

can

PRESSURE.

are

of

Compatibility

SURE

rated

this sprayer.

of

that all fluids and solvents

SAFETY

leak, split or rupture due

FLUID HOSES

for

to
not
NOT expose the hose to temperatures above 180°F (82°C)

below

Grounding

The spring guards help protect the hose from

all

fluid connections securely before

to

use a damaged hose.

cuts, leaks, abrasion, bulging cover, or damage or

of

the hose couplings.

ROUTE HOSES CAREFULLY.

move equipment. Do not

compatible

-40°F (-40°C).

to the right.

HAZARD

fire, explosion or property damage.

of

malfunction.

of

protective clothing and equipment.

develop 3000

Be

sure that

to

withstand the maximum working

DO

any component or accessory used

read

MUST

to

be emitted from the coupling.

it

with

the inner tube and cover

Continuity

or

this equipment; doing

or

psi

(210 bar)

all

spray equipment and

NOT exceed the maximum work-

used

are

in

the fluid and solvent manufac-

HAVE

the coupling which

Befo.re

with tape or any other device. A

poorly grounded hose

the Technical Data on

in

this sprayer.

can

be

very dangerous. If the

to

SPRING

each use, check entire

If

any

DO

NOT try

use

fluids

is

essential

If your hose does

voltage 'meter in the ap-

read

FIRE OR EXPLOSION

MAXIMUM

chemically com-

any kind

GUARDS

can

each

use. High

allow high

of

these conditions

to

Do

not pull on

or

solvents which

of

the hose.

to

maintaining a

can

as

can

so

replace

in

the

of

wear,

it

can

ON

result in

recouple

of

your

not

for

the

If

the

it

im-

make

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers or other
body parts.
operating the sprayer.
on page 2 before checking or servicing the sprayer to prevent
it

from starting accidentally.

KEEP

CLEAR

of

Follow the Pressure

moving parts when starting or

Relief

Procedure

,," IMPORTANT

United States Government' safety standards have been
adopted under the
standards-particularly the General
the Construction Standards, Part

Occupational Safety and Health Act. These

Standards, Part

1926-should

1910,

be

consulted.

and

FIRE

OR

EXPLOSION

Static electricity
through the pump and hose.
ment

is
system may become hazardous. Sparking may also occur
when plugging
can
dust particles and other flammable substances, whether you
are
plosion and serious bodily injury and property damage.
Always locate the sprayer at least
spray area.
the spray
in the air.

If
while using this equipment,

MEDIATELY.
ding.
identified and corrected.

Grounding

To reduce the risk
all
CHECK
structions
ground

1.

not

ignite fumes from solvents and the fluid being sprayed,

spraying indoors or outdoors, and

you experience any static sparking or even a slight shock

Do

not

other spray equipment used or located in the spray area.

your local electrical code

all

Sprayer: connect the ground wire and clamp (provided) to

a true earth ground.

is

properly grounded, sparking may occur, and the

in

Do

not

area

when there

Check the entire system for positive groun-

use

the system again until the problem

for

your

of

this spray equipment:

HAZARD

created by the high velocity

or

unplugging a power supply cord. Sparks

plug in or unplug any power supply cords in

of

static sparking, ground the sprayer and

area

If

every part

is

any chance

and type

See

Fig

can

20

feet

(6

of

STOP

for

detailed grounding in-

of

equipment.

1.

flow

of

of

the spray equip-

cause a fire

m) away from the

igniting fumes still

SPRAYING

BE

fluid

or

IM-

has

been

SURE to

ex-

o

o

o

Fig 1

2.

Fluid hoses:

500

feet
ing continuity. Refer to the section Hose
tinuity.

3.

Spray gun: obtain grounding through connection

perly grounded fluid hose and sprayer.

4. Object being sprayed: according to local code.

5.

Fluid supply container: according

6.

All

solvent pails

code.
place the pail on a non-conductive surface, such
or cardboard, which interrupts the grounding continuity.

7.

To

maintain grounding continuity when flushing

ing pressure,

the side

Flushing
Reduce the risk
splashing by
on page 6
cedure

Hold a metal part

pail and use the lowest possible fluid pressure during

metal

flushing.

GAS

ENGINE HAZARDS

NEVER
Fuel

spilled on a hot surface can ignite and

AL

WA

YS pour fuel

NEVER operate the engine in a closed building unless the

engine exhaust
monoxide, a poisonous, odorless and invisible
cause

serious illness and

NEVER alter the throttle setting which

maximum
with this

use

(150

Use

of

Safety

of

on page 2, and remove the spray tip before flushing.

fill the fuel tank while the engine

full load engine

can

only grounded hoses with a maximum

m)

combined hose length to ensure ground-

used

only

always hold a metal part

a

grounded

of

following the specific flushing procedure given

this manual. Follow the Pressure

of

is

piped outside. The exhaust contains carbon

damage the sprayer and will void the warranty.

when flushing, according

metal

pails, which are conductive.

metal pail, then trigger the gun.

fluid injection injury, static sparking, or

the gun firmly to the side

in

slowly to avoid spilling.

even

death

speed

of

Grounding

to

local code.

of

the gun firmly to

of

is

running or hot.

if

2800

gas

inhaled.

is

factory set at the

RPM. Tampering

Relief

a grounded

cause

which

to

to

as

or

Con-

a pro-

local

Do

not

paper

reliev-

Pro-

a fire.

can

of

307-293

3

TERMS
WARNING:

that

could cause bodily injury.

Alerts user to avoid or correct conditions

CAUTION: Alerts user

that

could

cause

damage to or destruction

TYPICAL

INSTALLATION

to

avoid or correct conditions

of

equipment.

NOTE: Identifies essential procedures or extra

information.

FUEL SHUTOFF
VALVE

FLUID HOSE

Fig 2

SETU P

U;;ti/'WH:nA

NOTE: Numbers in parentheses refer

on page

1.

Install

the

ing the screws

out

Pull

the
pivots and swing the pump
clips into the forward

2.

Install

page

the

20.

4 307-293

19.

handle

two

(58)

(33)

and lockwashers

clips

accessory

on

the back

(23)

from the pump support

(110)

holes

to

secure the pump.

suction

tube,

to

the parts list

of

the cart, us-

(9)

provided.

down. Put the

if

used.

See

'

___

)

I

3.

Connect
a.

b.

NOTE:

~

IHYDRAULIC

--,

WHIP

HYDRAULIC RETURN

FROM MOTOR

LINE

END HOSE

the

Hose

and

OIL FILL

Gun

CAP

Remove the plastic cap plug from the fluid filter
(88)

outlet nipple and screw on the fluid hoses

(170a,

170b) and the spray gun (170cl.

Don't

use thread sealant on the swiveling

nut

of
hose couplings, and don't install the spray tip
yeti

Use

thread sealer on

swivel unions. Swivel unions

at

all

male threads except

are

made

to

self-seal, and using thread sealer prevents

swivel from turning freely

the

to

ease

con-

necting or disconnecting parts.

4. Fill

5.

the

Packing

the

Seal

Hydraulic

to

it

in the hole, but do not thread

oil should

Graco Throat

Check
a.

Unscrew the oil fill cap.

is

attached
and set
place. The

Nut/Wet

Cup

Liquid nsu, supplied.

Oil Level

See

the cap. Wipe

be

up

dipstick.

------CAUTION

To prevent damage

hydraulic pump,

part no. 169-236

207-428

oil

b. Add

(1

gaI.l3.8Iiter).

may damage the hydraulic components.

oil

as

pletely full hydraulic system contains about

2-1/2 gallons (9.5 liter)

to

the cooling

use

only Graco Hydraulic

(5

gal.l20

Other types

needed

to

the proper level. A com-

of

(141)

1/4

Fig

3.

The dipstick

off

the dipstick

to

the full line on the

------..,

syster:n

liter) or part

of

hydraulic

oil.

full with

it

in

a~d

011,

nc.>.

6.

Check
a.

b.

the

Engine

Oil Level

Unscrew the oil fill plug.

is

dipstick
Without

attached

threading the plug into place, check

be sure the oil

is

to

up

to

See

Fig

the plug.

the

top

3 and 4. The

mark on the

dipstick.
If oil

is

c.

needed,

recommended

RECOMMENDED ENGINE

detergent
regular use and

SEASON

Spring, Summer,

7.

oil classified "FOR SERVICE

for

GRADE

OR

TEMPERATURE

30°F

to

Winter

Crankcase capacity:

Fill

the

Fuel

Tank

see

the chart below

oil type and weight.

OIL:

Use

the breaking-in

OF

ENGINE

OIL CHART

Autumn

0°

1-1/4 pints (0.6 liters)

a high quality,

SO

of

a new engine.

GRADE

SAE

SAE 10W-30

.-------WARNING-----

Fuel

spilled on a

plosion and cause serious bodily injury and pro-

perty

damage. Always shut

it

cool before filling the tank, and carefully follow

steps 7.a.

fuel.

any

hot

surface

to

7.c., below, being sure not

can

cause a fire or ex-

off

the engine and let

or

for

SE",

OF

30

to

to

the

for

OIL

...

spill

Fig 3

_______________

@

Fig 4

_______________

HYDRAULIC
OIL
FILL

CAP

ENGINE OIL

PLUG

FILL

100

IN PLACE TO

CHECK

NOT THREAD

LEVEll

a. Close the fuel shutoff valve.
b.

Use

only clean, fresh well-known brands

unleaded regular grade gasoline. The

octane requirements are 86 octane

U.S.A.

c. Remove the

which

Be

_

8.

so
the cap.

Grounding

and 96 octane elsewhere.

gasoline fill cap and fill the tank,

holds about 1 gallon (3.8 liters)

sure the air vent in the fill cap

fuel can

flow

See

to

the carburetor, then replace

Fig

2.

WARNING-----

To reduce the risk

of

static sparking, fire or explo-

See

Fig

3.

mi~imum

of

is

not

plugged

In

of

the

fuel.

...

sion which can result in serious bodily injury and
property damage, always ground the

~prayer

and
system components, and the object being sprayed
as

instructed under FIRE OR EXPLOSION

HAZARD

9.

Flush
in the pump after factory testing
pump from corrosion.

_

on page

on page

the

6.

sprayer

3.

to

remove the oil which was left

See

"Flushing Guidelines"

to

protect the

307-293 5

FLUSHING GUIDELINES

When

1.

to

Flush

New

Sprayer. Your new
tory tested in lightweight oil which was left in
protect pump parts from corrosion.

GH

433

Sprayer was fac-

to

Before using oil-base paint, flush with mineral

spirits only.

Before
spirits,
rinse.

2.

Changing
such

3.

Changing

Flush

4.

Changing
Flush
then a clean water flush.

How

------------WARNING----------~

Follow the Pressure
on page 2 or

flushing.

1.

Be
is

2.

Pour enough clean, compatible solvent into a large,
empty,

using water-base paint, flush with mineral

followed by soapy water, then a clean water

Colors.

as

mineral spirits.

from

with

soapy water, then mineral spirits.

from

with

mineral spirits, followed by soapy water,

to

Flush

B.

sure the gun safety latch

Flush with a compatible solvent
water-base
oil-base

Relief

Then remove the spray tip before

to

oil-base

to

water-base

Procedure

is

engaged, and there

Warning

no spray tip in the gun.

metal pail

to

fill the pump and hoses.

paint.
paint.

3. Place the accessory 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
feel it. The sprayer
setting. Turning the knob further will cause it
off. Tighten the knob locknut

5. Open the bypass valve. The lever will

the body

of

the valve.

is

relieved. You will

is

now

set at the lowest pressure

to

set.

See

Fig

5.

See
be

be

able

to

Fig

5.

parallel

fall

to

to

5.

Storage.

Water-base paint: flush with water, then mineral

spirits and leave the pump, hose and gun filled
mineral spirits
Pressure

Relief

to

prevent corrosion. Follow the

Procedure

Warning

on page 2 or

B.

Oil-base paint: flush with mineral spirits. Follow

the Pressure

2 or

B.

6.

Startup

Before using water-base paint, flush out mineral

spirits with soapy water and then a clean water

flush.

When using oil-base paint, flush out the mineral

spirits with the fluid

ready

to

6. Open the fuel shutoff valve by screwing it

as

it will go.

7. T urn the choke

horizontal.

B.

Brace one

starter rope
tinue pulling
into the starter. Then, holding the starter rope firm­ly, rapidly pull the rope

not start after one or

little more.

a
the way and continue pulling the rope.

---------WARNING-------..

Always hold the starter rope firmly while pulling or
recoiling
injured by the rope or
the starter assembly.

9.

After the engine

lever and close the bypass valve.

Relief

Procedure

after

storage.

to

use.

See

See

foot

out

all the way out and let

If

the engine floods, open the choke all

it

to

reduce the chance

be

Fig

5.

off

by turning the lever

Fig

6.

against the frame and gently pull the

until you feel

to

two

of

is

warm, gradually open the choke

Warning

sprayed and the sprayer

it

engage, then con-

it

recoil slowly

start the engine.
attempts, open the choke

of

jamming and damaging

being hit and

See

Fig

with

on page

out

as

so

it

If

it

does

5 and 6.

is

far

is

Fig 5

______________

6

307-293

....

CHOKE

ON~

Fig

6-----------------

~~OFF

10.

Point the gun into the metal pail and hold a metal

of

part

..-----~WARNING-----..,

To reduce the risk
cause fire or explosion, always

the gun firmly against the pail.

of

static sparking, which can

hold a metal part

See

the gun firmly against a grounded metal pail when
flushing. This

also reduces splashing.

Fig

of

7.

11.

Disengage the gun safety latch and squeeze the
gun trigger.
pressure control knob clockwise just enough
start the pump. See

A"ow

12.

At

the pump

the same time, slowly turn the

to

Fig

5.

to

operate until clean solvent

comes from the gun.

13. Release the trigger and engage the gun safety

latch.

Fig 7

-----------------

MAINTAIN
METAL
CONTACT WHEN
FLUSHING

TO

FIRM
METAL

14.

If

you

are

going

to

start

spraying,

place the
pump or accessory suction tube into the supply
container.

Release

the gun safety latch and trigger

the gun into another empty, metal container,

of

holding a metal part

the gun firmly against the
metal pail, and force the solvent from the pump and
hose. Engage the gun safety latch until you are

to

15.

ready

If

you

prime the pump

are

going

to

(see

store

Step 3, page 9).

the

sprayer,

the accessory suction tube or pump from the sol-

of

vent pail, holding a metal part

the gun firmly
against the metal pail, and force the solvent from
the pump and hose. Engage the gun safety latch.

to

the

Refer
"When

16.

Whenever

Pressure

"Storage"

To Flush",

you

shut

Relief

Procedure

procedure in the section

see

page 6.

off

the

sprayer,

Warning,

follow the
on page 2

or 8.

remove

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